1994-2003 HONDA Service Manual - Magna VF750C-CD - With Parts Fiche - V3

1994-2003
MAGNA VF750C/CD
HONDA MOTOR CO., LTD. 1994

,.------ Important Safety Notice -------,
INM@iih Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed.
N OTE: G ives helpful i nformation .
Deta iled descriptions of sta ndard workshop procedures, safety principles and service operations a re not included . It
is i mportant to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe . Please understand
that those warnings could not cover a l l conceivable ways in which service, whether or not recommended by Honda,
might be done or of the possi bly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways . Anyone using service procedu res or tool s, whether or not recommended by Honda, m ust satisfy h imself
thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected .
Introduction Contents
This service manual descibes the service procedures for
the M A G N A V F 7 50C/C D . G eneral I nformation
This Model S pecific Manual includes every service proce

Frame/Body Panels/Exhaust System
d u re that is of a specific nature to this particular m odel .
Basic service procedu res that are common to other Honda
M otorcycle/Motor Scooter/ATVs are covered in the Com Maintenance
mon Service Manual . This M odel Specific Service Manual
should be used together with the Common Service Manu Lubrication System
a l in order to provide complete service information on all
a spects of this m otorcycl e .
Fuel System
c:
Follow t h e M aintenance Schedule (Section 3) recommen a;
..
d ations to ensure that the vehicle is in peak operating I- Cooling System
condition and the emission levels are within the standards CD
>
set by the U . S . Environmental Protection Agency and the
;: Engine Removal/Installation
c
C alifornia Air Resources Board . Performing the first
"0
scheduled maintenance is very important. It compensates c:
ca Cylinder Head/Valves
for the initial wear that occurs during the break-in period .
CD
c:
Sections 1 a n d 3 apply to the whole motorcycl e . c, Clutch System
c:
Section 2 illustrates procedu res f o r removal/instal lation w
of components that may be required to perform service Gearshift Linkage
described in the following sectio n s .
Sections 4 t h r o u g h 1 9 describe parts of the m otorcycle,
g rouped according to locatio n . Crankshaft/Piston/Transmission
Find t h e section y o u want on this page, then turn t o the Front Wheel/Suspension/Steering
0
table of contents on the first page of the sectio n .
;;
0
ca Rear Wheel/Suspension
Most sections describe t h e service procedure throug h .c:
(J
syste m illustration . Refer t o t h e next page for details o n
h o w t o u s e this m a n u a l . Brake System
If y o u a re n o t familiar with this motorcycle, read Tech Charging System/Alternator

nical Feature in section 2 0 .
Ignition System
If you don't k n o w the source o f the trouble, go t o sec "Cii
u
tion 2 1 Trou bleshooting . ;:
t)

Electric Starter/Starter Clutch

CD
jjj
All information, illustrations, directions and specifi Lights/Meters/Switches
cations included in this publication are based on the
latest product information available at the time of
Wiring Diagram
approval for printing. Honda Motor Co., LTD .
reserves the right t o make changes a t any time
without notice and without incurring any obligation Technical Feature
whatever. No part of this publication may be
reproduced without written for permission. This
Troubleshooting
manual is written for persons who have acquired
basic knowledge of maintenance on Honda motor
cycles, motor scooters or ATVs . Index
HONDA MOTOR CO ., LTD .

Service Publications Office
Date of I ssue: J u n e, 1 99 4
H O N DA M OTOR C O . , LTD .
How To Use This Manual
Finding The Info rmation You Need
This manual is devided into sections which cover each of the

m ajor comonents of the motorcycl e .
T o quickly find t h e section you a r e i nterested in, t h e first page
of each sections is m arked with a black tab that lines up with
one of the t h u m b index tabs before this page .
The fi rst page of each section lists the table of contents wi
thin the section .
Read the service information and trobleshooting related to
the section before you begin working .
An index of the entire book is p rovided in the last chapter

to d irectly locate the information you need .
N ote On the Explanation M ethod Of This M anual
The removal and installation of parts are for the most part illustrated by l a rg e and clear i llustrations that should provide
the reader with visual aid i n understanding the major point for servicing .
The system illustrations are augmented by call outs whose numbers or letters indicate the order in which the parts should
be removed or insta l led .
The sequence of steps represented n u merically a re d ifferentiated from the ones represented alphabetically to notify
the reader that they m u st perform these steps separately.
The i l l u strations may contain symbols to indicate necessary service procedures and precautions that need to be taken .
Refer to the next page for the meaning of each symbo l .
Also in the i l l u stration is a chart that lists information such as the order in which the parts is removal/installed, the name
of the part , and some extra notes that may needed .
Step by step instructions a re provided to supplement the illustrations when datailed explanation of the procedu re is
necessary or i l l u strations alone would not suffice.
Service procedures requ i red before or after the procedu re described on that particular page, or i nspection/adjustment
procedures requ i red following the instal lation of parts, are described under the title Requisite Service .
Standard workshop procedures a n d knowledge covered in the Common Service Manual are abbreviated in this manual .
Detailed d escription
System i l l u stration Symbols of the procedure
-
....................
.......... _...._._, ... .......,....,..
I!SI
---
lllil -
---
Step
sequence
(numerals Cllwfully ............ ....... ............ ..
-
o r a l p h a bets) ....
......., ....... _ .... ,.._......
, . ......
. ......... .. ........ ....
..,_
...... .... g.,. ----- -
-- -
.... ......... .,___,,
...... .... .,..
._._..... .... 13-111
.. ........
t.eflllly,.. .... ...........
l
111UNMGDIWD
-
.... ..u-
...
, . ......
. ......... .. ......... .... 1'--' ._..
-
h u-
.....
12-14 12-16
Part name N u m ber of parts Extra notes or precaution

related to the service proced u re
$ymbols
The sym bols used throughout this manual show specific service procedu res . If supplementary information is required pertain
ing to these symbols, it would be explained specifically in the text without the use of the sym bols.
- Replace the part(s) with new one(s) before assembly.
ls.TOOl! Use special too l .
lo.POOLI Use optional tool . These tools are obtained as you order parts .
c
1 0 ( 1 . 0 , 7)
Torque specification . 1 0 Nm ( 1 . 0 kg-m , 7 ft-lb)
, Use recommended engine oil , unless otherwise specified .
, Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 1 ) .
- Use multi-purpose g rease ( Lithium based m ulti-purpose g rease N LG I # 2 or equivalent) .
Use molybdenum disulfide g rease (containing more than 3% molybdenum disulfide , N LG I # 2 o r

equivalent) .
Example: Molykote BR-2 plus manufactured by Dow Cornin g , U . S . A .
M ulti-purpose M-2 manufactured b y Mitsu bishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide , N LGI # 2 or
equivalent) .
Example: Molykote G-n Paste manufactured by Dow Corning , U . S . A .
...... Honda Moly 60 ( U . S . A . only)
Rocol ASP manufactured by Rocol Limited , U . K .
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone g rease .
0.. Apply a locking agent. Use the agent of the middle strength , unless otherwise specified .
Apply sealant.
.t.a!
I Use brake fluid DOT 4. Use the recommended brake fluid , unless otherwise specified .
... Use Fork or Suspension Fluid .

MEMO
1 General Information
.
General Safety 1-1 Lubrication & Seal Points 1-17

Model Identification 1-3 Cable & Harness Routing 1-20
Specifications 1-4 Emission Control System (U.S.A. Only) 1-27
Torque Values 1-12 Emission Control Information Labels

(U.S.A Only) 1-30
Tools 1-15
General Safety
Carbon Monoxide Used Engine/Transmission Oil
If the engine must be running to do some work, make sure
the area is well ventilated. Never run the engine in an en
closed a rea .
Used engine oH (or transmission oil in two-stroke) may
cause skin cancer if repeatedly left in contact with the
skin for prolonged periods. Althrough this is unlikely

The exhaust cotains poisonous carbon monoxide gas unless you handle used oil on a daily basis, it is still
that may cause loss of consciouness and may lead to advisable to thoroughly wash your hands with soap
death. and water as soon as possible after handling used oil.
KEEP OUT OF REACH OF CHILDREN.
Run the engine in an open a rea or with an exhaust evacua

tion system in an enclosed area. Brake Dust
Never use an air hose or dry brush to clean brake assem
Gasoline blies. Use an OSHA-approved vacuum c leaner or a lternate
Work in a well ventilated area. Keep cigarettes, flames or method approved by OSHA, designed to m inimize the haz
sparks away from the work area or where gasoline is stored. ard caused by airborne asbestos fibers .

Gasoline is extremely flammable and is explosive un
Inhaled asbestos fibers have been found to cause
der certain conditions. KEEP OUT OF REACH OF respiratory disease and cancer.
CHILDREN.
Brake Fluid
Hot Components
CAUTION

Spilling fluid on painted, plastic or rubber parts wiU

Engine and exhaust system parts become very hot and damage them. Place a clean shop towel over these
remain hot for some time after the engine Is run. Wear parts whenever the system is serviced. KEEP OUT OF
insulated gloves or walt until the engine and exhaust REACH OF CHILDREN.
system have cooled before handling these parts.
1-1
General Information
Coolant Nitrogen Pressure

Under some conditions, the ethylene glycol in engine coolant For shock a bsorbers with a gas-fi lled reservoir:
is combustible and its flame is not visible . If the ethylene
glycol does ignite, you will not see any flame, but you can
be burned .
Use only nitrogen to pressurize the shock absorber.
The use of an unstable gas can cause a fire or explo
sion resulting in serious injury.

Avoid spilling engine coolant on the exhaust system
The shock absorber contains nitrogen under high pres
or engine parts. They may be hot enough to cause the sure. Allowing fire or heat near the shock absorber
coolant to ignite and burn without a visible flame. could lead to an explosion that could result in serious
Coolant (ethylene glycol) can cause some skin irrita injury.
tion and is poisonous if swallowed. KEEP OUT OF
Failure to release the pressure from a shock absorber
REACH OF CHILDREN. before disposing of it may lead to a possible explo

Do not remove the radiator cap when the engine is sion and serious injury if it is heated or pierced.
hot. The coolant is under pressure and could scald
you.
To prevent the possibility of an explosion, release the nitro

Keep hands and clothing away from the cooling fan,
gen by pressing the valve core . Then remove the valve stem
as it starts automatically.
from the shock a bsorber reservoi r . Dispose of the oil i n a
manner acceptable to the Environmental Protection Agen
If it contacts your skin, wash the affected areas immedi cy ( E PA) .
ately with soap and water. If it contacts your eyes, flush
them thoroughly with fresh water and get i mmediate medi Before d isposal of the shock a bsorber, release the nitrogen
cal attention . If it is swallowed , the victim m ust be forced by pressing the valve core . Then remove the valve stem from
to vomit, then rinse mouth and throat with fresh water be the shock a bsorber.
fore obtaining medical attentio n . Because of these dangers,
always store coolant in a safe place, away from the reach Battery Hydrogen Gas & Electrolyte
of chi ldren .

The battery gives off explosive gases; keep sparks,
flames and cigarettes away. Provide adequate venti
lation when charging.

The battery contains sulfuric acid (electrolyte). Con
tact with skin or eyes may cause severe burns. Wear
protective clothing and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water
for at least 15 minutes and call a physician im
mediately.

Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk
and follow with milk of magnesia or vegetable oil
and call a physician. KEEP OUT OF REACH OF
CHILDREN.
1-2
General Information
Model Identification
'94 MAGNA VF750C shown
(1) FRA M E SERIAL N U M BE R
( 1) The frame serial number is stamped on the r i g h t side o f

t h e steering head .
( 2 ) E N G I N E SERIAL N U M BE R (3) V E H I C LE I DE N T I F I CATI O N N U MBER
( 2 ) The e n g i n e serial number is sta m ped on t h e right s i d e of ( 3 ) The vehicle Identification N u m ber (VI N ) is located on the
the upper cran kcsase . Safety Certification Label on the left side of the steering
head .
( 5 ) COLOR LABEL
(4) CARBU RETOR I D EN T I FI CATI O N N U M BER
(4) The carburetor indentification number is stamped on the ( 5) The color label is attached as shown . When ordering
carburetor body intake side . color-coded parts, a lways specify the desig nated color
code.
1-3
General Information
Specifications
r- General
Item Specifications
Dlmel..... Overall length '94-'00 2,332 mm (91.8 in)

After '00 2,338 mm ( 92 .0 in)
Overall width 854 mm (33.6 in)
OveraA height (VF750C) 1,136 mm (44.7 in)
(VF750CD) 1,1go mm (46.9 in)
Wheelbase 1,652 mm (65 in)
Seat height 7 10 mm (28 in)
Footpeg height 290 mm (11.4 in)
Group clearance 155 mm (6.1 in)
Dry weight
(VF750C: 49 states, Canadian type) 229 kg (5051bs)
(VF750C: California type) 231 kg (509 lbs)
(VF750CD: 49 states, Canadian type) 230 kg (507 lbs)
(VF750CD: California type) 232 kg (511 lbs)
Curb weight
(VF750C: 49 states, Canadian type) 247 kg (545 lbs)
(VF750C: California type) 249 kg (549 lbs)
(VF750CD: 49 states, Canadian type) 248 kg (547 lbs)
(VF750CD: California type) 250 kg (551 lbs)
Maximum weight capacity 180 kg (397 lbs)
Frame Frame type Double cradle

Front suspension Telescopic fork
Front wheel travel 150 mm (5.91 in)
Rear suspension 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
T ire brand (Front/Rear) K555F/K555 (Dunlop)
Front brake Hydraulic brake
Rear brake Internal expanding shoe
Caster angle 32 '
Trail length 13 7 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 Imp gal)
Engine Bore and stroke 70 .0 x 48.6 mm (2.76 x 1.91 in)

Displacement 748.1 cc (45.65 cu-in)
Compression ratio 10.8:1
Valve train Silent multi-link chain drive and DOHC
Intake valve opens (at 1 mm lift) 10 BTDC
Intake valve closes (at 1 mm lift) 25"ABDC
Exhaust valve opens (at 1 mm lift) 35' BBDC
Exhaust valve closes (at 1 mm lift) -5.ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Paper filter
Crankshaft type Unit-type, 4 main journal
Engine dry weight 80.3 kg (1n lbs)
Firing order 1 -go -4 - 270. -3- go -2 - 270. -1
Cylinder arrangement 4 cylinder oo v
LEFT
Cylinder number -
G 8 FRONT
8 8
-
1-4
General Information
r- General (Cont'dl
Item Specifications
Carburetor Carburetor type CV (Constant Velocity) type,with flat valve

Venturi diameter 33 mm (1.30 in)
Drive Train Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission 5 speeds
Primary reduction 1.939 (64/33)
Secondary reduction --
Third reduction --
Final reduction 2.500 (40/16)

Gear ratio 1st 2.846 (37/13)
Gear ratio 2nd 1.882 (32/17)
Gear ratio 3rd 1 .450 (29/20)
Gear ratio 4th 1.227 (27/22)
Gear ratio 5th 1.035 (29/28)
Gear ratio 6th --
Gear ratio reverse --
Gearshift pattern Left foot operated return system 1-N-2-3-4-5

Electrical Ignition system Full transistor ignition
Starting system Starter motor
Charging system Triple phase output alternator
Regulator/rectifier type SCR shorted/triple phase,full-wave rectification
Lighting system Battery
AC regulator type --
1-5
General Information
Unit: mm (in)
r- Lubrication ------.---,--,
Item Standard Service Limit
Engine oil capacity at draining 3. 0 lit ( 3. 2 US qt, 2. 6 Imp qt) --
at disassembly 3.8 lit ( 4. 0 US qt, 3 , 3 Imp qt) --
at oil filter change 3. 1 lit ( 3. 3 US qt, 2. 7 Imp qt) --
Recommended engine oil Use Honda GN4 4-stroke Oil or equivalent

OIL VISCOSITIES API Service Classification: SF or SG
Viscosity: SAE 1 0W - 40
Other viscosities shown in the chart may

I I
be used when the average temperature in
I
I
your riding area is within the indicated
o zo 40 eo eo tOO F range.
-20 -oo o 10 20 :so 40 'C
Oil pressure at oil pressure switch 490 - 588 kPa ( 5 - 6 kg/cm2, 7 1 . 1 - 8 5 . 3

psi) at 6 , 000 rpm (80C/ 1 7 6F)
Oil pump rotor tip clearance G) 0. 1 0 (0. 004) 0. 1 5 ( 0 . 006)
body clearance 0. 1 5 - 0. 2 2 (0. 00 6 - 0. 009) 0. 3 5 ( 0. 0 1 4)
end clearance @ 0. 0 2 - 0. 09 ( 0. 0 0 1 - 0. 004) 0. 1 0 ( 0. 005)
--, FueiSystem ------.----

Carburetor identification number (49 states type) VP31A
(California type) VP30A
(Canadian type) VP3 2 D
Main jet # 1 02
Slow jet # 40
Pilot screw initial opening see page 5- 1 6
Pilot screw high altitude adjustment see page 5- 1 7
Float level 1 3. 7 ( 0. 54)
Carburetor vacuum difference Within 20 mmHg ( 0. 8 inHg)
Base carburetor (For carburetor synchronization) No. 1 carburetor
Idle speed (49 states type) 1 ,000 1 00 rpm
(California type) 1 , 1 00 1 00 rpm
(Canadian type) 1 , 000 1 00 rpm
Throttle grip free play 2 - 6 ( 1 /8 - 1 /4)
Pulse secondary air (PAIR) injection system PAIR check valves are buit in to the PAIR
(California type) control valve
Pulse secondary air inje'ction control valve vacuum
pressure
--, Cooling System --------.---,.--,

Cooling capacity (Radiator and engine) 2. 4 i (0. 6 US gal, 0. 5 Imp gal)
(Reserve tank) 0. 4 i ( 0. 1 US gal, 0.09 Imp gal)
Radiator cap relief pressure 1 0 7.9 kPa ( 1 . 1 kg/cm2, 1 5. 64 psi)
Thermostat begins to open 80 - 84C ( 1 76 - 1 83F)
Thermostat fully open 9 5C ( 203Fl
Thermostat valve lift 8. 0 ( 0. 3 1 5) min.
1-6
General Information
Unit: mm (in)
Cylinder Head --------.--.--,
Cylinder compression 1,275 kPa (184.9 psi, 13.0 kg/cm2)/

500 rpm
Cylinder compression synchronization difference
Valve clearance IN 0.16 0.02 (0.006 0.001)
EX 0.25 0.02 (0.010 0.001)
Cylinder head warpage 0.10 (0.004)
Cam lobe height CD IN 35.980-36.140 (1.41651.4228) 35.95 (1.4153)
IN (California type)
EX 35.670-35.830 (1.4043-1.4106) 35.64 (1.4031)
EX (California type)
Camshaft runout 0.05 (0.002)
Camshaft oil clearance 0.030-0.072 (0.0012-0.0028) 0.10 (0.004)
H O LO
Camshaft journal O . D . 24.949-24.970 (0.9822-0.9831) 24.94 (0.982)

Camshaft holder I.D. 25.000-25.021 (0.9843-0.9851) 25.05 (0.986)
Valve stem O . D . IN 4.475-4.490 (0.1762-0.1767) 4.46 (0. 1 75)
EX 4.465-4.480 (0.4758-0.1764) 4.45 (0.175)
Valve guide I .D . IN 4.500-4.512 (0.1772-0.1776) 4.56 (0.179)
EX 4.500-4.512 (0.1772-0.1776) 4.56 (0.179)
Stem-to-guide clearance IN 0.010-0.037 (0.0004-0.0015)
EX 0.020-0.047 (0.0008-0.0019)
Valve guide projection above cylinder head I N 15.30-15.50 (0.602-0.610)
EX 15.30-15.50 (0.602-0.610)
Before guide installation:

1. Chill the valve guides in the
freezer section of the refrigerator
for about an hour.
2. Heat the cylinder head to
212-300F (100-150C)
Valve seat width 1.0 (0.04) 1.5 (0.06)

Valve spring free length 37.86 (1.49) 36.1 (1.42)
Valve lifter O . D . 25.978-25.993 (1.0225-1.0233) 25.96 (1.022)
Valve lifter bore I.D. 26.010-26.026 (1.0240-1.0246) 26.04 (1.025)
1 -7
General Information
Unit: mm (in)
..- Clutch System
Clutch lever free play 10-20 (0.4-0.8) --

Cl utchouter guide I . D . 24.995-25.012 (0.9841-0.9847) 25.08 (0.987)
Clutch spring free length 44.4 (1.75) 41.2 (1.62)
Clutch disc thickness A 2.92-3.08 (0.115-0.121) 2.5 (0.10)
B (Judder spring side) 2.92-3.08 (0.115-0.121) 2.5 (0.10)
Clutch palte warpage -- --
..- Cylinder/Piston
Cylinder I . D . 70.000-70.015 (2.755-2.756) 70.10 (2.759)
Cylinder out of round -- 0.10 (0.004)
Cylinder taper -- 0.10 (0.004)
Cylinder warpage -- 0.10 (0.004)
Piston mark direction With "IN" mark facing to the intake side --
Piston O . D . ( D ) 69.970-69.990 (2.755-2.756) 69.85 (2.750)
Piston O . D . measurement point (H) 10 (0.4) --
Piston pin hole O . D . (d) 17.002-17.008 (0.6694-0.6695) 17.02 (0.670)
d
!""-"'
[OJ ( 1'--<'l (0] H

W'
D
Cylinder-to-piston clearance 0.010-0.035 (0.0004-0.0014) --

Piston pin O . D . 16.994-17.000 (0.6691-0.6693) 16.98 (0.669)
Piston-to-piston p i n clearance 0.002-0.014 (0.0001-0.0005) --
Connecting rod-to-piston clearance 0.016-0.040 (0.0006-0.0016) --
Top ring-to-ri ng groove clearance 0.015-0.050 (0.0006-0.0019) 0.10 (0.04)
Second ring-to-ring groove clearance 0.015-0.045 (0.0006-0.0018) 0.10 (0.004)
Top ring end gap 0.20-0.35 (0.008-0.014) 0.5 (0.02)
Second ring end gap 0.35-0.50 (0.014-0.020) 0.7 (0.03)
Oil ring (side ra i l ) end gap 0.20-0.80 (0.008-0.031) 1.00 (0.039)
Top ring mark I nstal l with the marked side u p --
Second ring mark I nstal l with the marked side u p --
Crankshaft ------.-----
17.016-17.043 (0.6699-0.6706)
Connecting rod small end I . D . 17.04 (0.671)
0.10-0.30 (0.004-0.012)
Connecting rod big end side clerance 0.40 (0.016)
rad ial clearance
Crankshaft ru nout G) 0.05 (0.002)
Crankpin oil clearance 0.030-0.052 (0.0012-0.0020) 0.08 (0.003)

Connecting rod bearing selection See page 11-9
Main journal oil clearance 0.019-0.037 (0.0007-0.0015) 0.05 (0.019)
Main journal bearing selection See page 11-8
1-8
General Information
Unit: mm ( i n )
Transmission ------.--,--,
Transmission gear I . D . M 5 2 8 . 000 - 28 . 021 (1.1024 - 1.1032) 2 8 . 04 (1.104)

C2 31 . 000 - 31 . 016 (1. 2 2 0 5 - 1 . 2 211) 31. 04 (1. 2 2 2 )
C3 31. 000 - 31. 016 ( 1 . 2205 - 1.2 211) 31. 04 (1. 2 2 2 )
C4 31. 000 - 31 . 016 (1. 2205 - 1 . 2 211) 31. 04 (1. 2 2 2 )
Transmission gear bushing O . D . M 5 2 7 . 9 59 - 2 7 . 980 (1. 1007 - 1 . 1016) 2 7 . 94 (1. 010)
C2 30 . 9 70 - 30 . 9 9 5 (1. 2193 - 1 . 2 203) 30 . 9 5 (1. 219)
C3 30 . 9 50 - 30 . 9 7 5 (1. 218 5 - 1 . 219 5) 30. 93 (1. 218)
C4 30 . 9 50 - 30 . 9 7 5 (1. 218 5 - 1 . 2195) 30 . 9 3 (1. 218)
Transmission gear bushing I . D . M 5 24. 9 8 5 - 2 5 . 006 ( 0 . 9 8 34 - 0 . 9845) 2 7 . 94 (1. 010)
C2 2 8 . 000 - 2 8 . 021 (1.1024 - 1.1032) 2 8 . 04 (1. 104)
C3 2 7 . 99 5 - 2 8 . 016 (1.10 2 2 - 1 . 1 029) 2 8 . 04 (1. 104)
Gea r-to-bushing clearance a t M 5 gear 0 . 0 20 - 0 . 062 (0.0008 - 0 . 0024)
at C 2 gear 0 . 00 5 - 0 . 046 ( 0 . 0002 - 0 . 018)
at C 3 gear 0 . 02 5 - 0 . 066 ( 0 . 0001 - 0 . 0026)
at C4 gear 0 . 0 25 - 0 . 066 ( 0 . 0001 - 0 . 0026)
M a inshaft O . D . at M5 gear bushing 24. 9 5 9 - 24. 980 ( 0 . 9 8 26 - 0 . 9835) 24. 9 5 ( 0 . 9 8 2 )
Countershaft O . D . at C 2 gear bushing 2 7 . 967 - 2 7 . 980 (1. 1011 - 1 . 1016) 2 7 . 96 (1.10 1 )
Gear-to-shaft clearance
Gear bushing-to-shaft clearance at M5 gear 0 . 00 5 - 0 . 047 ( 0 . 0002 - 0 . 0019)
at C 2 gear 0 . 0 20 - 0 . 054 ( 0 . 0008 - 0 . 0021)
at C 3 gear 0 . 015 - 0 . 049 ( 0 . 0006 - 0 . 00 1 9)
at C4 gear 0 . 015 - 0 . 049 ( 0 . 0006 - 0 . 0019)
Shift fork claw thickness L 6 . 43 - 6 . 50 ( 0 . 2 5 3 - 0 . 2 56) 6 . 40 (0. 2 5 2 )
c 6 . 43-6 . 50 (0. 2 5 3 - 0 . 2 56) 6 . 40 ( 0 . 2 5 2 )
R 6 . 4 3 - 6 . 50 ( 0 . 2 53 - 0 . 2 56) 6 . 40 (0. 2 5 2 )
Shift fork I . D . L 14. 016 - 14. 034 ( 0 . 5518 - 0 . 5 5 2 5) 1 4. 043 (0. 5 5 2 9)
c 14. 016 - 14. 034 (0. 5518 - 0 . 5 5 2 5) 14. 043 ( 0 . 5 52 9 )
R 14. 016 - 14. 034 (0. 5 518 - 0 . 5 5 25) 1 4. 043 ( 0. 5 5 2 9 )
S hift fork shaft O . D . 13 . 9 7 3 - 13 . 984 (0. 5 50 1 - 0 . 5 506) 1 3 . 96 5 ( 0 . 5498)
1 -9
General Information
Unit: mm ( i n )
r- Wheel/Tires
Minimum tire tread depth (FR) -- 1.5 (0.06)

(RR) -- 2.0 (0.08)
Cold tire pressure U p to 90 kg (200 lb) load (FR) 250 kPa (2.50 kg/cm2, 36 psi) --
Up to 90 kg (200 l b ) load ( R R ) 250 kPa (2.50 kg/cm2, 36 psi) --
Up to maximum weight capacity (FR) 250 kPa (2.50 kg/cm2, 36 psi) --
Up to maximum weight capacity (RR) 290 kPa (2.90 kg/cm2, 42 psi) --
Front and rear axle runout -- 0.2 (0.01)

Front and rear wheel rim runout ( Radial) -- 2.0 (0.08)
(Axial) -- 2.0 (0.08)
Wheel balance weight (Front) -- 60 g (2.1 oz)
( Rear) -- 60 g (2.1 oz)
D rive chain slack 20-30 (3/4-13/16) --
Drive chain size/link ( D I D) D I D 50V4/118 --
IRK) RK 50 MFOZ1/118 --
r- Front Suspension -------.---.---,

410.7 (16.17)
Fork spring free length 402.5 (15.85)
Fork spring d i rection Tapered coil facing down
Fork tube runout 0.2 (0.01)
Recommended fork oil Fork fluid
Fork oil level 122 (4.80)
Fork oil capacity 521cc (17.62 U S oz, 18.29 I m p oz)
Steering bearing preload 0.1-0.15 kg-m
r- Rear Suspension ----------
Shock absorber spring free length 241.8 (9.52) 237.0 (9.33)

Shock absorber spring adjuster standard position 2nd g roove
Shock absorber spring d i rection Small coil end facing down
- Brakes --------,---
Front brake fluid DOT 4
brake pad wear ind icator G) To the g roove
~
brake disc thickness
brake disc runout
6.0 (0.24) 5.0 (0.20)
0.25 (0.01)
master cylinder J . D . 11.0-11.043 (0.4331-0.4348) 11.055 (0.4352)
master piston O . D . 10.957-10.984 (0.4314-0.4324) 10.945 (0.4309)
calipe r cylinder J . D . 25.400-25.450 (1.000-1.0020) 25.461 (1.002)
caliper piston O . D . 25.335-25.368 (0.9974-0.9987) 25.33 (0.997)
Rear brake pedal free play 20-30 (0.8-1.2)
brake drum J . D . 180-180.3 (7.086-7.098) 181 (7.12)
brake lining thickness 5.0 (0.2) 2.0 (0.08)
1 - 10
General Information
Unit: mm (in)
r- Battery/c harging System
Alternator/charging coil resistance (at 20C/68F) 0.1-1.0 0 --
Regulator/rectifier regulated voltage/amperage 14-15.5 V/below 0.5 A/3,000 rpm --
Battery capacity 12 V-10 Ah --
Battery charging rate (Normal) 1.2 A (5-10h) --
(Quick) 5 A (1h) --
Battery voltage (fully charged 20C/68F) Over 13.1 V --
(needs charging 20C/68F) Below 12.5 V --
r- Ignition System ------.--..,

Spark plug
(Standard NGK) CR8EH9
(Standard NIPPONDENSO) U24FER9
(For cold climate/below 5C/41F NGK)
(For cold climate/below 5C/41F NIPPONDENSO)
(For extended high speed riding NGK) CR9EH9
(For extended high speed riding NIPPONDENSO) U27FER9
Spark plug gap 0.8-0.9 (0.03-0.04)
Ignition timing "F" mark 12 BTDC at idle
Advance start 2,000 rpm
stop
Full advance
Ignition coil resistance (Primary: at 20C/68F) 2-4 0
(Secondary with plug cap) 23-27 kO
(Secondary without plug wire) 13-17 k0
Pulse generator resistance (At 20C/68F) 450-550 0
Starter System --------,--r--
Starter motor brush length 12.0-13.0 (0.47-0.51) 6.5 (0.26)

Starter clutch driven gear O.D. 47.175-47.200 (1.8573-1.8583) 47.16 (1.857)
- Lights/Meters/Switches -------.....---,-
Main fuse 30 A
Fuse 10 A x 3,15 A X 1
Headlight (high/low beam) 12 v 60/55 w
Tail/brake light 12 V 32/3 cp
Position light bulb 12 V 3 cp x 2
Front turn signal lights 12 V 32/3 cp x 2
Rear turn signal lights 12 V 32 cp x 2
Instrument lights 12 V 1.7 W X 1,12 V 1.4 W X 2
Oil pressure warning indicator 12 v 3 w
Side stand indicator 12 v 3 w
Coolant temperature indicator 12 v 3 w
High beam indicator 12 v 3 w
Turn signal indicator 12 v 3 w
Neutral indicator 12 v 3 w
Coolant temperature sensor resistance 85C (185F) 39-49 0
120C (248F) 14-18 0
Fan motor switch Starts to close (ON) 97-103C (207-217F)
Stops to open (OFF) 92-98C (198-208F)
1- 1 1
General Information
Torque Values
r- Standard
Torque Torque
Fasteners Type Fasteners Type
Nm (kg-m, ft-lb) Nm (kg-m, ft-lb)
5 mm hex bolt and nut 5 (0.5,3.5) 5 mm screw 4 (0.4,3)

6 mm hex bolt and nut 10 (1.0,7) 6 mm screw 9 (0.9,7)
8 mm hex bolt and nut 22 (2.2,16) 6 mm flange bolt (8 mm head ) 9 (0.9,7)
10 mm hex bolt and nut 35 (3.5,25) 6 mm flange bolt ( 10 mm head) and nut 12 (1.2,9)
12 mm hex bolt and nut 55 (5.5,40) 8 mm flange bolt and nut 27 (2.7,20)
10 mm flange bolt and nut 40 (4.0,29)
Torque specifications listed below are for important fasteners. Others should be tightened to standard torque values listed above .
Notes: 1. Apply sealant to the threads.

2. Apply a locking agent to the threads.
3 . Apply molybdenu m disulfide oil to the threads and flange surface .
4. Left hand threads .
5. Stake .
6. Apply oil to the threads and flange surface .
7. Apply clean engine oil to the 0-ring .
8 . Torque wrench scale reading using a special too l .
9 . Apply grease t o t h e threads a n d flange surface .
10. UBS bolt.
11. U-nut.
12. ALOC bolt; Replace with a new one.
r- Engine
Thread Torque
Item O'ty Remarks
dia . (mml Nm (kg-m, ft-lbl
Maintenance :
Timing hole cap 1 45 18 (1.8,13) Note 9
Lubrication :
Oil pressure switch 1 PT 1/8 12 (1.2,9) Note 1
Oil filter 1 20 10 (1.0,7) N ote 6
Oil filter stud bolt 1 20 18 (1.8,13) Note 2
Oil drain bolt 1 12 34 (3.4,25)
Oil pump bolt 3 6 13 (1.3,9)
Oil pump driven sprocket bolt 1 6 18 (1.8,13) N ote 2
Oil pipe nut (After '94) 1 6 12 (1.2,9) Note 11
Fuel Systems :
Connecting tube band screw 4 5 1 (0.1,0.7)
Cooling Systems:
Water pump cover 2 6 13 (1.3,9)
Water pump mounting bolt 2 6 13 (1.3,9)
Cylinder Head :
Spark plug 4 10 12 (1.2,9)
H ead cover protector 8 6 10 (1.0,7)
Cylinder head cover bolt 8 6 10 (1.0, 7)
Breather case bolt 6 6 10 (1.0,7)
Cylinder head protector bolt 12 6 12 (1.2,9)
Cylinder head sealing bolt 4 18 44 (4.4,32) N ote 2
Cylinder head bolt (9 m m ) 16 9 44 (4.4,32) N ote 6
Cylinder head bolt (6 m m ) 4 6 12 (1.2,9)
Camshaft holder bolt 32 6 12 (1.2,9) N ote 6
Cam chain tensioner mounting bolt 4 6 12 (1.2,9)
Boost joint bolt -
5 4 (0.4,2.9)
1 -12
General Information
r- Engine
Thread Torque
Item Q'ty Remarks
dia. (mml Nm (kg-m, ft-lb)
Clutch/Gearshift Linkage
Right crankcase cover bolt 13 6 12 (1.2,9)
C l utch cable holder bolt 1 10 23 (2.3,171
C l utch spring bolt 5 6 12 (1.2,9)
C l utch center lock nut ('94) 1 22 90 (9.0,65) N ote 5, 6
(After '94) 1 22 110 (11.0,80) N ote 5, 6
Gearshift link joint bolt 1 6 9 (0.9,6.5)
Change pedal pivot bolt 1 8 27 (2.7,20)
Drive sprocket cover bolt 3 6 10 (1.0,7)
Drive sprocket cover rubber bolt 2 6 12 (1.2,9)
Drive sprocket bolt 1 10 51 (5.1,37)
Sh ift drum center bolt 1 8 23 (2.3,17) Note 2
Sh ift return spring pin 1 8 23 (2.3,17)
Crankcase/Crankshaft :
U pper crankcase bolt (10 m m ) 2 10 39 (3.9,28)
U pper crankcase bolt (6 m m ) 7 6 12 (1.2,9)
lower crankcase bolt (9 m m ) 8 9 31 (3.1,22) Note 6
lower cran kcase bolt (8 m ) 1 8 23 (2.3,17)
lower crankcase bolt (6 m m ) 8 6 12 (1.2,9)
Cam chain tensioner slipper bolt 2 6 12 (1.2,9) N ote 2
Cam chain sli pper bolt 2 6 12 (1.2,9) N ote 2
Connecting rod bearing cap nut 8 8 33 (3.3,24) N ote 6
Sealing bolt 1 8 18 (1.8,13) N ote 2
Alternator:
left crankcase cover bolt 6 6 12 (1.2,9)
Flywheel bolt 1 10 83 (8.3,61) N ote 6
Stator mounting bolt 3 6 12 (1.2,9)
Ignition System :
Pulse generator mounting bolt 3 6 10 (1.0,7)
Starter Clutch:
Starter motor flange nut 1 6 10 (1.0,7)
Starter motor case bolt 2 5 5 (0.5,3.6)
Starter clutch bolt 1 12 90 (9.0,65) N ote 6
Starter clutch outer cover bolt 3 8 40 (4.0,29) N ote 2
Lights/Meters/Switches :
N eutral switch 1 10 12 (1.2,9)
.--- Frame
Thread Torque
Item Q'ty Remarks
dia . (mml Nm (kg-m. ft-lbl
Engine mounting:
Front cylinder head mounting bolt 2 10 54 (5.4,39)
Front engine mounting bracket bolt 4 8 39 (3.9,28)
Front engine mounting bolt 2 10 44 (4.4,32)
Rear engine mounting bracket bolt 2 8 39 (3.9,28)
Rear engine mounting bolt 1 12 64 (6.4,46) N ote 9
Rear cylinder head mount bolt 2 10 44 (4.4,32)
Rear cylinder head mount bracket bolt 4 8 39 (3.8,28)
1-13
General Information
r- Frame
Thread Torque
Item O'ty Remarks
dia. (mm) Nm (kg-m. ft-lb)
Front Suspension :
Handlebar upper holder bolt 4 6 23 (2.3, 17)
Front fender bolt
Steering stem nut
4
1
1
6
24
26
12 (1.2,9)
105 (10.5,76) =:] page 12-12
lock nut
Steering head bearing adjusting nut 1 26 30 (3.0,22)
Fork pinch bolt (upper) 2 8 27 (2.7, 20)
(lower) 2 10 39 (3.9,28)
Fork cap 2 37 23 (2.3,17)
Fork socket bolt 2 8 20 (2.0, 14) Note 2
Fork drain bolt 2 6 8 (0.8,5.8)
Rear Suspension :
Frame pivot adjusting bolt 1
1
20
20
15
64
(1.5,11)
(6.4,46)
.=j page 13-10
Frame lock nut
Frame lock bolt 1 10 39 (3.9,28)
Swingarm pivot nut 1 14 89 (8.9,65) Note 11
Chain slider screw 2 5 6 (0.6,4.3)
Chain tensioner 2 8 22 (2.2,16)
Shock absorber mounting bolt (upper) 2 8 27 (2.7,20)
(lower) 2 10 37 (3.7,27)
Wheels:
Speedometer cable screw 1 5 4 (0.4,2.9)
Rear axle nut 1 18 93 (9.3,63) Note 11
Front axle bolt 1 14 59 (5.9,43)
Axle pinch bolt 4 8 22 (2.2, 16)
Brake disc bolt 6 8 42 (4.2,30) Note 12
Driven sprocket nut 5 12 108 (10.8,79) Note 11
Brake System:
Brake hose bolt 2 10 35 (3.5,25)
Caliper bracket bolt 2 8 31 (3.1,22) Note 12
Front brake hose clamp nut 2 6 12 (1.2,9) Note 11
Front master cylinder holder bolt 2 6 12 (1.2,9)
Front master cylinder reservoir cover screw 2 4 1.5 (0.15, 1. 1)
Front brake light switch screw 1 4 1.2 (0.12,,0.9)
Front brake lever pivot bolt 1 6 1 (0.1,0.7)
nut 1 6 6 (0.6,4.3)
Pad pin plug 1 10 2.5 (0.25,1.8)
Pad pin 1 10 18 (1.8,13)
Brake caliper bleeder bolt 1 8 5.5 (0.55,4)
Brake caliper bracket pin bolt 1 8 13 (1.3,9) Note 2
Brake caliper pin bolt 1 8 23 (2.3,17) Note 2
Rear brake pedal pivot bolt 1 10 39 (3.9,28)
Rear brake pedal linkage joint pinch bolt 1 8 27 (2.7,20)
Rear brake arm pinch bolt 1 8 29 (2.9,21) Note 12
Rear brake stopper arm nut 2 8 22 (2.2. 16)
Frame/Exhaust Systems:
Exhaust pipe joint nut 8 8 12 (1.2,9)
Exhaust pipe band bolt 4 8 21 (2.1, 15)
Exhaust pipe protector bolt 6 6 12 (1.2,9)
Muffler mounting bolt 2 8 27 (2.7,20)
Lights/Meters/Switches:
Side stand pivot bolt 1 10 10 (1.0,7)
nut 1 10 30 (3.0,22)
Side stand switch 1 6 10 (1.0,7)
Others:
Footpeg bracket bolt 4 8 27 (2.7 20)
Fuel valve 1 22 23 (2.3,17)
1- 14
General Information
Tools
Description Tool Nunber Applicability

Maintenance :
Oil filter wrench 07HAA - PJ 7 0 1 00
Drive chain cutter 07H M H - M R 1 0 1 02
or 07H M H - M R 1 0 1 0B U . S . A . only
Link plate holder 07N M H - MW00 1 1 0
or 07PM H - MZ20 1 1 0
Lubrication :
Oil pressure gauge 07 506 - 3000000
Oil pressure gauge attachment 07 5 1 0 - 42 20 1 00
Fuel System:
Float level gauge 0740 1 - 00 1 0000
Pilot screw wrench (Canadian type) 07908 - 42 2020 1
(49 states , Cal ifornia type) 0 7 M M A - MV90 1 0A
Cylinder Head/Cylinder/Piston:
Valve spring com pressor 0 7 7 5 7 - 00 1 0000
Valve spring compressor attachment 07959 - KM 30 1 0 1
Tappet hole protector 0 7 H M G - M R 70002 N ot available i n U . S . A .
Valve guide drivier 0 7 H M D - M L00 1 0 1
Valve guide reamer, 4. 5 mm 07H M H - M L00 1 0 1
Valve seat cutter
seat cutter, 24. 5 m m ( 4 5 EX) 07780 - 00 1 0 1 00
29 m m (45 I N ) 07780 - 00 1 0300
flat cutter, 2 5 m m ( 3 2 EX) 07780 - 00 1 2000
30 m m ( 3 2 I N ) 07780 - 00 1 2 200
interior cutter, 26 m m ( 6 0 EX) 0 7 7 80 - 00 1 4 500
30 m m (60 I N ) 07780 - 00 1 4000
cutter holder, 4. 5 m m 0778 1 - 00 1 0600
Compression g a u g e attach ment 07JMJ - KY 20 1 00
Tensioner stopper 0 7 N M G - MY90 1 00 N ot available in U . S . A.
Clutch/Gearshift Linkage :
Lock nut wrench, 26 x 30 mm 07 7 1 6 - 0020203 ' 94 only
Extension bar 07 7 1 6 - 0020500 '94 only
Clutch center holder 0 7 7 2 4 - 00 5000 1 Equivalent commercia l ly
available in U . S . A .
Crankshaft/Transmission :
U niversal bearing puller 0763 1 - 00 1 0000
Inner d river C 07 746 - 0030 1 00
Attachment, I . D . 2 5 m m 0 7 746 - 0030200
Front Wheel/Suspension/Steering:
Bearing remover shaft 07746 - 0050 1 00
Bearing remover head , 20 m m 07746 - 0050600
Attachment, 42 x 47 m m 07746 - 00 1 0300
Pilot, 20 m m 07 746 - 0040500
Fork seal d river 07947 - KA 5 0 1 00
Fork seal d river attachment 07947 - KF00 1 00
Steering stem socket wrench 079 1 6 - 3 7 1 0 1 0 1
Ball race remover 0 7 9 5 3 - MJ 1 0000
- attachment 0 7 9 5 3 - MJ 1 0 1 00
or 0 7 9 5 3 - MJ 1 000A U . S . A . only
- d river handle 0 7 9 5 3 - MJ 1 0 200
or M 9 3 60 - 2 7 7 - 9 1 7 7 4 U . S . A . only
Ball race remover 07946 - 3 7 1 0 500
Attachment, 5 2 x 55 mm 07746 - 00 1 0400
Steering stem d river 07946 - M BOOOOO
Driver 07 749 - 00 1 0000
1- 1 5
General Information
Description Tool Number Applicability
Rear Wheel/Suspension :
Bearing remover shaft 07746-0050100
Bearing remover head, 20 m m 07746-0050600
Attachment, 42 x 47 m m 07746-0010300
Pilot, 20 m m 07746-0040500
Attachment, 52 x 55 m m 07746-0010400
Attachment, 62 x 68 m m 07746-0010500
Pilot, 25 m m 07746-0040600
Shock absorber compressor 07959-3290001
Driver shaft 07946-MJ00100
or 07949-3710001 U.S.A. only
Attachment, 28 x 30 m m 07946-1870100
Pilot, 22 mm 07746-0041000
Attachment, 32 x 35 m m 07746-0010100
Pilot, 15 m m 07746-0040300
Needle bearing remover attachment 07GMD-KT70200
Bearing remover or M967X-038-XXXXX U.S.A. only
Attachment, 30 m m 07746-0030300 U.S.A. only
Driver 07749-0010000
Brake :
Snap ring pliers 07914-3230001
Charging System/ Alternator:
Flywheel holder 07725-0040000
Rotor puller 07733-0020001
Electric Starter/Starter Clutch :
Gear holder 07724-0010100
Electrical Equipment :
Digital m u ltimeter (KOWAl 07411-0020000 Equivalent commercially
available in U.S.A.
Analog tester 07308-0020001 (SANWAl Not available in U.S.A.
or TH-5H (KOWAl
1- 1 6
General Information
Lubrication & Seal Points

Engine --
--------
Location Material Remarks
Crankcase mating surface Liquid sealant Wipe off the excess sealant
Do not apply the sealant to
near the bearing
L....
- ..J
Right crankcase cover mating surface
20-30 mm
1 (""
(0.8-1.2 i ) ' l
------..
T .)T
Left crankcase cover mating surface
20-30 mm 0
(0.8-1.2 in) 0

,\
--===::w
Cylinder head semi-circular cut-out
Crankshaft main bearing thrust surface Molybdenum disulfide oil
Connecting rod big end bearing (A mixture of 1/2 engine oil
small end and 1/2 molybdenum disulfide
Valve stem (valve guide sliding surface) grease)
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
Honda Bond A
(cover side)
1-17
General I nformation
-
Engme
.
Right crankcase cover rubber plate bolt threads Locking agent -

Clean and apply to the threads
Drive chain guard bolt threads Apply are a : 5.5-7.5 mm
Crankcase sealing bolt threads -
Oil pump d riven sprocket bolt threads -
Cam chain tensioner sli pper bolt threads -
Cam chain slipper bolt threads -
Mainshaft bearing set plate bolt threads -
Shift drum bearing set plate bolt threads -
Shift drum center bolt -
Starter clutch outer cover bolt -
Oil filter stud bolt threads

Cylinder head sealing bolt threads
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 threads and seating surface
Flywheel bolt threads and seating surface
Oil filter threads
Clutch disc lining surface
Clutch center lock nut
Each bearing
Clutch l ifter guide M u lti-purpose g rease
Timing hole cap threads
Each oil seal l i ps
Each 0-ring
1-18

Side stand pivot bolt sliding surface Multi-purpose grease
Rear brake pedal linkage sliding surface
Rear brake pedal pivot surface
Rear brake spindle sliding surface
Right/left footpeg sliding surface
Gearshift pedal pivot surface Apply thin coat of grease
Throttle pipe sliding surface
Clutch lever pivot bolt sliding surface
Steering head bearings '94-'02:
Steering head bearing dust seal lips Multi-purpose grease
After'02:
Urea based multi-purpose
grease for Extreme pressure
(example: EXCELITE EP2
manufactured by KYODO
YUSHI, Japan, 'Shell Stamina
EP2)
Or equivalent
Swingarm pivot nut flange surface Multi-purpose grease
Swingarm bearings
Swingarm dust seal lips
Front wheel dust seal lips
Rear wheel dust seal lips
Rear wheel sliding surface (driven flange)
Rear engine mounting nut threads and seating
surface
Each bearing
Each dust seal lips
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 Honda Hand Grip Cement
(U.S.A. only}
Front brake lever pivot and piston tips Silicone grease
Brake caliper pin bolt sliding surface
Brake caliper bracket pin bolt sliding surface
Brake cam sliding surface
Brake anchor pin sliding surface
Brake caliper pin bolt threads Locking agent Clean and apply to the threads
Brake caliper bracket pin bolt threads
Fork socket bolt threads
Front fork oil seal/dust seal lips Fork fluid
Front fork
Brake master cylinder DOT 4 brake fluid
1- 19
General Information
Cable & Harness Routing

(1) LEFT HANDLEBAR
(8) RIGHT HANDLEBAR SWITCH WIRE HARNESS
SWITCH WIRE HARNESS
(6) COMBINATION METER WIRE HARNESS

(2) CLUTCH CABLE
(5) HIGH BEAM/TURN "SIGNAL/
NEUTRAL INDICATOR WIRE HARNESS
3) SPEEDOMETER
CABLE
(10) 9P-RED CONNECTOR

(TURN SIGNAL SWITCH
HORN SWITCH,
DIMMER SWITCH)
(9) 9P-BLACK ECTOR

(STARTER SWITCH, ENGINE
STOP SWITCH)
1-20
General Information
(5) IGNITION
SWITCH WIRE (2) EVAPORATIVE
HARNESS EMISSION
PURGE
CONTROL
VALVE
(3) CLUTCH CABLE
1-21
General Information
(10) H I G HT BEAM/T U R N S I G NAL/

N E UTRAL I N D I CATO R W I R E
( 5) PULSE SECON DARY AIR I NJECTIO N

( 6 ) STARTER M O T O R CABLE PIPES (CALI F O R N I A TYPE O N LY)
1-22
General Information
(8) FRONT
PULSE SECON DARY
A I R I NJ E CT I O N
CONTROL
VALVE
(CALI F O R N I A
TYPE O N LY)
EVAPO RATIVE E M I S S I O N
CAR B U R ETOR
AIR VENT C O NTRO L VALVE
(CALI F O R N I A TYPE ONL Yl
FUEL TAN K B REATHER

TUBE
(6) EVAPORA VE E M I S S I O N
PURGE CONTROL VALVE
(CALI F O R N I A TYPE O N LYl
( 5) FUEL
(4) REAR P U L S E SECON DARY A I R

I N J ECTIO N C O N T R O L VALVE
(CALI F O R N I A TYPE ONL Yl
1 -23
General Information
( 1 } THERMO SENSOR
WIRE
( 7} ALTERNATOR W I R E
(3) I G N IT I O N PULSE GENERATOR

(6) E N G I N E G R O U N D CABLE
WIRE
(5) N EUTRAL SWITCH W I R E (4) STARTER MOTOR CABLE
1-24
General Information
(1) M A I N W I R E HARN ESS
(8) I G N IT I O N PULSE G E N E RATO R

C O N N ECTOR
(6) S I D E STA N D SWITCH --..\----H--t:;;.>.;:jrF'N 2) N EUTRAL

C O N N ECTOR SWITCH
C O N N ECTOR
(4) STARTER MOTOR

CABLE
1-25
A N D SWITCH
(4) F U E L TAN K BR T H EA TUBE

149 STATES, CANADIAN TYPE)
(7) RIGHT TURN SIGNAL WIRE
( 9 ) TAI L/STOP LIGHT W I R E
1 -26
General Information
Emission Control System

The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify that
their motorcycles comply with applicable exhaust emissions standard during their useful life,when operated and maintained
according to the instructions provided,and that motorcycles built after January 1 , 1 983 comply with applicable noise emis
sion standards for 1 year or 6 , 000 km ( 3. 730 miles) after the time of sale to the ultimate purchaser,when operated and
maintained according to the instructions provided. Compliance with the terms of the Distributor's Warranties for Honda Motor
cycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect.
Source Of Emissions
The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because,
under certain conditions,they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not
react in the same way,but it is toxic.
Honda Motor Co.,ltd. utilizes lean carburetor settings as well as other systems,to reduce carbon monoxide and hydrocarbons.
Crankcase Emission Control System
The crankcase emission control system routes crankcase emissions through the air cleaner and into the combustion chamber.
( 1 ) AIR CLEANER
(2) CARBURETOR
FRESH AIR
<=:>: ( 3 )
.. : (4) BLOW-BY GAS
1-27
General Information
Exhaust Emission Control System (Pulse Secondary Air Injection System)
California type only

The exhaust emission control system consists of a pulse secondary air injection system which introd uces filtered air i nto the
exhaust gases i n the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in
the exhaust system . This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable
amount of hydrocarbons and carbon monoxide i nto relatively harmless carbon dioxide and water vapor.
This model has two pulse secondary air i njection control valves with bu ilt-in check valves . The PAI R check valves prevent
reverse air flow through the syste m . The pulse secondary air injection control valve reacts to high intake manifold vacuum
and will cut off the supply of fresh air d u ring engine deceleration, thereby preventing afterburn in the exhaust syste m .
No adjustments t o t h e secondary air supply system should b e made, although periodic inspection o f t h e components is recom
mended .
(1I FRONT PU LSE SECON DARY A I R I NJECTIO N ( PA I R )

C O N T R O L VALVE
(2) AIR CLEA N E R
(4) EXHAUST PORT
1-28
Evaporative Emission Control System ( California Type Only)
This vehicle compl ies with the Cal ifornia Air Resou rces Board req uirements for control of evaporative em issions .
Fuel vapor from the fuel tank and carburetor is routed into the evaporative emission canister where it is a bsorbed and stored
while the engine is stopped . When the engine is running and the evaporative emission purge control diaphragm valve i s open
fuel vapor in the evaporative emission canister is drawn into the engine through the carburetor. At the same time, the evaporative
emission carburetor air vent control valve is open and air is drawn into the carburetor through the valve .
(1) EVAPO RATIVE E M I S S I O N ( EVAP) PU R G E CONTROL VALVE

(2) F U E L TAN K
(3) EVAPORATIVE
( EVAP)
CAN I STER
(4) FRESH AIR
(6) EVAPORATIVE E M I S S I O N CARBURETOR

' (5) DRAIN
A I R VENT ( EVAP CAV) CONTROL VALVE
c:::> : (7) FRESH A I R
.. : ( 8 ) F U E L VAPOR
Noise Emission Control System
TAM P E R I N G WITH T H E N O I S E CONTROL SYSTEM I S PRO H I BITE D : Federal law prohibits the following acts or the causing
thereof : (1) the removal or rendering inoperative by any person , other than for purposes of maintenance, repa ir or replace
ment, of any device or element of design incorporated into any new vehicle for purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is i n use; or (2) the use of the vehicle after such device or element of design
has been removed or rendered inoperative by any person .
Among those acts presumed to constitute tampering are the acts listed belo w :
1. Removal o f , or puncturing t h e muffler, baffles, header pipes or a n y other component w h i c h conducts exhaust gases .
2 . Removal of, or puncturing of any parts of the intake syste m .
3. lack o f proper maintenance .
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified
by the manufactu rer.
1 - 29
General Information
Emission Control Information labels

(U.S.A. Only)
An Emission I nformation Label is located on t h e frame a s

show n . T h e right s i d e cover must be removed t o v i e w i t .
I t g ives basic tune-up specifications.
( 1 ) E M I SS I O N CONTROL I N FORMATION LAB E L
Vehicle Emission Control Information Update Label
After making a high altitude carburetor adjustment, attach an

update l a b e l on the right d o w n t u b e as shown .
After re-adjusting the carburetor back to standard settings for

low alitude, remove the update label .
( 1 ) U PDATE LABEL
Vacuum Hose Routing Diagram Label

(California Type Only) VAC U U M H O S E R O U T I N G D I A G RAM
ENG I NE FAM I L Y-
The Vacuum Hose Routing Diagram Label is on the rear fender E V A P O R A T I V E F A M I L Y-
as shown. CAL I FORN I A VEH I CLE
The seat must be removed to view it.
Route the vacuum hoses as shown on this label .
( 1 l VAC U U M HOSE ROUTI N G LABEL
1 - 30
2 . Frame/Body Panels/Exhaust System
Service Information 2- 1 Front Side Cover Removal/I nstallation 2- 3
Trou bleshooting 2- 1 Exhaust System Removal/I nstallation 2-4
Seat Removal/Installation 2-2 Rear Fender Removal /Installation 2- 7
Fuel Tank Removal/Installation 2-2 U pper Fairing Removal/Installation

(VF7 50C D ) 2-8
Side Cover Removal/Installation 2-3
Service Information

Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.

Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
Work in a well ventilated area : Smoking or allowing flames or sparks in the working area or where gasol ine is stored can
cause a fire or explosion .
This section covers removal and instal lation of the frame body panels, fuel tank and exhaust system .
Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engi n e .
When insta l l i ng t h e exhaust pipe, install a l l t h e fasteners loosely . Next, tig hten t h e exhaust p i p e joint nuts first, t h e n tight
en th mounting fasteners . If you tighten the mounting fasteners first, the exhaust pipe may not seat properly .
Always inspect the exhaust system for leaks after insta llatio n .
Troubleshooting
Excessive Exhaust Noise
Broken exhaust system
Exhaust gas leak
Poor Performance
Deformed exhaust system
Exhaust gas leak
Clogged m uffler
2- 1
Seat Removal/Installation
Remove t h e seat b y removing t h e th ree mounting bolts .
(2) BOLTS
During seat installation, align the seat hook with the frame
hook and holes of the seat with the bosses on the side covers .
I nsta ll the three mounting bolts .
CAUTION
Be careful not to pinch the wire harness between the
seat and frame.
(5) BOSS
Fuel Tank Removal/Installation

Gasoline is extremely flammable and is explosive under ( 1 ) FUEL TANK
certain conditions .
Remove the seat (a bove ) .
Turn the fuel valve O F F .

D iscon nect t h e fuel tube .
Remove the mounting bolt and collar.
Disconnect the breather tube .
Remove the fuel tan k .
I nstall t h e f u e l t a n k i n t h e reverse order of remova l .

After i nsta llation, turn t h e fuel valve O N a n d check t h e fuel
line for leakage .
I nstall the seat (above ) .
(4) FUEL TUBE

(3) BR EATH ER TUBE
2 -2
Side Cover Removal/Installation

P u l l t h e cover bosses from t h e grom mets .
Slide the cover boss down from the hole in the seat and re
( 1 ) HOLE
move the side cover.
NOTE
I Be careful not to damage the boss .
I nstall the side cover in the reverse order of removal .
14) BOSSES
Front Side Cover Removal/Installation

Remove the front side cover mounting screw . Then remove
the cover by sliding it forward .
I nstal l the front side cover in the reverse order of removal . ( 1 ) FUEL TAN K BRAC K ET
N OTE
At installation, align the tab of the front side cover with
the g roove of fuel tank mount bracket .
2-3
Exhaust System Removal/Installation
( 1 4)
---'-__,-==_...::;"'7""-++-+---
( 5)--
c 2 1 ( 2 . 1 . 1 5) (3)
c 39 ( 3 . 9. 28)
\
c
(2)
44 (4.4, 32)
( 7)
(9)
(8)
c 2 7 ( 2 . 7, 20)
c 21 ( 2 . 1 , 1 5)
2 -4
NOTE
When insta l l i ng the exhaust pipe/muffler, always tig hten the exhaust pipe joint nuts first, then tighten the mounting
fasteners, see next pag e .
Procedure Q'ty Remarks
Removal Order I nstallation is in the reverse order of removal .

(1) Rear exhaust pipe protector 1 I nstal l ation (page 2-61
(2) R e a r cylinder h e a d 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) M uffler 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 gasket 1
( 1 3) Front exhaust pipe joint nut 2
( 1 4) Front exhaust pipe 1
( 1 5) Exhaust pipe gasket 1
2- 5
Rear Exhaust Pipe Protector Installation
I nstal l the rubber cap to the rear exhaust pipe hoo k .

A l i g n t h e h o o k o f t h e rear exhaust pipe with groove o f t h e rear
exhaust pipe protector .
Adjust t h e clearance b y moving the protector .
Standard : 2 -5 m m (0.08 - 0 . 1 9 in)
Tighten the exhaust pipe protector bolt.
Torque : 1 2 Nm ( 1 . 2 kg-m, 9 ft-lbl
Exhaust Pipe/muffler Mounting Fasteners

Tightening
When tighten the exhaust pipe/muffler mounting fasteners,

while push the exhaust pipe to inside .
( 1 ) EXHAUST PI PE
2- 6
Rear Fender Removal/Installation
(1) ( 5)
NOTE
Route the wire harness properly (page 1 -20) .
Requ isite Service
Seat remova l/installation (page 2-2) . Side covers removal/installation (page 2-3)
Procedure O'ty Remarks
Removal Order I nstal lation is in the reverse order of remova l .

(1) Rear turn signal light connector 4 D isconnect the connector.
(2) Brake/tai l l ight 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
Upper Fairing Removal/Installation (VF 7 50CD)
CAUTION
Do not scratch and damage the windscreen .
Removal Order I nstal lation is in the reverse order of remova l .

(1) Upper fairing mounting bolt 3
(2) Upper fairing 1 At i nstallation, align the tab of the upper fairing stay with
the hole of the cable g u i g e .
2-8
Windscreen Replacement
( 1 ) STAYS
Remove the screws, plastic washers and rubber washers .
Remove the wi ndscreen and upper fairing stays .
I nsta llation is in the reverse order of remova l .
(4) SCREW (3) PLASTI C WAS H E R
2-9
MEMO
3 . Maintenance
Service I nformation 3- 1 Valve Clearance 3-5
Service Access G u ide 3-2 Drive Chain 3 -8
Maintenance Schedule 3-4 Headlight Aim 3- 1 0
Air Cleaner 3- 5
Service Information
Refer to Common Service Manual for items not included in this manual .
Refer to Specifications ( Section 1) for mai ntenance data .
3- 1
Maintenance
Service Access Guide
The following shows the locations of the parts that m u st be removed for the m a i ntenance items listed below.
Refer to the Common Service Manual for items not included in this manual .
Refer to section 2 ( F rame/Body Panels/Exhaust System ) . for the parts that m ust be removed for service.
For example: Air Cleaner (Conta mination, clogging, replacement) : Parts

Rear Fairing - The part required to be removed for service .
( 1 ) Throttle Grip (Operation, free play)
( 1 8) Valve Clearance ( I nspection/Adj ustment : page 3-5) (2) Brake Lever (Air in system )
Fuel tank
( 3 ) Ma ster Cylinder
( Level check, fluid replacement)
( 1 7) Spark Plug (Wear, damage, color)
( 1 6) Suspension
(Loose, wear, damage)
(4) Headlight (Ai m : page 3- 1 0)
( 5 ) Wheel
( 1 5) Brake Drum ( Damage, runout,
(Shoe wear) corrosion)
( 1 4) Wheel (6) Tire

( Damage, runout,
(Wear, damage, air pressure)
corrosion)
( 7) Radiator Cap
( 1 3) Tire ( Coolant replacement)
(Wear, damage, air pressure)
( 8 ) Pulse Secondary Air I njection System
( 1 2) Brake Light Switch (Ope ration) (California type only; Air leaks,
d eterioration, damage)
( 1 1 ) Reserve Coolant Tank Cap

(9) Brake Peda l ( Free play, height)
( 1 0) Oil Level Gauge (Oil level check, replacement)
3-2
Maintenance
( 1 3) Air Cleaner ( 1 ) Synchronization Adjusting Screw

( Contamination, clogging, replacement; page 3-5) (Carbu retor synchronizatro n ; page 5- 1 4)
Fuel tank M iddle cover
( 1 2) C l utch lever ( Free play)
(2) Fuel line (Damage, leakage)

( 1 1 ) Steering Head Bearing ( Damage)
( 1 0) Suspension
( loose, wear, damage)
(9) Caliper ( Pad wear)

(3) Drive chain
( Free play, lubrication ,
( 8 ) Brake Hose replacement; page 3-8)
( leakag e , deterioration,
damage)
(4) Side stand (Operation)
(7) Oil Filter ( Replacement)
(6) Carburetor Choke ( Operation) ( 5) Throttle Stop Screw
3-3
Maintenance
Maintenance Schedule
Perform the PRE-R I D E I N SPECT I O N in the Owner's Manual at each sched uled maintena nce period .
1 : I nspect and clean, Adjust, Lubricate, or Replace if necessary .
R: Replace, C: Clea n , L: Lubricate, A: Adjust
The following items require some mechanical knowleg e . Certai n items (particularly those ma rked * and * * ) may req uire more
technical information and tools. Consult their authorized Honda dealer.

Odometer Rading ( N ote 1 )
Note Refer
x 1 , 000 mi 0. 6 4 8 12 16 20 24 To
Page
s x 1 00 km 10 64 128 1 92 256 320 384
* Fuel Line I I I Note 5
* Throttle Operation I I I Note 5
* Carbu retor Choke I I I Note 5
en
* Air Cleaner Note 2 R R 3- 5
Note 5

w Spark Plug I R I R I R
!:::
0
* Valve Clearance I 3- 5
Note 5
w
I- Engine Oil R R R R
<(
Note 5
....I
w Engine Oil Filter R R R R
a:
z
* Carburetor Synchronization I I I 5- 1 4
Q
en
* Carbu retor Idle Speed I I I I I I I Note 5
en
Radiator Coola nt Note 3 I I R Note 5

Note 5
w
* Cooling System I I I
* Secondary Air Supply System N ote 4 I I I Note 5
*
Note 5
Evaporative Emission Control
Note 4 I I
System
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
Note 5
....I
w * Headlight Aim I I I
a:
z Clutch System I I I I I I I Note 5
0
c;; Side Stand I I I Note 5
en

w
* Suspension I I I Note 5
z * N uts, Bolts , Fasteners I I I I 1- 12
0
z ** Wheels/Tires I I I Note 5
** Steering Head Bearings I I I I Note 5
* Should be serviced by an authorized Honda dealer, unless the owner has the proper tools and service data and is mechani
cally qualified .
* * I n the i nterest of safety, we recommended these items be serviced only by an authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency i nterval established here .
2 . Service more frequently when riding in u n usually wet or dusty areas.
3 . Replace every 2 years, or at indicated odometer interval , whichever comes first . Replace requires mechanical ski l l .
4. California type only.
5 . Refer to Common Service M a n u a l .
3-4
Maintenance
Air Cleaner ( 1 l A I R D UCT STO PPER
Remove the fuel tank (page 2-2) .

Remove the front side cover (page 2-3 ) .
Remove the two screws a n d airduct stopper.
Remove the air duct by sliding it backward .
Remove the nine screws and air cleaner housing cover/air

cleaner.
Remove the air cleaner from the air cleaner housing cover.
Discard the a i r cleaner i n accordance with the maintenance

schedule .
Also, replace the element any time it is excessively d i rty or
damaged .
I nstall the removed parts in the reverse order of remova l .
Valve Clearance
Inspection
NOTE

I nspect and adjust the valve clearance while the engine
is cold ( Below 3 5 C/9 5 F) .
Remove the following :

- timing hole cap
- seat (page 2-2)
- fuel tank (page 2-2)
- rear cylinder head cover (page 8- 2)
Remove the lower radiator hose guide.

Remove the lower radiator mounting bolts , loosen the upper
mounting bolt and swing the radiator forward , then secure it
out of the way.
CAUTION

Be careful not to damage the radiator fins.
Remove the front cylinder head cover (page 8-2) .
3- 5
Maintenance
Turn the crankshaft clockwise and align its "T 1 " mark with ( 1 ) I N DEX MARK
the index mark on the right crankcase cover.
Make sure that N o . 1 piston is at TDC (Top Dead Center) on

the compression stroke.
If it is not on the com pression stroke, turn the crankshaft one
full turn (360 ) clockwise .
( 2) "T 1 " MARK
I nsert the feeler gauge between the valve l ifter and the cam
lobe.
Check the valve clearances for the N o . 1 cyl inder i ntake and
exhaust valves using a feeler gauge .
Valve clearance :
IN: 0 . 1 6 0.02 mm (0.006 0 . 0 0 1 in)
EX: 0 . 25 0.02 mm (0.0 1 0 0.001 in)
NOTE

Record the clearance for each valve for reference in shim
selection if adjustment i s required .
Turn the crankshaft clockwise 1 /4-turn ( 90 ) and align its

"T2" mark with the index mark on the right crankcase cover.
( 1 ) The cylinder n u m bering is g iven below :

Check the valve clearances for the N o . 4 cylinder.
( 3 ) LEFT
Turn the crankshaft clockwise 3/4-turn ( 2 7 0 ) and align its
"T 1 " mark with the index mark on the right crankcase cover .
( 2 ) FRONT
C h e c k t h e valve clearances f o r t h e N o . 3 cylinder.
Turn the crankshaft clockwise 1 /4-turn ( 90 ) and align its

"T2" mark with the index mark on the right crankcase cover .
Check t h e valve clearances f o r t h e N o . 2 cylinder.

(4) Firing order
(5) # 1 - 90 - # 4 - 2 7 0 - # 3 - 90 - # 2 - 2 7 0 - # 1
Adjustment
Remove the camshafts (page 8-2 ) .

Remove the valve lifters a n d s h i m s .
( 1 )VALVE LIFTER
NOTE

Shims may stick to the inside of the valve l ifte r .
Do n o t a l l o w t h e shims t o fal l i nto the crankcase .

Mark all lifters and shims to ensure correct reassembly.

The valve lifter can be easily removed with a valve lap
ping tool or magnet .

The shims can be easily removed with tweezers or a
magnet.
3 -6
Maintenance
Clean the valve shim contact area in the valve lifter with com
pressed a i r .
Measure the shim thickness and record i t .

( 1 I SHIM
NOTE

Sixty-five different shim thickness are available : from the
thinnest ( 1 . 200 mml to the thickest ( 2 . 800 mml in in
tervals of 0.025 mm.
Calculate the new shim thickness using the equation below.
A = B - C + D
A: New shim thickness

B: Recorded valve clearance
C: Specified valve clearance
D: Old shim thickness
Example :
Recorded valve clearance : 0 . 1 6 mm

Old shim thickness: 1 . 725 mm
e e e e
Specified valve clearance : 0 . 20 mm
A = 0 . 1 6 - 0 . 20 + 1 . 725
A = 1 .685
NOTE 1 . 80 m m 1 .825 mm 1 . 85 mm 1 .875 mm

Make sure of the correct shim thickness by measuring
the shim with m icrometer.

Replace the valve seat if a carbon deposit results in a
calculated d imension of over 2 . 800 m m .
I nstall t h e newly selected s h i m on t h e valve retainer.

Apply molybdenum d isulfide oil to the valve l ifter.
I nstall the valve l ifter in the valve l ifter holes.
NOTE

I nstall the unchange shims and valve l ifters in their origi
nal locations.
3-7
Maintenance
I nstall the camshaft and camshaft holders (page 8-8) . ( 2 ) GROOVES ( 1 ) COVER GASKET
Rotate the camshafts by rotating the crankshaft clockwise
several times.
Recheck the valve clearance .
Apply Honda Bond A to the cylinder head cover g rooves as

show n .
I nstall t h e cover gasket w i t h t h e " I N " m a r k facing t h e intake
side .
I nstal l the cover bolt washer with the " U P" mark facing u p .
Tighten t h e cover bolts .
Torque: 1 0 Nm ( 1 .0 kg-m, 7 ft-lbl
I nstal l the removed parts in the reverse order of remova l .
( 3 ) CYLI N D E R H EAD COVE R
Drive Chain
Replacement
The MAG NA VF7 50C uses a drive chain with a staked master
link.
Loosen the drive chain.
Assemble the special too l .
I s.TooL I
Drive chain cutter 07HMH - M R 1 0 1 02 or
07HMH - M R 1 0 1 0B
( U . S . A . only)
NOTE
When using the special tool , follow the manufacture's
operating instructions.
(11 1 s . TooL I D R I V E C H A I N CUTTER
3- 8
M aintenance
locate the crim ped pin ends of the master l i n k from the out
side of the chain and remove the l i n k with the d rive chain
cutter .
! s TooL !
Drive chain cutter 07HMH-MR 1 0 1 02 or
07HMH-MR 1 0 1 0B
( U . S.A . only)
NOTE
When using the special tool, follow the manufacture's

operating instructions.
Remove the drive chai n .
Remove the excess drive chain l i n ks from the new drive chain
with the d rive chain cutter . ( 1 ) 1 LI
NOTE
( 21 MASTER LI N K
Include the master l i n k when you count the d rive chain

links.
lT
Standard link: 1 1 8 link
I II LJ I
Replacement chain : RK 50 MFOZ 1
: DID 50 V4
f-o!ICI--- ( 3) 1 1 8 L I N K
I s.TooL I
Drive chain cutter 07HMH-MR 1 0 1 02 or
07HMH-MR 1 0 1 0B
( U . S .A. only)
Link plate holder 07NMH-MW00 1 1 0
or 07PMH-MZ20 1 1 0
CAUTION
Never reuse the old drive chain, master link, master link
lOS:
plate and 0-rings.
I n stall the new d rive chai n . Assemble the new m aster link, 0- 1 .2- 1 .4 mm
rings and plate . I
CAUTION
(41 1 s. TooL I DRIVE C H A I N CUTTER
Insert the master link from the inside of the drive chain
and install the plate with the identification mark facing
the outside.
( 1 ) MASTER L I N K
Assemble and set the drive chain cutter .
Make sure t h a t the master link p i n s are i nstalled properly.

Measuring the master link pin length projected from the plate .
Standard length : 1 .2-1 .4 mm (0.05-0 .06 in)
\
Stake the master link pins.
. ( 21 1 s . Tool I DRIVE C H A I N CUTTER
3-9
Maintenance
Make sure that the pins are staked properly by measuring the ( 1 1 S L I DE CALIPER
diameter of the staked area using a slide calipers .
Diameter of the staked area :

DID: 5 . 50 - 5 .80 mm (0. 2 1 7 - 0 . 228 in)
RK: 5 . 5 5 - 5.85 mm (0 . 2 1 0 - 0 . 230 in)
After staking, check the staked area of the master link for
cracks . In there is any cracking, replace the master link, 0-
rings and plate .
CAUTION

Drive chain with clip-type master link must not be used .
0 X
Headlight Aim

An improperly adjusted headlight may blind oncoming
drivers, or it may fail to light the road for a safe distance.
V F 7 50C D :
Adjust the headlight a i m horizontally and vertically, turning the
adjusting screws as shown .
V F 7 50C :
Refer to section 2 of the common Service Manua l .
( 1 1 A D J U STI N G SCREWS
3- 1 0
4. Lubricatio n System
Service Information 4- 1 Oil Pump Removal/Installation 4-3
Troubleshooting 4- 1 Oil Pump Disassembly I Assembly 4-4
Lubrication System Diagram 4-2
Service Information

If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and
may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your
hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN.
The o i l p u m p can be serviced with the engine i n sta l led i n the frame.
For o i l pressu re check, refer to section 4 of the Common Service M a n u a l ; for the switch l ocation, see page 1 8-2 of this
manual
The service procedu res i n this section must be performed with the engine o i l dra i ned.
When removi ng a nd i n sta l l i ng the o i l pu m p use ca re not to a l l ow dust or d i rt to enter the engi ne.
If a ny portion of the o i l p u m p is worn beyond the specified service l i m its, replace the o i l p u m p as a n assem bly.
After the o i l p u m p has been i n sta l led check that there a re no o i l leaks and that o i l pressu re is correct.
Troubleshooting
Oil Level Low Low Oil Pressure
O i l cons u m ption
Clogged o i l stra i ner screen
External o i l leak
O i l p u m p worn or damaged
Wo rn pisto n ring or i ncorrect piston ring i n sta l lation

I ntern a l oil leak
Worn va lve g u ide or sea l

Pressu re rel i ef va lve stuck open

I ncorrect o i l bei n g used
Low Or No Oil Pressure
Low oil level
Clogged o i l orifice
I nco rrect o i l being used High Oil Pressure

Plugged o i l fi lter, gallery, or metering o rifice
No Oil Pressure
Pressu re rel i ef va lve stuck closed
O i l level too low

I ncorrect o i l being used
O i l p u m p d rive chain or sprocket broken
O i l p u m p damaged ( rotor shaft)
I nternal o i l leaks
4- 1
Lubrication System
Lubrication System Diagra m

AFTE R '94
( 1 ) CAM SHAFT
(9) OIL PRESS U R E

RELIEF VALVE
4-2
Lubrication System
Oil Pump Removal/Installation
)j- ( 10) r:w

_, : 0-ring
c 18 (1.8, 1 3)
N OTE

Use ca re to keep d ust or d i rt out of the engine.

After in sta l l ation, check that there a re no o i l leaks.
Requisite Service
E ngine o i l d ra i n i n g/refi l l ing

Exha u st system remova l/i nsta l lation ( page 2-4)
Cl utch remova l/i nsta l l ation ( page 9-4, 6)

Water p u m p rem ova l/i nsta l latio n ( page 6-7 )

Removal Order I nsta l l ation is in the reverse o rder of remova l.
(1) O i l pa n bolt 12 At insta l lation, tighten the bolts as shown.
(2) O i l pa n 1
(3) Gasket 1
(4) Pressu re rel ief va lve 1
(5) 0-ri n g 1
(6) Oil strainer 1
(7) 0-ri n g 1
(8) O i l pipe 2
(9) 0-ri ng 4
( 1 0) O i l p u m p d riven sprocket bolt 1 Apply a locki ng agent to the th reads.
(1 1 ) O i l p u m p d riven sprocket 1
(12) O i l p u m p m o unting bolt 3
(13) O i l p u m p assem bly 1
(1 4 ) Dowel pin 2
4-3
Lubrication System
Oil Pu mp Disassembly I Assembly

( 1 3) ( 1 2)
(1 1 )
( 1 0)
(1) (2)
Sit .,
NOTE

If any portion of the o i l p u m p is worn beyond the specified service l i m it, replace it as a n assem bly.

Before assem bly them, clean a l l d isassem bled pa rts thoroughly with clean engine o i l .

Refer to section 4 of the Com m o n Service M a n u a l for i nspection i nformation.

Refer to page 1 -6 for specification.
Requisite Service
O i l p u m p remova l/i nsta l lation ( page 4-3)

Disassembly Order Assem bly is i n the reverse order of d isassem bly.
(1 ) Cotter pin 1
(2) 0-ring 1
(3) Oil stra i ner pipe 1
(4) Bolt 3 After i n sta l lation, check that the rotor shaft turns freely.
(5) Pu m p cover 1
(6) Dowel p i n 2
(7) Feed p u m p cover 1
(8) Dowel pin 2
(9) Outer rotor 1 Insta l l with the punch m a rk facing the o i l p u m p body.
( 1 0) Inner rotor 1 Insta l l a l ig n i n g the cut out with the d rive pin.
(1 1 ) Rotor shaft 1
( 1 2) Drive pin 1 I n sta l l i n the rotor shaft hole.
( 1 3) Washer 1
( 1 4) O i l p u m p body 1
4-4
5. Fuel System
Service Information 5-1 Carburetor Synchronization 5- 1 4
Troubleshooting 5-2 Pilot Screw Adjustment 5- 1 6
Air Cleaner Housing Removal/ High Altitude Adjustment
Installation 5-3 (U .S.A. Only) 5- 1 7
Carburetor Removal/Installation 5-4 Evaporative Emission Canister (EVAP
Canister) Removal/Installation
Carburetor Separation 5-6
(California Type Only) 5- 1 8
Carburetor Disassembly I Assembly 5-8
Pulse Secondary Air Injection Control
Carburetor Combination 5- 1 0 Valve (PAIR Control Valve) Removal/
Installation (California Type Only) 5- 1 8
Carburetor Tube Routing
(California Type Only) 5- 1 3
Service Information

Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.

Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind,
resulting in loss of vehicle control.

Work i n a wel l venti l ated a rea. Smoking or a l lowi ng flames or spa rks i n the work a rea or where gaso l i n e is sto red
ca n ca use a fi re or explosion.
CAUTION

To prevent damage, be sure to removed the diaphragms before cleaning air and fuel passages with compressed
air. The diaphragms might be damaged.
Refer to section 2 for fuel tan k rem ova l and i nsta l lation.
When d i sasse m b l i ng fuel system pa rts, note the locations of the 0-rings. Replace them with new ones on reassem
bly.
Before removi ng the carbu retors, place the suitable container under the carbu retor d ra i n tu be, loosen the drain bolts
a n d d ra i n the carbu retors.
After removi ng the carbu retor, wra p the i ntake port of the engine with a shop towel or cover it with pieces of tape to
prevent any foreign m aterial from d ropping i nto the engine.
The vac u u m c h a m ber a n d float c ha m ber can be serviced with the carbu retors assem bled.
Cal ifornia Type On ly:

All hoses used in the evaporative em ission control system a re n u m bered for identification. When connecti ng one of
these hose, com pa re the hose n u m ber with the Vac u u m Hose Routi ng Diagram Label, page 1 -30, and ca rbu reto r
tu bes routi ng, page 5- 1 3.
NOTE

If the veh icle is to be stored for more than one month, d ra i n the float bowls. Fuel left i n the float bowls may ca use
clogged jets res ulting i n h a rd sta rti ng or poor d riveab i l ity.
5- 1
Fuel System
Troubleshooting
Engine Won't Start Afterburn When Engine Braking is Used
Too m uch fuel getting to the engine
Lea n m ixtu re i n slow circuit
- Air cleaner clogged
Ai r cut-off va lve ma lfu nction
- Flooded carbu retor
E m ission control system m a lfu nction (Cal ifornia Type
I ntake a i r leak O n ly) .
Fuel conta m i nated/deteriorated - Pu lse secondary a i r su pply system fa u lty
No fuel to carbu retor - Loose, d isconnected or dete rio rated hoses of the
- Fuel stra i ner clogged em ission contro l system
- Fuel tube clogged
- Fuel va lve stuck Backfiring Or Misfiring During Acceleration
- F loat level m i sadj usted
Ignition system fa u lty
- Fuel ta n k breather tube clogged
Fuel mixtu re too lean
Lean Mixture Poor Performance (Driveability) And Poor Fuel Economy
Fuel jets clogged

Fuel system clogged
Float va lve fa u lty

Ignition ma lfu nction _
Float level too low

E m ission control system ma lfu ncti on (Cal ifornia Type
Fuel l i n e restricted On ly)
Carbu retor a i r vent tube clogged - Loose, d isconnected or deterio rated hoses of the
I nta ke air leak e m ission control t!YStem
Th rottle va lve fa u lty
Vac u u m piston fa u lty
Cal ifornia Type On ly: Evaporative em ission carbu re

tor a i r vent control va lve fa u lty
Rich Mixture
Sta rting en rich ment va lve i n ON position
Float valve fa u lty
F loat level too h i g h
Ai r jets clogged
Air clea ner conta m i n ated
Flooded carbu retor
Engine Stall, Hard To Start, Rough Idling
Fuel l i ne restricted
Ignition ma lfu nction
Fuel m ixtu re too lean/rich
Fuel conta m i n ated/deteriorated
I ntake a i r leak
Idle speed m i sadjusted
Float level m i sadjusted
Fuel tan k breather tube clogged
Pi lot screw m i sadj usted
Slow c i rcuit or sta rting enrichment circuit clogged
E m ission control system m a lfu nction (Cal ifornia Type

On ly)
- Evapo rative e m i ss i o n carbu retor a i r vent control
valve fa u lty
- Evaporative emission p u rge control valve fa u lty
- Loose, d i sconnected or deterio rated hoses of the
em ission control system
5-2
Fuel System
Air Cleaner Housing Removal/Installation
Requisite Service
Fuel ta n k remova l/i nsta l lation (page 2-2) Air cleaner remova l/i nsta l lation ( page 3-5)

Removal Order Insta l l ation is in the reverse order of remova l .
(1) Left m i d d l e cover stay bolt 3
(2) Right m iddle cover stay bolt 1
(3) Front pu lse secondary a i r i njection control 2 Ca l ifornia type only
va lve bolt
(4) Rea r pu lse secondary air i njection control 1 Cal ifornia type only
va lve a i r i nta ke pipe
(5) Air cleaner housing screw 3
(6) Front pu lse secondary air i njection control 1 Ca l ifornia type only
va lve a i r i ntake tu be
(7) Rea r pu lse secondary air i njection contro l 1 Ca l ifornia type only
va lve a i r i nta ke tu be
(8) Cra n kcase breather tu be 1
(9) Air cleaner housing 1 Move the air cleaner housing out of the carbu retor o n
t h e left.
CAUTION
Be careful not to damage the air cleaner housing dur-
ing removal/ installation.
5-3
Fuel System
Carburetor Removal/Installation
5-4
Fuel System

Gasoline is extremely flammable and is explosive under certain conditions.
Work i n wel l venti lated a rea. Smoking or a l l ow flames or spa rks i n the worki ng a rea or where gasol i n e is stored ca n
ca u se a fi re or explostion.
N OTE
I
Route the cables and tu bes properly ( page 1 -20).
Requisite Service
Air cleaner housing remova l/i nsta l lation ( page 5-3)

Carbu retors d ra i n i ng

Removal Order Insta l lation is i n the reverse order of remova l .
(1) Choke cable 1 Remove the choke ca ble from the left m iddle cover stay.
(2) Th rottle stop screw 1 Remove the th rottle stop ca ble from the left m iddle cover
stay.
(3) S u b-ai r cleaner case tu be 1
(4) No. 5 vac u u m tube (from the 3 way joint) 1 Ca l ifornia type only
(5) No. 1 1 vac u u m tu be (from the No. 1 1 Cal ifornia type only
carbu retor)
(6) No. 10 vac u u m tube (from the 3way joint) 1 Ca l ifornia type o n ly
(7) Left middle cover stay assembly 1 Discon nect the i g n ition switch connector.
(8) Fuel tu be 1
(9) No. 6 vacu u m tube (from the AVCV) 1 Ca l ifornia type only
( 1 0) Th rottle ca ble 2
(1 1) Con n ecti ng tu be band screw 4 O n ly loosen.
( 1 2) Carbu retor assembly 1
5-5
Fuel System
Carburetor Separation
(1)
(5) (26)
5-6
Fuel System
Requisite Service
Carbu retor remova l/i nsta l lation ( page 5-4)

Carbu retor synchron ization ( page 5- 1 4)

Separate No. 4 carb. from No. 1 /2/3 carb.
(1) Air cha m ber screw 12
(2) Lock plate 4
(3) Air cham ber/a i r fu n nel 4/4
(4) 0-ri ng 4
(5) Choke ca ble 1
(6) Sta rting enrichment va lve arm screw 4
(7 ) Plastic washer 4
(8) Sta rting enrichment va lve a rm 2
(9) Plastic col l a r 4
( 1 0) Return spring 2
(1 1) Carbu retor connecti ng nut 6 NOTE

Loosen the n uts g ra d u a l ly a nd a lternately.

Do not remove the con necti ng bolts.
( 1 2) No. 4 carburetor 1
( 1 3) No. 5 vacuum tube (from the No. 4 carbu retor) 1 Cal ifornia type only
( 1 4) Th rust spri ng 1
( 1 5) Choke cable holder 1
Separate No. 3 carb. from No. 1 /2 carb.
( 1 6) No. 5 vacuum tube (from the No. 3 carburetor) 1 Cal ifornia type only
( 1 7) No. 3 carb u retor 1
( 1 8) Thrust spring 1
( 1 9) S u b-a i r j o i nt pi pe/tu be/0-ring 2/1/4
(20) No. 6 vacu u m tu be/joint pi pe/0-ring 2/2/4
(2 1 ) No. 5 vac u u m tube (from the No. 1 /2 6/3 Ca l ifornia type only
carbu retor)
(22) F ront col l a red dowel pin 1
(23) Rear col l a red dowel pin 1
(24) Center col l a r 1
(25) Fuel tu be/j oi nt pi pe/o-ri ng 2/3/6
(26) Sta rti ng en richment va lve l i n k asse m bly 1
Separate No. 2 carb. from No. 1 carb.
(27) arbu retor connecting bolt 3
(28) Th rottle l i n k 1
(29) No. 2 carbu retor 1
(30) No. 1 ca rbu retor 1
5-7
Fuel System
Carburetor DisassemblyI Assembly
(23)
( 1 2)
( 1 5)
( 1 4)
: 0-ring, gasket
5-8
Fuel S ystem
NOTE

Vac u u m cham ber, float chamber and jets ca n be serviced with out sepa rati ng the carbu reto rs.

N ote the location of the each ca rburetor parts so they can be back i n thei r origi na l locati o n.
Requisite Service
Carbu retor sepa ration ( page 5-6)

Disassembly Order Assembly is i n the reverse order of d isasse m bly.
Vacuum Chamber Disassembly Order
(1) Vac u u m ch a m ber cover screw 3
(2) Vac u u m cha m ber cover 1
(3) Diaphragm spring 1 NOTE
At i n sta l lation, be ca refu l not to damage the spri n g .
(4) Di ap h ra g m/vacu u m piston 1 NOTE

At insta l lation, a l i g n the tab of the d i a p h ra g m with the
carbu reto r body g roove.
(5) J et need le holder 1 Remova l/i nsta l l ation ( page 5- 1 2 )
(6) J et need le holder spring 1
(7) J et need le/washer 1/1
Float Chamber Disassembly Order
(8) Float chamber cover screw 3
(9) Float chamber 1
( 1 0) 0-ri ng 1
(1 1) Float pin 1
( 1 2) Float 1
( 1 3) Float va lve 1
( 1 4) Main jet 1
( 1 5) Need le jet holder 1
( 1 6) Slow jet 1
( 1 7) Pilot screw 1
( 1 8) Spring 1
( 1 9) Washer 1
(20) 0-ri ng 1
Starting Enrichment Valve Disassembly
Order
(2 1 ) Valve n ut 4
(22) Spring 1
(23) Sta rti ng earchment va lve 1
Air Cut Off Valve Disassembly Order
(24) Ai r cut off va lve cover screw 1 At i nsta l lati o n , be s u re the d i a p h ra g m a n d s p r i n g a re
properly seated, then tight them.
(25) Air cut off valve cover 1 Do not lose the spring when va lve cover rem ova l .
(26) 0-ri ng 3 At i nsta l latio n , i n sta l l the n ew 0-ri n g with its flat side
towa rd the carbu retor body.
(27) Air cut off va lve 1
5-9
Fuel System
Carburetor Combination
(27 )
D
D
No. 1 CAR B U R ETOR
,
(25)
: 0-RING, COTIE R PIN (5)
5- 1 0
Fuel System
NOTE
o
No. 1 carbu retor is the base carbu retor.
o
Before tighte n i ng the carbu retor con necti ng bo lt/n ut, check there is no cleara nce between each of the carbu retor
joi nts.
o
Tig hten the each connecti ng bolts/n uts g rad u a l ly a nd a lternately, be s u re the bolt thread projections a re eq u a l
h i g h . Hold t h e n ut a nd tighten t h e other n ut on other side.
Requisite Service
o
Carbu reto r remova l/i nsta l lation ( page 5-4) o
Carbu retor synchro n ization ( page 5- 1 4)

Assemble No. 2 carb. with No. 1 carb.
(1) Th rottle l i n k 1 Refer to the d rawi ng for the com b i nation of the washer.
(2) No. 2 carbu retor 1
(3) Carbu retor connecti n g bolt 3
Assemble No. 3 carb. with No. 1 /2 carb.
(4) Sta rting e n rich ment va lve link assembly 1
(5) Fuel tu be/j oi nt pi pe/0-ri ng 2/3/6
(6) Center col l a r 1
(7) Rea r col l a red dowel pin 1
(8) F ront co l l a red dowel pin 1
(9) No. 5 vacu um tube (to the No. 1/2 crabu retor) 6/3 Cal ifornia type only
( 1 0) S u b-ai r j oi nt pi pe/tu be/0-ring 2/1 /4
(1 1 ) No. 6 vac u u m tu be/j o i nt pi pe/0-ring 2/2/4
( 1 2) No. 5 vacu u m tube (to the No. 3 carbu retor) 1 Ca l ifornia type o n ly
( 1 3) No. 3 carbu retor 1
( 1 4) Thrust spri ng 1
Assemble No. 4 carb. with No. 1 /2/3 carb.
( 1 5) Choke ca ble holder 1
( 1 6) No. 4 carbu retor 1
(17) Thrust spring 1
( 1 8) No. 5 vacu u m tube (to the No. 4 carbu retor) 1 Ca l ifornia type o n ly
( 1 9) Carbu retor connecti ng n ut 6 CAUTION
o
Tighten each nuts gradually and alternately with the
above procedure. Do not over-tighten the nuts.
(20) Return spring 2
(21 ) Plastic col l a r 4
(22) Sta rting en richment valve a rm 2
(23) Plastic washer 4
(24) Sta rting en rich ment va lve arm screw 4
(25) Choke ca ble 1
(26) 0-ri ng 4
(27) Air cham ber/a i r fu nne l 4/4
(28) Lock plate 4
(29) Air cha m be r screw 12
5- 1 1
Fuel System
Jet Needle Holder Removal/Installation ( 1 ) J ET N E E DLE HOLDER
Removal
Remove the vacu u m piston ( page 5-8) .
Te m p o ra r i l y i n st a l l t he 4 m m s c rew o r e q u i v a l e n t
If
(Exam ple; vacu u m cham ber screw).
Pu l l the screw and remove the jet needle ho lder.
CAUTION

Be careful not to damage the diaphragm.

Do not remove the jet needle holder by pushing the (2) 4 m m SCREW
jet needle. (3) VAC U U M PISTO N
Installation ( 1 ) J ET N E I: DLE HOLDER

I n sta l l the jet need le holder i nto the vacu u m piston u ntil
yo u felt th e cl ick.
I nsta l l the vacu u m piston ( page 5-8) .
(4) J ET N E E DLE
Carburetor Body Cleaning

Clean the fue l stra i ne r i n the float va lve u s i n g the com
pressed a i r from the float va lve seat side.
( 1 ) FLOAT VALVE SEAT
5- 1 2
Fuel System
Carburetor Tube Routing (California Type Only)
(2) F U E L TUBE
(3) TO EVAP CAV CONTROL VALVE
gg===' ( 5) TO EVAP
PURGE
(4) TO
SU B-AI R CLEAN E R
CONTROL
VALVE
5- 1 3
Fuel System
Carburetor Synchronization ( 1 ) VC U U M PLUG
NOTE

Refer to section 2 of the Co m m o n Service M a n u a l
for carbu retor synchron ization proced u re.

Synchron ize the carbu retors with the engine at nor
m a l operati ng tem perature, the tra nsm ission i n neu
tra l and the m oto rcyc l e s u p p o rted sec u re l y o n a
level s u rface.
Remove the left and right middle covers.
Remove the No. 2 cyl i nder i ntake port vac u u m p l u g .
Con n ect t h e vac u u m g a u g e adaptor t o t h e No. 2 cyl inder

i ntake port.
D i sco n n ect t h e N o . 4 cyl i n d e r v a c u u m t u b e fro m t h e

engine i ntake port, a pply vac u u m t o t h e d isco nnected tu be
and pinch the tube with a clip.
C o n n ect the vac u u m g a u g e t u b e to the No. 4 cyl i n d e r

i nta ke p o rt adaptor.
( 1 ) VAC U U M TUBE
49 States type: ( 1 ) VAC U U M TUBE

Remove the No. 1 cyl inder i nta ke port vac u u m p l u g .
Connect t h e vac u u m gauge adaptor t o t h e No. 1 cyl i nder

i ntake port.
California type:
D i sco n n ect t h e N o . 1 cyl i n d e r va c u u m t u b e from t h e
engine i ntake port.
C o n n ect the vac u u m g a u g e t u be to the N o . 1 cyl i n d e r

i ntake p o rt adaptor.
49 States type:
Remove the No. 3 cyl i nder i ntake port vacu u m p l u g .
Connect t h e vac u u m g a u g e adaptor t o t h e No. 3 cyl inder

i nta ke port.
California type:
D i sco n n ect the N o . 3 cyl i n d e r va c u u m t u b e fro m t h e
engine i ntake port.
C o n n ect the vacu u m g a u g e t u b e to the N o . 3 cyl i n d e r

i nta ke port adaptor.
( 1 ) VACU U M TUBE
5- 1 4
Fuel System
Sta rt the engine. ( 1 ) THROTTLE STOP SCREW KNOB

Turn t h e th rott l e sto p sc rew knob and a dj u st t h e i d l e
speed .
Idle speed: 49 states type: 1 ,000 1 00 rpm

California type: 1 , 1 00 1 00 rpm
Canadian type: 1 ,000 1 00 rpm
Check the each carbu reto r i ntake vacu u m pressu re is with

in 20 mm (0.8 i n ) Hg of the base carbu retor.
N OTE
( 1 ) SCREW ( N o . 3 CAR BU RETO R )

The base carbu retor is the No. 1 carbu retor.
Syn c h ro n i z e to s pecificat i o n by t u r n i n g t h e a d j u st i n g
screws.
Recheck the i d l e speed a nd each cyl i nder i ntake vacu u m

pressu re s o i t is with i n 2 0 m m (0.8 i n ) Hg of the base ca r
bu retor read i n g after snapping the.th rottle grip 3 - 4 times.
Remove the vacu u m gauge a nd adaptors.
( 1 ) ... . ..... ,... ...

( N o . 2, 4 CARBU R ETOR )
5- 1 5
Fuel System
Pilot Screw Adjustment

Idle Drop Procedure

If the engine m ust be running to do some work,
make sure the area is well ventilated. Never run the
engine in an enclosed area.

The exhaust contains poisonous carbon monoxide
gas that may cause loss of consciousness and may
lead to death.
NOTE

M a ke s u re the carbu retor synch ro n izati o n is with i n
specification before pilot screw adj u stment ( page 5-
1 4).

The pilot screw is facto ry pre-set a nd no adju stment ( 1 ) I . -;;;OL I PI LOT
is necessary u n less it is replaced. SCREW

The e n g i ne m u st be wa rm fo r accu rate adju stment. WRE N C H
Ten m i n utes of stop-and-go riding is sufficient.

U se a ta c h o m ete r with g ra d u at i o n of 50 r p m o r
s m a l l e r t h a t w i l l a c c u ra t e l y i n d i c a t e a 5 0 r p m
change.
1. Using the special pilot screw wrench, turn each pi lot

screw clockwise u nti l it seats l i g htly. Then back it out
to the specificatio n.
CAUTION
(2) PI LOT SCREW

Damage to the pilot screw seat will occur if the pilot
screw is tightened against the seat.
I s . TOOL I
Pilot screw wrench: Canadian type: 07908 - 4220201
49 states, California type: 07MMA - MV901 0A
Initial Opening: 49 states type: 2-1 /2 turns out
California, Canadian type: 2-3/8 turns out
2. Warm u p the engine to operati ng tem peratu re.
3. Stop the engine and attach the tachometer acco rd i n g
t o t h e man ufactu rer's instruction.
4. Sta rt the e n g i n e and adj u st the idle speed with the
th rottle stop screw knob.
Idle Speed: 49 states type: 1 ,000 1 00 rpm
California, Canadian type: 1 , 1 00 1 00 rpm ( 1 ) THROTTLE STOP SCREW KNOB
5. Tu rn N o . 1 ca rbu retor p i l ot screw in or out slowly to
obta i n the h i ghest engine speed .
6. Perform step 5 fo r a l l the ca rbu retor pilot screws.
7. Lig htly open the th rottle 2 3 ti mes, adj u st the i d l e
-
speed with t h e th rottle stop screw.

8. Turn N o . 1 carbu retor pilot screw in g rad u a l ly u ntil the
engine speed d rops 50 rpm.
9. Tu rn N o . 1 ca rbu retor pilot screw cou nterclockwise to
the fi n a l ope n i n g from the positio n in step 8.
Final Opening: 49 states type: 3/4 turns out from step 8
California, Canadian type: 1 /4 turns out from step 8
1 0. Perform steps 8 a nd 9 fo r the No. 2, 3 a nd 4 carbu retor
pilot screws.
5- 1 6
Revised: July, 1 995, '94 - '95 Magna VF750C/CD
1 995 American Honda Motor Co., Inc. - All Rights Reserved
MSV 69 1 3 fQ04\
Fuel System
High Altitude Adjustment

(U. S. A. Only)
When the ve h icle i s t o be o pe rated conti n u ou sly a bove
2,000 m (6,500 feet), the carbu retors m u st be readj usted as
fo l l ows to i m p rove d rivea b i l ity a n d decrease ex h a u st
em ission.
Wa rm u p the engine to operati ng tem peratu re. Stop and

g o rid i n g for ten m i n utes is sufficient.
Turn each p i l ot screw clockwise 1/2 turn.
High Altitude Adjustment: 1 /2 turn in
i s. TOOL I
Pilot screw wrench 07908 - 4220201
07MMA - MV901 0A
(U .S.A. only)
VEHICLE EMISSION CONTROL INFORMATION UPDATE

Adj ust the idle speed to 1 ,000 1 00 rpm (Cal ifornia: 1 , 1 00 HONDA MOTOR CO., LTD
1 00 rpm) with the th rottle stop screw knob.
THIS VEHICLE HAS BEEN ADJUSTED TO
IMPROVE EMISSIO N . CONTROL PERFORMANCE
WHEN OPERATED AT HIGH ALTITUDE.
.
N OTE
ALTITUDE PERFORMANCE ADJUSTMENT INSTRUCTIONS

T h i s adj u stment m u st be made at h i g h a ltitude to ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER.
ensure proper h i g h a ltitude operati o n .
Attach a Ve h icle E m ission Control I nfo rmation La be l o n

the right down tu b e as shown i n t he label position i l l ustra
tion.
NOTE

Do n ot attach the label to any part that ca n be easily ( 1 ) E M ISSION CONTROL
rem oved from the veh icle. I N FOR MATI O N U P DATE LAB E L

Sustained operation at an altitude lower than 1 ,500
m (5,000 feet) with the carburetor adjusted for high
altitude may cause the engine to idle roughly and
the engine may sta ll i n traffic. If may also cause
engine damage due to overheating.
When the veh icle i s to be ope rated conti n u ously below

1 ,500 m ( 5,000 feet), turn each p i l ot screw cou nterclock
wise 1 /2 turn to its o ri g i n a l position a n d adj u st the i d l e
speed t o 1 ,000 1 00 r p m (Ca l iforn i a : 1 , 1 00 1 00 rpm ).
Be s u re to m a ke these adj ustment a t low a ltitude.
Remove the Veh icle E m i ssion Control U pdate La bel that is

attached to the rig ht down tube afte r adj usti ng for low a lti
tude.
( 1 ) PI LOT SCREW
5- 1 7
Fuel System
Evaporative Emission Can ister

(EVAP Canister)
Removal/Installation
(California Type Only)
Disconnect the No. 4 tube.
Disconnect the No. 1 tube.
Remove the bolts and EVAP ca n i ster.
Insta l lation is i n the reverse order of remova l .
Pulse Secondary Air Injection ( 1 )AIR I N J ECTIO N HOSE
Control Valve (PAIR Control Valve) \

(California Type Only)
CAUTION

To prevent damage to the PAIR control valve, do
not use high air pressure sources. Use a hand oper
ated air pump only.
Front cylinder
Remove the rad iator ( page 6-5) .
Disconnect and remove t ti e fol l owi ng:

- No. 1 0 vac u u m t ube
- a i r i njection h ose (5) PAI R CONTROL VALVE ( 1 ) No. 1 0 TUBE
- PAI R control va lve m o u nting bolt
- a i r i ntake h ose
PAI R control va lve
I nsta l lation is i n the reverse order of remova l .

After insta l l ing, check the tubes for loose con nections and
kinks.
I nsta l l the rad iator ( page 6-5).
Rear cylinder
Remove the seat ( page 2-2) .
Disconnect and remove the fol lowi ng:

- a i r i ntake hose
- air i njection h ose
- PAI R control va lve m o u nting bolt (2) AIR I NTAKE
- No. 10 vac u u m tube HOSE
- PAI R contro l va lve
(4) BOLTS
I nsta l l ation is in the reverse order of remova l . (3) AI R I NJ ECTI O N : HOSES
After i nsta l l i ng, check t h e tu bes for loose connections a n d
kinks.
Insta l l the seat ( page 2-2) .
5- 1 8
6. Coo l i n g System
Service Information 6- 1 Thermostat Removal/Installation 6-4
Troubleshooting 6- 1 Radiator Removal/Installation 6-5
System Flow Pattern 6-2 Radiator Disassembly I Assembly 6-6
Coolant Draining 6-3 Water Pump Removal/Installation 6-7
Service Information

Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot
and the coolant is under pressure may cause serious scalding.

Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes.
- If any coolant gets in your eyes, rinse them with water and consult a doctor immediately.
- If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
- If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.

Add coo lant at the reserve ta nk. Do not remove the radiator cap except to refi l l or d ra i n the system .
All coo l i n g system services can be done with the engine i n the fra me.
Avoid spi l l i ng coolant on pai nted surfaces.
Afte r servici ng the system, check for leaks with a coo ling system tester.
Refer to section 25 of the Common Service M a n u a l for fa n motor switch and thermo sensor i nspectio n.
Troubleshooting
Engine Temperature Too High Engine Temperature Too Low
Fau lty rad iator cap

Fau lty tem pe ratu re gauge or thermo sensor
I n sufficient coolant
Thermostat stuck open
Passages blocked i n radiator, hoses or wate r jacket

Fau lty coo l i n g fa n motor switch
Air i n system
Fau lty water p u m p Coolant Leaks
Thermostat stuck closed

Fau lty water p u m p mecha n ical sea l
Fau lty tem peratu re gauge or thermo sensor

Dete rio rated/fa u lty 0-ri ngs
Fau lty coo l i n g fa n motor

Damaged or deteriorated gasket
Fau lty fa n motor switch

Loose hose connection or cla m p
I ncorrect fa n s h roud insta l lation

Damaged or deteriorated hose

Fau lty rad iator cap
6- 1
Cooling System
System Flow Pattern
( 1 ) SIPHON TU BE
(5) TH E R MOSTAT
(2) RESERVE TAN K
(3) WATE PUMP
6-2
Cooling System
Coolant Draining

Wait until the engine i s cool before servicing the
cooling system . Removing the radiator cap while
the engine is hot and the coolant is under pressure
may cause serious scalding.
N OTE

For coo l a nt replace m e nt, refe r to section 5 of the
Common Service M a n u a l . {2) SEALI N G WASH E R
Remove t h e wate r p u m p d ra i n bolt and sea l i n g washer.
Remove the radiator cap screw and radiator cap and d ra i n

t h e coola nt.
Remove the cylinder d ra i n bolts and sea l i n g washers and ( 1 ) SEALI N G WAS H E R S
d ra i n the coolant.
I nstal l the water p u m p d ra i n bolt with a new sea l i ng wash

e r.
I n sta l l the cyl inder d ra i n bolts with new sea l i ng washers.
Refi l l the coolant to upper leve l .
6-3
Cooling System
Thermostat Removal/Installation
(5) (6)
Requisite Service
Coolant d rain in g ( page 6-3)

Coo l a nt refi l l i n g (Section 5 of the Com m o n Service
Manual)

Removal Order I nsta l lation is in the reverse order of remova l .
(1 ) Right middle cover 1
(2) G round wire connecto r 1
(3) Thermo sensor con n ecto r 1
(4) Radiator u pper hose 1 Loosen t h e c l a m p screw and d isconnect t h e hose.
(5) Thermostat housing cover bolt/term i n a l 3/1
(6) Thermostat housing cover 1
(7) 0-ri ng 1
(8) Thermostat 1 At i nsta l l ation, i n sta l l the therm ostat with its bleed hole
facing right side while a l i g n i ng it with the g rooves i n the
housing.
(9) Thermostat housing bolt 1
( 1 0) Cyl i nder head-to-housing hose 2 Loosen the clamp screws a nd d isconnect the hoses.
(1 1 ) Thermostat housing 1
( 1 2) Thermo sensor 1 At i n sta l lation, apply sea l a nt to the th reads of the sensor.
6-4
Cooling System
Radiator Removal/I nsta l lation
(4)
Requisite Service
Coolant d ra i n i ng ( page 6-3)

Front side cover rem ova l/i nsta l l ation ( page 2-3)
Coolant refil l (Section 5 of the Common Service Manual)

Removal Order Insta l lation is in the reverse order of remova l .
(1) Radiator siphon tube 1
(2) Radiator u pper hose 1 Loosen t h e c l a m p screw a nd d i sco nnect t h e hose.
(J) Radiator lower hose 1 Loosen the c l a m p screw and d isco nnect the hose.
(4) Fan motor switch connector 1
(5) Radiator m o u nting bolt 3
(6) Radiator asse m bly 1 Remove it after releasing the projection o n the right radi-
ator stay.
CAUTION

During removal and installation, be careful not to dam-
age the radiator core.
6-5
Cooling System
Radiator Disassembly I Assembly
(5)
\ (7} (8)
an:n.
-
:.
llliiii'
CAUTION
I o Be careful not to damage the radiator core.
Requisite Service
o Radiator remova l/i nstal l ation ( page 6-5)
Disassembly Order Assem bly is in the reverse order of d i sasse m bly.

(1) Radiator g ri l l 1 R e l ease the two g rooves fro m u nd e r of rad i ator, t h e n
remove t h e radiator g ri l l .
( 2) Fan motor switch connector 1
(3) Coo l i ng fan s h roud bolt 3 At i n sta l lati o n , i n sta l l the g ro u n d eye let j o i nt with the
bolt.
(4)
(7)
Coo l i ng fan n ut 1
(5) Coo l i ng fan 1 At i n sta l lation, a l i g n the coo l i n g fan g roove with the fan
m otor shaft.
(6) Fan m otor m o u nting n ut 3
Fan m otor 1
(8) Fan motor switch 1 At i n stal l ation, apply seal a nt to the switch th reads.
(9) 0-ri ng 1
6-6
Cooling System
Water Pump Removal/Installation

GN
O I L P U M P S HAFT
Requisite Service
Coolant d ra i n i n g ( page 6-3)

Coo l a nt refi l l ( S e ct i o n 5 of t h e C o m m o n S e rv i c e
Drive sprocket cover remova l/i nsta l lation ( page 1 0-2) Manual)

Removal Order I n sta l l ation is i n the reverse order of remova l .
(1) Exhaust p i pe protector 1
(2) Gears h ift l i n k joint bolt/j o i nt 1/1
(3) Radiator l ower hose 1 Loosen t h e clamp screw a nd discon nect t h e hose.
(4) Water pump cover bolt 2
(5) Water pu m p m o u nting bolt 2
(6) Water pump cover 1
(7) 0-ri ng 1
(8) Dowel pin 2
(9) P u m p-to-engine hose 1 Loosen the hose cla m p screw and disconnect it.
( 1 0) Water p u m p body 1 At i n sta l l ation, a l ig n the cut-out of the water p u m p shaft
with the o i l p u m p shaft.
(1 1) 0-ri ng 1 At insta l l ation, apply the engine oil to the new 0-ri ng.
6- 7
MEMO
7 . Engine Removal/Instal lation
Service Information 7- 1 Engine Removal/Installation 7-2
Service Information
During remova l and i n sta l lation, su pport the motorcycle using a safety stand or hoist.
The fol l owing components can be serviced with the engine i nsta l led i n the frame.
- O i l pump (Sectio n 4)
- Carbu retor (Sectio n 5)
- Water p u m p (Section 6)
- Ca mshaft/cylinder head (Section 8)
- Cl utch (Section 9)
- Gears h ift l i n kage (Section 1 0 )
- Alternator (Section 1 5)
- Pu lse generator (Sectio n 1 6)
- Sta rter cl utch (Sectio n 1 7 )
- Sta rte r motor (Sectio n 1 7 )
The fol l owing components req u i re engine rem ova l for service.
- Piston/connecti ng rod/cy li nder (Section 1 1 )
- Cra nkshaft/transmission (Section 1 1 )
- S h ift forks/shift drum (Section 1 1 )
7- 1
Engine Removal/Installation
(7)
c 54 ( 5.4, 39)
c 3 9 (3.9, 28)
(24)
c 9 (0.9, 6.5)
(2 1 )
( 1 9)
0 27 (0.7, 20)
(22)
c 27 (0.7, 20)
( 1 2)
(1 1)
J?)
C s 1 (5. 1 , 37)
., ( 1 3) ( 1 5)
(25)
( 1 0) .,
(9)
(26)
c 44 (4.4, 32)
(28)
(27)
c 39 (3.9, 28) (3) (8)
7-2
CAUTION
I
Do not support the engine using the oil filter.
NOTE

S u pport the m otorcycle using safety sta nd or a hoist.

A floor jack or other adjusta ble su pport is req u i red to support a nd m a neuver the engine. The jack height m u st be
conti n u a l ly adjusted to rel ieve stress for ease of bolt remova l .

Turn the ignition switch OFF a nd disco nnect the battery g ro und (-) term i n a l .

N ote the d i rection of the engine m o u nting bolts.

Route the wi re ha rnesses a nd tu bes properly ( page 1 -20) .
Requisite Service
Fuel tan k rem ova l/i nsta l l ation (page 2-2)

Drive sprocket cover remova l/i nsta l latio n ( page 1 0-2)
Carbu retor remova l/i nsta l latio n ( page 5-4)

Radiator rem ova l/i nsta l latio n ( page 6-5)
Exha u st system remova l/i nsta l latio n ( page 2-4)

Right m i d d l e cover stay remova l/i nsta l l ation

Removal Order I n sta l lation is in the reverse order of rem ova l .
(1) Alternator 3P con n ector 1
(2) I g n ition pu lse generator 3P connector 1
(3) Sta rter m otor cable 1
(4) G ro u n d ca ble eyelet 1
(5) Spark plug cap 4
(6) Auto fuel va lve m o u nting bolt 2
(7) Auto fuel va lve 1
(8) F ro nt air suction pipe joint bolt 4 - Ca l ifornia type on ly.
(9) F ront air suction pipe 2 -
( 1 0) Gasket 2 -
(1 1 ) Rea r a i r suctio n pipe joint bolt 4 -
( 1 2) Rea r a i r suctio n pi pe 2 -
( 1 3) Gasket 2 -
( 1 4) No. 4 vacu u m tube 1 -
( 1 5) Drive sprocket bolt 1
( 1 6) Washer 1
(17) Drive sprocket 1
( 1 8) Brake pedal l i n kage j o i nt pinch bolt/joint 1/1 Align the punch ma rks.
( 19) R i g ht foot peg bracket bolt 2
(20) R ig ht foot peg bracket assem bly 1
(21 ) Gearshift l i n k joint bolt/joint 1/1 Align the punch m a rks.
(22) Left foot peg bracket bolt 2
(23) Left foot peg bracket assembly 1
(24) Front cylinder head mounting bolt/nut/Washer 2/2/2 Tighte ning procedu re ( page 7-4)
(25) Col l a r (f624 x 30 m m ) 2
(26) F ro nt engine m o u nti ng bolt/n ut 2/2 -
(27) F ro nt engine m o u nti ng bracket bolt 4 -
(28) F ront engine m o u nti ng bracket 2
(29) Rea r engine m o u nti ng bolt/nut 1/1 - Apply clean g rease to the n ut threads and flange surface.
(30) Col l a r (f62 1 x 29.8 m m ) 1
(31 ) Rear engine m o u nting bracket bolt/n ut 2/2-
(32) Rea r engine m o u nting bracket 2
(33) E n g i n e assem bly 1 Move the engine assembly out of the fram e to right.
CAUTION

Carefully align mounting points with the jack to pre-
vent damage to mounting bolt threads, wire harnesses
and cable.
7-3
Engine Mounting Bolt lightening Procedure

Loosely i n sta l l a l l engine m o u nting bolts, n uts a nd engine
mounting bracket.
Tig hten the 1 0 mm front cyl i nder head m o u nting bolts CD

and .
Torque: 54 Nm (5.4 kg-m, 39 ft-lb)
Tig hten the 8 mm engine m o u nting bracket bo lts @, @,

@ , @ and .
Tig hten the 1 0 mm engine m o u nting bolts , @, @l and

@.
Torque: 44 Nm (4.4 kg-m, 3 2 ft-lb)
Tig hten the 1 2 mm engine m o u nting n ut @ .
7-4
8. Cyl i nder Head/Va lves
Service Information 8- 1 Cylinder Head Removal/Installation 8-4
Troubleshooting 8- 1 Cylinder Head Disassembly I Assembly 8-6
Camshaft Removal 8-2 Camshaft Installation 8-8
Service Information
Front a n d rea r cyl inder head service ca n be done with the engine i n the fra me.
Camshaft l u b ricati ng o i l is fed through o i l passages i n the cyl i n der head. Clean the o il passages before assem b l i n g
t h e cyl i nder head. F i l l t h e cyl inder h e a d o i l pockets with t h e clean e n g i n e o il o f t h e proper type a n d viscosity.
Clean a l l d i sassem bled pa rts with clean so lvent a n d d ry them by blowi ng them off with co m p ressed a i r befo re
inspection.
When d i sassem bli ng, m a rk a n d store the disassem bled pa rts to ensu re that they a re rei nsta l led i n thei r proper loca
tions.
The cyl i nder n u m beri ng is g iven below:
( 1 ) FRONT
..
Troubleshooting
E n g i n e top-en d problems usua l ly affect engine performa nce. These ca n be diagnosed by a com p ression or leak down
test, or by traci n g noises to the top-en d with a sou n d i n g rod or stethoscope.
If performa nce is poor at low speeds, check for white smoke i n the cra n kcase breather tube. If there i s smoke i n the
tube, check for a seized piston ring.
Compression Too Low, Hard Starting Or Poor Excessive Noise

Performance At Low Speed Cyl inder head
Va lves - I ncorrect va lve adju stment
- I ncorrect va lve adjustment - Sticki n g va lve or broken va lve spri n g
- Bu rned or bent va lves - Da maged or worn ca mshaft
- I ncorrect va lve t i m i n g - Loose or worn ca m cha i n
- Broken va lve spri n g - Worn o r damaged c a m cha i n
- U n even va lve seati ng - Worn or damaged ca m cha i n tensioner
Cyl i n der head - Worn ca m sprocket teeth
- Lea king or damaged head gasket Cyl i nder, piston
- Wa rped or cracked cyl i nder head - Worn cyl i nder and piston
Cyl inder/piston - Wo rn piston pin and piston pin hole
- Worn, stuck or broke n piston ring
- Worn or damage cyli nder a n d piston Rough Idle
Low cyl i n der compression
Compression Too High, Overheating Or Knocking
Excessive carbon b u i ld-up i n cyl i n der head or on top Piston Knocking
of piston Worn cyl i n der, piston or piston ring
Worn piston pin a n d piston p i n hole
Excessive Smoke
Worn connecti n g rod sma l l end
Cyli n der head
- Worn va lve stem or va lve g u i de Excessive Smoke
- Da maged stem sea l Worn, stuck, or broken piston ring
Cyl i n de r, piston
- Worn cyl i n der, pisto n, or piston rings Abnormal Noise
- I m proper i nstal lation of piston ri ngs Worn cyli n der a n d piston
- Scored or scratched piston or cyli nder wall
8- 1
Cylinder Head/Valves
Camshaft Removal
AFTER '95 (Except some '96 early production units)
Revised : July, 1 995, '94 - '95 Magna VF750C/CD

8- 2 1 995 American Honda Motor Co. , Inc. - All Rights Reserved
MSV 691 3 (9504)
N OTE

Service the front cyli nder camshaft using the sa me proced u re as the rea r cyl i nder.

Remove the ca m chain tensioner before removi ng the camshaft.

The "T1 " ti m i n g ma rks on the sta rter cl utch a re for rea r cyl inder head service.

The "T2 " ti m i ng ma rks on the starter cl utch a re for front cyl i nder head service.

Be carefu l n ot to d rop pa rts i nto the e n g i ne ope n i ng .
Requisite Service
Rear cylinder:
Fuel tan k remova l/i nsta l lation ( page 2-2)

M uffler remova l/i nsta l lation ( page 2-4)
Spark p l u g cap remova l/i nsta l latio n
Front cylinder:
Fuel tan k remova l/instal l ation ( page 2-2)

Spark plu g cap remova l/i nstal latio n
Radiator remova l/i nsta l lation ( page 6-5)

F ront PAI R control va lve rem ova l/insta l latio n
(Ca l ifornia type only pa ge 5- 1 8)

Removal Order
(1) Side sta nd switch con nector 1- Rea r cyl inder head o n ly.
(2 ) Auto fuel valve 1-
(3) B reathe r tu be 1-
(4) B reather case bolt 6-
(5) Breathe r case 1-
(6) B reathe r plate 1-
(7) Head cover protector bolt 4
(8) Head cover protector 2
(9) Head cover p rotector rubber 6
( 1 0) Rear cyl i nder head cover bolt 4
(1 1 ) Washer 4
( 1 2) Rear cyl inder head cover 1
( 1 3) Head cover gasket 1
( 1 4) Cam chain tensioner sea l i n g bolt/washer 1/1
( 1 5) Cam c h ai n tensioner m o u nting bolt 2
( 1 6) Cam cha i n tensioner 1
( 1 7) Gasket 1
( 1 8) Camshaft holder bolt 16 NOTE

Before loose n i ng, a l i g n the "T1 " (front cyli nder: "T2 " )
m a rk o n the sta rter cl utch with the i n dex m a rk o n the
right cra n kcase cover, a nd m a ke s u re the No. 1 piston
(front cyl i n der: No. 4 pisto n ) is on com p ression stroke.
If it is not o n the com pression stroke, turn the cra n k-
shaft clockwise 360 a n d a l i g n the m a rks aga i n .

Loosen t h e holder bolts i n a g ra d u a l , crisscross
pattern.
( 1 9) Cam cha i n g u ide 1
(20) Camshaft holder 4
(2 1 ) Camshaft I N/EX 2
(22) Cam chain 1 Dera i l the ca m chain from the sprocket a n d attach a
piece of mechanic's wire to it to prevent it from d ropping
i nto the cra n kcase.
(23) Dowel pin 8
8-3
Cyl inder 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
NOTE

Service the front cyl i nder head using the sa me proced u re as the rea r cyl i nder.

Apply e n g i n e o i l to the seat a n d threads of the cyl i nder head bo lts.

Before removi ng the engine m o unting bolts from the cyl i nder head, support the e n g i n e with a jack or oth er s u p
port to avoid over-loading the other bolts.
Requisite Service
Rear cylinder:
Ca mshaft remova l/i nsta l lation ( page 8-2, 8)

Thermostat remova l/i nsta l lation ( page 6-4)
Carbu retor remova l/i nsta l lation ( page 5-4)

Air suctio n pipe remova l/i nsta l latio n (Ca l ifornia type
on ly)
Front cylinder:
Ca mshaft remova l/i nsta l lation ( page 8-2, 8)

Carbu retor remova l/i nsta l latio n i page 5-4)
M uffler remova l/i nsta l lation (page 2-4)

Thermostat rem ova l/i nsta l lation (page 6-4)
Air suction p i pe remova l/i nsta l lation (Ca l ifornia type

on ly)

Removal Order
(1) Cyl inder head 6 m m bolt
88] Loosen the fasteners in a criss-cross pattern i n 2 or 3

(2) Cyl inder head 9 m m bolt/washer steps.

Refer to page 8- 1 7 for insta l l ation.
(3) Cyl i nder head protector bolt 6
(4) Cyl i nder head protector 2
(5) Cyl i nder head 1 Disasse m bly ( page 8-6)
(6) Cyl i n der head gasket 1 Insta l l with the U P m a rk facing up a n d " I N " m a rk fac-
" "
ing i nta ke side.

(7) Dowel pin 2
8-5
Cylinder Head Disassembly I Assembly
HANDLAPP I N G TOOL
( 2 ) ?1
DOWN
(4)
j s.TooL I ---- . e
( page 1 - 1 5)

() (3)
G ROOVE LUG
e ( 51
(91
( 1 0) ------
(11)
l s.TooL I ( page 1 - 1 5)
8-6
NOTE
Service the front cyl inder head using the sa me proced u re as the rea r cyl i nder head.
M a rk a l l pa rts d u ring d i sassem bly so they can be placed back thei r orig i n a l position.
Remove carbon deposits from the com b ustion cha m ber and clean off the head gasket s u rface, before asse m bly.
- Avoid damaging the gasket s u rface.
- Gaskets wi l l come off easier soaked in solve nt.
Va lve g u ide replacement see Section 9 of the Com mon Service M a n u a l .
Requisite Service
Cyl i n d er head remova l/i nsta l lation (page 8-4)

Disassembly Order Assem bly is in the reverse order of d isassembly
(1) I n s u l ator 2 NOTE
Align the g roove of the insu lator with the l u g of the
cyl inder head.
(2) Va lve l ifter 8 NOTE
Remove using a hand lapping tool . Do not da mage the
cyli nder head-l ifter sliding s u rface.
(3) Valve shi m 8
(4) Va lve spring cotter 16 NOTE
Remova l/I nsta l latio n ( page 8- 1 7 )
To prevent loss of tension, d o not com press the va lve
spri ng m o re than necessa ry.
(5) Valve spring retainer 8
(6) Va lve spring 8 At i n sta l lation, i nsta l l the va lve springs with the tig htly
wou l d coi ls end facing the com bustion cham ber.
(7) I ntake valve NOTE
(8) Exha u st valve :=r Before i n sta l lation, l u b ricate each va lve stem with
molybde n u m disu lfide o i l .
(9) Stem seal 8
( 1 0) Valve spring seat 8
(1 1) Valve g u ide 8 Va lve g u i de projection ( page 1 -7 )
8-7
Camshaft Installation
AFTER '95 ( Except some '96 early production units)
IN
r:
@ ...
EX
@
(2)
(9) c 1 2 ( 1 .2, 9 )
(7)
-
(1)
8-8
Revised : July, 1 995, '94 - '95 Magna VF750C/CD
MSV 691 3 f9504l
Cylinder Head/Va lves
NOTE

Service the front cyl inder camshaft using the same proced u re as the rea r cyl inder.

Each ca mshaft has an identification m a rk. Use these ma rks d u ri n g insta l l ation to ensure that the camshafts a re
properly located.
FRONT I NTAKE: " F R " , " I N " REAR I NTAKE: " R R " , " I N "
FRONT EXHAUST: " F R " , "EX" REAR EXHAUST: "RR", " EX"

Be ca refu l not to d rop a ny pa rts i nto the engine ope ning.
Requisite Service
Rear cylinder:
Fuel tan k remova l/i nsta l lation ( page 2-2)

M uffle r re mova l/i nsta l lation ( page 2-4)
Spark plug cap remova l/i nsta l latio n
Front cylinder:
Fuel ta n k remova l/i nsta l lation ( page 2-2)

Radiator remova l/i nsta l lation ( page 6-4)
Spark p l u g cap remova l/i nsta l l ation

F ront PAI R control valve removal/i nsta l l ation
(Ca l ifornia type only page 5- 1 8)

Installation Order
(1) Dowel p i n 8
(2) Cam chain 1
(3) Ca mshaft I N/EX 2- Refer to page 8- 1 0 for i nsta l l ation
(4) Camshaft holder 4-
(5) Ca m chain g u ide 1-
(6) Camshaft holder bolt 16-
(7) Gasket 1-
(8) Ca m cha i n tensioner 1-
(9) Cam chai n tensioner m o u nting bolt 2
( 1 0) Ca m cha i n tensioner sea l i n g bolt/washer 1/1
(11) Head cover gasket 1 NOTE

Apply Honda Bond A or equ iva lent to the head cover
a nd i n sta l l the gasket with " I N " m a rk facing the i ntake
side.
( 1 2) Rear cyli nder head cover 1
( 1 3) Washer 4 I n sta l l with the " U P" m a rk facing u p.
( 1 4) Rea r cyl i nder head cover bolt 4
Tighten the bolts i n the o rder shown.

Tig hten the G) bolt again after tighte n i n g the othe r
bolts.
( 1 5) Head cover protector rubber 6
( 1 6) Head cover protector 2
( 1 7) Head cover protector bolt 4
( 1 8) B reather plate 1-
I n sta l l with the " U P" m a rk facing u p a n d " I N " m a rk fac-
( 1 9) Breather case 1- ing the i ntake side.
(20) B reather case bolt 6-
Rear cyl inder head o n ly.
(21 ) Breather tube 1-
(22) Si de sta nd switch connector 1-
(23) Auto fuel va lve 1-
8-9
Camshaft Installation
( 1 ) EX or I N MAR K
E a c h ca m s h a ft h a s an i d e ntificat i o n m a rk. I n sta l l t h e
camshafts i n the correct positions, noting t h e identification
m a rks below:
Front Intake: "FR", "IN"

Front Exhaust: "FR", "EX"
Rear Intake: "RR", "IN"
Rear Exhaust: "RR", "EX"
(2) F R or R R MARK
When Both Front And Rear Cylinder Camshaft Were

Removed ( 1 ) I N DEX MARK
Rear cylinder
Align the "T1 " m a rk on the sta rter cl utch with the i n dex
mark on the right c ra n kcase cover.
(3) "T1 " MARK (2) R I G HT CRAN KCASE COVE R
I n sta l l the c a m s h aft h o l d e r dowel p i n s o nto the rea r (2) " R-I N " MARK
cyl i nder head.
Lubricate the camshaft journal su rface of the cyl i nder
head, camshaft holder and ca m lobes with molyden u m
disulfide o i l .
I n sta l l the camshafts o nto the rea r cyl i nder head.

The " R-EX" ti m i ng m a rk on the rea r exha ust ca mshaft
sprocket is level with the cyl i nder head u pper edge as
shown .
Check that the " R-I N " ti m i ng m a rk on the rea r i ntake

(3) REAR CYLI N D E R H EAD
camshaft sprocket is level with the cyl i nder head u pper
U PPER EDGE
edge as shown.
I nsta l l the ca m s h aft h o l ders in the correct positi ons,

checki ng the identification m a rks o n the h o lders and
cyli nder hea d .
In sta l l t h e cam chain g u ide.
8- 1 0
Rear cylinder (cont'dl

Torq u e t h e c a m s h aft h o l d e r bo lts i n the seq u e nce
shown.
Torque: 1 2 Nm ( 1 .2 kg-m, 9 ft-lb)
Turn the ca m chain tensioner shaft fu lly in (clockwise)

secu re it using special tool . ( 1 ) TE N S I O N E R SHAFT
I .TooL I
Tensioner stopper 07NMG - MY901 00
(Not available in U.S.A.)
Cam c h a i n tensioner stopper too l ca n easily be made

from a thi n ( 1 mm th ickness) piece of steel .
15 mm 19 mm
(2) I a .TooL I TE N S I O N E R STOPPER TOO L
15 mm 8.5 m m
( 1 ) CAM CHAI N TE N S I O N E R
4.5 m m
MATE RIAL TH ICKN ESS: 1 .0 m m
Insta l l the new gasket a n d cam c ha i n tensioner to rea r

cyl i nder head.
Torq u e the ca m chain tensioner m o u nting bolts.
Torque: 12 Nm ( 1 .2 kg-m, 9 ft-lbl
Remove the ca m c ha i n tensioner stopper tool .
Insta l l the c a m c h a i n tensioner sea l i ng bolt a n d washer.

(1) TE N S I O N E R O L
Make s u re the ti m i ng m a rks on the ca mshaft sprockets

a re level with the cyl i nder head u pper edge.
8- 1 1
Front cylinder ( 1 ) I N DEX MARK

Rotate the cra n kshaft clockwise 90 to a l i g n the "T2 "
mark with the i n dex m a rk on the right cra n kcase cover.
(3) "T2" MARK (2) R I G HT CRAN KCASE COVER
I n sta l l the camshaft holder dowel p i n s o nto the front ( 1 ) " F-I N " MAR K
cyli nder head.
(2) " F-EX" MARK
Lubricate the camshaft journal surface, camshaft holder
and cam lobes with m o lybdenum d i s u lfide o i l .
Insta l l t h e ca mshafts onto t h e front cyl inder head.

Check that the F EX tim i ng m a rk o n the front exha u st
" - "
camshaft sprocket is level with the cyl i nder head u pper

edge as shown.
Check that the " F-I N " timing m a rk on the front i ntake (3) FRONT CYLI N DER H EAD
camshaft sprocket is level with the cyl i nder head u pper UPPER EDGE
edge as shown.
I n sta l l the ca m s h aft h o l d e rs in the correct posit i o n s,

checki ng the i d e ntification m a rks on the h o l d e rs a n d
cyli nder head.
Instal l the cam chain g u ide.
Torq u e the cam s h aft h o l d e r bo lts in the seq u e nce

shown.
Torque: 1 2 Nm ( 1 .2 kg-m, 9 ft-lbl
8- 1 2
cylinder Head/Valves
Front cylinder (cont'd)

Turn the cam chain tensioner shaft com pletely in (clock ( 1 ) TE N S I ON ER S HAFT
wise) and secu re it using the stopper tool .
Th is tool c a n easily b e made from a thi n ( 1 m m thick
ness) piece of steel.
15 m m 1 3.5 mm
...
- -
J 3 mm
I
' I
15 mm
lr
r- -
I
--
+ 8.5 m m
(2) TE N S ION ER STOPPER TOO L
3.5 m m
MATE R IAL TH ICKNESS: 1 m m
(2) CAM CHAI N
Insta l l a new gasket a n d ca m cha i n tensioner. TE N S I O N E R
Torq ue the cam cha i n tensioner m o unting bolts.
Torque: 12 Nm ( 1 .2 kg-m, 9 ft-lb)
Remove the cam c ha i n tensioner stopper tool .
Insta l l the c a m chain tensioner sea l i ng bolt a n d washer.
M a ke s u re the ti m i n g ma rks on the camshaft sprockets

a re level with the cyl i nder head u pper edge.
When The Rear Cylinder Camshaft Only Was Removed

( 1 ) I N DEX MARK
A l i g n the " T2 " m a rk with the i ndex m a rk on the right
c ra n kcase cover.
Remove the front cyli nder head cover ( page 8-2).
M a ke s u re #2 cyl i nder is TDC on the com p ression stroke.
If it is n ot, t u rn the c ra n ks haft c l oc kwise 360 a n d m a ke

s u re "T2" m a rk a l ig n s with the i ndex mark o n the right
cra n kcase cover.
Rotate the cra n ks haft c lockwise 270 to a l ig n the "T1 " /

(3) "T2 " MARK (2) R I G HT CRANKCASE COVE R
m a rk with the i ndex m a rk on the right cra n kcase cover.
8- 1 3
I nsta l l the ca mshaft holder dowel pins in the rea r cyl i nder
head.
Lubricate the camshaft journal su rfaces, ca mshaft holder

and cam lobes with molybden u m d isu lfide oil.
I
I n sta l l the camshafts onto the rea r cyl i nder head.
Check that the " R-EX" ti m i n g m a rk o n the rea r exh a u st

camshaft sprocket is level with the cyl i n d e r head u pper
edge as shown. (3) REAR cYLI NDER H EAD
C h ec k that the " R- I N " t i m i n g m a rk on the rea r i ntake

U PPER EDGE ('Ali
camshaft sprocket i s level with the cyl i nder head u pper
edge as shown .
I nsta l l the camshaft holders i n the correct positions, check

i n g the identification m a rks on the ho ld e rs a n d cyl i nder
head.
I nsta l l the cam chain g u ide.
Torq ue the cam shaft holder bolts i n the seq uence shown.
Torque: 1 2 Nm ( 1 .2 kg-m, 9 ft-lb)
Turn the cam ch a i n tensioner shaft com pletely in (clock

wise) and secu re it using the special too l .
l a.TooL I
Tensioner stopper 07NMG - MY901 00
Cam cha i n tensioner stopper tool can easily be made from

a th i n (1 mm th ickness) piece of steel .
15 mm 19 mm
15 mm 8.5 m m
4.5 m m
MATE RIAL TH ICKNESS: 1 .0 m m (2) I a. TooL I TE N S I O N E R STOPPE R TOOL
8- 1 4
I n sta l l a new gasket a n d ca m chain tensioner.

( 1 ) CAM CHAI N TE N S I O N E R
Torque the cam chain tensioner mounting bolts.
Remove the cam chain tensioner stopper tool .
I nsta l l the cam chain tensioner sea l i n g bolt a n d washer.

STO
( 1 ) I a.TooL I TE NS l O N E R
M a ke s u re the ti m i n g ma rks on the ca mshaft sprockets a re

level with the cyl i nder head u pper edge.
When The Front Cylinder Camshaft Only Was Removed

( 1 ) I N DEX MARK
A l i g n the " T 1 " m a rk with t h e i n dex m a rk on t h e right
cra n kcase cover.
Remove the rea r cylinder head cover ( page 8-2) .
M a ke s u re #1 cylinder is TDC on the com p ression stroke.
If it is n ot, turn the cra n kshaft c lockwise 360 a n d m a ke

s u re " T 1 " m a rk a l ig n s with the i ndex m a rk on the right
cra n kcase cover.
(3) "T1 " MARK (2) RIGHT CRAN KCASE COVER
Rotate the cra n kshaft clockwise 90 to a l ign the "T2 " m a rk
with the index m a rk on the right cra n kcase cover.
I n sta l l the camshaft holder dowel pins onto the front cylin ( 1 ) " F-I N " MARK
der head.
(2) " F-EX" MARK
L u b ricate the ca m s h aft j o u rn a l su rface, camshaft holder
a n d cam lobes with m olybden u m disu lfide o i l .
I nsta l l t h e csmshafts onto t h e front cyl inder head.

Check that the " F-EX" ti m i n g m a rk o n the front exhaust
ca m s h aft sprocket i s l evel with the cyli nder head u pper
edge as shown.
C h ec k t h at t h e " F- I N " ti m i n g m a rk o n the front i nta ke (3) FRONT CYLINDER H EAD

ca m s h aft s procket is leve l with the cyl i n de r head u pper U PPER EDGE
edge as shown.
8- 1 5
I nsta l l the ca mshaft holders in the correct positio ns, check

i n g the i ndetification m a rks on the holders a n d cyl i nder
head.
I nsta l l the cam cha i n g u ide.
(2) IDE NTIFICATIO N MARKS
To rq u e the cam sh aft h o l d e r bo lts in the seq u e nce as

shown .
Turn the cam c h a i n tensioner shaft co m pletely in (clock

wise) and secu re it using the stopper tool . ( 1 ) TE N S I O N E R SHAFT
This tool c a n easily b e made from a th i n ( 1 m m th ickness)
piece of steel .
1 5 m m 1 3.5 mm
..
- .
J 3 mm
.I
I
1 5 mm
lr
-
I
- ----1
+ 8.5 m m
(2) TE N S I O N E R STOPPER TOOL
3.5 m m
MATE RIAL THICKNESS: 1 m m
I nsta l l a new gasket a n d cam chain tensioner. (2) CAM CHAI N

TE N S I O N E R
Torq ue the cam cha i n tensioner m o u nting bolts.
8- 1 6
Cyl i nder Head/Valves
Remove the cam chain tensioner stopper tool .
I n sta l l the cam chain tensioner sea l i n g bo lt a n d washer.
Make s u re the ti m i n g ma rks on the camshaft sprockets a re

level with the cyl inder head u pper edge.
Valve Cotter Removal/Installation
Remove the va lve l ifte rs and shi ms.
N OTE

M a rk the positions of a l l va lve l ifte rs and s h i m s to
ensure correct reassem bly.

It is easy to remove the va lve lifte r with a va lve lap
ping too l or magnet.

Remove the s h i ms with tweezers or a magnet.
I nsta l l the ta ppet hole protector i nto the va lve l ifter bore.
( 1 ) l s.TooL I TAPPET H O LE PROTECTO R
l s .TooL I
Tappet hole protector 07HMG - MR70002
Not available in U.S.A
I n sta l l the va lve s p r i n g com presso r o nto the va lve a n d

com p ress the va lve spri ng.
CAUTION:

To prevent loss of tension, do not compress the
valve springs more than necessary.
Remove the va lve cotters.
l a.TooL I
Valve spring compressor 07757 - 001 0000
(2) I s .TooL I COMPRESSOR
Valve spring compressor attachment
07959 - KM30101
I nsta l lation i s i n the reverse order of remova l .

6 m m BOLT
Cyl i nder Head Bolt Installation
Apply engine oil to the seating su rface and threads, then

tig hten the cyl i n der head m o u nting bolts g ra d u a l ly in a
crisscross pattern i n the order as shown .
Torque:
6 mm bolt: 1 2 Nm ( 1 .2 kg-m, 9 ftlb)
9 mm bolt: 44 Nm (4.4 kgm, 32 ftlb)
8- 1 7
MEMO
9. Clutch System
Service Information 9- 1 Clutch Removal 9-4
Troubleshooting 9 1 Clutch Installation 9-6
Right Crankcase Cover Removal/

Installation 9-2
Service Information
Cl utch mai ntenance can be done with the engine i n the frame.
Transm ission oil viscosity a n d level have a n effect on cl utch d isengagement. When the c lutch does not d isengage or
th e veh icle creeps with cl utch d isengaged, inspect the transm ission o i l level before servicing the cl utch system .
Troubleshooting
Clutch Slips When Accelerating Motorcycle Creeps With The Engine Idling
I ncorrect cl utch adj ustment I ncorrect cl utch adjustment
Worn cl utch discs Clutch plates wa rped
Wea k cl utch springs Fau lty cl utch l ifter
T ra n s m i s s i o n o i l m i x e d w i t h m o l y b d e n u m o r
I ncorrect engine o i l weight
g ra p h ite additive
9- 1
Clutch System
Right Crankc ase Cover Remov al/Insta llation
(6)
(7)
(1) c 1 2 ( 1 . 2. 9)
c 27 (2.7. 20) (2)
c 27 (2.7. 20)
Jl.ru
20 - 30 m m
==
(0.8 - 1 .2 i n ) =: =---
9 -2
Clutch System
Requisite Service
E n g i ne o i l d ra i n i n g/refi l l i n g

Removal Order Insta l lation is in the reverse o rder of remova l ,
(1) Brake peda l pivot bolt/nut 1/1
(2) R i ght foot peg bracket bolt 2
(3) R i g ht foot peg bracket 2
(4) F ront exha u st p i pe protector bolt 2
(5) F ront exhaust p i pe protector 1
(6) Eva porative em i ssion can i ster p i pe bolt 1 Ca l ifornia type only
(7) R i g ht cra n kcase cover bolt 13 NOTE
I n stal l the cla m ps in the correct positions a n d cla m p the
sta rter m otor cable.
(8) R i g ht cra n kcase cover 1
(9) Gasket 1
( 1 0) Dowel pin 2
9-3
Clutch System
Clutch Removal
( 1 3)
( 1 2)
l a .TooL I ( page 9 -8)
( 1 0)
(9)
(7)
(3)
9-4
Clutch System
NOTE

When rem ovi ng the o i l p u m p d riven sprocket, loosen the sprocket bolt before removi ng the cl utch assem bly. The
bolt is treated with a locki ng agent so be ca refu l not to damage the bolt when loosen ing.
Requisite Service
Right cra n kcase cover rem oval ( page 9-2)

Sta rter cl utch remova l ( page 1 7- 1 0)

Removal Order
(1) Cl utch spring bolt 5
(2) Cl utch spring 5
(3) Cl utch p ressure plate 1
(4) Cl utch press u re plate bearing 1
(5) C l utch l ifter guide 1 Deta c h fro m t h e p r es s u re p l ate b e a r i n g o n l y w h e n
replacing the bea ri ng.
(6) Stopper ring 1
(7) Lifter rod 1
(8) Clutc h disk A/cl utch p late 8/8
(9) Cl utch disk B 1 La rger I . D. tha n cl utch disc A
( 1 0) J udder spring 1
( 1 1 ) Spring seat 1
( 1 2) Cl utch center lock n ut 1
Unstake the lock n ut.

Hold the clutch center with the special tool ( page 9-8).
{ 1 3) Spring washer 1
( 1 4) C lutch center 1
( 1 5) C lutch outer 1
( 1 6) N eedle bearing 1
(17) O i l pu m p d riven sprocket bolt 1
( 1 8) O i l p u m p d riven sprocket 1 -
Remove them as a n assem bly.
( 1 9) Cl utch outer g u ide 1
( 2 0) O i l pu m p d rive chain 1 -
(2 1 ) O i l p u m p d rive sprocket 1 -
(22) Col l a r 1
9-5
Clutch System
Clutch Installation
( 1 0)
9-6
Clutch System
Requisite Service
Sta rter cl utch in sta l lation ( page 1 7- 1 0)

Right crankcase cover i nstallation ( page 9-2)
Installation Order
(1) Col l a r 1
(2) C l utch outer guide 1 NOTE
Lubricate the i n ner and oute r sliding s u rfaces with a
engine oil.
(3) Oil p u m p d rive sprocket Insta l l them as an assembly.
Er
-
(4) Oil pump d rive chain Install the drive sprocket with the boss side facing out.

(5) Oil p u m p d riven sprocket

(6) Oil pu m p d riven sprocket bolt 1 Clean and apply a locking agent to the threads.
(7) Needle bea ring 1
(8) Cl utch outer 1 Instal lation (page 9-8).
(9) Cl utch center 1
( 1 0) Spring washer 1 "OUT SIDE" mark facing cover.
(1 1) Cl utch center lock n ut 1
Hold the clutch center with the special tool ( page 9-8) .
Stake the lock nut with a punch.
( 1 2) Spring seat - I nsta l l the spring seat and judder spring on the clutch
( 1 3) J udder spring =r center as shown.
( 1 4) Cl utch d isc B 1 Larger I. D. than clutch disc A.
( 1 5) Clutch d isc A/cl utch plate 8/8
( 1 6) Lifter rod 1 Instal l the lifter rod as shown.
(17) Stoppen ring 1 I nsta l l securely into the l ifter guide g roove.
( 1 8) Cl utch l ifter g u ide 1 Instal l into the pressure plate bearing.
( 1 9) Pressu re plate bearing 1 Instal l into the pressure plate.
(20) Pressu re plate 1
(2 1 ) C lutch spring 5
(22) Cl utch spring bolt 5 Tighten them in a gradual, crisscross pattern.
9-7
Clutch System
Clutch Center Lock Nut (3) I s.TooL I
G
CLUTCH CE NTER
Removal HOLDER
U nstake the c l utch center lock n ut.
D
N OTE ( 1 ) U N STAKE
Be ca refu l not to d a m age the m a i nshaft threads.
Hold the c l utch cente r with the spec i a l too l a n d loosen the
cl utch center l ock n ut. Rem ove the tools and the lock n ut.
(2) [ s.TooL I
I s. TooL I LOCK N UT
Clutch center holder 07724 - 0050001 WRE N C H ('94 O N LYl
Equivalent commercially
'94 only: available in U.S.A.
Lock nut wrench, 26 x 30 mm 077 1 6 - 0020203
( 1 ) STAKE
*
Installation
H o l d the cl utch center with the cl utch center holder, a n d
tig hten t h e new l ock n ut t o the specified torq u e .
I s.TooL I
Clutch center holder 07724 - 0050001
'94 only: available in U.S.A.
Lock nut wrench, 26 x 30 mm 077 1 6 - 0020203 (3) I s.TooL I
CLUTCH CE NTE R
HOLDER
Stake a new lock n ut with a cente r punch.
N OTE
Be ca reful not to damage the m a i nshaft th reads. ( 1 ) O I L PU M P DR IVE S PROCKET
Clutch Outer Installation

I n sta l l the c l utch outer onto the m a i nshaft.
Turn the oil p u m p d riven sprocket a n d a l i g n the pins on

the oil pump d rive sprocket with the h o les of the c l utch
o uter.
(3) CLUTCH OUTE R (2) P I N S
9 -8
1 0. Gearsh ift Li n kage
Service Information 1 0- 1 Gearshift Linkage Removal/
Installation 1 0-4
Troubleshooting 1 0- 1
Drive Sprocket Cover Removal/

Installation 1 0-2
Service I nformation
The gearsh ift l i nkage m a i ntena nce ca n be done with the e n g i n e i n the fra me.
N eve r a l l ow fo re i g n materials to get i nto the e n g i ne .
Troubleshooting
Hard To Shift Transmission Jumps Out Of Gear
I m proper o i l viscosity

Worn s h ift d r u m stopper a rm
I nco rrect c l utch adjustment

Worn gea r engagement dogs or s lots
Bent shift fo rks

Wea k or broken s h ift arm return spring
Bent shift fo rk shaft

Loose stopper p late bolt
Bent fo rk claw

Damaged or bent shift fo rk
Loose stopper plate bolt
Damaged stopper plate a n d p i n Gearshift Pedal Will Not Return
D a m a g e d gearshift s p i n d l e

Wea k or b roken gearsh ift s p i n d l e retu rn spri n g
Damaged s h ift d r u m g roove

Bent gearshift s p i n d l e
Damaged g u ide p i n
1 0- 1
Gearshift Linkage
Drive Sprocket Cover Removal/Installation
(9) (3) c 1 0 ( 1 .0, 7)
( 1 2)
( 1 3)
( 1 4) ____.ii!111
c
....::;:
....,:;: :,__
_ __
1 2 ( 1 .2, 9)
1 0- 2
Gearshift Linkage

Removal Order I nsta l lation is in the reve rse order of rem ova l .
(1) Cl utch ca b l e h o l d e r bolt 1
(2) C l utch cable/h o l der 1
(3) D rive sprocket cover bolt 3
(4) Drive sprocket cove r 1
(5) G asket 1
( 6) Dowel p i n 2
Disassembly Order Assem bly is in the reverse order of d i sasse m bly.
(7) C l utch l ifter piece 1 Rem ove the piece by t u r n i n g the l ifter a rm clockwise.
(8) C l utch l ifter arm 1
(9) Return spring 1
( 1 0) Washer 1
(1 1 ) Dust sea l 1
( 1 2) D rive c h a i n g u a rd bolt 2
( 1 3) D rive c h a i n g u a rd 1
( 1 4) D rive sprocket cover rubber bo lt/Washer 212
( 1 5) D rive s procket cover r u b be r 1
1 0-3
Gearshift Linkage
Gearshift Linkage Removal/Installation

(8) S H I FTE R PLATE ASSEM BLY
(1)
1 0 -4
Gearshift Linkage
N OTE

G e a rs h ift l i n kage service can be perfo rmed with the e n g i n e in the fra me.

When rem ovi ng the wate r pu m p, it is not necessa ry to d iscon nect the water h oses.

Afte r i n sta l l ation, check the gears h ift l i n kage fo r proper operatio n .
Requisite Service
D rive sprocket cove r re m ova l/i nsta l lation ( page 1 0-2)

Water p u m p re m ova l/i nsta l lation ( page 6-7 )

Removal Order I nsta l lation is i n the reve rse order of remova l .
(1) G e a rsh ift l i n kage cove r bolt/washer 5/2
(2) G e a rshift l i n kage cover 1 NOTE
When rem ovi n g a n d i n sta l l i ng , turn the l i n kage cove r
s l i g htly c lockwise.
(3) Gasket/dowe l p i n 1 /2
(4) Gear s h ift s p i n d l e a sse m bly 1 I n sta l l t h e s h ifte r co l l a r i nto t h e s p i n d l e h o l e , and the
retu rn spring onto the return spri n g p i n .
( 5) Washer 1
(6) S h ifter col l a r 1
(7) S h ifter plate attach i n g bolt 2
(8) S h ifter plate asse m b ly 1 L u b ri cate e a c h pa rt w i t h e n g i n e o i l , a n d assem b l y a s
i l l ustrated. I nsta l l o n the sh ift d r u m ce nte r with the d r u m
center positioned a t any gea r stop except neutra l .
(9) S h ift drum cente r bolt 1 Apply a locki n g agent t o the t h reads.
( 1 0) S h ift d r u m cente r 1 I n sta l l by a l i g n i n g the cut out with the d owe l p i n as
shown .
(11) Dowel p i n 1
( 1 2) Washer 1
( 1 3) Sto pper a rm spri n g 1
( 1 4) Stopper a rm asse m b ly 1 I n sta l l t h e s n a p r i n g w i t h t h e c h a m fe red s i d e fac i n g
i nside, a n d seat fu l l y i n the flange col l a r g roove.
( 1 5) Co l l a r 1
( 1 6) Dowel p i n 2
(17) S h ift d r u m bea ri n g stopper p late 1
1 0-5
MEMO
1 1 . Cra n kshaft/ Piston /Tra nsmissio n
Service Information 1 1 -1 Countershaft DisassemblyIAssembly 1 1-12
Troubleshooting 1 1 -1 Crankcase Combination 1 1-14

Crankcase Separation 1 1 -2 Crankshaft Bearing Replacement 1 1-16
Crankshaft/Connecting Rod Removal/ Connecting Rod Selection 1 1 -18

Installation 1 1 -4
Liquid Sealant Application 1 1-18
Piston DisassemblyI Assembly 1 1 -6
Crankcase Bolt Location 1 1-18
Transmission Removal/Installation 1 1 -8
Mainshaft DisassemblyI Assembly 1 1-10
Th is section cove rs cra n kcase sepa ratio n for service of the cra n kshaft, cyl i n d e r sl eeve, piston a n d transm issio n .
The fol l owing pa rts m u st be removed before servici ng.
Service Item Removed Components

Con necting rod Cyl i nder head ( page 8-2) Cra n kcase sepa ration ( page 1 1 -2)
Piston ( page 1 1 -6)
Cra n ks haft

Sta rter cl utch ( page 1 7- 1 0)
Cra n kcase separation ( page 1 h2)

F lywheel (page 1 5- 1 0)
Connecti n g rod bea ring ca p (page 1 1 -4) Dl
Tra n s m ission Gea rshaft l i n kage ( page 1 0-4) Cra n kcase sepa ratio n ( page 1 1 -2)
M a rk a n d store the bea ring i nse rts fo r reasse mbly. If the i nserts re i m properly i n sta l led they wi l l block the o i l h oles,
ca using insufficient l u brication and eventua l engine se izu re .
Prior to asse m b l i n g the cra n kcase ha lves a pply a sea lant to the i r mati ng s u rface. Wi pe off excess sea l a nt thoro u g h ly.
M a rk a n d store the d i sasse m bled pa rts to ensure that they a re re insta l led i n their o r i g i n a l l ocati ons.
Remove the piston, cyl i nder s leeve a n d connecting rod as an asse m b ly.
Be ca refu l not to damage the cra n kshaft m a i n journal bea ring wh i l e rem ovi ng or i n sta l l i n g the cra n kshaft.
A l l bea ring i nserts a re select fitted and a re identified by co lor code. Select replacem e nt bea rings fro m the selection
table (page 1 1 - 1 6) .
After i n sta l l i ng new bea rings, recheck them with plastigauge to verify cleara nce.
Apply m o lybde n u m disu lfide o i l to the m a i n j o u rnals a n d cra n kpins d u ri n g asse m b ly.
Troubleshooting
Cylinder Compression Is Too Low, Or Engine Is Hard To Engine Vibration
Start Excessive cra n kshaft ru n o ut
Wo rn, stuck or broken piston ring
Hard To Shift
Worn or da maged cyl inder or piston
I m p roper cl utch operation
Cylinder Compression Is Too High, Or Engine Overheats I ncorrect transm issi o n o i l wei g ht
Or Knocks I ncorrect c l utch adjustment
Carbon deposits on the cyl i n der head a n d/or piston Bent s h ift fork
Bent fo rk shaft
Piston Sounds Bend fork claw
Worn cyl i n d e r, piston and/or piston ring Da maged s h ift d ru m ca m g rooves

Worn piston p i n hole a n d piston p i n Bent s h ift spi n d l e
W o r n co n n ecti ng rod s m a l l end
Transmission Jumps Out Of Gear
Excessive Smoke
Worn gear dogs or slots
Worn, stuck or broken piston ring
Bent fork shaft
Weak va lve ste m sea l
B ro ken s h ift d r u m stopper
Excessive Noise Worn or bent s h ift forks
Worn connecti ng rod big-end bea ring

B roken s h ift l i nkage return spri ng
Bent connecti ng rod Worn gear s h ift fork claw
Worn cra n kshaft m a i n bearing

Worn transm ission bea ring
1 1 -1
Crankshaft/Piston/Transmission
Crankcase Separation
(6)
(5)
1 1 -2
N OTE

Before rem ovi ng the parts, m a ke a note of their locati on fo r correct i n sta l l at i on .
Requisite Service
E n g i n e remova l ( page7-2)
C l utch rem ova l ( page 9-4)

Alte rnator cove r re m ova l (page 1 5- 1 0)
O i l p u m p re mova l ( page 4-3)

Separation Order
(1)(2) Upper Crankcase Side

M a i nshaft bea r i n g sto pper p l ate bolt 3
(3)
M a i nshaft bea r i n g sto pper p l ate
U pper cra n kcase bolt, 6 m m/washer 71, ]
1
Loosen g ra d u a l ly.
(4)
(5)
Ca b l e g u i d e
U pper cra n kcase bo lt, 10 m m/washer 2/2
Lower Crankcase Side
(7)
(6)
(8)
Lowe r cra n kcase bo lt, 6 mm
Lowe r cra n kcase bo lt, a m m
Lowe r cra n kcase bo lt, 9 mm
8
1
8
Loosen in a g ra d u a l , crisscross patter n .
Loosen i n a g ra d u a l , crisscros patter n .

(9) Lowe r cra n kcase 1
(11)
( 1 0)
(12)
Dowe l p i n
O i l orifice
0-ri n g
3
1
1
1 1 -3
Crankshaft/Con necting Rod Removal/Installation

AFTE R '94
(1 1 ) naa
c 1 2 ( 1 .2, 9)
0 1 2 ( 1 .2. 9 )
(11) cw --:7J
0g
,
(9)
(1)
c 1 2 ( 1 .2, 9)
c 33 (3.3, 24)
(4)
--- ( ) cw
c 1 2 ( 1 .2, 9 )
ROTATI N G
D I R ECTIO N
1 1 -4
N OTE

M a rk a l l pa rts d u ri n g d i sassembly so they can be re placed i n the i r ori g i n a l locations.

A l l bea ring inserts a re se l ect fitted a n d a re identified by co lor code. Select repl acement bea ri ngs from the code
ta ble ( page 1 1 - 1 6) . After i nsta l l i n g new bea rings, recheck them with plastigauge to verify the clea rance.

Apply m o lybde n u m disu lfide o i l to the con necting rod/m a i n j o u rn a l bea rin gs, m a i n j o u rn a l a n d cra n kpi n .
Requisite Service
Refer to Service I nformation ( page 1 1 - 1 )

Removal Order I nsta l lation is in the reverse order of remova l .
(1) Connecti ng rod bea ri ng cap n ut 8
(2) Con necting rod bea ring ca p 4 N OTE

Note the d i rectio n of the bea ring ca p.
(3) Connecti n g rod/piston assem bly 4 CAUTION

Do not try to remove the connecting rod/piston as-
sembly from the bottom of the cylinder. The oil ring
will become wedged in the gap between the cylinder
liner and the upper crankcase.
(4) Connecti ng rod bea ring 8 Wi pe a l l o i l fro m bea ring seating a reas.
(5) Cra n kshaft 1
(6) Cra n kshaft main j o u rn a l bea ring 8 Wi pe a l l o i l from bea ring seating a reas.
(7) Front ca m c h a i n tensioner s l i pper bolt 1
(8) F ront ca m chain tensioner s l i pper 1
(9) Rea r ca m chain tensioner s l i pper bolt 1
( 1 0) Rea r cam c h a i n tensioner s l i pper 1
(1 1) F ro nt/rear cam c h a i n s l i pper bolt 2
(12) F ront/rea r cam ch a i n s l i pper 1
Installation Order
( 1 2) Fro nt/rear cam cha i n s l i pper 1
(1 1 ) F ro nt/rear cam chain s l i pper bolt 2 Clean a n d apply a l ocki ng agent to the th reads.
( 1 0) Rea r ca m c h a i n tensioner s l i pper 1
(9) Rea r cam cha i n tensioner s l i pper bolt 1 Clea n a n d apply a l ocking agent to the threads.
(8) Front ca m cha i n tensioner s l i pper 1
(7) F ront ca m chain tensioner s l i pper bolt 1 Clean a nd apply a l ocking agent to the th reads.
(6) Cra n kshaft main journal bea ring 8 NOTE

At insta l l ation, a l i g n the oi l h o l es between the cra n k-
c a s e a n d bea r i n g , a n d t h e b e a r i n g ta b s w i t h t h e
g roove i n the cra n kcase.
(5) Cra n kshaft 1
(4) Con necting rod bea ring 8 NOTE
At i n sta l l ation, a l i g n the o i l h o les betwee n the con-
necting rod and bea ring, a n d the bea ri n g tabs with the
g roove i n the con n ecti ng rod and beari n g ca p.
(3) Con nect i n g rod/piston assembly 4 N OTE

Each connecti ng rod has an identification m a rk; " M L7-
F " (Front), " M L7-R" ( Rear).
At i n sta l l a t i o n , i n sta l l the c o n n e c t i n g r o d/ p i st o n
asse m bly with the o i l h o l e on the connect i n g rod fac-

ing opposite the rotati ng d i rection of the cra n kshaft.
(2 ) Connecti ng rod bea ring cap 4
(1) Con necting rod bea ring cap n ut 8 N OTE

At i n sta l l ati o n , a p p l y e n g i n e o i l to the th rea d s a n d
seati ng su rface of the n ut.

Tig hten the n uts g ra d u a l ly and a lternate ly.
1 1 -5
Piston Disassembly I Assembly
(1) .,
" I N " MARK
, (2)
(4)
I DE NTIFICATI O N
( 1 0) ,
.---t-20 m m (0.8 i n ) OR M OR E
1 1 -6
N OTE
I Apply m o lybden u m d isu lfide o i l to the connecti ng rod sma l l end and piston p i n .
Requisite Service
Pisto n rem ova l ( page 1 1 -4)

Disassembly Order Assem bly is in the reve rse order of d i sasse m bly.
(1) Pisto n p i n c l i p 8 CAUTION
Do not reuse the piston pin clips.
(2) Piston p i n 4 N OTE

Apply mo lybde n u m disu lfi de o i l to the piston p i n a n d
connecti ng rod sma l l e n d .
(3) F ront piston asse m b l y 2 N OTE
Identify the fro nt con nect i ng rod by the m a rk i ng " M L7-
F " . I nsta l l the piston on the front con n ecti ng rod so that
the " I W m a rk on the pisto n head faces the o i l hole side
of the con necti ng rod .
It is n ot necessa ry t o rem ove the p i ston ri n g s u n less
they need replacing.

(4) F ront con n ecti ng rod 2
(5) Rea r piston asse m b l y 2 N OTE
Identify the rea r con n ecti ng rod by the m a rk i n g " M L7-
R " . I nsta l l the piston on the rea r con nect i n g rod so that
the " I N " m a rk o n the piston head faces the side oppo-
site the con necti n g rod oil h o l e .

It i s n ot n ecessa ry t o rem ove the p i ston ri n g s u n l ess
they need replaci n g .
(6) Rea r con n ecti n g rod 2
(7 ) Top ri ng At i n sta l lati o n , i n sta l l the piston r i n g s with t h e i r m a rks
(8) Secon d ring : J faci n g u p .
(9) Side ra i l 8
( 1 0) S pacer 4
1 1 -7
Transmission Removal/Installation
, (1)
1 1 -8
N OTE

Turn the m a i nshaft a n d cou ntershaft to ensure that the gears turn smoothly after reassem bly.

After i nsta l lati o n , l u b ricate gears with clean reco m m ended e ngi ne o i l .
Requisite Service
Refer to service I nformation ( page 1 1 - 1 )

Removal Order
(1) M a i nshaft/co u ntershaft asse m b ly 1
Remove the m a i nshaft a n d cou ntershaft as a n assem -
bly.

Disassembly ( page 1 1 - 1 0, 1 2 )
(2) Cou ntershaft bea r i n g set plate 1
(3) Dowe l pin 1
(4) S h ift fo rk s h a ft 1
(5) S h ift fo rk 3
(6) S h ift d r u m 1
Installation Order
(6) S h ift d r u m 1
(5) S h ift fo rk 3 I n sta l l t h e m w i t h t h e i d e n t i f i c at i o n m a r k ( R : R i g ht ,
C: Center, L: Left) side fac i n g t h e rig ht s i d e as s h own .
( 4) S h ift fo rk shaft 1
(3) Dowe l pin 1
(2) Cou ntershaft bea ri n g set plate 1 Fit i n the u pper cra n kcase secu rely.
(1) M a i nshaft/co u ntershaft asse m b ly 1
I nsta l l the m a i nshaft a n d cou ntershaft as a n asse m bly.
F i t t h e c o u nte rs h aft bea r i n g set pin a n d p l ate in the
u pper cran kcase g roove, a n d the dowel p i n i n the hole
i n the need le bea r i n g case.
1 1 -9
Mainshaft Disassembly I Assembly
( 1 4) ( 1 3) ( 1 2) ( 1 0)
(11) (9)
( 5)
(7) '94 - '95 (and some '96 early (3) (1)

production units)
( 1 2) (8) (5) (4)
'94 95
- '
(and some '96 early

production units)
AFTER '95
(Except some '96 early (1)
production units)
==--- t-L-==
( 1 3) ( 1 0) (9) (8) (7) (6) (3)
---:71) : S H I FTE R GEAR ---:71) : GEAR S L I D I N G

m G ROOVE m S U RFACE
1 1 -1 0
MSV 691 3 19504)
N OTE

Apply mo lybden u m o i l sol ution to the sh ifter gear g rooves. Apply o i l to a l l s l i d i n g su rfaces of the m a i nshaft, c o u n
tershaft a n d bush i n gs.

I n sta l l the thrust washers a n d snap ri ngs with the cha mfe red edge faci n g the th rust load side.

Refe r to section 1 3 of the C o m m o n Service M a n u a l fo r inspection i nformatio n .
Requisite Service
Tra n s m ission rem ova l/i nsta l l ation ( page 1 1 -81

Disassembly Order Asse m bly is in the reve rse o rder of d i sasse m bly.
(1) N eedle bea ri ng case 1
(2) N eed le bea ring 1
(3) Thrust washer 1
(4) M 2 gear ( 1 7TI 1
(51 Co l l a r 1 '94 - '95 (and some '96 early production units)
(6) S p l i n e washer 1
(7) S n a p ring 1
(8) M3/M 4 gea r (20/22TI 1
(9) S n a p ri n g 1
( 1 0) S p l i n e washer 1
(11) M 5 bush i n g 1
( 1 2) M5 gear (28TI 1
( 1 3) Washer 1
( 1 4) M a i nshaft/M 1 gea r ( 1 3TI 1

1 995 American Honda Motor Co. , Inc. - All Rights Reserved
MSV 691 3 f9504l
1 1 -1 1
Countershaft Disassembly I Assembly
ALI G N O I L HOLES
( 1 4) ( 1 5) (22) (23)
( 1 0) ( 1 5) ( 1 8)
(3) (6) (8) (9) ( 1 2) ( 1 3) ( 1 6) ( 1 7) ( 1 9) (20)

--:7D : S H I FTE R G EAR
. I G R OOVE
-:7ll : G EAR S LI D I N G
. I S U R FACE
1 1 -1 2
N OTE

Apply mo lybde n u m o i l so l ution to the sh ifte r gear g rooves. Apply o i l to a l l s l i d i n g su rfaces of the m a i n shaft, c o u n
tershaft a n d bush i n gs .

I nsta l l the th rust washers a n d snap rings with the cha mfe red edge faci n g to the th rust load side.

Refe r to secti on 1 3 of the co m m o n Service M a n u a l fo r i nspection i nfo rmati o n .
Requisite Service
Transm ission remova l/i nsta l lation ( page 1 1 -8)

Disassembly Order Assem bly is in the reve rse order of d i sasse m bly.
(1) N eed l e bea ri ng case 1
(2) N eedle bea ring 1
(3) Thrust washer 1
(4) C 1 gea r (37T) 1
(6) Thrust washer 1
(7) C5 gea r ( 29T) 1
(8) Snap ri ng 1
(9) S p l i ne washer 1
( 1 0) C4 gea r ( 27T) 1
(1 1 ) C4 spl i ne bush i n g 1 A l i g n the o i l h oles of the b u s h i n g a n d cou nte rshaft.
(12) Ta nged washer 1 At asse m b ly, fit the ta ngs i nto the lock wash e r c ut-outs.
( 1 3) Lock washer 1
( 1 4) C3 s p l i n e b u s h i n g 1
( 1 5) C3 gear ( 29T) 1
( 1 6) S p l i n e washer 1
(17) S n a p ri n g 1
( 1 8) S h ifter gea r 1
( 1 9) S n a p ri n g 1
(20) Spline washer 1
(2 1 ) C2 gea r (32T) 1
(22) C2 bush i n g 1
(23) Cou ntershaft 1
1 1 -1 3
Crankcase Combination
-,0 3 1 (3. 1 , 2 2 1
c 1 2 ( 1 . 2, 91
(7) ALI G N
(51
c 23 (2.3, 1 71
(6)
(9)
<1
c
(81
1 2 ( 1 .2, 91
c 39 (3.9, 28)
1 1 -14
CAUTION

Install the oil orifice with the larger inner diameter side facing the lower crankcase.

If the lower crankcase installation is difficult, make sure the transmission assembly is installed correctly.
N OTE

Refe r to page 1 1 - 1 8 fo r cra n kcase sea l a nt a rea and deta i l of the bolt l ocati ons.
Requisite Service
O i l pu m p i nsta l lation ( page 4-3)

Gearshift i i n kage i n sta l lati o n ( page 1 0-4)
Sta rter m otor i n sta l lati on ( page 1 7-7 )

Cyl i nder head/ca mshaft i n sta l l atio n ( page 8-2 )
Alte rnator i n sta l l ation ( page 1 5- 1 0)

E n g i n e i n sta l latio n ( page 7-2)
C l utch i n sta l latio n ( page 9-6)

Combination Order
(1) U pper cra n kcase 1 CAUTION

Do not apply sealant around the oil passage area and
main journal bearing area.
Refe r to page 1 1 - 1 8 fo r deta i l fo r the a p p l icatio n a rea.
(2) O i l orifice/0-ring 1/1 I nsta l l it as i l l ustrate d.
(3) Dowe l p i n 3
( 4) Lower cra n kcase 1 A t i n sta l lati on, m ake s u re the shift fo rks engage properly
with the correspo n d i n g gea rs.
Lowe r cra n kcase bo lt, 9 mm f.-Tig hte n i n g o rder ( page 1 1 - 1 8)
!I
(5)
(6) Lower cra n kcase bolt, 8 mm
(7) Lowe r cra n kcase bo lt, 6 m m/washer
(8) U pper cra n kcase bo lt, 10 m m/washer
2 2 Tig hten i n g order ( page 1 1 - 1 9 )
(9)
( 1 0)
Ca b l e g u ide
U pper cra n kcase bo lt, 6 m m/washer 7/1 J
(11) M a i nshaft bea ring set plate 1 A l i g n t h e cut out o f t h e shift fo rk shaft with t h e set plate.
( 1 2) M a i nshaft bea ring set plate bolt 3 Clean and a pply a l ocki ng agent to the bolt th reads.
1 1 -1 5
Crankshaft Bearing Replacement

Main Journal Bearing Selection
Record the cra n kcase I . D . code letters from the pad o n the
left side of the upper cra n kcase.
N OTE
The letters (A, B or C) on the u pper cra n kcase a re the

codes fo r the m a i n j o u rn a l I . D . s . fro m t h e l eft to
rig ht.
( 1 ) CRAN KCASE 1.0. CODE
Reco rd the co rrespo n d i n g m a i n j o u r n a l O . D . code n u m

be rs from t h e cra n k weig ht.
N OTE

The n u m bers ( 1 , 2
or 3) on the cra n k wei g ht a re the
codes fo r the main j o u rn a l O. D.s.
( 1 ) MAI N J O U R NAL O.D. CODE
C ross-refe rence the case a n d journal codes to determ i n e

t h e replacement bea ring co l o r codes.
Main Journal Bearing Selection Table:

U n it: mm ( i n )
::
.
nal
37.000 37.005 37 .006 37.01 1 37.0 1 2 37 .018
( 1 .4567 - 1 .4569) ( 1 .4569 - 1 .4572) ( 1 .4572 - 1 .4574)
34 007 - 34 0 1 3
1 Yellow G reen B rown
( 1 .3389 - 1 .339 1 )
34.001 - 34.006
2 G reen B rown Black
( 1 .3386 - 1 .3388)
( 1 ) MAI N J O U R NAL BEAR I N G S
33.995 - 34.000
3 Brown B l a ck Blue
( 1 .3368 - 1 .3385)
Beari ng thickness:
Blue:
Black:
B rown:
l
Th ick
G reen:
Yel low: Th i n
1 1 -1 6
Connecting Rod Bearing Selection

I n spect the con necti ng rod bea ring and cra n kpin oil clea r
a n ce (See section 1 4 of the Co m m o n Service M a n u a l ) .
Record t h e con necti ng r o d I . D. code n u m be r ( 1 , 2 or 3) or

measu re the I . D . w i t h the bea r i n g cap i n sta l l ed with out
bea r i n g i n se rt.
( 1 ) CO N N ECTI N G ROD I . D. CODE
If you re p l ace the c ra n ks h aft, record the co rrespo n d i ng

cra n kp i n O . D . code n u m be r (A, B or C ) .
If you a re re u s i n g the c ra n ks h aft, measu re the c ra n kp i n

O . D . with a m icrometer.
N OTE

N u m be rs (A, B o r C) o n t h e c ra n k we i g ht a re t h e
codes for t h e c ra n k p i n O . D.s.
Cross-refe rence the cra n kp i n a n d rod codes to dete rm i ne

( 2 ) REAR
the replacement bea ri n g color.
N OTE

One pa i nted mark identifies the fro nt connecti n g rod
bea rings and two pai nted ma rks the rea r.
Connecting Rod Bearing selection Table:

U n it: m m ( i n )
:
:: :
35.995 36.000 35.989 35.994 35.982 35.988
( 1 . 4 1 7 1 - 1 .4 1 73) ( 1 . 4 1 69 - 1 .4 1 7 1 ) ( 1 . 4 1 66 - 1 . 4 1 69)
(3) CON N E CTI N G R O D BEAR I N G
39.000 - 39.005
1 Yellow Green Brown
( 1 .5354 - 1 .5356)
39.006 - 39.01 1
2 G reen B rown Black
( 1 .5357 - 1 .5359)
39.01 2 - 39.0 1 8
3 Brown Black Blue
( 1 .5359 - 1 .536 1 )
Bearing thickness:
Blue:
B lack:
Brown:
l
Thick
G reen:
Yel l ow: Th i n
1 1 -1 7
Connecting Rod Selection

T h e weight code is sta m ped on t h e co n n ecti ng rod u s i n g
a n a l p h a betical code.
I f a co n n ecti n g rod req u i res re p l a ce m e nt, you s h o u l d

select a rod with the same weight code a s t h e o ri g i n a l . B ut
if that is u nava i lable, you may use one of the oth e rs speci
fied i n the c h a rt.
O ri g i n a l rod code Othe r rod code

R e place m e nt rod
(The rod you wi l l o n that sa m e
code
be re placi n g ) cra n kp i n ( 1 ) CO N N E CTI N G ROD WE I G HT CODE
B A, B or C
A
c A or B
A B or e
B B A, B or C
c A or B
0 0
A B or C
c
B A, B or C
0 0
Liquid Sealant Application o
Apply a l i g ht but th ro u g h coating of l i q u i d sea l a nt to the

cra n kcase mati ng su rface exce pt to the main bea ri ng j o u r ( 1 ) LIQU I D
n a l bolt ( l ower cra n kcase, 9 m m ) a rea a n d the o i l passage S EALANT
a rea as shown . AREA
Cran kcase Bolt Location LOWE R CRAN KCASE S I D E :
Clean t h e cra n kcase 9 m m bo lts t h o ro ug h ly with solvent

a n d blow them d ry.
Apply clean e n g i n e oil to the 9 m m bolt th reads a n d seat
i n g su rface a nd i nsta l l them .
Loosely i nsta l l a l l the l ower cran kcase bolt.

M a ke s u re t h e u p p e r a n d l ow e r c ra n kc a s e a re s eat ed
sec u rely.
2
F rom the i nside to o utside, torq u e the l owe r cra n kcase 9
mm bo lts i n a crisscross pattern i n or 3 steps.
Torque: 31 Nm (3.1 kg-m, 22 ft-lbl
Torq ue the 8 m m bo lts, and then the 6 mm bo lts.
Torque: 8 mm bolt: 23 Nm (2.3 kg-m, 17 ft-lbl

6 mm bolt: 12 Nm ( 1 .2 kg-m, 9 ft-lbl
9 x 88
1 1 -1 8
Loose ly i nsta l l a l l the u pper cra n kcase bo lts, the sea l i n g U PPER CRAN KCASE S I D E :
was h e rs a n d ca b l e g u i de.
To rq u e the 1 0 m m bo lts, a n d then the 6 m m bo lts.
Torque: 10 mm bolt: 39 Nm (3.9 kgm, 28 ftlb)

6 mm bolt: 12 Nm ( 1 .2 kg-m, 9 ft-lb)
1 1 -1 9
MEMO
1 2. Front Wheel/Suspension/Steeri n g
Service Information 1 2- 1 Fork Removal/Installation 1 2-6
Troubleshooting 1 2- 1 Fork Disassembly 1 2-8
Handlebar Removal/Installation 1 2-2 Fork Assembly 1 2- 1 0
Front Wheel Removal/Installation 1 2-4 Steering Stem Removal/Installation 1 2- 1 2
Front Wheel Disassembly/Assembly 1 2-5
Service Information
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
Refer to section 1 4 fo r b ra ke system i nfo rmati o n .

Refe r to section 1 8 fo r l i g ht, mete r a n d switc h i nformati o n .
When servicing the front whee l , fo rk or steeri n g stem , su pport the m otorcycle sec u rely with a safety sta n d o r h o i st.
Do n ot use the oil fi lter as a jack poi nt.
Troubleshooting
Hard Steering Wheel Turns Hard
Steering head bea ring adj ustment n ut too tight Fau lty wheel bea ring
Fau lty stee ri ng head bea rings Fau lty speedomete r gear
I n s ufficient t i re p ressu re Bent front axle
F a u lty t i re B ra ke d rag
Steers To One Side Or Does Not Track Straight Soft Suspension

Bent fo rk I nsufficient fl u i d i n fork
Bent front axle Wea k spri ngs
Wheel i n sta l led i ncorrectly
L ow fl u i d level in fork
Fau lty stee ring head bea rings Low t i re p ressu re
Bent fra m e
W o r k w h e e l bea ri n g Hard Suspension
Worn swi n g a rm pivot components I ncorrect fl u i d wei g ht
Bent fo rk tu bes
Front Wheel Wobbling C logged fl u i d passage
Bent ri m Hi g h ti re pressu re
Worn front wheel bea ri ngs
Fa u lty ti re Front Su1pen1ion Noisy
U n ba l a nced t i re a n d wheel I nsufficient fl u i d i n fork
Loose fo rk fasteners
Lack of g rease i n speedometer gear
1 2- 1
Front Wheel/Suspension/Steering
Handlebar Remova l/Insta l lation
(1)
c 2 3 ( 2 .3, 1 7 )
(1)
( 1 0)
( 1 5) ,
1 2-2
Contaminates in the system may cause a reduction or loss of braking ability.
N OTE
U s i n g wi res, h a n g the front bra ke master cyl i n der at l east as h i g h as the positi on it was orig i n a l l y i n sta l le d at to
prevent a i r fro m getting i nto the master cyl i nder. Do not twist the brake hose.
Ro ute the ca bles a n d wi re harnesses properly ( page 1 -20).
After i nsta l l i ng the h a n d lebar, adjust-
the th rottle ca b l e
the c l utch ca b l e
the c h o ke ca b l e

Removal Order I nsta l lati on is in the reve rse o rde r of remova l .
(1) Rea rview m i rror 2
(2) Wi re ba n d 2
(3) C l utch switch con necto r 2
(4) C l utch lever asse m b l y 1 A l i g n the s p l it betwee n the h o l d e r a n d l ever support with
the punch m a rk on the h a n d l e b a r a n d face th e h o l d e r
" U P" m a rk u pwa rd .
Tig hte n the u pper bolt fi rst, then the l ower bolt.
(5) L eft h a n d lebar switc h h o u s i n g screw 2 Tig hten the fro nt screw fi rst, t hen the rea r screw.
(6) Left h a n d lebar switch h o u s i n g 1 A l i g n the l ocati ng pi n i n the l eft h a n d l e b a r switch with
the h o l e in the ha ndlebar.
(7) Handle grip 1 Apply H o n d a Bond A or H o n d a H a n d G ri p Cement
( U .S .A. on ly) to the inside su rface of the g ri p .
(8) Switch h o u s i n g side protector 1
(9) B ra ke l i g ht switch con n ector 2
( 1 0) Master cyl i n d e r 1 A l i g n the s p l it between the h o l d e r a n d m a ster cyl i n d e r
body with the pu nch m a rk o n t h e h a n d l e b a r a n d face t h e
h o l d e r " U P" ma r k u pwa rd .
Tig hten the upper bolt fi rst, then the l ower bolt.
(1 1 ) R i g ht h a n d lebar switch h o u s i n g screw 2 Tig hten the front sc rew fi rst, then the rea r screw.
( 1 2) R i g ht h a n d lebar switch h o u s i n g 1 A l i g n the l ocati n g p i n i n the right h a n d lebar switch with
the h o l e in the h a n d lebar.
( 1 3) H a n d l e b a r h o l d e r bolt 4 Tig hten the front bo lts fi rst, then the rea r bo lts.
( 1 4) H a n d l e b a r u pper h o l de r 2 I n sta l l the upper h o l d e r with its p u n c h m a r k fac i n g for-
wa rd .
( 1 5) Th rott l e ca b l e e n d 2
( 1 6) Th rottle p i pe 1
(17) H a n d lebar 1 P lace the h a n d lebar o nto the l ower h o l d e r a n d a l i g n the
punch m a rks on the h a n d l e b a r with m ati n g s u rface of
the h a n d lebar h o l der.
1 2-3
Front Wheel Removal/Insta llation
c 59 (5.9, 43)
(2)
(1)
(3)
c 2 2 (2.2. 1 6)
(7)

CAUTION

Do not use the oil filter as a jack point.
N OTE

When servicing the front wheel, support the m otorcycl e u s i ng a safety sta nd or h o i st.

Do not operate the b ra ke leve r after the front wheel rem oved .

Removal Order I nsta l l ation is in the reve rse order of rem ova l .
(1 ) S peedometer ca ble 1
(2) Axle bolt 1
(3) Axle p i nch bolt 4
(4) F ront axle 1 At i n sta l l ation, a pply a t h i n coati ng of g rease to the front
axle.
(5) F ront wheel assembly 1 At i n sta l latio n , a l i g n the p rojection of the speedometer
gea r box with the projection on the fork leg.
(6) Side co l l a r 1
(7) Speed ometer gear b o x assem bly 1
1 2-4
Front Wheel Disassembly I Assembly
(2)
(1 ) (2)
c 42 (4.2, 30)

N OTE

Always replace wheel bea rings as a set.

For wheel bea ring replacement, refer to section 1 of the C o m m o n Service M a n u a l .
Requisite Service
F ro nt wheel remova l/i n sta l lati o n ( page 1 2-4)

Removal Order I n sta l latio n is i n the reverse order of rem ova l .
(1) Brake d i sc bolt 6
(2) Brake d i sc 1 I nsta l l with sta m ped side o utwa rd .
(3) Dust sea l 2 At i n sta l lati on, apply g rease to the d u st sea l l i ps.
(4) Speedometer gear reta i ne r 1
(5) R i g ht w h e e l bea ri n g (6004 U U ) 1
(6) Distance co l l a r 1
(7) Left wheel bea ring (6004 U U ) 1 N OTE
At asse m b ly, d rive in the left side bea r i n g fi rst, then the
right side bea r i ng.
(8) F ront wheel/ti re 1/1
1 2-5
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 3 1 (3. 1 , 2 2 )
1 2-6
Front Wheel/Suspension/Steerin g
CAUTION
Support the removed caliper so that it does not hang from the brake hose. Do not twist the brake hose.
N OTE
If the fork legs wi l l be d i sassem bled, tem porarily tig hten the bottom bridge pinch bolt to l oosen the fo rk cap.
Requisite Service
F ront wheel remova l/i nsta l latio n ( page 1 2-4) U pper fairing remova l/i nsta l lation (VF750CD: page 2-8)

Removal Order I n sta l latio n is in the reverse order of rem ova l .
(1) F ro nt fender bolt 4
(2) F ront fender col l a r 1
(3) F ront fen d e r 1
(4) Brake hose c l a m p 1
(5) Ca l i pe r bracket bolt 2
(6) C a l i pe r asse m bly 1
(7) F ront turn s i g n a l bo lt/co l l a r 2/2
(8) F ro nt turn signal assembly 2
(9) Fork p i nch bolt ( u pper) 2 O n ly l oosen the bolts.
( 1 0) Fork pinch bolt ( l ower) I 2 Only l oosen the bo lts.
If the fo rk leg wi l l be disasse m bled, tem pora rily tig hten
the bottom pi nch bolt to l oosen the fork cap.
(11) Fork asse m b l y 2 At i nsta l lati on, a l i g n the tops of fo rk tu bes with the u pper
su rface of the top bridge.
1 2- 7
Fork Disassembly
(1
(1)

(10)
(12 lr-----...Ja!:ill!'i(
(4)
( 1 8) -------s

6)
(19
(7)
(91.. (14)
(15)
lB------< 1 6)
(9) 1 7 1
(8)
1 2-8

The fork cap is under spring pressure. Use care when removing it. Use face protection.
N OTE

If the fo rk piston m oves with the socket bolt d u ri n g rem ova l , tem po ra ri l y i nsta l l the spri ng, spacer a n d the fo rk
cap.

Always replace the o i l sea l s with new ones.
Requisite Service
Fork rem ova l ( page 1 2-6)

Disessembly Order
(1) F o rk ca p 1
(2) 0-ring 1
(3) S pacer 1
(4) S p r i ng seat 1
(5) F o r k spring 1 Afte r removi n g , p o u r out any rem a i n i n g fo rk o i l .
T
(6) Dust seal When rem ovi n g , do n ot damage the fork t u be .
(7 ) Stopper ri ng
(8) Fork socket bolt 1
(9) Sea l i n g washer 1
( 1 0) Fork piston 1
(1 1 ) Fork piston ri n g 1 Do n ot rem ove it u n less rep l acement is necessary.
( 1 2) Rebo u n d spring 1
( 1 3) F o rk tu be 1
( 1 4) O i l sea l 1
( 1 5) Back u p ring 1
( 1 6) Slider bushing 1
(17) Fork tu be bush i n g 1 Do not remove it u n less replacement is n ecessa ry.
( 1 8) O i l lock piece 1
( 1 9) F o rk s l ider 1
1 2-9
Fork Assembly
c 17) 23 (2.3,

1 7) -
( 1 8)
(2)
(3)
- ( 1 5)
-------s
(4)
( 1 3) ., ...
e
P
c 8 (0.8, 5.8)
~
1 4)
(5)
(8)
c 20 ( 2.0,
1 2- 1 0
N OTE

Always replace the o i l sea ls with new ones.

Coat the new o i l sea l with the reco m mended fo rk o i l a n d i nsta l l it with its m a rk fac i n g u p .

After assem b l i n g the fo rk legs, i n sta l l each fo rk leg i nto the lowe r fo rk bridge fi rst, then torq u e the fo rk cap.
Requisite Service
Fork d i sa sse m bly ( page 1 2-8) Fork i nsta l lati on ( page 1 2-6)

Assembly Order
(1) Rebo u n d spring 1
(2) Fork piston ri n g 1 Replace with a new one if it was removed from the piston .
(3) Fork piston asse m b l y 1 I nsert i nto the fo rk tube.
(4) O i l l o c k piece 1 I n se rt onto the pisto n .
(5) F o rk tu be b u s h i n g 1 Replace with a new one i f i t was re moved fro m t h e fo rk
tube.
(6) F o r k tu be 1
(7 ) Sea l i n g was h e r 1
(8) F o r k socket b o l t 1 If the socket bolt turns with the fork pisto n, tem porarily
i nsta l l the fork spri n g , spacer a n d fo rk cap, then tig hten
the socket bolt.
(9) Slider b u s h i n g 1
( 1 0) Back u p ring 1
(11) O i l sea l 1 Wra p vinyl ta pe a rou nd the fo rk tube top e nd to avo i d
d a m a g i n g the o i l sea l d u ri n g i nsta l lati o n .
U s e fo rk sea l d river (07947 - KA50 1 00) a n d atta c h ment
(07947 - KF00 1 00) fo r fo rk sea l i nsta l l at i o n .
( 1 2) Stopper r i n g 1
( 1 3) Dust sea l 1 Afte r i n sta l l i n g , co m p ress the fo rk tu be fu l ly a n d p o u r t h e
specified a m o u nt o f fo rk fl u i d ( page 1 - 1 0) i nto the fo rk
tube.
( 1 4) Fork spri n g 1 Wi pe all oil off the spri n g thoro u g h ly using a c l ea n , l i nt
free c loth a n d i nsta l l with the ta pered e n d fac i n g down .
( 1 5) S p r i n g seat 1
( 1 6) S pacer 1
(17) 0-ri n g 1 Apply o i l to the new 0-ri n g .
( 1 8) F o r k ca p 1 CAUTION
Be careful not to cross-thread the fork cap.

Screw in the cap, but do not tighten yet.
1 2- 1 1
Steering Stem Removal/Installation

,,, c
6) c 30 (3.0, 22)
1 .-;;c,..
I ( page 1 - 1 5)
-
NOTE
-!f'tl-...,..::::..__ ( 1 4)
J a.T -. h pag e 1 2-1 3)
(5)
.,
(8)
T
( 1 5) J s. -. I ( page 1 2- 1 3)
J a.T-. I (page 1 2-1 3)
(13)
NOTE --------
Use the specified grease : Urea based multi-purpose grease for

Extreme pressure (example: EXCELITE SHORTER TABS:
EP2 manufactured by KYODO YUSHI Bend down
Japan, 'Shell Stamina EP2) or equivalent
LONGER TABS:
Bend up
1 2- 1 2
N OTE
Replace the bea rings a n d races as a set.
At i n sta l latio n , a p p ly g rease to a l l bea ring a rea.
Check the stee ring head bea ring preload ( page 1 - 1 0) after torq u i n g the ste m n ut.
Requisite Service
Fork rem ova l/i nsta l lati o n ( page 1 2-6) M eter rem ova l/i nsta l lati on ( page 1 8-7 )
H a n d lebar rem ova l/i n sta l l ation ( page 1 2-2) Head l i g ht re m ova l/i nsta l l ation ( page 1 8-6)

Removal Order
(1) Steeri n g ste m n ut 1 Afte r re movi ng, remove the fo rk.
(2) Th rust was h e r 1
(3) Top bridge 1
(4) Lock nut 1 Remove, after stra i g hte n i n g the lock was h e r ta bs.
(5) Lock was h e r 1
(6) Stee ri n g head bea ri n g adjustment nut 1
(7) D u st seal 1
(8) Stee ring stem 1
(9) U pper bea ring inner race 1
( 1 0) U pper bea r i ng 1
(1 1 ) Lowe r bea ring 1
( 1 2) Lowe r bea ri ng i n n e r race 1 - Replace if rem oved.
( 1 3) D u st seal 1 - U se race re m o v e r atta c h m e nt ( 079 5 3 - M J 1 0 1 00 o r
( 1 4) U pper bea ring o uter race 1 - 07953 - M J 1 000A [ U . S .A. o n ly ) ) with d rive r (07953 -
( 1 5) Lowe r bea ring o uter race 1 - MJ 1 0200 or M9360 - 277 - 9 1 77 4 [ U . S.A. on ly]) for u pper
outer race remova l .
U s e r a c e re mover (07946 - 37 1 0500) fo r l owe r o uter
race re mova l .
( 1 6) Lower h o l d e r n ut/washer 2/2
(17) Lower h o l d e r 2
Installation Oder
(17) Lowe r h o l d e r 2
( 1 6) Lowe r h o l d e r n ut/washer 2/2 Tig hte n i n g proce d u re ( page 1 2- 1 4) .
( 1 5) Lowe r bea r i n g o uter race 1- Replace as a set, if n ecessary.
( 1 4) U pper bea ri ng o uter race 1- U se attach me nt, 52 x 55 m m (077 46 - 00 1 0400) and dri-
( 1 3) D u st sea l . 1- ve r (07749 - 00 1 0000) fo r l ower o uter race i n sta l l atio n .
(12) Lowe r bea ring i n n e r race 1- U s e attachment, 4 2 x 4 7 m m (07746 - 00 1 0300) a n d d ri-
(1 1 ) Lowe r bea ri n g 1- ver (07749 - 00 1 0000) fo r u pper o uter race i n sta l lati o n .
( 1 0) U pper bea r i n g 1- Use steering stem d river (07946 - M BOOOOO) f o r l ower
(9) U pper bea ri ng i n n e r race 1- i n n e r race i n sta l lati o n .
(8) Steering stem 1
(7) D u st s e a l 1
Steering head bea ring adjustment n ut I n sta l l ati o n : refe r t o section 1 8 o f t h e Co m m o n S e rvice
Er
{ 6)
(5) Lock was h e r M a n u a l ( Reta i n e r-Type Ba l l Bea r ings ).
(4) Lock n ut
(3) Top bridge 1
(2 ) Th rust was h e r 1
(1) Steering ste m nut 1 Tem po rarily i n sta l l fo rk a n d torq u e the n ut.
1 2- 1 3
Handlebar Lower Holder Nut Tightening Procedure

I nsta l l the h a n d lebar l owe r h o l d e r.
Loose ly i n sta l l the washers a n d n uts.
I nsta l l the h a n d lebar and upper h o l d e r ( page 1 2-2).
Tig hten the u pper holder bo lts. ( 2 ) U PPER HOLDER
Torque: 5 Nm (0.5 kg-m, 3.6 ft-lb)
Adj ust the h a n d lebar stra i g ht-a head by tap the end of h a n
d l ebar. Make s u re that the l ength A and B a re eq u a l .
Tig hten t h e lower h o l d e r n uts.
Tig hten the u pper holder bolts ( page 1 2-2).
Torque: 23 Nm (2.3 kg-m, 1 7 ft-lb)
Make s u re th at th e l ength A and B a re eq u a l .
1 2- 1 4
1 3 . Rea r Wheel/Suspensio n
Service Information 1 3- 1 Shock Absorber Removal/Installation 1 3-6
Troubleshooting 1 3- 1 Shock Absorber DisassemblyIAssembly 1 3-7

Rear Wheel Removal/Installation 1 3-2 Swingarm Removal/Installation 1 3-9
Rear Wheel DisassemblyI Assembly 1 3-4 Swingarm DisassemblyIAssembly 1 3- 1 1
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by
OSHA, designed to minimize the hazard caused by airborne asbestos fibers.
A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contami
nated drum with a high quality brake degreasing agent.
Any attempt to mount automobile tires on a motorcycle rim may cause the tire . bead to separate from the rim
with enough explosive force to cause serious injury or death.
When servicing the rea r wheel, su pport the moto rcycle using a safety sta n d or hoist.
Refe r to the section 1 4 fo r bra ke system i nformatio n .
Tubeless ti re rem ova l , repa i r, a n d re m o u nting proce d u res a re covered i n the section 1 6 of the Com m o n Service
Manual.
Troubleshooting
Soft Suspension Steers To One Side Or Does Not Track Straight
Wea k spri ng Bent rea r axle
O i l leakage from d a m per u n it Ax le a l i g n ment/cha i n adj u stment n ot eq u a l o n both

I nco rrect suspension adjustment sides
Low ti re pressu re
Rear Wheel Wobbling
Hard Suspension Bent rim
I nco rrectly suspension adj u stment Worn rea r wheel bea ri ngs
Bent swi ngarm pivot Fau lty ti re

Damaged swi ngarm pivot bea rings U n ba l a nced ti re a n d wheel
Bent d a m per rod Low ti re pressu re
High ti re pressu re Fau lty swi n g a rm pivot bea rings
1 3- 1
Rear Wheel/Suspension
Rear Wheel Removal/Installation
( 1 5)
( 1 8)
(7)
0 22 ( 2 . 2 . 1 6)
( 1 2)
c 93 (9.3, 63)
(2)
(9)
( 1 0)
1 3-2

brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA
designed to minimize the hazard caused by airborne asbestos fibers.

A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoe and clean a contami
N OTE

When se rvicing the rea r whee l , su pport the moto rcycle u s i ng a safety sta nd or hoist.

Adj u st the d rive cha i n free play after i n sta l l i n g the whee l .

Apply th i n layer of g rease to the rea r axle su rface.

Removal Order I n sta l latio n is in the reve rse order of remova l .
(1 ) B ra ke adj usti n g n ut 1
(2 ) B ra ke rod 1
(3) Spring 1
(4) B ra ke rod j o i nt piece 1
(5) Drive c h a i n adjusti n g nut 2 Loosen t h e adjusti n g n ut fu l ly.
(6) Cotte r p i n 1
(7) N ut 1
(8) Washer 1
(9) R u bber cushion 1
( 1 0) Brake sto pper a r m pivot bo lt 1
(11) Brake stopper arm 1
(12) Rea r axle n ut/washer 1/1
( 1 3) D rive c h a i n adj uste r 1
( 1 4) Drive c h a i n 1 M ove the rea r wheel forwa rd and rem ove the d rive c h a i n
from t h e d riven sprocket.
( 1 5) Rea r axle 1
( 1 6) Rea r wheel asse m bly 1
(17) R i g ht side col l a r 1
( 1 8) Left side c o l l a r 1
( 1 9) B ra ke panel assembly 1 Disassembly ( page 1 4-7 ) .
1 3-3
Rear Wheel Disassembly I Assembly
(9)
(7)
(4)
(8) (3)
.,
( 2) (5)
c 1 08 ( 1 0.8, 79)
- (8) - (6)
(1 1 ) ( 1 0) (3) (4)
1 3-4
Rear Whee/Suspension


A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean contaminat
ed drums with a high quality brake degreasing agent.
N OTE

For d riven sprocket rem ova l , l oosen the sprocket n uts with the d riven flange i n sta l led i nto the wheel h u b.

Replace wheel bea rings as a set.

For wheel bea ring replacement, refer to the sectio n 1 of the Co m m o n Service M a n u a l .
Requisite Service
Rea r wheel rem ova l/i nsta l latio n ( page 1 3-2)

Disassembly Order Assem bly is in the reve rse order of d i sasse m b ly.
(1) D u st sea l 1 At asse m bly, apply grease to the d u st sea l l i ps.
Driven Flange Disassembly Order
(2) Driven fla nge assembly 1
(3) - Driven flange c o l l a r 1
(4) - D riven flange bea ri ng (6305 U U ) 1
(5) - Driven sprocket nut 5
(6) - Driven sprocket 1
(7) - D riven flange 1
(8) 0-ri n g 1
(9) Rea r wheel d a m pe r 5
( 1 0) Left wheel bea ring (6304 U U ) 1
(11) Distance col l a r 1
( 1 2) R i g ht wheel bea ri n g (6204 U U ) 1 Drive i n the rig ht side bea ri n g fi rst, then the l eft si de
bea ri n g .
( 1 3) Rea r wheel/ti re 1/1
1 3-5
Shock Absorber Removal/Installation
c 2 7 (2.7, 20)
N OTE

When servicing the shock a bsorber, support the m otorcycle u s i n g a safety sta nd or hoist.

Adj ust the shock a bsorber to the softest position fo r d i sasse m b ly.
Procedu re O'ty Remarks

Removal Order I nsta l latio n is in the reve rse o rder of re m ova l .
(1) S h ock a bsorber m o u nt i n g bolt ( u pper) 1
(2) P l a i n washer 1
(3) S h ock a bsorber m o u nt i n g bolt ( l ower) 1 N OTE

M ove the m uffler outside, rem ove the m o u nting bolt.
(4) S h ock a bsorber assem bly 1
1 3-6
Shock Absorber Disassembly I Assembly
( 1 ) I a.TooL I ( page 1 3-8)
(3)
Requisite Service
Rea r shock a bsorber remova l/i nsta l lation ( page 1 3-6)

Disassembly Order Assem bly is i n the reverse order of d i sasse m bly.
(1) U pper seat 1 See page 1 3-8.
(2) Spring cover 1
(3) Spring 1 I nsta l l the spring with the s ma l l coi l end towa rd the
bottom .
(4) Preload adj uster 1
(5) Damper u n it asse m b l y 1
1 3-7
Spring, Upper Seat Removal/Installation ( 1 ) I a . TooL I COMPRESSOR
I n sta l l t h e sh ock a bsorber com p resso r o n t h e s h ock a b

sorber.
l a.TooL I
Shock absorber compressor 07959 - 3290001
C o m p ress t h e s h oc k a bs o r b e r s p r i n g a n d re m ove t h e
u pper seat.
CAUTION
Do not compress the spring more than necessary.
L o o s e n t h e s h o c k a b s o r b e r c o m p re s s o r s l o w l y a n d
rem ove the shock a bsorber.
Remove the spring cover and shock a bsorber spri n g .
I nsta l l t h e spri n g with the sma l l coi l end towa rd the bot
tom .
I n sta l l t h e spring cove r.
( 1 ) DOWN
I nsta l l the spec i a l tool s and com p ress the shock a bsorber
spri n g .
I nsta l l t h e s p r i n g seat sec u re ly.
l a .TooL I
Shock absorber compressor 07959 - 3290001
L o o s e n t h e s h o c k a b s o r b e r c o m p re s s o r s l o w l y a n d
rem ove the shock a bsorber.
1 3-8
Swingarm Removal/Installation
/ (7 1 - Cas (8.9, 651
(6)
c(1) 39 (3.9, 28)

c 37 (3.7 , 27 )
Requ isite Service
Rear wheel rem ova l/i nsta l lation ( page 1 3-2)

Drive s procket cove r remova l/i nsta l latio n ( page 10-2)
Removal Order I n sta l lation is in the reve rse o rder of re mova l .
(1 ) Frame pivot lock bolt t- Adj u stment ( page 1 3-10)
(2)
(3)
(4)
F ra m e p ivot l ock nut
F ra m e pivot a dj u sti n g bolt
Drive c h a i n cover
1 j
( 5) S h ock abso rber l ower m o u nting bolt 2 N OTE
M ove the m uffle r outsi de, rem ove the m o u nt i n g bolts.
2

(6) Cap
(7 ) Swi n g a rm pivot n ut 1
1
(8)
(9)
Swi n g a rm pivot bolt
Swi ngarm asse m b l y 1
-- -- - - ----- ----- ---- -

1 3-9
Frame Pivot Adjusting Bolt Adjustment ( 1 ) L O CK N UT

Removal
Remove the pivot lock bolt.
Remove the adjusting bolt lock n ut.
NOTE

R e m ove the lock n ut w h i l e h o l d i n g t h e a dj u sti n g
bolt.
Remove the adjusti ng bolt.
Installation ( 1 ) ADJ U STI N G BOLT

Tighten the adjusting bolt.
Torque: 15 Nm ( 1 .5 kg-m, 1 1 ft-lb)
Tighten the lock n ut wh i l e holding the adjusti ng bolt.
Tighten the pivot lock bolt.
1 3- 1 0
Swingarm DisassemblyI Assembly

(5) (2) 0 22 (2.2, 1 6)

(61 0 6 (0.6, 431
(7 )
N OTE

F o r p ivot bea ring replacement, see next page.
Requisite Service
Swi n g a rm rem ova l/i nsta l l ation ( page 1 3-9)

Disassembly Order Assembly is in the reverse order of disassembly.
(1) Cotter p i n 1
(2) N ut 1
(3) Pla i n washer 1
( 4) R u bber cushion 1
( 5) Brake stopper arm 1
(6) D rive chain slider screw 2
(7 ) D rive c h a i n s l i d e r 1
(8) R i g ht pivot col l a r 1
(9) Left pivot col l a r 1
( 1 0) Dust sea l 2 Apply grease to the l ip.
(11) Dista nce col l a r 1
( 1 2) Needle bea ring 1
( 1 3) S n a p ri ng 1 Insta l l it i nto the groove securely.
( 1 4) Ba l l bea ring 1
1 3- 1 1
Swingarm Pivot Bearing Replacement
Press the rig ht pivot bea ring ( b a l l bea ring) out of swi ngarm.
l s.rooL I
Driver Shaft 07946 - MJ00100 or
07949 - 37 1 0001
(U.S.A. only)
Set the need l e bea ring rem over o nto the l eft pivot bea ring
( need le bea ri n g ) as shown .
Needle bearing remover attachment

07GMD - KT70200
Driver Shaft 07946 - MJ001 00
or (U.S.A. only):
Bearing remover M967X - 038 - XXXX
Driver 07949 - 37 1 0001
Pilot, 15 mm 07746 - 0040300
Attachment, 30 mm 07746 - 0030300
P ress t h e n e e d l e b e a r i n g i nto t h e swi n g a rm w i t h t h e

( 1 ) N E E DLE
m a rked side faci ng out. BEARI N G
N OTE

The bea ring su rface s h o u l d be fl u s h with the p ivot
i nside su rface as shown .
/
/
l s.rooL I /
/
Driver 07749 - 001 0000 /
/
Attachment, 28 x 30 mm 07946 - 1 8701 00 ( 41 PI LOT
Pilot, 22 mm 07746 - 0041 000
Press the ba l l bea ri ng in u nt i l it bottoms in the swi n g a r m .
l .rooL 1
Driver 07749 - 001 0000
Attachment, 32 x 35 mm 07746 - 001 0100
Pilot, 1 5 mm 07746 - 0040300
1 3- 1 2
1 4. Bra ke System
Service Information 1 4- 1 Front Master Cylinder Removal/
Installation 1 4-5
Troubleshooting 1 4- 1
Front Brake Pad Replacement 1 4-2

Front Master Cylinder DisassemblyI
Assembly 1 4-6
Front Brake Caliper Removal/ Rear Brake Panel DisassemblyI
Installation 1 4-3
Assembly 1 4-7
Front Brake Caliper DisassemblyI Brake Pedal Removal/Installation 1 4-8
Assembly 1 4-4
A contaminated brake disc, drum, pad or shoe reduces stopping power. Discard contaminated pads/shoes and
clean a contaminated disc/drum with a high quality brake degreasing agent.
S p i l led b rake fl u i d wi l l seve re ly damage i nstrument lenses a n d pai nted s u rfaces. It is a lso h a rmfu l to some rubber
pa rts. Be ca refu l whenever you re move the reservo i r cap: m a ke s u re the reservoi r i s h o rizonta l fi rst.
N ever a l low conta m i nates ( d i rt, wate r, etc . ) to get i nto an o pe n rese rvo i r.
Once the hydra u l ic system has been opened, or if the bra ke fee l spon gy, the syste m m ust be b l e d .
Always use fresh DOT 4 b ra ke fl u i d from a sea led conta i ner when servic i ng the syste m . Do n ot m i x d ifferent types of
fl u i d as they may not be com pati b l e .
Always check brake ope ration before r i d i n g the m oto rcycle.
Troubleshooting
Front Brake: lEI
Brake Lever Soft Or Spongy Brake Lever Hard
A i r bu bbles i n the hyd ra u l i c system Clogged/restricted b ra ke system
Lea k i n g hydra u lic syste m Sticki ng/wo rn ca l i pe r piston
Conta m i nated b rake pad/d isc Ca l i pe r not s l i d i n g properly
Worn ca l i pe r piston seal Clogged/restricted fl u i d passage
Worn master cyl i n d e r piston seal Wo rn ca l i pe r piston sea l
Worn b ra ke pad/d isc Sticki ng/wo rn master cyl i nd e r piston

Conta m i n ated ca l i pe r Bent b ra ke l eve r
Ca l i pe r n ot s l i d i n g properly
Low fl u i d level Brakes Drag
Clogged fl u i d passag e Conta m i nated brake pad/d i sc
Warped/defo rmed b ra ke d i sc M isa l i g ned wheel
Sticking/worn ca l i pe r piston Worn bra ke pad/d i sc
Stick i n g/wo rn master cyl i n d e r piston Wa rped/deformed b ra ke d i sc

Conta m i n ated master cyl i n d e r Ca l i pe r not s l i d i n g properly
Rear brake:
Poor Brake Performance Brake Pedal Hard Or Slow Return
I m properly adj u sted brake Worn/broke n retu rn spring
Worn b ra ke l i n i ng s I m properly adj u sted b ra ke
Wo rn b ra ke d r u m Sticking b ra ke d r u m d u e to conta m i nation
Worn brP.ke c a m Worn b ra ke s h oes at cam co ntact a rea
I m properly i n sta l led brake l i n i ngs
B ra ke l i n kage needs l u b ricatio n
Brake l i n kage needs l u bri c ation I m properly i nsta l led bra ke l i n i ngs
Conta m i nated bra ke l i n i n gs
Conta m i n ated bra ke d r u m Brake Squeaks
Worn b ra ke sh oes at cam contact a rea Worn brake l i n i ngs

I m proper eng a g e m e nt between brake arm a n d cam
Worn b ra ke d r u m
se rrations Conta m i nated b ra ke l i n i ngs
Conta m i n ated bra ke d r u m
1 4- 1
Brake System
Front Brake Pad Replacement

ALI G N
(2 )
\l
I
/!
I
0 2 .5 ( 0 . 2 5 . 1 .8 )
------- . - - -
Check the brake system by applying the brake after the pad replacement.
N OTE
Operate the brake l ever to seat the ca l i pe r pi ston s agai nst the pads after the pad rep lacement.
The b ra ke pad rep l acem e nt can be done without d i sco n n ecti ng the hyd ra u l ic system .
Always rep l ace the b ra ke pads i n pai rs to assu re even d i sc p ressu re .

Removal Order I n sta l latio n is in the reve rse order of remova l .
(1) Pad p i n p l u g 1 After rem ovi ng the pad p i n p l u g , l oosen the pad p i n .
(2) Pad p i n 1 I nsert the p i n , push i ng the pads agai nst the pad spri n g .
(3) B ra ke pad 2 At i nsta l lation, positio n the pad o nto the pad reta i ner i n
t h e ca l i per a s shown.
1 4-2
Brake System
Front Brake Caliper Removal/Installation
( 3)
c 3 5 ( 3 .5 , 2 5 )
(1)
( 5)

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contam inated

Check the brake system by applying the brake after bleeding air from the system.
CAUTION

Avoid spilling brake fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
Requisite Service
F ront brake pad replacement ( page 1 4-2)

B ra ke fl u i d replacement/a i r bleed i n g
( Section 1 7 o f t h e Com m o n Service M a n u a l )

Removal Order I n sta l latio n is i n the reverse order of rem ova l .
(1) B ra ke h ose bolt 1
(3) B ra ke h ose eyelet j o i nt 1 A t i n sta l l at i o n , p ress t h e b ra ke h o s e e n d a g a i n st t h e
stopper w h i l e tighte n i n g t h e h ose bolt.
(4) Ca l i pe r b racket bolt 2
( 5) F ront brake ca l i pe r asse m b ly 1
1 4-3
Brake System
Front Brake Caliper Disassembly I Assembly
(7)
.,
c
(8)
(6) 23 (2.3, 1 7)
1 oa /c 5. 5 (0 . 55, 41
I

(3)
CAUTION

serviced.
Requisite Service
F ront bra ke ca l i pe r rem ova l/i n sta l latio n ( page 1 4-3)

Disassembly Order Asse m bly is in the reverse order of d i sassem bly.
(1) Pad spring 1 N ote spring dj rection as shown.
(2) Ca l i pe r b racket 1
((45))
(3) B racket p i n bolt boot
Ca l i per p i n bo lt boot
B racket p i n bolt
1
1
1
I n sta l l i nto the b racket g roove secu re ly.
At i nsta l l ation, apply a l ocki n g agent to the th reads.
(6) Ca l i pe r p i n bolt 1 At i nsta l lati on, a pply a l ocki ng agent to the th reads.
(7) C a l i p e r piston 2 At i n sta l l at i o n , i n sta l l t h e p i st o n with t h e d i s h e d e n d
towa rd t h e ca l i per.
(8) Dust sea l CAUTION
=r
r-
(9) Piston sea l

Be careful not to damage the piston sliding surface
when removing the seals.
1 4-4
Brake System
Front Master Cylinder Removal/Instal lation

( 1 0) (2) c 1 (0. 1 , 0.7)
(1)
(3)
(8)
c 12 ( 1 .2, 9)
(9)
CAUTION
serviced.
When removing the hose bolt, cover the end of the brake hose to prevent contamination.
Do not allow foreign material to enter the system.
N OTE
I Use DOT 4 bra ke fl u i d from a sea led conta i ner.
Requisite Service
Brake system a i r b l eed i n g (Section 1 7 of the Com m on Service M a n u a l )

Removal Order I n sta l latio n is in the reverse of o rder of rem ova l .
(1) R i g ht rea rview m i rro r 1 Loosen the m o u nting n ut a n d rem ove the m i rror.
(2) F ront b ra ke l ever pivot bo lt/nut 1/1
(3) B ra ke lever 1
(4) F ront b ra ke h ose bolt 1
(5) F ront b ra ke hose 1 At i nsta l lati o n , p ress the hose e n d a g a i n st the sto pper
wh i l e t i g hte n i n g the h ose bolt.
(7) B ra ke l i g ht switch co n n ecto r 2
(8) Maste r cyl i nder holder bolt 2 At i n sta l lation, tig hten the upper bolt fi rst, then th l ower
bolt.
(9) Maste r cyl i nd e r h o l d e r 1 I nsta l l the holder with its " U P" m a rk faci n g u p .
( 1 0) Maste r cyl i nder assem bly 1 At i n sta l lation, a l ig n the mating su rface with the p u nch
m a rk o n the h a n d lebar.
1 4-5
Brake System
Front Master Cylinder Disassembly I Assembly

K..--- C 1 . 5 (0. 1 5, 1 . 1 )
"---- ( 1 )
(2)
NOTE

Replace the master piston , spring, cu ps, stopper p late, s n a p ring a n d boot as a set.
Requisite Service
Front m aster cyl i nder remova l/i nsta l latio n ( page 1 4-5)
B ra ke system a i r bleed i n g ( Section 1 7 of the Com mo n Service M a n u a l )

Disassembly Order Assem bly is i n the reverse order of d i sasse m b ly.
(1) Reservoi r cover 1
(2) D i a p h ra g m p l ate 1
(3) Dia p h ra g m 1
(4) B ra ke l i g ht 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 p i ston assembly 1
(9) Spring 1 I nsta l l the spring with the sm a l l coi l e nd faci ng the
piston .
14-6
Brake System
Rear Brake Panel Disassembly IAssembly
( 1 ) 0 29 (2 .9, 2 1 )
(4) ,
( 2 ) ------4....,
( 1 0)
- (5)
(9)
(5) .,


A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contami
Requisite Service
Rear wheel remova l/i n sta l lation ( page 1 3-2)

Disassembly Order Assembly is in the reverse order of d isassem bly.
(1) Brake a rm pinch bolt 1
(2) B ra ke a rm 1 At i n sta l l ation, a l i g n the p u nch m a rks on the brake cam
and arm.
(3) Brake i n d icato r 1 At i n sta l lati o n , a l i g n the wide tooth with the wide slot i n
the bra ke ca m .
(4) F e l t sea l 1
(5) Cotter pin 2 I n sta l l with c losed end faci n g out.
(6) Cotte r p i n plate 1
(7) Brake s h o e 2
(8) Shoe spri ng 2
(9) B ra ke cam 1 At i n sta l l at i on, a pply s i l icone g rease to the s l i d i n g s u r-
face a n d cam porti o n .
( 1 0) Brake panel 1
1 4-7
Brake System
Brake Pedal Removal/Installation
( 1 4)
( 1 6) -
c 27 (2.7, 20) (8)

Removal Order I n sta l l ation is i n the reverse o rd e r of rem ova l .
(1) B rake rod adj usti ng n ut 1
(2) B rake rod spri ng 1
(3) Brake rod j o i nt piece 1
( 4) B rake ped a l p ivot bo lt/n ut 1/1
(5) Col l a r 1
(6) Dust sea l 2
(7) B ra ke ped a l l i n kage j o i nt pinch bolt 1 A l i g n the p u nc h m a rks.
(8) B rake ped a l l i n kage assem bly 1
(9) Cotte r pin 2
( 1 0) J o i nt p i n 2
(11) B ra ke ped a l l i n kage j o i nt 1
( 1 2) B ra ke ped a l 1
( 1 3) B rake l i g ht switch spring 1
( 1 4) B ra ke ped a l return spring 1
( 1 5) Cotte r p i n 1
( 1 6) J o i nt p i n 1
(17) B ra ke rod l i n kage 1
( 1 8) B rake rod 1
1 4-8
1 5. Charg i n g System/ Alternator
Service Information 1 5- 1 Charging System Inspection 1 5-6
System Location 1 5-2 Regulator/Rectifier 1 5-7
Troubleshooting 1 5-3 Alternator 1 5-9
Battery Removal/Installation 1 5-5 Alternator Removal/Installation 1 5- 1 0
Service i nformation

The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation
when charging or using the battery in an enclosed space.

The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protec
tive clothing and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 1 5 minutes and call a physician immediately.

Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or
vegetable oil and call a physician.

Always tu rn off the i g n ition switch before d isco nnecti ng any electrica l com ponent.
CAUTION

Some electrical components may be damaged if terminals or connectors are connected or disconnected while
the ignition switch is ON and current is present.
For extended sto rage, rem ove the batte ry, g ive it a fu l l charge, and store it i n a cool , d ry space. For maxi m u m service
l ife, charge the stored battery eve ry two weeks.
For battery rem a i n i n g i n a stored m otorcycle, disconnect the negative batte ry ca ble fro m the batte ry termi n a l .
N OTE

The m a i ntena nce free battery m u st be replaced when it reaches the end of its service l ife.
CAUTION

The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.
Battery can be dam aged if ove r charged or u ndercharged, or if left to d i sc h a rge for long periods. These same condi
tions contri b ute to shorte n i n g the " l ife spa n " of the batte ry. Even u nder normal use, batte ry performa nce dete rio rates
after 2-3 years.
Batte ry voltage may recover afte r battery charg i n g , but u nder heavy load, batte ry voltage wi l l d ro p q u ickly a n d even
tua l ly die out. For this reason, the charg i n g system is often suspected to be the pro b l e m . If one of the battery cel l s is
shorted a n d batte ry voltage does not i ncrease, the reg u lato r/rectifier suppl ies excess voltage to the battery. U nder
these conditions, the electrolyte level goes down qu ickly.
Befo re tro u bleshooti ng the charg i n g syste m , check the proper use a n d m a i ntena nce of the battery. Check if the bat
tery is frequently u n d e r heavy load, such as havi ng the head l ight a n d ta i l l i g ht ON fo r long periods of t i m e without rid
i n g the m otorcycle.
The battery wi l l self-d ischarge when the m otorcycle is not is use. For this reason, charge the battery every two weeks
to prevent su lfati on from form i n g .
F i l l i n g a new batte ry with e lectrolyte wi l l prod uce some voltage, but i n order to achieve its maxi m u m performa nce,
a lways charg e the battery. Also, the batte ry l ife is lengthened when it is i n itia l-charged.
When checki ng the charg i n g system , a lways fol l ow the steps i n the tro u b l eshooti ng fl ow c h a rt ( page 1 5-::S).
For battery testing/c h a rg i ng , refe r to Section 22 of the Com m o n Service M a n u a l .
For charg i n g system location, see page 1 5-2.
1 5- 1
Charging System/Alternator
System Location
( 1 ) BATIE RY
( 2 ) MAI N F U S E
30 A
(3) R E G U LATOR/RECTI F I E R
( 2) MAI N F U S E
30 A
( 1 ) BATIE RY
1 2 V 1 0 Ah
(3) R E G U LATOR/
RECTI F I E R
(4) ALTE R N ATOR R: Red

W: Wh ite
Y: Yel low
G : G reen
1 5-2
Troubleshooting
Battery Overcharging
Fa u lty reg u lato r/rectifier
Battery Undercharging
N OTE

I n order to o bta i n an accu rate test read i n g when c h a rg i n g the system , the battery m u st be fu l l y c h a rged a n d i n
good con d iti o n . See Com m o n Service M a n u a l Section 22 fo r check the battery co n d iti o n .
Meas u re the battery c u rrent leakage a m pere

( leak test: page 1 5-6).
I ncorrect
Check the reg u lator/rectifi e r ( page 1 5-7 ) .
Standard: 0.01 mA max.
Correct
I ncorrect Correct

S h o rted wi re h a rness

Fau lty i g n ition switch
I n s pect the reg u l ated voltage ( page 1 5-6).
Correct
Check the battery u s i n g t he battery tester.
I ncorrect Correct

.
. . ! .
0 pen c 1 rcu 1t 1 n w1 re h a rness
Poorly c onnected con nectors

E lectric system over- l o a d i n g
Standard: 1 4 - 1 5.5 V/3,000 rpm
F a u lty battery
N ot c h a rg i n g
1 5-3
Charging System/ Alternator
Abnorm a l
Check t h e voltage between t h e reg u lat o r/recti- 1----. . Open c i rc u it in wire h a rness
fi e r batte ry c h a rg i n g l i n e a n d g ro u n d l i n e Poorly connected con n ecto rs
( page 1 5-7 ) .
Connection: Red/White ( + ) - Green (-)

Standard: Battery voltage
N o rm a l
Abnormal
Check t h e a lternator (charg i n g coi l ) resistance Check the charg i n g coi l resista nce at the a lte r
at the reg u l ator/rectifier con n ecto r ( page 1 5-7 ) . nator connecto r ( page 1 5-9) .
.--;? w_ J l!lfW!l#)lt
Connection: Yellow - Yellow Connection: Yellow - Yellow
Standard: 0.1 - 1 .0 0 Standard: 0.1 - 1 .0 0
Abno r m a l Normal
L
Normal

t
Poorly con n ected a ltern tor con necto r
Open or s h ort c i rcuit i n Yel l ow wi re
Fau lty a lternator
Abnormal
Check the reg u lator/rectifie r u n it ( page 1 5-8) . 1------- F a u lty reg u l ator/rectifi e r
Normal
'-----. Fau lty battery
1 5-4
Charging System/ Alternator
Battery Removal/Installation
N OTE
Always turn the i g n ition switch OFF befo re re m ovi ng or i nsta l l i n g the batte ry.
Requisite Service
Seat rem ova l/i nsta l lation ( page 2-2)

Removal Order I n sta l lation is in the reve rse o rder of rem ova l .
(1) Batte ry h o l d e r ba n d 1
(2) Negative term i n a l After i nsta l lati on, apply clea n g rease to the ca b l e e n d ,
=r
-
(3) Positive term i n a l battery te rm i n a l s a n d bo lts.

At i nsta l l ation, pu l l the cover over the positive ter m i -
nal.
(4) Battery 1
1 5-5
Charging System Inspection ( 1 ) A M M ETER
Leakage Test
Turn the i g n ition switch off, a n d d iscon n ect the g ro u n d (-)
cable from the battery.
Connect the a m m eter (+) probe to the g ro u n d ca b l e a n d

the a m m eter (-) probe t o the battery (-) term i n a l .
With t h e i g n ition switch off, check for cu rrent leakage.
N OTE
When measu ring the cu rrent u s i n g a tester, set it to (2) G R O U N D CABLE

a h ig h ra nge, a n d then bring the ra nge down to a n
a p p ropriate leve l . C u rrent flow l a rger t h a n t h e ra nge
selected may b l ow o ut the f u s e i n the teste r.
Wh i l e m e as u r i n g c u rrent, do n ot t u r n the i g n it i o n
switch O N . A sudden s u rge o f cu rrent m a y b l ow out
the fuse in the teste r.
Specified Current Leakage: 0.01 rnA max.
If cu rrent leakage exceeds the specified va l ue, a s h o rted

c i rc u it i s l i kely.
Regulated Voltage/Ampere Inspection
If the engine m ust be running to do some work,

make sure the area is well-ventilated. Never run the
lead to death.
N OTE

Befo re p e rfo rm i n g t h i s test, be s u re t h e batte ry i s ( 1 ) BATTERY
fu l l y c h a rged a n d that the voltage betwee n its termi
n a l s i s g reater than 1 3.0 V.
Sta rt t h e e n g i n e and wa rm it to ope rati n g te m pe ratu re,

then turn the i g n ition switch O F F .
Connect the m u lti m eter betwee n the batte ry term i n a l s .
i a.TooL I
Digital multimeter 0741 1 - 0020000
available in U.S.A.
Analogue tester 07308 - 0020001
1 5-6
Disco n n ect the sta rte r re lay switch con n ecto r a n d remove ( 1 ) (+) PROB E : R E D/WH ITE
the m a i n fuse (30 A).
Reco n n ect the co n n ecto r o nto the re lay switc h .
C o n n ect the a m m eter betwee n the f u s e h o l d e r term i n a l s

as shown.
Sta rt the engine a n d i ncrease the engine speed g ra d u a l ly
a n d check that the voltage a n d a m pe re a re reg u l ated .
CAUTION

Be careful not to short any tester probes.

Although the current could be measured when the
ammeter is connected between the battery positive
terminal and the positive cable, a sudden surge of
cu rrant to the sta rter motor could damage the
ammeter.

Always turn the ignition switch OFF when conduct
ing the test. Disconnecting the ammeter or wire
when currant is flowing may damage the ammeter.
N OTE

Befo re m a k i n g this test, a l l the l i g hts a n d the other
e l ectrica l eq u i p m e nt s h o u l d b OFF.

U se fu l ly c h a rged batte ry to m a ke this test i n order
to get a correct measurement.
Regulated:
Battery terminals: 1 4 - 1 5.5 V/3,000 rpm
Charging current: 0 - 0.5 A/3,000 rpm
Regulator /Rectifier
System Inspection
R e m ove the seat ( page 2-2 ) .
Disco n n ect t h e reg u lato r/rectifi e r con n ecto rs.

C h eck the co n n ecto rs fo r l oose o r corroded term i n a l .
Measu re the fo l l owing betwee n co n nector term i n a l o f the

wi re h a rness side.
I
( 1 ) R E G U LATO R/RE CTI F I E R 4P CO N N E CTO R

Terminals Specification (WI R E HAR N ESS S I D E )
Item
Batte ry c h a rg i n g Red/Wh ite (+) Batte ry voltage
line a n d G reen (-) s h o u l d reg ister.
G ro u n d l i n e G reen a n d g ro u n d Conti n u ity exist.
C h a rg i n g coi l Yel l ow a n d Ye l l ow 0. 1 - 1 .0 (}
line (20C/68F)
If the c h a rg i n g co i l l i n e rea d i n g is o u t of s pecificati o n ,

c h eck t h e a lternator ( page 1 5-9 ) .
( 1 ) R E G U LATO R/RECTI F I E R 3P CO N N E CTOR

(WI R E HAR N ESS S I D E )
1 5 -7
Unit Inspection
Provided the ci rc u it on the wi re h a rness side is n o rm a l a n d
there a re no loose co n n ections a t the co n n ecto rs, i n spect
t h e reg u l ator/rectifi e r u n it by m e a s u r i n g t h e res i sta nce
between the term i n a ls.
N OTE

You' l l get fa lse rea d i n g s if the p robes touch you fi n
gers.

U se t h e spec ifi ed m u lt i m eters. U s i n g oth e r eq u i p
ment may not a l l ow you to o bta i n the correct resu lts.
This is due to the cha racte ristic of sem ico n d ucto rs,
w h i c h h a v e d i ffe r e n t v a l u e s d e p e n d i n g o n t h e
appl ied voltage.
Specific Multimeter:
- 0741 1 0020000 (KOWA Digital type)
-
- 07308 - 0020001 (SANWA Analogue type)

Select the fo l l owing ra nge:
SANWA: x kO
p
KOWA: x 1 00

U s i n g a n o l d batte ry sto red i n t h e m u lti m ete r c a n
cause i n accu rate rea d i ngs. C h eck the batte ry if t h e
m u lti m eter resista nce is i ncorrect. (2) GREEN

When u s i n g the KOWA m u lt i m ete r, re m e m be r that
a l l rea d i ngs s h o u l d be m u lt i p l ied by 1 00. (3) R E D/WH ITE
( 1 ) YELLOW
Replace the reg u lato r/rectifi e r u n it if the resi sta nce va l u e

betwee n t h e term i n a l s is a b n o rm a l .
U n it 0
e
Red/White
Red/White
------
Yellow

Yellow

Yellow

Green
Yellow 500 - 1 0k ----
Yellow 500 - 1 0k
------
Yellow 500 - 1 0 k
----
G reen 700 - 1 5k 500 - 1 0k 500 - 1 0 k 500 - 10k ----
Removal/Installation ( 1 ) R E G U LATO R/RE CTI F I E R
Disco n nect the reg u lator/rectifier co n n ecto rs.

Remove the m o u nting n uts a n d reg u l ator/rectifie r u n it.
I n sta l l ation is i n the reve rse order of rem ova l .
( 3 ) N UTS
1 5-8
Alternator
N OTE

It is not necessa ry to remove the stato r to m ake this
test.
Remove the fuel ta n k ( page 2-2 ) .

Disco n n ect the a lternator 3P con n ecto r.
Measu re the resista nce between the Ye l l ow wi re term i n a l s

a n d c h e c k fo r n o conti n u ity betwee n e a c h term i n a l a n d
body g ro u n d .
( 1 ) A LTE R N ATOR 3P CO N N E CTOR
Standard: 0.1 - 1 .0 0 (20C/68F)
Replace the stato r if the resista nce is o ut of specification

o r if there is co nti n u ity between Ye l low wi re term i n a l and
g ro u n d .
1 5 -9
Alternator Removal/Installation
(5) (1)
(4) -
0 12 (1. 2 , 9)
(7)
(6)
) c 12 (1. 2 , 9)
LIQU I D SEALANT AREA
1 5- 1 0
N OTE

The e n g i n e o i l wi l l r u n out when the l eft cra n kcase cove r is re m oved . Set a clean o i l pa n u nd e r the e n g i n e a n d a d d
the reco m m ended o i l t o the specified leve l after the i n sta l lati o n .

The l eft cra n kcase cove r (stato r) is magnetica l ly attached to the flywheel, be ca refu l to the remova l/i n sta l lati o n .

Apply a l i g ht but thoro u g h coati n g of l i q u i d sea l a nt to the cra n kcase as s h own .
Requisite Service
F u e l ta n k rem ova l/i n sta l l ation ( page 2-2)

Removal Order I n sta l lation is i n the reverse order of rem ova l .
(1) Alternato r con n ector 1
(2) Left cra n kcase cove r bolt 6
(3) Left cra n kcase cove r 1
(4) Gasket 1
(5) Dowel p i n 2
(6) Stato r w i re h o l d e r 1
(7) Stator m o u nt i n g bolt 4
(8) Stato r asse m bly 1 At i n stal latio n , apply sea l a nt to the g ro m met a n d i n sta l l
the g ro m m et sec u re l y i nto t h e . g roove i n t h e l eft
cra n kcase cover.
Flywheel Removal Order I n sta l lation is in the reverse order of remova l .
(9) F lywheel bolt 1 Apply clean e n g i n e o i l to the bolt th reads.
( 1 0) Was h e r 1
(11) F lywhe e l 1 Before i n sta l lation, wipe an y o i l off the mati ng s u rface of
the c ra n kshaft a n d flywhe e l .
1 5- 1 1
MEMO
1 6. I g n ition System
Service Information 1 6- 1 Ignition Coil Removal/Installation 1 6-9
System Location 1 6-2 Ignition Control Module (ICM)
Removal/Installation 1 6- 1 0
Troubleshooting 1 6-3
Ignition System Inspection 1 6-8

Ignition Pulse Generator
Removal/Installation 1 6- 1 1
Ignition Coil Inspection 1 6-8
Ignition liming 1 6- 1 2
Ignition Pulse Generator Inspection 1 6-9
Service Information
o
H the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an
enclosed area.
o The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
CAUTION
o
Some electrical components may . be damaged if terminals o connectors are connected or disconnected while
the ignition switch is ON and current is present.
o
When checki n g the i g n ition system , a lways fo l low the steps in the tro u b leshooti n g flow c h a rt ( page 1 6-3).
o
The I g n ition control m od u l e ( I C M ) may be d a m aged if d ropped. Also, if the con n ecto r is d i sco n n ected when c u rrent is
present, the excessive voltage may damage the u n it. Always turn off the i g n ition switch befo re servici n g .
o
I g n ition ti m i ng ca n n ot be a dj u sted si nce the I g n ition control m o d u l e ( I C M I is n o n-adj u sta b l e . If i g n it i on ti m i n g i s
i nco rrect, check the system components a n d replace any fa u lty parts.
o
A fa u lty i g n ition system is often related to poorly con nected or co rroded co n necto rs. Check those con nections before
p roceed i n g .
o
U se spark p l u g s of the correct heat ra nge. Us ing spark p lu g s with an i nco rrect h eat ra nge ca n d am ag e the e n g i n e .
Refer to Sectio n 2 o f the C o m m o n Service M a n u a l .
o
For neutra l switch i nspectio n , refer to Section 25 of the Common Service M a n u a l . For switch l ocatio n , see page 1 6-2
o
of t h i s manual ( System Locat i o n ) .
For side sta n d switch , e n g i n e sto p switch a n d i g n ition switch i n s pecti o n , check for conti n u ity c h a rt of the W i r i n g
...

D i a g ra m , page 1 9- 1 . Disco n n ect the i g n ition a n d e n g i n e sto p switch co n necto rs i n the front side cover ( page 2-3), side
sta n d switc h con n ector u n de r the fue l ta n k a n d check it.
1 6- 1
Ignition System
System Location
( 1 3) N E UTRAL
I N DICATOR ---,ff---.,;
(6) CLUTCH
SWITCH
DIODE
(9) S I D E STA N D SWITCH (8) N E UTRAL SWITCH ( 7 ) MAI N F U S E (30 A)
( 1 3) N E UTRAL I N DICATO R
(6) C LUTCH SWITCH DIODE
( 1 1 ) I G N ITION SWITCH
(3) F U S E 1 5 A
B I/Br ---- Lg/B I I IJ)ll l l I I
R <r RfBI B I/Br a:
0; (!)
( 7 ) MAI N F U S E 30 A ....J
a
L--___. ( 1 ) S I D E STA N D I N DICATO R
(3) F U S E 1 0 A
(4) B ATT E RY
DOWN
(8) N E UTRAL
(2) E N G I N E STO P SWITCH
Y/B i "
J
G SWITCH
B lfW o- B I
------ G/W
UP
(9) S I D E STA N D -
SWITCH
...----___,,
:t_I --
G/W ---<Y o-G/R -------'
iii iii
00
( 1 2) CLUTCH SWITCH
I G N ITION ( 1 0) I G N ITION PU LSE G E N E RATO R

COILS ( 5 ) 1CM
S PAR K Bl . . . . . B LACK
PLUGS Y ...... YELLOW
Bu . . . . BLUE
G ...... GREEN
R ...... RED
W ..... WH ITE
Lg . . . . . L I G HT G R E E N
1 6-2
Ignition System
Troubleshooting
I n spect the fo l lowi ng befo re d iagnosing the system .

- Loose spa rk p l u g caps o r spark p l u g wi re con nections.
- Wate r i n the spa rk plug ca p.
- Loose o r poo r contact of i g n ition system co n nectors.
No Spark At All Plugs (Faulty Input System)
If there is no spa rk to the p l ugs, the p roblem cou l d be the i n p ut to the i g n ition syste m ( i g n ition pu lse g e n e rator,
powe r i n put c i rc u it of the i g n ition control mod u l e ( I C M ) , neutra l switch , or side sta n d switch beca use if contro l s the
i g n ition control module ( I C M ) ) .
Check if the batte ry voltage i s measu red be

twee n powe r sou rce i n put l i n e at the i g n ition
contro l m od u l e (ICM) co n n ecto r with the i g n i
tion switch ON a n d the e n g i n e stop switch at
R U N ( page 1 6-8) . 14------1 .,J
No voltage tt/
(
l ...
_. F a u lty i g n ition switch or e n g i n e sto p switch
1------,::.____.
.._
O pen c i rc u it i n wire h a rness
"" / Loose o r poo r con n ecto r contact
Connection: Black/White (+) - Green (-)
Batte ry voltage
measured
A b n o rm a l
M e a s u re t h e i g n it i o n p u lse g e n e rato r res i s 1-----______--..t Check the i g n ition p u l se g e n e rato r ( page 1 6-
t a n c e at t h e i g n it i o n c o n t r o l m o d u l e ( I C M ) 9).
con n ecto r ( page 1 6-8).
Connection: Black/Yellow - Black/White Connection: Black/Yellow - Black/White

Standard: 450 - 550 0 Standard: 450 - 550 0
Ab n o r m a l
Normal
+

Normal
Fau lty i g n ition p u l se g en e rator
O pen c i rc u it in B l ack/Wh ite wire

Open c i rc u it i n B lack/Ye l l ow wire
Loosen or poor i g n ition p u lse generator con
nector contacts
1 6-3
Ignition System
C h eck the n e utra l switc h at the i g n ition con

trol module (ICM) co n n ector ( page 1 6-8).
/
Connection: Black/Light green - Ground
Standard:
Continuity in neutral Abnormal
No continuity in any gear except neutral
Normal
Connection: Light green/Red - Ground

Standard: Continuity in neutral
No continuity in any gear
Normal Abnorm a l

I F a u lty n e utra l switch
Open c i rc u it in Light g reen/Red wi re

Loose or poor neutra l switch con necto r co ntacts
Abnormal
Check the side sta n d switch a t i g n ition control
m o d u l e ( I C M ) con necto r ( page 1 6-8) .

Side stand up: Side stand u
Black/Green - Black: Continuity Green/White - Green: Continuity
Side stand down: Side stand down:
Black/Green - Black: No continuity Yellow/Black - Green: Continuity
Normal Normal Abno r m a l

J F a u lty side sta nd switch
Open c i rc u it in G reen/Wh ite wi re

Open c i rc u it in Yel l ow/Black wi re
Loose or poor side sta n d switch con n ector con
Fau lty i g n ition control m o d u l e ( I C M )
tacts
1 6-4
Ignition System
No Spark At Either Ignition Group
If there is no spa rk at eithe r g ro u p, the problem is proba bly i n the primary coi l side of the i g n ition system ( i g n ition
co i l , o r u n it a n d i g n ition coi l c i rcu it) .

Switch the i g n ition co i l p ri m a ry term i n a l con
nection between the fa u lty pa i r and good pa i r .
Try s p a r k test aga i n .
" N o spark"
con d iti o n
Rem ove t h e fa u lty i g n ition coi l s a n d check the
rem a i n s with i g n ition coi l resista nce ( page 1 6-8) .
the fa u lty pa i r
" N o spark" con d ition

shift to other pa i r
Standard:
Primary: 2 - 4 0
Between the plug caps: 23 - 27 kO
Between the spark plug wire: 1 3 - 1 7 kO
Abno r m a l

Fa u lty i g n ition c oi l
Fau lty spa rk p l u g w i re
Fau lty spa rk p l u gs
M ea s u re resi sta n c e o f t h e i g n it i o n p ri m a ry
coi l at i g n ition control m o d u l e ( I C M ) con nec
tor.
Abnorm a l
------... Poor or l oose i g n ition coi l con nector contacts
Connection: Open c i rc u it in B lack/Wh ite w i re
No. 1 -3: Black/White - Black/Yellow Open c i rc u it i n Black/Ye l low wi re
No. 2-4: Black/White - Black/Blue Open c i rc u it i n Black/B l ue w i re
Standard: 2 - 4 0
Normal

F a u lty i g n ition control m o d u l e ( I C M )
1 6-5
Ignition System
No Spark At One Plug (Trouble In Secondary Coil Side)
Fau lty spark p l u g is m ost l i kely.
R e p l a c e ( s u s p e c t e d bad s p a r k p l u g ) w i t h
known g o o d s p a r k p l u g a n d c o n d u ct s p a r k
test.
Normal
Condact spa rk test o n good i g n ition coi l .
Standard: 23 - 27 kO
Abnormal
R e m ove the s p a r k p l u g cap, a n d m e a s u re

resista nce of the i g n ition coi l ( page 1 6-9).
Standard: 1 3 - 1 7 kO
Abnormal T"
1--------... . Fau lty i g n ition c oi l
N o rm a l

Poor contact of spark p l u g cap
Fau lty spark p l u g cap
Fau lty spa rk plugs
1 6-6
Ignition System
Engine Starts, But Side Stand Switch Does Not Function
NOTE
The side sta nd switch s h o u l d fu nction as fo l l ows:

When the tra nsm ission is sh ifted i nto a gear from neutra l with the side sta nd down, the i g n ition s h uts off a n d the
e n g i n e sto ps.
When i n neutra l , the neutra l switch l i ne (a ) of the i g n ition control m o d u l e ( I C M ) is co n nected to g ro u n d via the side
sta n d switc h .
W h e n t h e s i d e sta n d is up, t h e s i d e sta n d switch l i n e ( b ) o f t h e i g n ition control m o d u l e ( I C M ) passes t o g ro u n d v i a
the s i d e sta n d switc h . T h e i g n ition control m o d u l e ( I C M ) m o n itors l i nes ( a ) a n d ( b ) , a n d provides spark o n l y when
one o r both of those l i nes is connected to ground via the neutra l switch o r the side sta nd switc h .
Normal
Check the s i d e sta n d i n d icato r fu nction. 1--------... Open ci rc u it i n G reen/Wh ite wi re
Abnorm a l
Normal
Check for conti n u ity between each term i n a l of 1--------.... . Loose or poor contact of rel ated con n ectors
side sta n d switch as fo l l ows. Open ci rc u it in G reen/Wh ite w i re
B u rnt i n dicator b u l b
-->,....-<.)C.:::
Side stand up: Green/White - Green
Side stand down: Yellow/Black - Green
Abnormal
'----- Fau lty side sta nd switch
1 6-7
Ignition System
Ignition System I nspection

N OTE

C h eck t h e syste m co m po n e nts a n d wi res ste p- by
ste p a c c o r d i n g to t h e t ro u b l e s h o ot i n g c h a rt o n
pages.
Remove the seat ( page 2-2 ) .

Disco n n ect t h e con n ecto r fro m the i g n ition control m o d u l e
( I C M ) a n d cond uct th ese tests a t the co n necto r.
( 1 ) CO N N ECTO R
Item Terminals Standard

Powe r sou rce i n put l i n e B l ack/Wh ite (+) - G reen (-) Battery voltage s h o u l d reg ister with the i g n ition
switch O N a n d the engine stop switch at R U N .
I g n ition pri m a ry coi l N o . 1 -3: B l ack/Wh ite - B lack/Ye l l ow 2-4 0
N o . 2-4: B l ack/Wh ite - B lack/B l u e
I g n ition pu lse generato r B l ack/Ye l l ow - B l ack/White 450 - 550 0
coi l
N e utra l switch l i n e B lack/Lig ht g reen - Body g ro u n d Conti n u ity i n neutra l
No co nti n u ity i n a ny gear exce pt n e utra l
Side sta n d switch l i n e B lack/G reen - B lack Co nti n u ity with the side sta n d u p
N o co nti n u ity with t h e s i d e sta n d d own
G ro u n d l i n e G reen - Body g ro u n d Conti n u ity
Ignition Coil Inspection ( 1 ) I G N ITION C OI L
Measu re t h e p ri m a ry co i l res i sta nce betwe e n t h e te r m i

nals.
Standard: 2 - 4 0
Measure the resista nce betwee n the spa rk p l u g caps. ( 1 ) I G N ITION CO I L
Standard: 23 - 27 kO
( 2 ) S PA RK P L U G CAPS
1 6-8
Ignition System
If the measu red va l u e out of the specification, rem ove the ( 1 ) I G N ITIO N CO I L
--------->
spa rk plug caps fro m the spark plug wi res a n d measu re
the resista nce betwee n the spark p l u g wires.
Standard: 1 3 - 1 7 kO
Ignition Pulse Generator Inspection

N OTE ( 2 ) S PARK PLU G W I R E S

It is n ot n ecessa ry to re m ove t h e p u l s e g e n e rato r
fro m the e n g i n e .
Remove the fue l ta n k ( page 2-2 ) .
Disco n n ect t h e i g n ition pu lse generato r 3P (Wh ite ) con n ec

tor.
M e a s u re the re s i sta n c e betwe e n the B l a ck/Ye l l ow a n d

B lack/Wh ite term i n a ls.
Standard: 450 - 550 0

( 1 ) PU LSE G E N E RATOR 3 P CON N E CTOR
R efe r to page 1 6- 1 1 fo r i g n ition p u l se g e n e rato r re p l ace
m e nt.
Ignition Coil Removal/Installation ( 1 ) P R I MARY

WIRES
Front
R e m ove the a i r clea n e r h o u s i n g ( page 5- 3 ) .
Remove the spa rk p l u g ca ps fro m s p a r k p l ugs.

Disco n n ect the i g n ition co i l p r i m a ry wi res from the co i l .
R e m ove t h e i g n ition c o i l m o u nting bo lts a n d front i g n ition
co i l .
I n sta l lati o n is i n t h e reve rse order o f re m ova l .
Rear ( 1 ) BOLTS
R e m ove the seat a n d l eft side cove r ( page 2-2, 3 ) .
R e m ove the fuse b o x stay bo lts a n d fra me grou n d ca b l e .

1 995 American Honda Motor Co. , I n c . - All Rights Reserved
04\
1 6-9
Ignition System
Remove the spark p l u g caps from spark pl ugs. ( 1 ) BOLTS (2) P R I MARY WIRES
Discon nect the i g n ition coi l pri m a ry wi res from the coi l .
Remove the i g n ition coil m o u nting bolts a n d fro nt i g n ition
coils.
I n sta l latio n is i n the reverse o rder of rem ova l .
(3) I G N IT I O N COIL
Ignition Control Module (ICM)

Removal/Instal lation
Remove the battery case m o u nting bolts.
M ove the battery case l eft wa rd and d isco n n ect the i g n i

tion control modu l e ( I C M ) con necto r.
Remove the i g n ition control m od u l e ( I C M ) .
I nsta l l ation is i n the reverse order o f removal .
( 2 ) BATTE RY CASE
1 6- 1 0
Ignition System
Ignition Pulse Generator Removal/Installation
Requisite Service
R i g ht cra n kcase cover re mova l/i nsta l lation ( page 9-2)
F u e l ta n k rem ova l/i n sta l l ation ( page 2-2)

Removal Order I n sta l latio n is in the reverse o rd e r of remova l .
(1) I g n ition p u l se g e n e rator con necto r 1
(2) O i l pressu re switch term i n a l 1
(3) I g n ition pu lse g e n e rato r w i re g ro m m et 1 At i nsta l lation, apply sea l a nt t o t h e wi re g ro m met, a n d
i n sta l l t h e i nto t h e rotor cover g roove sec u rely.
(4) I g n ition p u l se g e n e rato r m o u nt i n g bolt 3
(5) I g n ition pu lse generato r asse m bly 1 R oute the i g n ition pu lse generato r wi re as s h own.
(6) Dowel pin 2
1 6- 1 1
Ignition System
Ignition liming
N OTE
The i g n ition co ntro l m o d u l e ( I C M ) system is facto ry
p re - s et a n d c a n n ot be a d j u st e d . I g n i t i o n t i m i n g
i nspectio n proced u res a re g iven to i n spect the fu nc
t i o n of t h e i g n it i o n control m o d u l e ( I C M ) c o m po
nents.
If t h e ti m i n g a p p e a rs wro n g , c h e c k a n ot h e r s p a r k
p l u g wire fo r confi rmat i o n .
W a r m u p the e n g i n e t o operati ng tem perat u re .
If the engine must be running to do some work,

make sure the area is well-ventilated. Never run the
lead to death.
Stop the e n g i n e and rem ove the t i m i n g h o l e cap.
Connect a ti m i n g l i g ht to the spark p l u g wire.

Sta rt the e n g i n e and l et it i d l e .
T h e ti m i n g is correct if the F m a rk a l i g n s with the i ndex

" "
m a rk o n the right cra n kcase cove r. ( 1 ) I N DEX MARK ( 2 ) "F" MARK
I ncrease the e n g i n e speed by rotat i n g t h e t h rott l e sto p

screw k n o b a n d m a ke s u re the " F " m a rk beg i n s t o m ove
cou nterclockwise at a p p roxi m ately 2,000 rpm .
Check t h e ti m i n g h o l e cap's 0-ri n g fo r d a m age, rep l ace the

new one if desi red.
Apply g rease to the th reads, and i n sta l l t h e ti m i n g h o l e

cap.
Torque: 18 Nm ( 1 .8 kg-m, 1 3 ft-lb)
1 6- 1 2
1 7 . E lectric Starter /Starter Cl utch
Service Information 1 7- 1 Starter Motor Disassembly/Assembly 1 7-8
System Location 1 7-2 Starter Clutch Removal/Installation 1 7- 1 0
Troubleshooting 1 7-3 Starter Clutch Disassembly/Assembly 1 7- 1 2
Starter Motor Removal/Installation 1 7-7
Service Information

Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing
serious injury.
A wea k battery may be u na b l e to tu rn the starte r motor q u ickly e n o u g h , or su pply adeq u ate i g n ition cu rrent.
If c u rrent is appl ied to the sta rter m oto r wh i le the e n g i n e is n ot turn i n g ove r, the sta rte r m oto r may be damaged.
For the fol l owi n g components i nspections, refe r to the C om m on Service M a n u a l or the fo l lowi n g pages; fo r the pa rts
l ocatio n s, see page 1 7-2 of this m a n u a l (System Locatio n ) .
Component Inspection method Remarks

Cl utch switch diode Section 2 4 of the Common Service M a n u a l
Sta rter m otor Section 2 4 of the Co m m o n Service M a n u a l
C l utch switch Section 25 of the Common Service M a n u a l
N e utra l switch Sectio n 2 5 of the Com m o n Service M a n u a l Torque: 1 2 Nm ( 1 .2 kg-m, 9 ft-lb)
I g n ition switch Check fo r co nti n u ity o n the conti n u ity c h a rt of
the Wiring Diagram, page 1 9- 1 .
S i d e sta n d switch See page 1 8-9.
1 7- 1
System Location
( 1 3) SIDE STAND
INDICATOR
1 1 1 ENGINE STOP SWITCH
( 1 2 ) NEUTRAL
INDICATOR
(2) STARTER SWITCH
(3) FUSE BOX

( 1 0 A,1 5 AI (4) BATTERY
(After 2000:
CLUTCH SWITCH
DIODE I
( 5) CLUTCH SWITCH
DIODE
( :'94 - 2000)
( 1 0) IGNITION
SWITCH
(8) NEUTRAL SWITCH

(S) STARTER RELAY SWITCH
(MAIN FUSE 30 A)
( 1 0) IGNITION SWITCH (4) BATTERY
(3) FUSE 1 5 A (6) MAIN

(3) FUSE 1 0 A FUSE

.
30 A
i
121 STARTER SWITCH a

(1 2) NEUTRAL

1 ) EN GINE ST0 ( 5) CLUTCH SWITC
DIODE
1 1 T I I 1
INDICATOR ( 1 1 ) CLUTCH SWITCH
'--+-- Lg/81 G/R /R
Lg/R
(8) NEUTRAL SWITCH (7) SIDE STAND
C)
SWITCH
( 1 3) SIDE STAND DOWN UP
INDICATOR
Bl ..... BLACK
y . . .... YELLOW
L------Y/BI Bu .... BLUE
G ...... GREEN
R ...... RED
W ..... WHITE
Lg ..... LIGHT GREEN
1 7-2
Troubleshooti ng
N OTE

Check fo r the fo l l owi ng befo re tro u b l eshooti ng the system .
- B l own m a i n fuse (30 A ) o r s u b fuse ( 1 0 A).
- Loose batte ry and sta rte r motor cable.
- Disc h a rged battery.
The sta rte r moto r s h o u l d ope rate when the tra n s m ission is in n e utra l .
The sta rte r moto r s h o u l d ope rate when the tra n s m ission is i n a ny gea r as i n d icated the c h a rt be l ow.
Gear Position Side Sta n d Cl utc h Lever Sta rte r M otor
Up P u l led i n Operates
Released Does N ot O pe rate
I n Any G e a r
Down P u l led i n Does N ot Ope rate
Released Does N ot Ope rate
Starter motor will not turn

Abnorm a l
C h ec k fo r loose or poorly co n n ected batte ry 1------i., . Poorly con nected batte ry term i n a l s
te r m i n a l s a n d o p e n e d o r s h o rt e d b a tt e ry O p e n or s h o rt c i rcu it batte ry ca ble

ca b l e .
Normal
Abnorm a l
C h eck fo r l oose o r poorly con nected sta rte r 1------ Poorly con n ected term i n a l s of 4P co n n ecto r
re lay switch term i n a l s a n d 4P con n ecto r.
Normal
j
1 7-3
Abnormal
C h eck fo r l oose or poorly c o n n ected sta rte r r------. . Poorly con nected batte ry te rm i na l s
moto r cable, a n d o p e n ca b l e . O p e n c i rc u it i n sta rte r m otor ca ble
Normal
C l icks
With the i g n ition switch " O N " push the sta rte r r-----1 C o n n ect the sta rte r m otor term i n a l to the bat-
butto n a n d check fo r a " C l ick" sou n d fro m the tery positive term i n a l d i rectly.
sta rte r relay switch . ( Beca use a l a rge a m o u nt o f cu rrent flows, d o
n ot u s e t h i n wi res)
-
-
-
-
l-
N o c l ick Sta rte r m otor turns Sta rter m oto r does not turn
1
Disco n n ect sta rter re lay switch co n nector, a n d

F a u lty sta rter motor
check t h e re lay co i l g ro u n d l i n e as below fo r
conti n u ity:
1 . G reen/Red term i n a l-to-cl utch switch d iode Loose o r d i sco n n ected sta rter m oto r cable
to- n e utra l switch l i n e (with t ra n s m i s s i o n F a u lty sta rte r relay switch
i nto ne utra l a n d c l utch l ever re lease d ) .
2 . G reen/Red term i n a l -to-cl utch switch-to-si d e
sta n d switch l i n e ( i n any gear except neu N o conti n u ity
tra l , a n d with the c l utch l ever p u l led i n a n d ------.... F a u lty n e utra l switch
the s i d e sta n d u p ) . F a u lty cl utch switch
F a u lty side sta n d switch
Loose or poor co ntact of con n ecto r
Open ci rc u it i n wi re h a rness
Cont i n u ity

1 7-4
N o Vo lta ge
C o n n ect the sta rte r re l a y switc h co n n ecto r. -----=-- . Fau lty i g n ition switch
With t h e i g n i t i o n switc h O N a n d t h e sta rte r Fau lty e n g i n e sto p switch
b utto n pushed, measure the sta rte r relay vo lt- Fau lty sta rter switch
age at the sta rte r switch co n necto r. B lown out m a i n or s u b fuses
Loose or poor co ntact of co n necto r
Open ci rcuit i n wi re h a r n ess
Connection: Yellow/Red (+) - Body ground (-)

Batte ry vo lta ge registe rs
Normal
Rem ove the sta rte r re lay switc h . ------ Loose or poor contact of the sta rter re lay
C o n n ect a fu l ly c h a rged 1 2 V batte ry t o t h e switch con n ecto r
sta rter re lay switc h .
Check the conti n u ity betwee n the switch l a rge
term i n a l .
Battery Connection:
Yellow/Red (+) - Green/Red 1-1 Abnorm a l
1-------.. F a u lty sta rte r re lay switch
Standard: Continuity
Starter motor turns when the transmission is in neutral, but does not turn with transmission in any gear with the side
stand up, and the clutch lever pulled in.
Abnorm a l
C h eck that the side sta n d switch is operati ng 1-------___, . F a u lty side sta n d switch
properly with the i g n ition O N . B u rnt b u l b

O p e n c i rc u it i n wire h a rness

Normal
1
1 7-5
Abnormal
Check the cl utch switch operatio n . 1------ F a u lty cl utch switch
Normal
Abnormal
Check the side sta nd switch ( page 1 8-9) . 1------ Fau lty side sta n d switch
Normal
L---- Open c i rc u it i n wi re h a r n ess
Loose o r poor co ntact of con n ector
Starter motor turns slowly

Low specific g ravity i n battery ( o r dead battery)
Poorly con n ected battery term i na l ca b l e
Poorly con n ected sta rter m otor ca b l e
Fau lty sta rte r m otor
Starter motor turns, but engine does not turn

Sta rter m otor is ru n n i n g backward
- Case assem bled i m p ro perly
- Te rm i n a l s con n ected i m p roperly
Fau lty sta rter cl utch
Da maged red uct i o n g e a r
Starter relay switch "clicks", but engine does not turn over
C ra n kshaft does n ot turn d u e to i nternal mecha n ical e n g i n e p roblem
Excessive red uctio n gear frictio n
1 7-6
Starter Motor Removal/Installation
.$B fl (5)

With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor.
N OTE
I
R oute the wi re a n d cables properly ( page 1 -20).

Removal Order I nsta l latio n is in the reverse order of remova l .
(1) F l a nge n ut 1 After i nsta l lation, i nsta l l the r u b be r cap.
(2) Sta rte r m otor cable eye let 1
(3) Sta rter m otor m o u nt i n g bo lt 2
(5)
(4) Sta rter m otor 1 Disasse m b ly ( page 1 7-8)
0-ri ng 1 Apply o i l when i n sta l l i ng .
1 7-7
Starter Motor Disassembly I Assembly
(6)
(8)
(1) C 5 (0.5, 3.6)
(9
( 1 6)
(2)
(3)
(4)

(5)
ALI G N
1 7-8
Requisite Service
Sta rte r m otor re m ova l/i nsta l lati o n ( page 1 7-7 ) .

Disassembly Order Asse m bly is i n the reve rse order of d isasse m b ly.
(1) Case bolt 3
(2) F ront cove r 1 A l i g n the i ndex m a rks on the fro nt cove r a n d case .
(3) Lock was h er 1
(4) 0-ri ng 1
(5) M otor case 1 A l i g n the i ndex ma rks on the rea r cover a n d case.
(6) I ns u lated was h e r 1
(7) Was h e r 1
(8) Arm atu re 1
(9) Brush term i n a l h o l d i n g n ut 2
( 1 0) Was h e r 1
(1 1 ) I n s u l ated was h e r 3
( 1 2) 0-ri n g 1
( 1 3) B ru s h h o l d e r asse m bly 1 A l i g n the h o l d e r ta b with the rea r cover g roove.
( 1 4) Brush a n d term i n a l 1
( 1 5) 0-ri n g 1
( 1 6) Rea r cover 1
1 7-9
Starter Clutch Removal/Installation
W I D E G ROOVE
(1
tf!!t
t. 90 (9.0, 65) i a.TooL I ( pa ge 1 7- 1 1 )
SCREW DR IVE R
1 7- 1 0
Requisite Service
R i g ht cra n kcase cover re mova l/i n sta l lati on ( page 9-2)

Pu lse generato r re m ova l/i n sta l lati o n ( pa g e 1 6- 1 1 )

Removal Order I nsta l lati on is in the reve rse order of rem ova l .
(1) Sta rter c l utch bolt 1
U s e t h e gear h o l d e r (07724 - 00 1 0 1 00) a s s h own .

Apply clean e n g i n e o i l to the t h reads.
(2) Was h e r 1
(3) Sta rter cl utch asse m bly 1
Disasse m bly/assem bly ( page 1 7- 1 2)

At i n sta l lati on, a l i g n the wide g roove with the wide
tooth of the cra n kshaft.
(5) Pri m a ry d rive gear g u id e 1
(6) Sta rter red u ction gear shaft 1
(7) Sta rter red uctio n gear/washer 1/1
(8) Pri m a ry d rive gear asse m b l y 1 N OTE

When pri m a ry d rive gear remova Vi n sta l lati o n , a l i g n i n g
t h e pri m a ry d rive g e a r a n d s u b-gear ( a ntibacklash
gear) teeth with a screw d river.
1 7- 1 1
Starter Clutch Disassembly I Assembly
(7 ) (1)
(3)
r
c
(2)
40 (4.0, 29)
(6)
Requisite Service
Sta rter cl utch rem ova l/i nsta l latio n ( page 1 7- 1 0 ) .

Disassembly Order Asse m bly is i n the reve rse order of d isasse m bly.
(1) Sta rter d riven gear 1 Rotate c lockwise, when i n sta l l i n g .
(2) Sta rter cl utch outer cove r bolt 3 Apply a l ocki ng agent to the th read s at i n sta l lati o n .
(3) Sta rte r cl utch outer cover 1 A l i g n the p i n on the outer with the h o l e of the cove r
when i nsta l l i ng .
(4) Roller 3 Be ca refu l not to pop them out.
(5) Plunger 3
(6) Spring 3
(7 ) Sta rte r cl utch outer 1
1 7- 1 2
1 8. Lig hts/Meters/Switch es
Service Information 1 8- 1 Combination Meter DisassemblyI
Assembly 1 8-8
System Location 1 8-2
Ignition Switch Replacement 1 8-9
Troubleshooting 1 8-3
Side Stand Switch 1 8-9
Bulb Replacement 1 8-5
Headlight Removal/Installation 1 8-6
Combination Meter Removal/

Installation 1 8-7

A halogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after it is
turned OFF. Be sure to let it cool down before servicing.

Use an electric heating element and heated water/coolant mixture for the thermo sensor inspection. Keep all
flammable materials away from the burner. Wear protective clothing, insulated gloves and adequate eye protec
tion.

An improperly adjusted headlight may bling on-coming drivers, or it may fail to light the road for a safe distance.
N ote the fo l l owing when re placing the h a logen h ea d l i g ht b u l b.

- We a r clean g l oves w h i l e replacing the b u l b. Do n ot put fi nger pri nts on the head l i g ht b u l b, as they may create h ot
spots on the b u l b a n d cause it to break.
- If you to uch the b u l b with yo u r ba re h a nds, clean it with a clotch m o i ste ned with a lco h o l .
- Be s u re t o i n sta l l the d u st cove r afte r re pl aci ng t h e bu l b.
A l l p l a stic c o n n ecto rs have locki n g tabs that m u st be re leased befo re d i sco n n ecti n g , a n d m u st be a l i g n e d a n d
engaged fu l l y when recon necti n g .
Always turn off the i g n ition switch before d i sco n n ecti n g any e l ectrica l component.
A conti n u ity test can be m a d e with switches i n sta l led on the m oto rcycle.
C h eck the batte ry co n d ition befo re perfo rm i n g any i n s pection that req u i res proper battery voltage.
F o r t h e fo l l owi n g c o m p o n e nt l ocati o n s see t h e Co m m o n S e rvice M a n u a l or page 1 8-2 of t h i s m a n u a l ( S yste m

Locat i o n ) ; fo r i n s pections, refer to the a p p l icable pages.
Component Inspection method Remarks

F ront bra ke l i g ht switch Section 25 of the Com m o n Service M a n u a l
Horn Section 2 5 of the Com m o n Service M a n u a l
H a n d l e b a r switch Check fo r conti n u ity on the conti n u ity c h a rt
of t h e Wiring Diagra m , page 1 9- 1
I g n ition switch
N e utra l switch Section 25 of the Com mon Service M a n u a l Torque: 1 2 Nm ( 1 .2 kg-m, 9 1b-ftl
Apply sea l a nt to the t h reads.
O i l p ressure switch/ Section 2 5 of the Com m o n Service M a n u a l O i l pressu re c heck: Section 4 o f t h e
wa r n i n g l i g ht Com m o n Service M a n u a l .
Torque: 1 2 N m ( 1 .2 kg-m, 9 lb-ft)
Apply sea l a nt to the t h reads.
Rear b ra ke l i g ht switch Section 2 5 of the Co m m on Service M a n u a l
T u r n s i g n a l l i g hts Section 25 of the Co m m on Service M a n u a l
1 8- 1
Lights/Meters/Switches
System Location
( 1 ) F R O N T B RAKE LI G HT
SWITC
(8) N E UTRAL (6) COOLANT TE M P E RATU R E

I N DI CATOR U N IT (5) F U S E BOX
(7) S I DE STA N D SWITCH
1 8-2
Troubleshooting
Coolant Temperature Indicator
Turn the i g n ition switch O N , check that the tem perat u re i n d icato r l ig ht comes on fo r 3 seconds then goes out.
Coolant Temperature Indicator Remain ON

I nd icator
co m es o n
Disco n n ect the coo l a nt tem perat u re i n d icator 1---________ S h o rt c i rc u it i n Li g ht g ree n/B lack wi re
con n ecto rs. Turn the i g n ition switch O N .
I n d icato r does n ot come o n
Normal
C o n n ect t h e c o o l a nt t e m pe ratu re i n d icato r 1-------_. F a u lty thermo sensor (page 1 - 1 1 )
c o n n ecto rs . D i sc o n n ect t h e t h e r m o s e n s o r
co n n ecto r a n d t u r n t h e i g n it i o n switch O N .
Check the coo l a nt tem pe ratu re i n d icator o pe r
atio n .
Abnorm a l
F a u lty coo l a nt tem pe ratu re i n d icato r u n it

S h o rt c i rc u it i n G reen/B l ue wi re
1 8-3
Coolant Temperature Indicator Remains OFF

I n d icator does
not come on
Disco n n ect the cool a nt tem peratu re i n d icato r 1-------.
B l own i n d icator b u l b
co n n ecto rs. Co n n ect a j u m pe r w i re to the 4P
Open c i rc u it i n L i ght g reen/B l ack wi re
co n nector a n d body g ro u nd, t u rn the i g n ition
switch O N .
I n d icato r come o n
Abnormal
C h eck t h e coo l a nt tem pe ratu re i n d i cato r 4P to------,....
Open c i rc u it i n G reen w i re
con n ecto r a n d body g ro u n d for co nti n u ity.
Abnormal
C h eck the voltage betwee n the coo l a nt te m - 1-------.
Open c i rc u it i n Black/B rown w i re
p e rat u re i n d i c a t o r 4 P c o n n ecto r a n d b o d y
g round, t u r n t h e i g n ition switch O N .
Normal

Faulty cool a nt tem peratu re i n d icato r u n it
1 8-4
Bulb Replacement ( 1 ) R ETAI N E R
Headlight Bulb

A halogen headlight bulb becomes very hot while
the headlight is ON, and remain hot for a while after
it is turned OFF. Be sure to let it cool down before
servicing.
Remove the head l i g ht ( page 1 8-6) .

P u s h t h e reta i n i n g tabs a n d re m ove the h ea d l i g ht b u l b
socket. Remove t h e d ust cove r. ( 2 ) B U LB
U n hook the b u l b reta i n e r and rem ove the hea d l i g ht b u l b.
I n sta l lation is i n the reverse order of rem ova l .
N OTE

I n sta l l the d u st cover with its "TO P " m a rk faci n g u p.
Tail/Brake Light B ulb

(2) LENS
Remove the screws a n d tai l/brake l i g ht lens.
Remove the ta i l/bra ke l ig ht bulb by turning it cou nterclock

wise.
I n sta l l a new b u l b in the reverse o rder of remova l .
( 1 ) SCREW
Turn Signal Light Bulb (3) B U LB

R e m ove the screw a n d t u rn signal l ight lens.
Rem ove the turn s i g n a l l i g ht b u l b by t u rn i n g it cou nter

c lockwise.
I n sta l l a n ew b u l b in the reverse order of remova l .
1 8-5
Headlight Removal/Installation
An improperly adjusted headlight may blind on-comil'!g drivers, or it may fail to light the road for a safe distance.
N OTE
Adj ust the hea d l i g ht bea m as specified by loca l laws a n d reg u l ations.
After i n sta l l ation, route the wi res a n d ca ble properly ( page 1 -20).
Requisite Service
U pper fa i r i n g rem ova l/i nsta l l ation (VF7 50CD: page 2-8)

Removal Order I nsta l lati o n is in the reverse order of re m ova l .
(1) Screw 2
(2) Head l i g ht con necto r 1
(3) Head l i g ht assembly 1
( 4) Head l i g ht case bolt/nut 2/2
(5) U pper fa i r i n g stay 1 VF750CD o n ly.
(6) Head l i g ht case 1
1 8-6
Combination Meter Removal/Installation
N OTE

Ro ute the wi res a n d cables properly ( page 1 -20).
Requisite Service
F ront side cove r re mova l/i nsta l lati o n ( page 2-3)

U pper fa i r i n g re mova l/i nsta l latio n (VF750CD: page 2-8)

Removal Order I n sta l l ation is in the reve rse order of rem ova l .
(1) Speedomete r cable 1
(2) Com b i n ation meter con n ecto r 3
(3) Com bi nation mete r m o u nting bolt/g u ide 2/2
(4) Com bi nation meter assem bly 1 Disasse m b l y/Assem bly ( page 1 8-8)
1 8- 7
Combination Meter Disassembly I

Assembly ( 1 ) SCREWS
Remove t h e screws a n d c l a m ps.
Remove the m eter rea r cover and m ete r stay.
P u l l the i n d icator b u l bs out of the m eter.

Remove the wi re h a rness c l a m p .
Discon nect the m eter term i n a ls, a n d rem ove the wire h a r
ness.
Separate the m eter rea r covers and m eter stay.

( 1 ) REAR COVE R S
Asse m b l e the m eters i n the reverse order of d i sasse m b ly.
N OTE

C o n n ect t h e proper co l o r w i re to t h e m ete r term i
nals.
Y/G: Yellow/Green G: Green
1 8-8
Ignition Switch Replacement

Remove the l eft m i d d l e cover stay assem bly ( page 5-4).
Remove the screw a n d i g n ition switch cove r.

Remove the i g n ition switch m o u nt i n g bo lts u s i n g a d ri l l,
then rem ove the switc h .
I nsta l l the new i g n ition switch a n d n e w m o u nting bolts.

Tighten the m o u nt i n g bolts u nt i l the head twist off.
I n sta l l the left m i d d l e cove r stay a sse m b ly ( page 5-4).
(3) COVER
( 2 ) M O U NTI N G BO LTS .,
Side Stand Switch

Inspection
Disco n n ect the side sta n d switch 3P ( G reen ) connecto r a n d
check fo r conti n u ity betwee n e a c h color o f wi re term i n a l
as shown i n t h e c h a rt below.
( 1 ) S I DE STA N D SWITCH CO N N ECTOR
There s h o u l d be conti n u ity between the o-o positions on

the fol l ow i n g c h a rt u nder the con d itions shown here.
G reen/Wh ite Yel low/Black G reen

Side
sta n d ,....

,....

up
Side
stan d
,.... ,....

d own
Disco n n ect the side stan d switch 3P ( G reen) connector.
R e m ove the s i d e sta n d switc h m o u nt i n g b o l t a n d s i d e

stan d switc h .
I n sta l l t h e switch i n the reverse order o f remova l .
Torque: 1 0 Nm ( 1 ,0 kg-m, 7 ftlb)
N OTE

A l i g n t h e switc h p i n with t h e s i d e sta n d ho l e a n d
a l ig n the switch g roove with the s i d e stan d retu rn
spring h o l d i ng p i n .
1 8-9
MEMO
'94 - 2000:
19. Wirin g Dia g ra m
,.,..,.. UGMT
12Y1.4WI2
1132/!CP

;===::::;-]
liLAC< a, ........
BROWN
YELlOW
BLUE
0
lb
ORANGE
LIGHT BLUE
::u
-
STARTDtS'I'lT'OI .. .
GREEN " UGHT GREEN z
C)
162 ST HL HLI REO PINK
WIITE .. . . ... . GRAY
I QiQ.
STNiftll MOTOR
c
FREE

;;:
PUSH
...... 0030Z- M Z 5 - 6700 C)

::u
CD l>
I
...... 31:
......
CD After 2000:
.,
N
lAOCIMEltJI UGIIT
12V1.4W X 2

IIIGHT II[AR TIA'I $1GML
12V21W
lAAlE AND l.t.llltc>T
12V32/3cp

REAR lAAKE UGtiT SWITCH
00 00
IQNITlCfi COIL
81 BUCK 8< BROWN

y YELLOW ORANGE
a. llltlE "' LIGHT lUI:
GAEN l.t LIGHT GREEN
... PINK
WHITE "' GRAY
0030Z- M Z 5 -ABOO
20. Tech n ical Featu re
CT Bolt
( 1 ) STA N DARD TH R EAD
Some pa rts of this m oto rcycle a re tig htened with the CT
b o lts, i . e . C o m b i n a t i o n T h re a d b o lts w h i c h m a ke t h e
fe m a l e th reads when they screw i n .
T h e l ower h a lf o f t h e C T bolt featu res t h e co m bi n ation of

the sta n d a rd t h reads a n d the low th reads.
When t h e CT bolt i s screwed i nto t h e u nt h re a d e d p i l ot

hole, the bolt m a kes the fe m a l e t h reads i n the p i l ot hole by
d efo rm i n g t h e wa l l of the h o l e . Few c h i ps a n d shavings
a re produced this time, which is d iffe rent fro m t h rea d i n g
b y a mach i n e .
N OTE

W h e n t h e CT bolt is re u s e d , t i g hten t h e bolt with ( 1 ) AFTE R PLASTIC
care n ot to ru i n the fe m a l e threads that were made DEFOR MAT I O N
when the bolt was tightened fi rst t i m e .

The sta n d a rd bolt is a p p l ica b l e to the fem a l e th reads
that were made by means of the plastic d eformation
d u ri n g tig hte n i n g the CT bolt.

The service rep l acement pa rts of the pa rts tig hte ned
with the CT bolts h ave the th reads. ( 2 ) I NTROD U CT I O N PART
(3) LOWE R HALF O F BOLT
(CO M B I NATION OF STA N DA R D
T H READS A N D LOW T H R EADS)
'----- ( 4 ) U PP E R HALF OF B O LT
(STA N DA R D T H READS)
14------ '----+1
W h e n the CT bolt re p l a c e m e n t i s req u i red, use new CT
bolt o r H o n d a gen u i n e sta n d a rd bo lt ( l en gth ).
CAUTION
( 1 ) CT BOLT
I
Do not use the length ' standard bolt.
(3) I NTRO D U CT I O N
Application list PART
Parts Bolt ( 2 ) STAN DARD

Qty
BOLT
B reather case, Rear cyl i n d e r head cove r M6 6
Cyl i n d e r head fi n , Cyl i n d e r head M6 12
Oil pump M6 3
Wate r p u m p M6 3
20- 1
MEMO
2 1 . Troubleshooti ng
Engine Does Not Start Or Is Hard Poor Performance At High Speed 2 1 -4
To Start 21 -1
Poor Handling 2 1 -4
Engine Lacks Power 2 1 -2
Poor Performance At Low And Idle

Speeds 2 1 -3
Engine Does Not Start Or Is Hard To Start
r
Possible Cause
1 . Check the fue l flow to ca rbu retor -- N ot Reac h i n g Carbu retor -----
Clogged fue l tu be or fue l stra i n e r
scree n
Rac no carbu retor Sticking float va lve

Clogged fue l ta n k b reather tu be

Disco n n ected or fa u lty a uto fue l
va lve vacu u m t u b e
2 . Perfo rm a spa rk test ------ Wea k Or No Spark ------ Fau lty s p a r k p l u g s

Fou led s p a r k p l u g s
Good Spa rk
Fau lty I C M

B roken or s h orted spark p l u g wi res

B ro ke n or s h o rted i g n ition co i l s

Fau lty i g n ition switch

Fau lty i g n ition p u l se g e n e rato r

Fau lty e n g i n e stop switch

Loose or d i sco n n ected i g n ition
system wi res
r
3. Test cyl i n d e r com p ression ---- Low Com p ression ------
Va lve stuck open

Worn cyl i n d e r a n d piston ri n g s
com ess i o n N o r m a l
Damaged cyl i n de r head gasket

Seized va lve

I m proper va lve ti m i n g
4. Sta rt b y fol lowi n g normal ---- E n g i n e Sta rts But Stops ------1
I m p roper choke o peration
p roced u re
Carbu retor i nco rrectly a dj u sted

I nta ke p i pe leaki n g

I m proper i g n ition t i m i n g ( F a u lty
I C M or i g n ition p u l se g e n e rato r)

F u e l conta m i n ated
5. Remove a n d i nspect spark p l u g -- Wet P l u g _________ ..,.

F looded carbu retor

Ch oke closed
Th rottle va lve o pe n
fD

Air c l e a n e r d i rty
21 -1
Troubleshooting
Engine Lacks Power

Possible Cause
1 . Raise wheels off the g ro u n d W h e e l s Do N ot S p i n F reely . B ra ke d ragg i n g

and spin by hand . Worn or d a m aged wheel bearings
. Drive c h a i n too tig ht
Wheel Spins Freely
'
2 . Check tire press u re Pressu re Low . F a u lty t i re valve
Pressu re N o r m a l
+ .
3. Accel e rate ra pidly from E n g i n e Speed N ot Ch a nged C l utch s l i p p i n g
l o w t o second When C l utch Is Released . Worn cl utch d iscs/pl ates
. Warped c l utch d iscs/pl ates
E n g i ne S peed Lowe red . Wea k c l utch spring
When C l utch I s R e leased
+ .
4. Accel e rate l i g htly E n g i n e S peed Does N ot Carbu retor chock cl osed
I ncrease . C l ogged a i r c l ea n er
E n g i n e S peed I ncrease . Restricted fue l flow
j
. C l ogged m uffler
. Pi nched fuel ta n k b reather
5. Check i g n ition ti m i n g I nco rrect . F a u lty I C M

. F a u lty i g n ition p u lse g e n e rato r
Correct
' .
6. Test cyl i nd e r com p ression Too Low Valve stuck open
. Worn cyl i nd e r a n d piston rings
Normal . Lea king head gasket
.

I m p roper va lve ti m i ng
7 . Check carbu reto r for c l og g i ng -- Clogged . Carbu retor n ot serviced freq u e ntly
enough
N ot clogg i n g
+ .
8. Remove spark p l u g Fou led O r Disco l o red P l u g s not serviced freq u e ntly
enough
N ot fou led O r Disco l o red . Spa rk p l u g s a re i ncorrect h eat
i
ra n g e
9. Check oil l eve l a n d condition I nco rrect . O i l l evel too h i g h

. O i l level too l ow
Correct . Conta m i n ated o i l

1 0. Remove cyl i nd e r head cover Va lve Tra i n N ot L u b ri cate . Clogged o i l passag e
a n d i n spect l u b ricatio n Properly . C l ogged o i l contro l orifice
Valve Tra i n L u b ricate P roperly
2 1 -2
Troubleshooting
Possible Cause
1 1 . Check for e n g i n e ove rheati n g -- Overheati ng -------.

Excessive ca rbon b u i lt-u p in com-
bu stion cha m be r
N ot Overheati n g
Use of poor q u a l ity fue l
j

C l utch s l i pp i n g

Lea n fue l m ixtu re

Wrong type of fue l
1 2 . Accel e rate or run at h i g h speed -- E n g i n e Knocks --------..

Worn piston a n d cyl i nd e r

Wro n g type of fue l
E n g i n e Does N ot Knock
Excessive carbon b u i lt-u p i n com
bustion cha m be r

I g n ition ti m i n g too a dva nced
(Fau lty I C M )

Lea n fue l m i xtu re
Poor Performance At Low And Idle Speeds

Possible Cause
1 . Check i g n ition t i m i n g ------ I ncorrect -------t

I m proper i g n ition ti m i n g
( F a u lty I C M )
Correct
+ I ncorrect
2 . C h eck ca rbu reto r p i l ot screw --- -------
See F u e l System section
adj u stment
Correct
+
3. C h eck fo r leaking i nta ke pipe --- Lea king --------
Loose i n s u l ator c l a m ps

Damaged i n s u l ator
N o Leak
+ Wea k Or I nterm ittent Spark Fau lty carbon or wet fou led spa rk
4. Perfo rm spark test -------
----t
plug
Good Spark Fau lty I C M
F a u lty i g n ition coi l

B ro ke n or s h o rted spa rk p l u g wi res
Fau lty e n g i n e stop switch
Fau lty i g n ition p u l se g e n e rator
Troubleshooting
Poor Performance At High Speed

Possible Cause
1 " Check i g n ition t i m i n g ------ I nco rrect _________ __..

F a u lty I C M

Fau lty i g n ition p u lse g e n e rator
Correct

2. Disc n nect fu e l tube at carbu retor - F u e l F l ow Restricted __..
_____

C l ogged fue l l i n e
C l ogged fuel ta n k breather
F u e l F l ows Freely
C l ogged fuel stra i n e r screen
+
3. Remove the ca rbu reto r a n d c h eck - C l ogged ------
C l ea n
fo r clogged j uts
N ot clogged
t
4. Check va lve t i m i n g I ncorrect _________ __..
Cam sprocket n ot i n sta l led properly
Correct

5. Check va lve spri ng VVea k -----
F a u lty spri n g
N ot VVea kened
Poor Handling
Possible Cause
1 . I f steering i s heavy ------

Stee r i n g ste m adj usti n g n ut too
tig ht

Damaged stee r i n g head bea rings
22. I ndex
Air Cleaner ........................... ...................................... 3-5 I g n ition contro l Mod u l e ( I C M )
H o u s i n g Rem ova l/I n sta l lati on . . . . . . . . . . . . . . . . . . .. . .. 5-3 Remova l/I n sta l l atio n .... ... ...... ... ...... ..
..... . . .. . ... . 1 6- 1 0
Alternator . . . . . . . . . . . . . . . . . . . . .. .. .. .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . .. ..
.. 1 5-9 I g n ition Pu lse Generato r I n s pection . . . . . . . . . . . . . . . . . . . ... .. 1 6-9
Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5- 1 0 Remova l/I nsta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . .... .. 1 6- 1 1
Batte ry Remova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-5 I g n ition Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-9
Brake Peda l Rem ova l/I n sta l l ati o n . . . . . . . . . . . . . . . . . . . . . .. .. . . . 1 4-8 I g n ition Syste m I nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 1 6-8
B u l b Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-5 I g n ition Ti m i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . . ... .. . . . .. . . 1 6- 1 2
CT Bolt (Tec h n ical Feat u re) ..... .... ...... .........
...... ... .... . 20- 1 Liq u i d Sea l a nt Appl ication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . 1 1-18
Ca b l e & H a rness Routi n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -20 Lubrication & Sea l Poi nts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Camshaft I n sta l lation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. . .. . 8-8 Lubrication Syste m Di a gra m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .. . . .. 8-2 M a i n s h aft Disasse m bly/Assem bly . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-10
Carbu reto r Com bi nation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
... . . 5- 1 0 Ma i ntena nce Sched u l e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ... . .. 3-4
Disasse m bly/Assem b l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .. . . 1 -3
Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 5-4 O i l P u m p Disassembly/Asse m b l y . . . . . . . . . . . . . . . . . . . . . . . . .. . 4-4
Sepa rati o n . . . . . . . . . . . . . . . . . . . . . . ... ........ .... .. ..
. ..... . .. ... . 5-6 Remova l/I n sta l lation . . . . . . . . . . . . . . . . . . . . . ..... ... ... . . . ... 4-3
Syn c h ro n izatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
... .. . . .... . 5- 1 4 Pu lse Seco n d a ry Ai r I njection Control Valve
Tu be R o uti ng ( Ca l ifornia Type O n ly) . . . . . . . . . . . . 5- 1 3 ( PA IR Control Va lve) Rem ova l/I n sta l l ation
C h a rg i n g System I nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-6 (Cal ifornia Type O n ly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 5- 1 8
C l utch I nsta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Pi lot Screw Adj u stment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1 6
Remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . 9-4 Piston Disasse m bly/Asse m b ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -6
C o m b i n ation Mete r Disasse m bly/Assembly . . . . . . . . . . 1 8-8 Rad iator Disasse m b l y/Asse m b l y . . . . . . . . . . . . . . . . . ... .... . ... . 6-6
Rem ova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . 1 8-7 Remova l/I nsta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 6-5
Co n n ecti n g Rod Selection . . . . . . .............................
..... 1 1-18 Rear Brake Pa n e l Disasse m bly/Asse m bly . . . . . . . . . . . . . . 1 4-7
Coo l a nt D ra i n i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . 6-3 Rea r Fender Rem ova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Cou ntershaft Disasse m b l y/Asse mbly . . . . . . . . . . . . . . . . . . . . . 1 1-12 Rea r Wheel Disasse m b ly/Asse m b l y . . . . . . . . . . . . . . . . . . . . . . . . 1 3-4
C ra n kcase Bolt Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 1 1-18 Remova l/I n sta l l atio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
... .. .. . . 1 3-2
C o m b i n ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .. 1 1-14 Reg u lator/Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-7
Sepa ratio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -2 R i g ht C ra n kcase Cover Rem ova l/I n sta l l ation . . . . . . . . . 9-2
C ra n kshaft Bea r i n g Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-16 Seat Remova l/I nsta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cra n kshaft/Con n ecti ng Rod Remova l/I nsta l latio n . . . 1 1 -4 Service Access G u i de . . . . .. .. ...... ....... . ... .
. ....... . .. . ... . . .. . . 3-2
Cyl i nder Head Disasse m bly/Assem bly . . . . . . . . . . . . . . . . . . . 8-6 Service I nfo rmatio n ( B ra ke System ) . . . . . . . . . . . . . . . . . . . . . . . 1 4- 1
Remova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 (C h a rg i n g System/Alte rnato r) . . . . . . . . . . . . . . . . . . . . . . . 1 5- 1
D rive C h a i n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. ... . . . . . 3-8 (Cl utch System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9- 1
D rive S p rocket Cove r Remova l/I nsta l lati o n . . . . . . . . . . . . 1 0-2 (Coo l i n g System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6- 1
E m ission Control I nfo rmatio n La bels (Cra n ks haft/Piston/Tra nsm issi o n ) . . . . . . . . . . . . . . . . . 1 1-1
( U . S .A. O n ly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . 1 -30 (Cyl i n d e r HeadNalves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 8- 1
E m i ssi o n Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. .... 1 -27 ( E l ectric Sta rter/Sta rte r C l utc h ) . . . . . . . . . . . . . . . . . . . . . 1 7- 1
E n g i n e Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ( E n g i ne Remova l/I n sta l lati o n ) .... . ..... .... .... .. .. . 7-1
Eva porative E m ission Ca n i ster ( EVAP Ca n i ste r) ( F ra m e/Body Pa n e ls/Ex h a u st System ) . . . . . . . .. 2-1
Remova l/I n sta l l ation ( F ront Wheel/Suspension/Stee ri n g ) . . . . . . . . . . . . . 1 2-1
( C a l ifo r n i a Type O n ly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1 8 ( F u e l System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 5- 1
E x h a u st Syste m Remova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . 2-4 ( G e a rs h ift Li n kage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 1 0- 1
Fork Assem bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 2- 1 0 ( I g n ition Syste m ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6- 1
Disasse m b l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. . .. 1 2-8 ( Lig hts/Mete rs/Switches) . . . . . . . . . . . . . . . . . . . . . . .... . . . .. 1 8- 1
Rem ova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 2-6 ( L u b ricati on Syste m ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
F ront Brake Ca l i pe r Disasse m bly/Asse m bly . . . . . . . . . . . 1 4-4 ( M a i nte na nce) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3-1
Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-3 (Rear Wheel/S uspens i o n ) . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 1 3- 1
F ront Brake Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-2 S h ock Abso rber Disasse m bly/Assem bly . . . . . . . . . . . . . . . . 1 3-7
F ront Master Cyl i nder Disassembly/Assem bly . . . . . . 1 4-6 Remova l/I nsta l lati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 3-6
Rem ova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-5 Side Cover Remova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
F ront Side Cover Rem ova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . 2-3 Side Sta nd Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-9
F ront Wheel Disasse m bly/Assembly . . . . . . . . . . . . . . . . . . .
Rem ova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Fuel Ta n k Remova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .. . .
..
.
..
. 1 2-5
1 2-4
2-2
a
e c
i :; oibiii.\'t;j:::::::::::::::::::: 1 7
Remova l/I n sta l l ati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17-10
flJI
Gea rshift Li n kage Remova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . 1 0-4 Sta rter Moto r Disasse m b l y/Assem bly . . . . . . . . . . . . . . . . . . . . 1 7-8
Genera l Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . .. 1-1 Rem ova l/I n sta l l ati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-7
H a n d lebar Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2-2 Steering Stem Rem ova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . .. . . 1 2- 1 2
Hea d l i g ht Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 0 Swi n g a rm D isassem bly/Assem b l y . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3- 1 1
Remova l/I nsta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-6 Remova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. ... . . . . . 1 3-9
H i g h Altitude Adj ustment ( U .S.A. O n ly) . . . . . . . . . . . . . . . . . 5- 1 7 System F l ow Patte rn . . . . . . . . . . . . . . . . . . . . .
. ... . . ....... .... . .. . ..... . 6-2
I g n ition Coi l I nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-8
Remova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 6-9
22- 1
Index
System Location (Charg i n g System/Alternator) . . . 1 5-2

( E lectric Sta rter/Sta rter Cl utc h ) . . . . . . . . . . . . . . . . . . . . . 1 7-2
( I g n ition System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-2
( Lig hts/Meters/Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-2
Thermostat Remova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-4
Too l s .......................................................................... 1-15
Torq ue Va l ues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1-12
Transm ission Remova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -8
Tro u bleshooti ng ( B ra ke System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 1
(Charg i n g System/Alternato r) . . . . . . . . . . . . . . . . . . . . . . . 1 5-3
(Cl utch System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1
(Coo l i ng System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
(Cran kshaft/Piston/Transm issio n ) . . . . . . . . . . . . . . . .. 1 1 -1
(Cyl i nder HeadNa lves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8- 1
( E l ectric Sta rter/Sta rter Cl utc h ) . . . . . . . . . . . . . . . . . . . . . 1 7-3
( E n g i n e Does N ot Sta rt Or Is H a rd To Sta rt) 21-1
( E n g i n e Lacks Powe r) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 1 -2
( F rame/Body Panels/Ex h a u st System ) . . . . . . . . . 2-1
( F ront Wheel/Suspension/Steer i n g ) . . . . . . . . . . . . . 1 2- 1
( F u e l System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
(Gea rs h ift L i n kage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 0- 1
( I g n ition System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-3
( Li g hts/Meters/Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-3
( L u b ri cation System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
( Poor H a nd l i n g ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 -4
( Poor Performa nce At H i g h S peed ) . . . . . . . . . . . . .. 2 1 -4
(Poor Performance At Low And Idle Speeds) . . . 2 1 -3
( Rear Wheel/Suspe n s i o n ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 3- 1
U pper Fairing Remova l/I n sta l latio n (VF750CD) . . . . . . . 2-8
Valve Cleara nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Water P u m p Remova l/I nsta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9- 1
22-2 (232)
23. Appendix: Part Numbers
Air Cleaner 23-2 Mark VF750C (1994-1997) 23-33
Air Suction Valve 23-3 Mark VF750C (1998-2003) 23-34
Alternator 23-4 Mark VF750CD (1996-1997) 23-35
Battery 23-5 Mark VF750C2 (1998-2000) 23-36
Bikini Cowl 23-6 Muffler 23-37
Cam Chain 23-7 Oil Pump 23-38
Camshaft 23-8 Pedal 23-39
Carburetor Assembly 23-10 Pulse Generator 23-40
Carburetor Components 23-12 Radiator 23-41
Carburetor Side Cover 23-13 Rear Brake Panel 23-42
Caution Label 23-14 Rear Cylinder Head 23-43
Clutch 23-15 Rear Fender 23-44
Crankcase 23-16 Rear Shock Absorber 23-45
Crankshaft 23-17 Rear Wheel 23-46
Cylinder Head Cover 23-18 Right Crankcase Cover 23-47
Evaporation Canister 23-19 Seat 23-48
Frame 23-20 Side Cover 23-49
Front Brake Caliper 23-21 Speedometer Tachometer 23-50
Front Brake Master Cylinder 23-22 Stand 23-52
Front Cylinder Head 23-23 Starting Motor 23-53
Front Fender 23-24 Steering Stem 23-54
Front Fork 23-25 Step 23-55
Front Wheel 23-26 Swingarm @ Drive Chain 23-56
Fuel Tank 23-27 Taillight 23-57
Gasket Kit A 23-28 Tools 23-58
Gasket Kit B 23-28 Transmission 23-59
Gearshift Drum 23-29 Turn Signal 23-60
Handle Switch Cables 23-30 Water Pipe 23-61
Handlebar 23-31 Water Pump 23-62
Headlight 23-32 Wire Harness 23-63
23-1
Appendix A: Part Numbers
Air Cleaner
# Description Qty Price # Description Qty Price

01 CLIP, DRAIN TUBE 004 $2.45 11 STOPPER 001 $11.42
15772-GB5-670 17259-MZ5-000
02 AIR CLEANER 001 $47.21 12 TUBE A, BREATHER 001 $3.22
17210-MZ5-000 17355-MZ5-000
03 COVER, A/CLNR HSG 001 $67.73 13 SCREW (5X12) 004 $2.02
17220-MZ5-000 90105-MB1-000
04 AIR CLEANER HOUSING 001 $88.79 14 SCREW, PAN (5X19) 003 $3.65
17230-MZ5-910 (replaces 17230-MZ5-000) 90141-KT8-000
04 AIR CLEANER HOUSING 001 $84.37 15 SCREW, PAN (4X40) 005 $7.11
17230-MZ5-740 90141-MZ5-000
05 PIPE, AIR 001 $15.15 16 NUT, SPECIAL (6X7) 002 $2.64
17234-MZ5-740 61304-958-003(replaces 90301-471-000)
06 CASE, SUB A/CLNR 001 $17.60 17 CLIP, SWITCH CORD 001 $3.27
17251-KT8-000 91400-MR8-000
07 DUCT 001 $44.45 18 SCREW-WASHER (5X10) 002 $0.43
17251-MZ5-000 93891-05010-07
08 FILTER, SUB A/CLNR 001 $2.08 19 BULK HOSE (12X1000) 001 $31.53
17254-KAZ-000 95005-12001-10M
09 COVER, SUB A/CLNR 001 $16.56 20 BOLT, FLANGE (6X45) 001 $0.97
17256-MM4-000 95701-06045-07 (replaces 95701-06045-00)
10 TUBE, SUB A/CLNR 001 $11.07 NI TIE, CABLE 001 $2.10
17258-MZ5-000 32901-VB5-800
23-2
Air Suction Valve

01 CLIP B, FUEL HOSE 006 $4.67 13 PIPE, R. FR. AIR 001 $47.54
16968-MC7-000 18640-MZ5-740
02 JOINT, VACUUM TUBE 002 $12.51 14 GSKT, AIR FEED PIPE 004 $1.96
17201-MG9-000 18645-MT4-730
03 CLIP, BREATHER TUBE 004 $2.78 15 PIPE, L. FR. AIR 001 $47.54
17369-KB4-670 18645-MZ5-740
04 CONTROL VALVE, FR. 001 $129.72 16 PIPE, RR. AIR 001 $99.53
18600-MZ5-740 18650-MZ5-740
05 HOSE A 002 $19.67 17 BOLT 002 $2.88
18612-MZ5-740 90007-PY3-000
06 HOSE A, RR. AIR 002 $18.62 18 CLAMP, TUBE (D17) 002 $2.51
18613-MZ5-740 91405-MF5-860
07 HOSE C, RR. AIR 001 $20.69 19 CLIP, TUBE (B7) 010 $0.82
18615-MZ5-740 95002-02070
08 TUBE, FR. 001 $17.16 20 BULK HOSE (3.5X1000) 001 $5.42
18616-MZ5-740 95005-35001-20M
09 STAY, FR. 002 $12.13 21 BULK HOSE (3.5X1000) 002 $5.42
18617-MZ5-740 95005-35001-20M
10 CONTROL VALVE, RR. 001 $153.78 22 *95701-06016-08 008 $0.73
18620-MZ5-740 95701-06016-00
11 TUBE 001 $31.86 23 BOLT, FLANGE (6X20) 004 $0.60
18625-MZ5-740 95701-06020-00
12 TUBE 001 $10.66
18626-MZ5-740
23-3
Alternator

01 GASKET 001 $12.98 07 BOLT, FLANGE (6X60) 001 $3.93
11636-MY7-000 90001-GHB-750
02 COVER, ALTERNATOR 001 $329.16 08 BOLT, FLANGE (10X35) 001 $4.76
11641-MZ5-920 (replaces 11641-MZ5-000) 90003-MN4-000
03 FLYWHEEL 001 $386.83 09 BOLT, SOCKET (6X40) 004 $3.18
31110-MZ5-004 90116-375-000
04 STATOR 001 $332.99 10 WASHER (10X25X4) 001 $4.76
31120-MZ5-004 90405-ML0-000
05 CLAMP, CABLE 001 $6.36 11 PIN, DOWEL (8X14) 002 $1.00
32111-MZ5-000 94301-08140
06 BOLT, FLANGE (6X32) 005 $2.96
90001-GHB-690
23-4
Battery

01 BATTERY (YTX12-BS) 001 $69.17 09 BOX ASSY., BATTERY 001 $86.89
31500-HF1-678 (replaces 31500-HA0-686, 50330-MZ5-000
31500-HF1-677, 31500-KM1-836, 31500- 10 BODY, KEY 001 $2.76
KM1-837) 83507-422-000
02 CABLE 001 $25.07 11 STOPPER, KEY BODY 001 $2.04
32401-MZ5-000 83508-KBG-000 (replaces 83508-438-000)
03 CABLE, STARTER MOTOR 001 $51.75 12 BOLT, SOCKET (5X9) 002 $1.87
32410-MZ5-000 90111-MR5-000
04 COVER 001 $5.60 13 NUT, SPECIAL (6X7) 003 $2.64
32411-230-000 (replaces 32411-253-000) 61304-958-003 (replaces 90301-471-000)
05 COVER 001 $4.04 14 PIN, SPRING (2X14) 001 $0.67
32414-MZ5-000 94305-20141
06 CABLE 001 $27.51 15 BAND F, BATTERY 001 $5.89
32601-MZ5-000 95012-17001
07 SWITCH ASSY. 001 $83.87 16 BOLT, FLANGE (6X12) 003 $0.78
35850-MR5-007 96001-06012-00
08 RUB, SHOCK ABSORBER 001 $6.95 17 FUSE, BLADE (30A) 002 $0.67
35856-MR5-000 98200-33000
23-5
Bikini Cowl

01 CLIP, SCREEN MOLDING 002 $3.58 10 STAY B, R. COWL 001 $17.18
64102-MJ0-000 64508-MZ5-870
02 MOLDING, WINDSCREEN 001 $8.60 11 STAY B, L. COWL 001 $17.18
64105-MZ5-870 64509-MZ5-870
03 WINDSCREEN 001 $218.56 12 BOLT, SPECIAL (6X17) 002 $2.84
64150-MZ5-870 90085-MZ1-000
04 WASHER 006 $1.62 13 SCREW, PAN (6X14) 001 $3.09
64205-166-610 90106-KBV-000
05 RUBBER, BIKINI COWL 001 $35.91 14 SCREW, TRUSS (5X20) 006 $2.00
64215-MZ5-870 90109-MT3-000
06 COWL SET (TYPE10) 001 $579.87 15 NUT (5MM) 006 $3.55
64220-MZ5-870ZA 90111-KW3-003
06 COWL SET (TYPE9) 001 $579.87 16 WASHER (5MM) 006 $1.60
64220-MZ5-870ZB 90501-MY2-700
07 STAY, COWL 001 $19.36 17 BOLT, FLANGE (8X16) 002 $0.85
64505-MZ5-870 95701-08016-08
08 STAY A, R. COWL 001 $33.87 18 BOLT, FLANGE (6X50) 002 $1.30
64506-MZ5-870 96300-06050-07
09 STAY A, L. COWL 001 $33.87
64507-MZ5-870
23-6
Cam Chain

01 GSKT, TENSIONER HOLE 001 $1.78 11 GUIDE, RR. CAM CHAIN 001 $51.58
12194-HC5-740 14625-MZ5-000
02 GSKT, TENSIONER HOLE 001 $1.67 12 STAY 001 $23.11
12194-KW3-880 14627-MZ5-000
03 CHAIN, CAM 002 $89.02 13 BOLT, FLANGE (6X10) 002 $2.47
14401-MZ5-921 (replaces 14401-MZ5-003) 90004-GHB-600 (replaces 90001-GHB-600)
04 TENSIONER, FR. 001 $108.09 14 BOLT, FLANGE (6X25) 004 $2.22
05 TENSIONER, RR. 001 $108.09 15 BOLT (6X14) 002 $1.15
14515-MZ5-770 (replaces 14515-MZ5-000) 90009-MZ8-H00 (replaces 90009-ME5-000)
06 LIFTER ASSY., RR. 001 $75.99 16 WASHER (6MM) 002 $1.33
14520-MZ5-003 90442-397-000
07 LIFTER ASSY., FR. 001 $75.99 16 WASHER (6MM) 002 $0.93
14530-MZ5-003 90502-KBV-000
08 PIN, TENSIONER 001 $7.04 17 WASHER (6.5MM) 002 $2.25
14531-MZ5-000 90463-ML7-000
09 GUIDE B, CAM CHAIN 002 $28.15 18 PIN (6MM) 001 $1.95
14546-MZ5-000 90607-ME5-000
10 GUIDE, FR. CAM CHAIN 001 $50.43 19 BOLT, FLANGE (6X14) 002 $0.63
14620-MZ5-000 95701-06014-00
23-7
Camshaft

01 SEAL, EX. VALVE STEM 008 $8.07 14 SHIM, TAPPET (1.375) 016 $6.78
12208-ML0-721 14908-KT7-013
02 SEAL, VALVE STEM 008 $7.69 14 SHIM, TAPPET (1.400) 016 $6.78
12209-MZ5-003 14909-KT7-013
03 CAMSHAFT, FR. IN. 001 $261.83 14 SHIM, TAPPET (1.425) 016 $6.78
14110-MZ5-000 14910-KT7-013
04 CAMSHAFT, RR. IN. 001 $278.02 14 SHIM, TAPPET (1.450) 016 $6.78
14120-MZ5-000 14911-KT7-013
05 CAMSHAFT, FR. EX. 001 $258.56 14 SHIM, TAPPET (1.475) 016 $6.78
14130-MZ5-000 14912-KT7-013
06 CAMSHAFT, RR. EX. 001 $261.83 14 SHIM, TAPPET (1.500) 016 $6.78
14140-MZ5-000 14913-KT7-013
07 VALVE, IN. 008 $25.73 14 SHIM, TAPPET (1.525) 016 $6.78
14711-MT4-000 14914-KT7-013
08 VALVE, EX. 008 $45.22 14 SHIM, TAPPET (1.550) 016 $6.78
14721-MY3-000 14915-KT7-013
09 LIFTER, VALVE 016 $33.35 14 SHIM, TAPPET (1.575) 016 $6.78
14731-MT4-010 (replaces 14731-MT4-000) 14916-KT7-013
10 SPRING, VALVE 016 $7.96 14 SHIM, TAPPET (1.600) 016 $6.78
14751-MZ5-003 14917-KT7-013
11 RETAINER, VLV SPR 016 $8.36 14 SHIM, TAPPET (1.625) 016 $6.78
14771-KW3-900 14918-KT7-013
12 SEAT, VALVE SPRING 016 $3.38 14 SHIM, TAPPET (1.650) 016 $6.78
14775-PM3-000 14919-KT7-013
13 COTTER, VALVE 032 $2.71 14 SHIM, TAPPET (1.675) 016 $6.78
14781-ML0-720 14920-KT7-013
14 SHIM, TAPPET (1.200) 016 $6.78 14 SHIM, TAPPET (1.700) 016 $6.78
14901-KT7-013 14921-KT7-013
14902-KT7-013 14922-KT7-013
14903-KT7-013 14923-KT7-013
14904-KT7-013 14924-KT7-013
14905-KT7-013 14925-KT7-013
14906-KT7-013 14926-KT7-013
14907-KT7-013 14927-KT7-013
23-8

14928-KT7-013 14950-KT7-013
14929-KT7-013 14951-KT7-013
14930-KT7-013 14952-KT7-013
14931-KT7-013 14953-KT7-013
14932-KT7-013 14954-KT7-013
14933-KT7-013 14955-KT7-013
14934-KT7-013 14956-KT7-013
14935-KT7-013 14957-KT7-013
14936-KT7-013 14958-KT7-013
14937-KT7-013 14959-KT7-013
14938-KT7-013 14960-KT7-013
14939-KT7-013 14961-KT7-013
14940-KT7-013 14962-KT7-013
14941-KT7-013 14963-KT7-013
14942-KT7-013 14964-KT7-013
14943-KT7-013 14965-KT7-013
14944-KT7-013 14966-KT7-013
14945-KT7-013 14967-KT7-013
14946-KT7-013 14968-KT7-013
14947-KT7-013 14969-KT7-013
14 SHIM, TAPPET (2.375) 016 $6.78
14948-KT7-013
14 SHIM, TAPPET (2.400) 016 $6.78
14949-KT7-013
23-9
Carburetor Assembly
23-10

01 ROD SET, LINK 001 $45.42 25 STAY, JOINT 001 $21.11
16018-MZ5-600 16169-MZ5-670
02 JOINT SET 001 $31.65 26 COLLAR 001 $19.36
16026-MZ5-600 16172-MZ5-670
03 JOINT SET, FUEL 001 $28.47 27 COLLAR 001 $15.85
16027-MB6-671 16173-MZ5-670
04 JOINT SET 001 $31.65 28 COLLAR 001 $19.36
16027-MZ5-600 16174-MZ5-670
05 LEVER SET, LINK 001 $31.51 29 COLLAR 004 $9.40
16035-MZ5-600 16175-MZ1-000
06 GASKET B SET 002 $13.73 30 T-JOINT 001 $22.62
16040-MZ5-600 16179-MB2-881
07 JOINT SET, FUEL 001 $32.87 31 BASE, AIR CLEANER 001 $149.59
16047-KE7-003 16188-MZ5-600
08 JOINT SET 002 $30.27 32 TUBE (15X170) 001 $4.64
16047-MZ5-600 16195-MZ5-670
09 SPRING 001 $9.69 33 TUBE, FUEL 001 $12.65
16050-MZ5-600 16197-MZ5-670
10 SPRING 002 $7.91 34 TUBE, FUEL 001 $15.31
16051-MZ5-670 16198-MZ5-671
11 SPRING 001 $7.09 35 TUBE 001 $3.62
16053-MB0-671 16199-MZ5-670
12 SCREW-WASHER 004 $2.22 36 T-JOINT 001 $13.60
16081-KAZ-000 17193-MN5-000
13 BOLT 002 $23.65 37 T-JOINT 002 $8.89
16083-MZ5-670 17194-MN5-000
14 BOLT 001 $23.65 38 SCREW, PAN (4X16) 016 $0.47
16084-MZ5-670 93500-04016-0G
15 WASHER, PLAIN 004 $1.95 39 NUT, FLANGE (6MM) 006 $0.72
16085-MV4-000 94050-06000
16 WASHER 004 $2.95 40 CLIP, TUBE (B18) 008 $0.76
16090-MZ5-600 95002-02089
17 CARBURETOR ASSY. 001 $1,644.16 41 CLIP, TUBE (B10) 004 $1.02
16100-MZ5-670 95002-02109
18 CARBURETOR ASSY. 001 $1,644.16 42 CLIP, TUBE (B12) 004 $1.02
16100-MZ5-740 95002-02129
19 CARBURETOR ASSY. 1 001 $480.69 43 CLIP, TUBE (B12.5) 001 $1.02
16101-MZ5-670 95002-02139
19 CARBURETOR ASSY. 1 001 $480.69 44 BULK HOSE (4.5X1000) 001 $19.42
16101-MZ5-740 95005-45001-20M
16102-MZ5-670 95005-45001-20M
16102-MZ5-740 95005-45001-20M
16103-MZ5-670 95005-55003-20M
16103-MZ5-740 95005-55003-20M
22 CARBURETOR ASSY. 4 001 $480.69 49 BULK HOSE (7X1000) 001 $7.63
16104-MZ5-670 95005-70001-50M
22 CARBURETOR ASSY. 4 001 $480.69
16104-MZ5-740
23 LEVER, STARTER 002 $30.40
16121-MZ5-600
24 FUNNEL, AIR 004 $20.85
16141-MZ5-600
23-11
Carburetor Components

01 GASKET SET A 004 $32.85 18 SCREW 004 $1.73
16010-MZ5-600 16108-MW0-750
02 NEEDLE SET, JET 004 $34.20 19 PISTON, VACUUM 004 $119.21
16012-MZ5-600 16111-MZ5-600
02 NEEDLE SET, JET 004 $33.85 20 PLATE, STAY 001 $13.64
16012-MZ5-670 16119-MZ2-600
03 FLOAT SET 004 $36.55 21 PLATE, STAY 001 $13.96
16013-MY1-000 16119-MZ5-600
04 CHAMBER SET, FLOAT 002 $100.65 22 STAY, WIRE 001 $17.35
16015-MV9-670 16119-MZ5-670
05 SCREW SET 004 $17.36 23 VALVE, FLOAT 004 $23.04
16016-MAS-670 (replaces 16016-MV9-730) 16155-MN9-004
06 CHAMBER SET, FLOAT 002 $127.01 24 HOLDER, NEEDLE JET 004 $14.63
16023-MV9-670 16165-MN4-013
07 SCREW SET 003 $32.13 25 VALVE ASSY., AIR CUT 004 $59.62
16028-MZ5-600 16510-MZ2-650
08 SCREW SET 001 $24.80 26 SCREW-WASHER (4X10) 001 $0.60
16029-MZ5-600 93892-04010-00 (replaces 93892-04010-10)
09 PLATE SET, VALVE 004 $18.07 27 SCREW-WASHER (5X10) 002 $0.30
16037-MV4-000 93892-05010-00 (replaces 93892-05010-10)
10 GASKET SET C 004 $12.42 28 BULK HOSE (3.5X1000) 004 $5.42
16041-MZ5-600 95005-35001-20M
11 VALVE SET, STARTER 004 $47.54 29 JET, MAIN (#102) 004 $5.20
16046-MV9-670 99101-GHB-1020 (replaces 99101-393-1020)
12 SPRING 004 $13.67 29 JET, MAIN (#102) 004 $5.20
16051-MV4-000 99101-GHB-1020
13 SPRING 004 $7.91 30 JET, SLOW (#40) 004 $8.38
16051-MZ5-600 99103-MT2-0400
14 SPRING 003 $2.95 31 JET, SLOW AIR (#110) 004 $4.56
16052-MV4-000 99108-MW0-1102 (replaces 99108-MW0-
15 SCREW, PAN 012 $1.67 1100)
16080-MV4-000 31 JET (#110) 004 $8.24
16 BOLT-WASHER (5X16) 012 $2.16 99108-MY1-1100
16082-PH9-005
17 TOP 004 $38.78
16107-MZ5-671
23-12
Carburetor Side Cover

01 CVR, CARBURETOR SIDE 001 $72.38 12 KEY, BLANK (TYPE1) 001 $7.38
17255-MZ5-000 35121-MR1-770
02 BASE, R. 001 $48.58 12 KEY, BLANK (TYPE2) 001 $7.38
17256-MZ5-000 35122-MR1-770
03 BASE, L. 001 $46.88 13 GROMMET, A/CLNR HSG 004 $3.18
17266-MZ5-000 83551-GE2-000
04 PROTECTOR 001 $12.13 14 BOLT, BREAK OFF 002 $6.16
17267-MZ5-300 90107-MR1-000
05 COVER SET, L. 001 $91.70 15 BOLT, FLANGE (6MM) 002 $2.84
17268-MZ5-000 90113-KW3-000
06 CABLE, CHOKE 001 $23.56 16 SCREW, RR. COVER 001 $1.18
17950-MZ5-000 90114-GB6-920
07 LOCK SET 001 Call For Price 17 BOLT, FLANGE (6X10) 002 $0.75
35010-MZ5-000 95701-06010-00
08 SWITCH, COMBINATION 001 $49.44 18 *95701-06016-08 002 $0.73
35100-MZ5-A01 (replaces 35100-MZ5-007) 95701-06016-00
09 BASE 001 $9.75 19 BOLT, FLANGE (6X30) 001 $0.83
35102-MR1-000 95701-06030-00
10 COLLAR 001 $15.58 20 BOLT, FLANGE (6X35) 001 $0.75
35103-MR1-000 95701-06035-00
11 COVER 001 $14.45
35110-MZ5-000
23-13
Caution Label

01 DIAGRAM 001 $3.27 07 LABEL (R201) (TYPE1) 001 $2.16
87135-MZ5-740 87565-MZ5-670ZA
02 LABEL, HIGH ALTITUDE 001 $5.02 07 LABEL (NH1) (TYPE2) 001 $2.16
87139-463-670 87565-MZ5-670ZB
03 LABEL, TIRE 001 $3.78 07 LABEL (Y124) (TYPE3) 001 $2.16
87505-MZ5-670 87565-MZ5-670ZC
04 LABEL, DRIVE CHAIN 001 $3.78 08 LABEL, FUEL (TYPEG) 001 $2.33
87507-MZ5-670 87586-MR6-670ZA
05 MARK 001 $4.51 08 LABEL, FUEL (TYPEB) 001 $2.22
87512-MZ3-670 87586-MR6-670ZF
06 LABEL, DRIVE (TYPE2) 001 $4.62
87560-MW0-670ZB
23-14
Clutch

01 SPROCKET 001 $28.64 14 ROD, CLUTCH LIFTER 001 $24.56
15131-ML7-000 22850-MZ5-000
02 CLUTCH (OUTER) 001 $349.77 15 GEAR, PRIMARY DRIVE 001 $167.74
22100-MZ5-010 (replaces 22100-MZ5-000) 23110-ML7-010
03 GUIDE, CLUTCH 001 $22.93 16 SPRING 003 $2.33
22116-MB0-000 23115-MG8-300
04 COLR, CLUTCH (OUTER) 001 $8.11 17 BOLT-WASHER (6X25) 005 $2.33
22117-ML7-690 90022-MM5-000
05 CENTER, CLUTCH 001 $96.21 18 NUT, LOCK (22MM) 001 $7.93
22120-ML7-010 (replaces 22120-ML7-000) 90231-MK7-670
06 SEAT, JUDDER SPRING 001 $8.11 19 NUT, LOCK (22MM) 001 $8.22
22125-ML7-000 90231-MZ7-000
07 DISK, CL FRICTION 008 $11.24 20 WASHER (22MM) 001 $6.58
22201-MS6-620 (replaces 22201-KG0-980, 90432-MB0-010
22201-KM4-000) 21 GUIDE 001 $35.22
08 DISK B, CL FRICTION 001 $12.51 90509-MR7-000
22202-ML4-611 22 BEARING (16003) 001 $12.09
09 PLATE, CLUTCH 008 $10.64 91011-KK6-013 (replaces 91008-362-000,
22321-MR7-000 (replaces 22321-ML7-000) 91008-KK6-000, 91010-HC0-003)
10 PLATE, CLU PRESS 001 $52.03 23 BEARING (35X42X30) 001 $56.71
22350-ML7-000 91024-MB0-003
11 PIECE, CLUTCH JOINT 001 $8.73 24 CIRCLIP (32MM) 001 $0.97
22366-KE8-000 94510-32000
12 SPRING, CLUTCH 005 $3.51 25 CLIP (15MM) 001 $0.68
22401-KZ3-000 (replaces 22401-ML7-000) 94601-15000
13 SPRING, JUDDER 001 $17.18
22402-ML7-000
23-15
Crankcase

01 CRANKCASE SET 001 $2,318.80 14 O-RING (7.7X2.3) 001 $1.45
11000-MZ5-000 91301-PC9-003 (replaces 91308-283-000,
02 GUIDE, HOSE 001 $7.62 91313-393-003)
11337-MZ5-000 15 PIN, DOWEL (8X14) 001 $1.00
03 RECEIVER 001 $22.47 94301-08140
22821-MZ5-000 16 BOLT, FLANGE (6X12) 002 $0.72
04 SWITCH, OIL PRESSURE 001 $32.20 95701-06012-00
35500-MJ4-024 17 BOLT, FLANGE (6X28) 002 $0.85
05 BOLT, FLANGE (6X96) 001 $4.37 95701-06028-00
90003-PC9-000 18 BOLT, FLANGE (6X35) 001 $0.75
06 BOLT, UBS (9X88) 004 $7.33 95701-06035-00
90014-ML7-000 19 BOLT, FLANGE (6X40) 003 $0.85
07 BOLT, UBS (9X108) 004 $8.73 95701-06040-00
90016-ML7-000 20 BOLT, FLANGE (6X45) 002 $0.97
08 BOLT, FLANGE (10X20) 002 $3.18 95701-06045-07 (replaces 95701-06045-00)
90130-126-900 21 BOLT, FLANGE (6X50) 003 $0.98
09 WASHER (10MM) 002 $2.62 95701-06050-00
90403-MG7-000 22 BOLT, FLANGE (6X55) 001 $1.70
10 WASHER (6.5MM) 003 $2.25 95701-06055-00
90463-ML7-000 23 BOLT, FLANGE (6X65) 002 $1.03
11 ORIFICE (1.0) 001 $5.65 95701-06065-00
90701-ML7-000 24 BOLT, FLANGE (8X45) 001 $1.02
12 PIN, DOWEL (10X16) 002 $3.38 95701-08045-00
90701-MV9-670 25 BOLT, FLANGE (10X90) 002 $2.72
13 OIL SEAL (8X25X8) 001 $3.18 95701-10090-00
91204-MB0-013
23-16
Crankshaft

01 RING SET, PISTON 004 $39.05 09 BRG B, RR. CONN ROD 004 $9.09
13011-MT4-315 13235-ML7-690
01 RING SET (OS 0.25) 004 $35.42 09 BRG C, RR. CONN ROD 004 $10.18
13021-MT4-315 13236-ML7-690
01 RING SET (OS 0.50) 004 $38.65 09 BRG D, RR. CONN ROD 004 $9.09
13031-MT4-315 13237-ML7-690
02 PISTON 004 $53.41 09 BRG E, RR. CONN ROD 004 $9.09
13101-MZ5-000 13238-ML7-690
02 PISTON (OS 0.25) 004 $53.41 10 CRANKSHAFT 001 $809.82
13102-MZ5-305 13310-MZ5-000
02 PISTON (OS 0.50) 004 $53.41 11 BEARING A 004 $10.02
13103-MZ5-305 13313-ML7-691
03 PIN, PISTON 004 $18.15 11 BEARING B 004 $10.02
13111-MZ5-000 13314-ML7-691
04 ROD, FR. CONNECTING 002 $164.95 11 BEARING C 004 $10.02
13210-ML7-020 13315-ML7-691
05 BOLT, CONNECTING ROD 008 $6.31 11 BEARING D 004 $10.02
13213-ML7-020 13316-ML7-691
06 NUT, CONNECTING ROD 008 $3.07 11 BEARING E 004 $10.02
13215-ML7-000 13317-ML7-691
07 ROD, RR. CONNECTING 002 $164.95 12 BEARING A 004 $10.02
13220-ML7-020 13323-MR7-013
08 BEARING A, FR. 004 $9.09 12 BEARING B 004 $10.02
13224-ML7-690 13324-MR7-013
08 BRG B, FR. CONN ROD 004 $9.09 12 BEARING C 004 $10.02
13225-ML7-690 13325-MR7-013
08 BRG C, FR. CONN ROD 004 $10.18 12 BEARING D 004 $10.02
13226-ML7-690 13326-MR7-013
08 BRG D, FR. CONN ROD 004 $8.58 12 BEARING E 004 $10.02
13227-ML7-690 13327-MR7-013
08 BRG E, FR. CONN ROD 004 $9.09 13 CLIP (17MM) 008 $0.82
13228-ML7-690 94601-17000
09 BEARING A, RR. 004 $9.09
13234-ML7-690
23-17
Cylinder Head Cover

01 COVER, BREATHER 001 $73.92 09 PLUG, HEX. (6MM) 008 $3.55
12230-MZ5-000 12392-MJ0-000
02 GASKET, BTHR CVR 001 $12.02 10 CLIP B, TUBE 001 $2.38
12231-MZ5-920 (replaces 12231-MZ5-000) 16106-KW7-900
03 COVER, FR. CYL HD 001 $166.66 11 BOLT, CYL HD CVR 008 $8.53
12311-MZ5-A00 (replaces 12311-MZ5-000) 90002-MZ5-000
04 RUBBER A 008 $3.09 12 BOLT, SPECIAL (6X34) 008 $11.09
12312-MZ5-000 90003-MZ5-000
05 RUBBER B 004 $7.04 12 BOLT (6X34.5) 008 $6.09
12313-MZ5-000 90003-MZ5-920
06 COVER, RR. CYL HD 001 $181.64 12 RUBBER, MOUNTING 008 $4.42
12321-MZ5-305 90543-MZ5-920
07 COVER A, CYL HD 004 $135.39 13 BOLT, FLANGE (6X25) 006 $1.74
12340-MZ5-000 90123-VA4-800
08 GASKET, CYL HD CVR 002 $22.42 14 RUBBER, SETTING 008 $3.89
12391-MT4-000 90543-MV9-670
23-18
Evaporation Canister

01 CLIP, TUBE 003 $1.62 17 RUBBER 001 $9.24
15772-MB3-000 17451-ME5-760
02 CLIP, BREATHER TUBE 004 $3.09 18 TUBE 001 $8.38
15772-500-010 (replaces 15772-500-013) 17525-MZ5-740
03 JOINT, FUEL TUBE 001 $8.29 19 TUBE 001 $12.94
16958-MB0-000 18630-MZ5-740
04 JOINT, VACUUM TUBE 001 $12.51 20 JOINT B, WASHER TUBE 001 $4.57
17201-MG9-000 38562-663-920
05 TUBE, OPEN AIR 001 $13.66 21 COLLAR (6.3X13) 002 $3.96
17290-MZ5-740 50324-425-010
06 VALVE ASSY. 001 $192.58 22 RUBBER 002 $3.51
17300-MZ5-740 84703-MN5-000
07 TUBE 001 $14.18 23 CLAMP, TUBE (12.5MM) 001 $1.16
17301-MZ5-740 90661-GHB-610
08 RUBBER, SETTING 001 $8.11 24 CLIP, TUBE (B7) 008 $0.82
17305-MJ4-771 95002-02070
09 CANISTER 001 $241.47 25 CLIP, TUBE (B8) 004 $0.82
17410-MR1-682 95002-02080
10 TUBE 001 $14.80 26 CLIP, TUBE (B12) 005 $0.90
17411-MZ5-740 95002-02120
11 TUBE 001 $6.98 27 BULK HOSE (3.5X1000) 001 $5.42
17412-MZ5-740 95005-35001-20M
12 TUBE 001 $14.46 28 BULK HOSE (3.5X1000) 001 $5.42
17413-MZ5-740 95005-35001-20M
13 TUBE 001 $16.58 29 BULK HOSE (3.5X1000) 001 $5.42
17414-MZ5-740 95005-35001-20M
14 PIPE 001 $81.68 30 BULK HOSE (4.5X1000) 001 $19.42
17415-MZ5-740 95005-45001-20M
15 TUBE 001 $17.44 31 BOLT, FLANGE (6X25) 002 $0.75
17416-MZ5-740 95701-06025-07
16 VALVE 001 $60.45
17440-MZ5-740
23-19
Frame

01 COLR, FR. WHEEL SIDE 001 $3.76 16 BOLT, FLANGE (8X25) 008 $3.09
44311-045-670 90103-MZ5-000
02 FRAME 001 $1,794.77 17 BOLT, FLG (12X265) 001 $17.84
50100-MZ5-600 (replaces 50100-MZ5-000) 90105-MM8-880
02 FRAME 001 $1,794.77 18 BOLT 002 $3.51
50100-MZ5-740 90107-MJ1-000
03 PLATE, R. FR. 001 $21.64 19 BOLT 001 $22.76
50136-MZ5-000 90116-MZ5-000
04 PLATE, L. FR. 001 $21.64 20 SCREW, TRUSS 002 $1.05
50137-MZ5-000 90133-SD4-000
05 PLATE, R. RR. 001 $29.60 21 CAP, R. LOCK NUT 002 $13.84
50138-MZ5-000 90302-ME5-000
06 PLATE, L. RR. 001 $29.60 22 WASHER, FLAT (10MM) 002 $0.57
50139-MZ5-000 94102-10700 (replaces 90503-MZ5-000)
07 PLATE, RR. ENG HGR 001 $12.00 23 CLIP (15) 001 $1.69
50141-MZ5-000 90690-GHB-601
08 COLLAR, ENG HGR 002 $9.15 24 CLIP, CABLE (8MM) 003 $1.60
50350-MZ5-000 90690-GHB-631
09 COVER, R. FR. SIDE 001 $47.84 25 CLIP, CABLE (25MM) 004 $1.60
50650-MZ5-000 90690-GHB-671
10 HOLDER ASSY., HELMET 001 $51.71 27 NUT, FLANGE (8MM) 002 $0.33
50710-GB4-007 94050-08070
11 HOLDER ASSY., HELMET 001 $45.65 28 NUT, FLANGE (10MM) 002 $2.62
50710-086-007 90303-428-900 (replaces 94050-10070)
12 COVER, L. FR. SIDE 001 $72.97 29 NUT, FLANGE (12MM) 001 $0.76
50750-MZ5-000 94050-12000
13 NUT, ACCUMULATOR 001 $4.04 30 BOLT, FLANGE (10X35) 002 $1.35
57071-SB0-800 95701-10035-07
14 BOLT, UBS (8X60) 002 $3.89 31 BOLT, FLANGE (10X45) 002 $2.45
90029-MG8-000 95701-10045-02
15 BOLT, FLG (10X105) 002 $7.69 32 BOLT, FLANGE (10X85) 001 $1.95
90101-MZ5-000 95701-10085-00
23-20
Front Brake Caliper

01 SEAL SET, PISTON 002 $8.67 10 BOLT A, PIN 001 $11.71
06451-GE2-405 45131-ML7-921
02 PAD SET, FR. 001 $40.00 11 PIN, BOLT 001 $6.00
06455-MS9-405 45131-166-016
03 SCREW, BLEEDER 001 $5.07 12 BUSH, PIN 001 $4.29
43352-568-003 45132-166-016
04 CAP, BLEEDER 001 $3.96 13 BOOT B 001 $4.29
43353-461-771 45133-MA3-006
05 CLPR, L. FR. BRAKE 001 $412.36 14 CALIPER SUB-ASSY. 001 $342.69
45100-MZ5-006 45150-MZ5-305
06 PISTON 002 $28.75 15 PLUG, PIN 001 $4.00
45107-MN5-006 45203-MG3-016
07 SPRING, PAD 001 $4.85 16 PIN, HANGER 001 $8.11
45108-ML7-922 45215-ML7-922
08 BRACKET, L. FR. 001 $91.77 17 BOLT (8X32) 002 $5.31
45110-MZ6-006 90101-MZ8-000
09 RETAINER 001 $4.29
45112-MS9-611
23-21
Front Brake Master Cylinder

01 SWITCH, FR. STOP 001 $15.44 11 MASTER CYLINDER SET 001 $38.51
35340-MM5-600 45530-MN9-305
02 HOSE, FR. BRAKE 001 $55.67 12 LEVER, R. HANDLEBAR 001 $14.31
45126-MZ5-003 53175-MR1-671
03 BOOT 001 $9.24 13 BOLT, R. 001 $7.15
45504-410-003 90114-MA5-671
04 SPRING 001 $4.15 14 BOLT, OIL (10X22) 002 $5.29
45506-KA3-731 90145-MS9-612 (replaces 90145-MS9-611)
04 SPRING 001 $3.71 15 NUT, CAP (6MM) 001 $1.58
45506-KA3-831 90201-415-000
05 M/CYL SUB-ASSY, FR. 001 $241.36 16 WASHER, OIL BOLT 004 $2.18
45510-MZ8-305 90545-300-000
06 PROTECTOR 001 $3.38 17 CIRCLIP 001 $2.07
45512-MA6-006 90651-MA5-671
07 CAP, MASTER CYLINDER 001 $23.25 18 SCREW, FLAT (4X12) 002 $0.32
45513-MR1-016 (replaces 45513-MR1-006) 93600-04012-1A
08 HOLDER 001 $19.49 19 SCREW-WASHER (4X12) 001 $0.70
45517-MR1-671 93893-04012-07 (replaces 93893-04012-17)
09 PLATE, DIAPHRAGM 001 $8.09 20 BOLT, SOCKET (6X22) 002 $1.20
45518-MM5-006 96600-06022-10 (replaces 96700-06022-10)
10 DIAPHRAGM 001 $11.47
45520-MM5-006
23-22
Front Cylinder Head

01 CYLINDER HEAD, FR. 001 $834.03 12 BOLT, SOCKET (6X28) 006 $1.60
12010-MZ5-315 90012-MZ5-000
01 CYLINDER HEAD, FR. 001 $834.03 13 BOLT, FLG (6X45.5) 008 $2.62
12010-MZ5-316 90017-MA6-000
02 GUIDE, VALVE (OS) 008 $16.15 14 BOLT, FLG (6X39.5) 008 $2.25
12204-MT4-305 90019-MA6-000
03 GASKET, CYL HD 001 $46.67 15 BOLT, STUD (6X28) 004 $3.87
12251-MT4-014 (replaces 12251-MT4-004) 90035-MZ5-000
04 FIN A, CYLINDER HEAD 001 $113.93 16 WASHER (9MM) 008 $2.82
12350-MZ5-000 90445-MM4-000
05 RUBBER, SEAT 002 $2.44 17 WASHER (5MM) 002 $0.85
12352-MZ5-300 90452-323-000
06 FIN B, CYLINDER HEAD 001 $73.62 18 SCREW, PAN (5X8) 001 $0.45
12360-MZ5-000 93500-05008-0A
07 INSULATOR, CARB 002 $38.78 19 PIN, DOWEL (8X14) 008 $1.00
16211-MZ5-000 94301-08140
08 JOINT, BOOSTER 001 $3.51 20 PIN, DOWEL (12X20) 002 $1.17
16214-MB0-000 94301-12200
09 BAND A, INSULATOR 002 $8.07 21 BOLT, FLANGE (6X30) 002 $0.83
16219-MM4-000 95701-06030-00
10 BAND B, INSULATOR 002 $8.07 22 SPARK PLUG (CR9EH9) 002 $8.14
16220-MM4-000 98059-59916 (replaces 98059-58926,
11 BOLT, FLANGE (9X93) 008 $7.85 98059-59910)
90007-ML7-920
23-23
Front Fender

01 CLAMP B, BRAKE HOSE 001 $16.56 03 FENDER, FR. *R201* 001 $154.96
45158-MZ5-000 61100-MZ5-000ZE
02 GUIDE, FR. 001 $5.15 04 PLATE, FR. FENDER 001 $11.33
45451-473-000 61103-MZ5-000
03 FENDER, FR. *NH1* 001 $154.96 05 BOLT (6X25) 004 $3.07
61100-MZ5-000ZC 90080-MG8-000
03 FENDER, FR. *Y124P* 001 $154.96
61100-MZ5-000ZD
23-24
Front Fork

01 FORK ASSY., R. FR. 001 Call For Price 14 RING 002 $3.55
51400-MZ5-912 (replaces 51400-MZ5-671) 51447-KA4-711
02 SPRING, FR. FORK 002 $66.38 15 BOLT, FR. FORK 002 $44.11
51401-MZ5-671 51454-MM9-671
03 COLLAR, SPRING 002 $18.24 16 SEAL SET, FR. FORK 002 $25.16
51402-KV3-701 51490-MN8-305
04 SEAT, SPRING 002 $3.76 17 FORK ASSY., L. FR. 001 Call For Price
51403-KF0-003 51500-MZ5-912 (replaces 51500-MZ5-671)
05 PIPE, FR. FORK 002 $246.51 18 CASE, L. (LOWER) 001 $218.67
51410-MZ5-671 51520-MZ5-671
06 RING, BACK-UP 002 $7.33 18 CASE, L. (LOWER) 001 $218.67
51412-MB4-003 51520-MZ5-912
07 BUSH, GUIDE 002 $10.64 19 BOLT, FLANGE (8X45) 004 $3.89
51414-KCR-003 (replaces 51414-MN5-003) 90109-MR7-000
08 BUSH, SLIDER 002 $8.78 20 BOLT, SOCKET (8MM) 002 $3.07
51415-KCR-003 (replaces 51415-MM8-003) 90116-KV3-701
09 SPRING, FR. REBOUND 002 $5.22 21 GASKET, FR. 002 $1.60
51416-KF0-003 90543-273-000
10 CASE, R. (LOWER) 001 $295.28 22 WASHER (8MM) 002 $2.05
51420-MZ5-912 (replaces 51420-MZ5-671) 90544-283-000
11 PIECE, OIL LOCK 002 $18.85 23 DUST SEAL 002 $13.55
51432-MV9-003 91254-MM8-003
12 RING, PISTON 002 $4.22 24 O-RING (21.7X3.5) 002 $2.93
51437-MM5-003 91356-KF0-003
13 PIPE, SEAT 002 $48.46 25 BOLT, HEX. (6X8) 002 $0.63
51440-MZ5-671 92101-06008-0A
23-25
Front Wheel

01 WEIGHT (10G) AR $9.07 08 TIRE (120/80-17) 001 $138.46
42704-MB0-000 44711-MZ5-024
01 WEIGHT (20G) AR $10.36 10 BOX ASSY. 001 $73.35
42705-MB0-000 44800-ML7-691
01 WEIGHT, BALANCE (20) AR $10.36 11 GEAR, SPEEDOMETER 001 $22.22
42705-MCF-D60 44806-ML7-691
01 WEIGHT, BALANCE (30) AR $10.36 12 WASHER 002 $2.25
42706-MCF-D60 (replaces 42706-MB0-000) 44809-ML7-003
02 VALVE, RIM 001 $9.67 13 DISK, FR. BRAKE 001 $273.18
42753-ML7-004 45251-MS9-750
03 AXLE, FR. WHEEL 001 $47.29 14 BOLT, DISK (8X24) 006 $4.87
44301-MZ5-000 90105-MV9-003
04 COLR, FR. WHEEL SIDE 001 $13.69 15 BOLT, FR. AXLE 001 $7.96
44311-MM8-000 90305-ML7-000
05 COLLAR, FR. 001 $13.07 16 BEARING (6004UU) 002 $24.45
44620-MT3-000 91054-MAM-003 (replaces 91054-MN8-741)
06 WHEEL SUB-ASSY., FR. 001 $526.65 17 DUST SEAL (28X42X8) 001 $6.93
44650-MZ5-335 (replaces 44650-MZ5-305, 91257-MAY-003 (replaces 91257-KA3-711,
44650-MZ5-315, 44650-MZ5-325) 91257-KA3-712)
07 RETAINER, GEAR BOX 001 $3.76 18 DUST SEAL (45X55X5) 001 $6.56
44680-ML7-000 91258-ML7-003 (replaces 91258-ML7-004)
08 TIRE (120/80-17) 001 $138.46
44711-MZ5-024 (replaces 44710-MZ5-004,
44711-MZ5-004, 44711-MZ5-014)
23-26
Fuel Tank

01 CLIP, OIL DRAIN TUBE 001 $5.73 16 RUB, RR. FUEL TANK 001 $12.55
15771-551-000 17613-MR7-000
02 CLIP, BREATHER TUBE 002 $3.20 17 CAP, FUEL FILLER 001 $66.87
15772-500-010 (replaces 15772-500-013) 17620-KR3-751
03 T-JOINT 001 $10.18 18 PROTECTOR, HOSE 002 $4.04
16180-195-731 64233-MR7-300
04 PETCOCK ASSY. 001 $79.82 19 SCREW, OVAL (5X12) 001 $2.82
16950-MZ5-672 (replaces 16950-MZ5-670, 90111-MZ5-000
16950-MZ5-671) 20 BOLT 001 $7.24
05 SCREEN SET 001 $20.44 90128-KL4-000
16952-KAZ-000 21 COLLAR 001 $3.62
06 TUBE B, FUEL 001 $1.33 90502-MZ5-000
16952-MZ5-000 22 SCREW-WASHER (4X16) 002 $0.33
07 TUBE A, FUEL 001 $10.40 93892-04016-00 (replaces 93892-04016-10)
16956-MZ5-000 23 SCREW-WASHER (4X20) 002 $1.35
08 O-RING 001 $2.95 93892-04020-10
16958-KM9-005 24 CLIP, TUBE (B7) 002 $0.85
09 LEVER, PETCOCK 001 $7.40 95002-02070
16963-MZ5-000 25 CLIP, TUBE (B8) 003 $0.85
10 MARK, FUEL 001 $6.09 95002-02080
16965-MZ5-300 26 BULK HOSE (3.5X1000) 001 $5.62
11 PETCOCK ASSY., AUTO 001 $155.16 95005-35001-20M
16970-MZ5-003 (replaces 16970-MZ5-000) 27 BULK HOSE (4.5X1000) 001 $20.17
12 CLIP, BREATHER TUBE 001 $5.55 95005-45001-20M
17316-611-000 28 BOLT, FLANGE (6X12) 002 $0.82
13 TANK, FUEL (TYPE5) 001 $590.71 96001-06012-00
17520-MZ5-A40ZA 29 COVER SET, PETCOCK 001 $42.18
14 TUBE 001 $13.18 16953-MN5-023 (replaces 16953-MN5-003)
17525-MZ5-000
15 CUSHION, FR. 002 $4.15
17611-KE5-000
23-27
Gasket Kit A
00 GASKET KIT A 001 $171.63 06 GASKET, CYL HD 002 $46.67
06111-MZ5-010 (replaces 06111-MZ5-000) 12251-MT4-014 (replaces 12251-MT4-004)
01 GSKT, TENSIONER HOLE 001 $1.78 07 GASKET, CYL HD CVR 002 $22.42
12194-HC5-740 12391-MT4-000
02 GSKT, TENSIONER HOLE 001 $1.67 08 GASKET, EX. PIPE 004 $4.22
12194-KW3-880 18291-MN4-920
03 SEAL, EX. VALVE STEM 008 $8.07 09 WASHER (6.5MM) 002 $2.25
12208-ML0-721 90463-ML7-000
04 SEAL, VALVE STEM 008 $7.69 10 RUBBER, SETTING 008 $3.89
12209-MZ5-003 90543-MV9-670
05 GASKET, BTHR CVR 001 $12.02 11 O-RING (21.2X2.4) 002 $1.95
12231-MZ5-920 (replaces 12231-MZ5-000) 91331-PC9-003
Gasket Kit B
00 GASKET KIT B 001 $58.31 12 O-RING (18.3X2.3) 002 $1.42
06112-MZ5-000 91301-147-023
01 GASKET, OIL PAN 001 $10.31 13 O-RING (22X3.0) 001 $1.47
11315-MY7-000 91307-425-003 (replaces 91301-250-000)
02 GASKET, L. 001 $4.57 14 O-RING (32.95X2.62) 001 $2.07
11343-MZ5-000 91302-MB0-013
03 GASKET, R. 001 $18.08 15 O-RING (6X2) 002 $1.87
11394-MY7-000 91307-ML7-004
04 GASKET, SHIFT COVER 001 $9.47 16 O-RING 001 $2.93
11632-MY7-000 91309-MA6-000
05 GASKET 001 $12.98 17 O-RING (14.6X3.7) 002 $2.93
11636-MY7-000 91309-MB0-003
06 GASKET, OIL STRAINER 001 $5.20 18 O-RING (14.8X2.2) 001 $2.35
15154-ML7-000 91313-MG7-004 (replaces 91313-MB0-003)
07 GASKET 001 $3.53 19 O-RING (7.7X2.3) 001 $1.45
19226-ML7-000 91301-PC9-003 (replaces 91308-283-000,
08 WASHER (10MM) 002 $2.62 91313-393-003)
90403-MG7-000 20 SEAL, WATER PIPE 001 $1.95
09 WASHER (6.5MM) 006 $2.25 91315-MB0-013
90463-ML7-000 21 O-RING (8.4X2.4) 001 $1.87
10 GSKT, CONNECTING CAP 002 $3.05 91316-MJ8-003
91301-MB0-000 22 O-RING (21.2X2.4) 001 $1.95
11 O-RING (48.1X3.6) 001 $3.11 91331-PC9-003
91301-ML7-003 23 WASHER, DRAIN (12MM) 001 $0.50
94109-12000
23-28
Gearshift Drum

01 FORK, R. GEARSHIFT 001 $52.64 17 COLLAR, DRUM STOPPER 001 $6.36
24211-MZ5-000 24434-MR7-000
02 FORK 001 $58.36 18 SPRING 001 $3.40
24212-ML7-000 24435-KBV-000
03 FORK, L. GEARSHIFT 001 $66.61 19 SPINDLE, GEARSHIFT 001 $79.90
24213-ML7-000 24610-MR7-000
04 SHAFT 001 $35.95 20 SPRING 001 $5.71
24261-ML7-000 24651-MR7-000
05 DRUM, GEARSHIFT 001 $132.91 21 PIN 001 $3.13
24310-MZ5-000 24652-035-000
06 CENTER 001 $26.78 22 PLATE 001 $9.67
24312-KT7-752 24655-MR7-000
07 PIN, SHIFTER 001 $9.58 23 SWITCH, NEUTRAL 001 $14.33
24315-HA0-000 35600-KE8-003 (replaces 35600-KE8-010)
08 SHIFTER, DRUM 001 $39.36 24 WASHER (14MM) 001 $3.15
24321-KT8-030 90451-155-000
09 COLLAR, SHIFTER 001 $4.00 25 WASHER (12MM) 002 $3.76
24322-MM4-000 90485-MR7-000
10 PAWL A, RATCHET 001 $10.02 26 WASHER, OIL BOLT 001 $2.18
24324-KA3-711 90545-300-000
11 PAWL B, RATCHET 001 $10.02 27 BEARING (16005) 001 $11.40
24325-KA3-711 91008-374-003
12 PLUNGER, PAWL 002 $4.56 28 PIN, DOWEL (8X31.5) 002 $3.51
24326-KBH-901 91104-KT7-000
13 PLATE, GUIDE 001 $13.07 29 CIRCLIP (12MM) 001 $1.02
24328-MR7-010 94510-12000
14 SPRING, PAWL PLUNGER 002 $2.07 30 CIRCLIP (14MM) 001 $0.57
24329-KA3-740 94510-14000
15 COLLAR 001 $3.89 31 BOLT, FLANGE (6X45) 002 $0.97
24329-KT7-000 95701-06045-07 (replaces 95701-06045-00)
16 STOPPER, DRUM 001 $18.04 32 ROLLER (4X8) 001 $0.33
24430-MR7-000 96220-40080
23-29
Handle Switch Cables

01 CABLE A, THROTTLE 001 $25.63 16 BOLT, CABLE ADJ. 001 $5.45
17910-MZ5-910 (replaces 17910-MZ5-000, 53192-268-000
17910-MZ5-770) 17 MIRROR ASSY., R. 001 $56.29
02 CABLE B, THROTTLE 001 $25.63 88110-MZ5-003
17920-MZ5-910 (replaces 17920-MZ5-000, 18 MIRROR ASSY., L. 001 $56.29
17920-MZ5-770) 88120-MZ5-003
03 ADAPTER 001 $14.64 19 BOLT, L. 001 $5.96
17962-MR1-000 90113-438-000
04 CABLE, CLUTCH 001 $26.47 20 NUT, CAP (6MM) 001 $1.58
22870-MZ5-770 (replaces 22870-MZ5-000) 90201-415-000
05 SWITCH, STARTER STOP 001 $64.44 21 NUT, FIXING 001 $7.91
35013-MZ8-U10 (replaces 35130-MZ5-671) 90321-MA6-750
06 SWITCH, TURN SIGNAL 001 $102.59 22 BAND, WIRE HARNESS 004 $2.78
35200-MZ5-671 90651-MA6-720
07 SWITCH, FR. LEVER 001 $16.64 22 BAND, CABLE (120MM) 004 $1.80
35330-413-003 90674-WA8-003
08 HOLDER 001 $19.49 23 SCREW, PAN (5X20) 001 $0.67
45517-MR1-671 93500-05020-0B
09 GRIP ASSY., R. 001 $30.80 24 SCREW, PAN (5X22) 001 $0.70
53145-MM8-000 93500-05022-0B
12 GRIP, L. HANDLE 001 $20.11 25 SCREW, PAN (5X25) 001 $0.63
53166-MM8-000 93500-05025-0B
13 CAP, GRIP END 002 $7.09 26 SCREW, PAN (5X32) 001 $0.91
53167-MM8-000 93500-05032-0B
14 BRACKET, HANDLEBAR 001 $25.53 27 BOLT, SOCKET (6X22) 002 $1.20
53172-MR1-000 96600-06022-10 (replaces 96700-06022-10)
15 LEVER, L. HANDLEBAR 001 $13.96
53178-KV0-000
23-30
Handlebar

01 HANDLEBAR 001 $142.97 07 BOLT, SOCKET (8X32) 004 $4.47
53101-MZ5-000 90154-ME9-000
02 HLDR, HANDLE (UPPER) 002 $14.58 08 NUT, STEERING STEM 001 $15.02
53131-MM8-000 90304-415-000
03 HLDR, HANDLE (LOWER) 002 $25.84 09 NUT, FLANGE (8MM) 002 $2.98
53231-MM8-000 90309-428-731
04 BRIDGE, FORK TOP 001 $217.98 10 WASHER 001 $3.51
53300-MZ5-000 90503-283-000
05 EMBLEM, WING MARK 001 $5.91 11 WASHER 002 $4.67
86150-MR1-760 90535-KB9-000
06 BOLT, SOCKET (8X30) 002 $2.98 12 CAP (8MM) 004 $2.95
90112-KM4-000 91455-MB0-010
23-31
Headlight

01 HDLT (12V 60/55W) 001 $182.85 15 BULB (12V60/55W) 001 $7.65
33100-MK7-671 34901-MC7-601AH (replaces 34901-MC7-
02 RIM, HEADLIGHT 001 $47.61 601)
33101-MK7-671 16 CASE, HEADLIGHT 001 $73.70
03 STAY 001 $8.07 61301-MN0-003
33102-MK7-671 17 COLLAR 002 $2.73
04 SCREW, BEAM ADJ. 002 $3.22 61304-292-000
33103-MK7-671 18 STAY, HEADLIGHT 001 $49.05
05 SCREW, SPECIAL 002 $2.33 61305-MZ5-000
33104-MK7-671 19 RUBBER 004 $2.07
06 NUT, SPECIAL 002 $3.33 61315-MZ5-000
33105-MK7-671 20 COLR, HEADLIGHT STAY 002 $2.33
07 SCREW, SPECIAL 001 $2.33 61316-MK7-000
33106-MK7-671 21 BOLT, CAP (6MM) 002 $2.25
08 SPRING 002 $2.98 90132-MK7-000
33107-MK7-671 22 NUT, CAP (6MM) 002 $3.33
09 SPRING, SETTING 002 $2.33 90201-425-700
33108-MK7-671 23 NUT, U (6MM) 002 $5.40
10 NUT, BEAM ADJUSTING 002 $1.60 90301-MG3-000
33117-415-003 24 SCREW, PAN (5X16) 002 $0.68
11 HEADLIGHT UNIT 001 $78.44 93500-05016-0B
33120-MK7-671 25 SCREW, TAP (4X10) 002 $0.47
12 NUT, UNIT HOLDER 001 $1.20 93901-34210
33128-471-003 26 WASHER, SPRING (5MM) 002 $0.50
13 CVR, ADJUSTING SCREW 002 $1.44 94111-05000
33136-111-671 27 CLIP (4X90) 002 $2.38
14 COVER, RUBBER 001 $11.67 94591-49000
33180-MJ0-010
23-32
Mark VF750C (1994-1997)

01 MARK A (TYPE1) 002 $34.98 01 MARK A (TYPE3) 002 $34.98
87121-MZ5-300ZA 87121-MZ5-300ZC
01 MARK A (TYPE2) 002 $34.98
87121-MZ5-300ZB
23-33
Mark VF750C (1998-2003)

01 MARK (TYPE5) 002 $24.02 01 MARK (TYPE7) 002 $22.60
87121-MZ5-A00ZA 87121-MZ5-M10ZA
01 MARK (TYPE6) 002 $20.96
87121-MZ5-A40ZA
23-34
Mark VF750CD (1996-1997)

01 MARK (TYPE10) 001 $20.29 03 MARK (TYPE4) 002 $21.73
64221-MZ5-870ZA 87121-MZ5-A10ZB
01 MARK (TYPE9) 001 $20.29 04 STRIPE, R. (TYPE1) 001 $93.75
64221-MZ5-870ZB 87123-MZ5-950ZA
02 STRIPE, RR. (TYPE1) 001 04 STRIPE, R. (TYPE2) 001 $93.75
80111-MZ5-950ZA 87123-MZ5-950ZB
02 STRIPE, RR. (TYPE2) 001 $96.40 04 STRIPE, R. (TYPE3) 001 $82.16
80111-MZ5-950ZB 87123-MZ5-A10ZA
02 STRIPE, RR. (TYPE3) 001 $79.53 04 STRIPE, R. (TYPE4) 001 $76.33
80111-MZ5-A10ZA 87123-MZ5-A10ZB
02 STRIPE, RR. (TYPE4) 001 $79.53 05 STRIPE, L. (TYPE1) 001 $93.75
80111-MZ5-A10ZB 87124-MZ5-950ZA
03 MARK (TYPE1) 002 $26.47 05 STRIPE, L. (TYPE2) 001 $93.75
87121-MZ5-950ZA 87124-MZ5-950ZB
87121-MZ5-950ZB 87124-MZ5-A10ZA
87121-MZ5-A10ZA 87124-MZ5-A10ZB
23-35
Mark VF750C2 (1998-2000)

98 STRIPE, RR. (TYPE5) 001 $70.87 99 STRIPE, RR. (TYPE7) 001 $71.89
80111-MZ5-A30ZA 80111-MZ5-A50ZA
98 STRIPE, RR. (TYPE6) 001 00 STRIPE, RR. (TYPE8) 001 $73.13
80111-MZ5-A30ZB 80111-MZ5-A70ZA
23-36
Muffler

01 MUFFLER, R. EX. 001 $699.35 17 RUB, MUFFLER SETTING 002 $4.98
18100-MZ5-003 18421-MB0-000
02 MUFFLER, L. EX. 001 $699.35 18 COLLAR 002 $5.22
18200-MZ5-003 18422-MB0-000
03 GASKET, EX. PIPE 004 $4.22 19 CVR, L. FR. EX. PIPE 001 $106.57
18291-MN4-920 18440-MZ5-003
04 RUBBER 002 $1.95 20 JOINT, L. RR. CYL HD 001 $87.87
18293-ME9-000 18450-MZ5-003
05 PIPE, R. FR. EX. 001 $114.12 21 CVR, L. RR. EX. PIPE 001 $99.99
18320-MZ5-981 (replaces 18320-MZ5-003) 18480-MZ5-003
06 CVR, R. FR. EX. PIPE 001 $105.55 22 RUBBER, STOPPER 002 $3.09
18340-MZ5-003 50501-KT7-810
07 JOINT, R. RR. CYL HD 001 $87.87 23 RUBBER, BATTERY BOX 001 $3.05
18350-MZ5-003 83618-GF0-751
08 BAND, R. EX. PIPE 001 $21.73 24 BOLT (8X50) 002 $5.11
18373-ML4-003 90109-MZ5-000
09 BAND, EX. PIPE 001 $15.44 25 BOLT, FLANGE (8X35) 004 $2.84
18373-KAB-000 (replaces 18373-MN1-670) 90161-ML7-000
10 BAND, L. EX. PIPE 001 $12.42 26 NUT, SPECIAL (6MM) 004 $4.76
18374-ML4-003 90304-HB3-771
11 BAND, L. EX. PIPE 001 $10.95 27 NUT, FLANGE (6MM) 004 $0.72
18374-MN1-670 94050-06000
12 BAND, EX. PIPE COVER 006 $6.45 28 NUT, FLANGE (8MM) 002 $0.33
18376-MR1-000 94050-08070
13 CVR, R. RR. EX. PIPE 001 $96.68 29 WASHER, PLAIN (8MM) 002 $0.29
18380-MZ5-003 94103-08000
14 GASKET, MUFFLER 002 $13.58 30 WASHER, PLAIN (8MM) 002 $0.45
18391-MB0-891 94103-08700
15 GASKET, MUFFLER 002 $13.73 31 WASHER, SPRING (6MM) 004 $0.50
18391-ML8-000 94111-06800
16 PIPE, L. FR. EX. 001 $114.12 32 BOLT, FLANGE (6X20) 006 $0.60
18420-MZ5-981 (replaces 18420-MZ5-003) 95701-06020-00
23-37
Oil Pump

01 PAN, OIL 001 $151.28 15 BOLT-WASHER (6X12) 001 $4.00
11211-MZ5-000 90021-MM5-000
02 GASKET, OIL PAN 001 $10.31 16 NUT, U (6MM) 001 $2.15
11315-MY7-000 90301-473-003
03 FILTER SET, OIL 001 $21.67 17 O-RING (6X2) 002 $1.87
15010-MCE-H51 (replaces 15010-MW0-000) 91307-ML7-004
04 PUMP ASSY., OIL 001 Call For Price 18 O-RING (14.6X3.7) 002 $2.93
15100-MZ5-003 91309-MB0-003
05 SPROCKET 001 $27.53 19 O-RING (14.8X2.2) 001 $2.35
15134-MZ5-000 91313-MG7-004 (replaces 91313-MB0-003)
06 CHAIN, OIL PUMP 001 $29.55 20 O-RING (21.2X2.4) 001 $1.95
15140-ML7-003 91331-PC9-003
07 PIPE, OIL STRAINER 001 $26.24 21 BOLT, DRAIN (12MM) 001 $1.73
15151-ML7-000 92800-12000
08 STRAINER, OIL 001 $14.87 22 WASHER, DRAIN (12MM) 001 $0.50
15153-ML7-690 94109-12000
09 GASKET, OIL STRAINER 001 $5.20 23 PIN, COTTER (2.0X35) 001 $0.65
15154-ML7-000 94201-20350 (replaces 94201-20250,
10 VALVE ASSY., RELIEF 001 $26.78 94201-20280, 94201-20320)
15220-MZ5-000 24 PIN, DOWEL (8X14) 002 $1.00
11 FILTER, OIL 001 $11.98 94301-08140
15410-MFJ-D01 (replaces 15410-MM9-013) 25 BOLT, FLANGE (6X14) 002 $0.63
12 PIPE A, OIL 001 $38.51 95701-06014-00
15511-MZ5-000 26 BOLT, FLANGE (6X28) 012 $0.85
13 PIPE B, OIL 001 $14.04 95701-06028-00
15512-ML7-000 27 BOLT, FLANGE (6X40) 003 $0.85
14 BOSS, OIL FILTER 001 $6.80 95701-06040-00
90019-MB0-000
23-38
Pedal

01 PEDAL, GEARSHIFT 001 $54.18 19 BOLT, SOCKET (10X52) 001 $5.04
24705-MZ5-700 (replaces 24705-MZ5-000) 90153-MW0-000
02 RUBBER, DUST SEAL 002 $3.51 20 NUT 001 $0.55
24706-MK3-770 90201-700-000
03 ARM, GEARSHIFT 001 $35.67 21 WASHER (10.3MM) 001 $1.44
24706-MZ5-000 90527-230-000
04 COVER, DUST 002 $5.67 22 DUST SEAL (17X23X3) 002 $2.98
24724-422-000 91206-968-003
05 RUB, GEARSHIFT PEDAL 001 $2.65 23 BOLT, HEX. (6X18) 001 $0.62
24781-KR3-770 92101-06018-0A
06 SWITCH, RR. STOP 001 $12.13 24 NUT, HEX. (6MM) 001 $0.63
35350-MZ5-003 94001-06020-0S
07 SPRING, STOP SWITCH 001 $3.71 25 NUT, HEX. (6MM) 001 $1.60
35357-MF8-000 94002-06000-0S
08 ROD, RR. BRAKE 001 $24.84 26 NUT, FLANGE (8MM) 001 $0.67
43451-MZ5-000 94050-08000
09 PIN 002 $6.45 27 NUT, FLANGE (10MM) 001 $0.93
43456-MK7-000 94050-10000
10 PEDAL, BRAKE 001 $62.88 28 PIN, SPLIT (2.0X12) 001 $0.47
46500-MZ5-000 94201-20120
11 ARM, RR. 001 $29.73 29 PIN, SPLIT (2.0X15) 002 $0.35
46501-MZ5-000 94201-20150
12 SPRING SET 001 $7.96 30 SPRING A, BRAKE ROD 001 $0.53
46513-KY7-000 95014-73100
13 TUBE 001 $3.86 31 JOINT, BRAKE ARM 001 $0.49
46515-KY7-000 95015-32001
14 COLLAR, RR. 001 $8.89 32 NUT B 001 $1.40
46515-MM8-000 95015-42000
15 ARM, RR. 001 $10.51 33 PIN, JOINT 001 $2.42
46530-MZ5-000 95015-53000
16 ROD, RR. 001 $44.51 34 BOLT, FLANGE (8X25) 001 $1.00
46540-MZ5-000 95701-08025-00
17 BOLT, TIE ROD 001 $3.89 35 BOLT, FLANGE (6X20) 001 $0.83
90065-MN4-000 96001-06020-00
18 BOLT, CHANGE PIVOT 001 $14.96
90115-KAF-000
23-39
Pulse Generator

01 GEAR (21T/83T) 001 $76.41 10 WASHER (12X30X4.5) 001 $7.91
28101-ML7-920 90401-KK9-960
02 PIN (10X36.5) 001 $6.56 11 WASHER (18X10.2) 001 $2.84
28102-ML7-000 90405-ML7-000
03 GEAR (48T) 001 $109.19 12 PIN, DOWEL (8X8) 002 $2.73
28110-MB0-010 90702-MB0-000
04 FLANGE 001 $73.01 13 BEARING (30X35X17) 001 $26.51
28115-MZ5-000 91022-MB0-004 (replaces 91022-MB0-003)
05 CLUTCH, STARTER 001 $152.21 14 ROLLER (15X13) 003 $4.53
28120-MZ5-000 91101-516-000
06 SPRING 003 $1.42 15 BOLT, FLANGE (8X14) 003 $0.78
28125-MT4-000 95701-08014-08
07 CAP 003 $12.98 16 BOLT, FLANGE (6X25) 003 $0.93
28126-415-000 96001-06025-00
08 GEN, IGNITION PULSE 001 $98.46 17 ROLLER (6X15) 001 $0.62
30300-MZ5-003 (replaces 30300-MZ5-000) 96220-60150
09 BOLT, FLANGE (12X45) 001 $7.96
90023-MA6-000
23-40
Radiator

01 RADIATOR COMP 001 $612.40 22 CLAMP B, WATER HOSE 004 $6.13
19010-MZ5-P00 (replaces 19010-MZ5-671) 19506-KS6-700
02 SHROUD 001 $57.00 23 CLAMP, HOSE (30-37) 004 $10.95
19015-MZ5-003 19516-GAG-003
03 FAN, COOLING 001 $42.05 24 CONNECTOR, GROUND 001 $1.33
19025-MN4-003 32152-MB3-000
04 MOTOR ASSY., FAN 001 $240.71 25 REFLECTOR, FR. 002 $22.31
19030-MZ5-003 33740-KR3-671
05 CAP, RADIATOR 001 $30.69 26 SENDING UNIT 001 $43.83
19045-MY3-671 37750-PC1-004
06 RUBBER 004 $2.67 27 SWITCH, THERMOSTAT 001 $49.49
19051-KA3-830 37760-MT2-003
07 COLLAR 003 $2.04 28 NUT, SPECIAL (6X7) 001 $2.64
19052-MN8-000 61304-958-003 (replaces 90301-471-000)
08 TANK, RESERVE 001 $30.89 29 NUT, SERRATE (5MM) 004 $1.67
19101-MZ5-000 90315-MK3-003
09 CAP, RESERVE TANK 001 $9.24 30 WASHER, FR. 001 $1.91
19104-MB0-700 90556-MB4-000
10 TUBE, RESERVE TANK 001 $25.16 31 O-RING (13.5X1.4) 001 $1.72
19106-MZ5-000 91307-PH7-660 (replaces 91307-611-000)
11 GRILLE, RADIATOR 001 $70.69 32 O-RING (47.5X2) 001 $1.64
19112-MZ5-670 (replaces 19110-MZ5-000) 91311-KE8-000
12 PROTR, RADIATOR HOSE 001 $36.55 32 O-RING (45.5X2.5) 001 $3.20
19120-MZ5-910 (replaces 19120-MZ5-000) 91373-733-003
13 PROTR, RADIATOR HOSE 001 $10.15 33 SCREW, TAPPING (3X8) 001 $0.47
19121-MZ5-000 93901-22180
14 THERMOSTAT ASSY. 001 $33.89 34 NUT, FLANGE (6MM) 001 $0.72
19300-ML7-003 94050-06000
15 COVER, THERMOSTAT 001 $60.67 34 CLIP, TUBE (B10) 003 $0.90
19311-MZ5-000 95002-02100
16 COVER, THERMOSTAT 001 $48.56 35 BULK HOSE (5.5X3000) 001 $18.33
19315-MV9-670 95005-55003-20M
17 HOSE, RADIATOR 001 $20.91 36 BOLT, FLANGE (6X12) 002 $0.72
19500-MZ5-000 95701-06012-00
18 HOSE, RADIATOR 001 $29.96 37 BOLT, FLANGE (6X22) 001 $0.72
19501-MZ5-000 95701-06022-00
19 HOSE, FR. 001 $13.64 38 BOLT, FLANGE (6X10) 003 $0.85
19502-MZ5-000 96001-06010-00
20 HOSE, RR. HEAD WATER 001 $12.42 39 BOLT, FLANGE (6X22) 003 $0.91
19503-MZ5-000 96001-06022-00
21 GUIDE, WATER HOSE 001 $7.71 40 BOLT, SOCKET (6X25) 003 $0.88
19504-MZ5-000 96600-06025-07
23-41
Rear Brake Panel

01 SHOE KIT, BRAKE 001 $40.27 10 INDICATOR, RR. BRAKE 001 $4.58
06430-MZ5-003 43145-ME5-000
02 AXLE, RR. WHEEL 001 $47.41 11 SPRING, RR. 002 $4.64
42301-MZ5-003 43151-346-000
03 COLR, RR. WHEEL SIDE 001 $16.18 12 ARM, RR. BRAKE 001 $26.58
42311-MZ1-610 (replaces 42311-MZ1-000) 43410-MZ5-000
04 COLLAR, RR. 001 $15.69 13 BOLT, FLANGE (8X25) 001 $3.65
42313-MZ5-000 90107-MZ5-000
05 PANEL, RR. 001 $182.85 14 NUT, U (18MM) 001 $11.42
43100-MJ1-832 90305-KZ4-891 (replaces 90305-KZ4-890)
06 WASHER, ANCHOR PIN 001 $4.96 15 WASHER (18X32X2) 001 $3.58
43102-319-000 90401-KZ4-890
07 TUBE 002 $5.48 16 WASHER, RR. AXLE 001 $10.16
43124-MZ5-000 90559-MJ0-630
08 DUST SEAL, BRAKE CAM 001 $1.62 17 PIN, COTTER (2.5MM) 002 $0.53
43134-300-000 94201-25300 (replaces 94201-25200,
09 CAM, RR. BRAKE 001 $28.64 94201-25250)
43141-MB0-010 (replaces 43141-MB0-000)
23-42
Rear Cylinder Head

01 CYLINDER HEAD, RR. 001 $834.03 12 BOLT, SOCKET (6X28) 006 $1.60
12020-MZ5-315 90012-MZ5-000
01 CYLINDER HEAD, RR. 001 $834.03 13 BOLT, FLG (6X45.5) 008 $2.62
12020-MZ5-316 90017-MA6-000
02 GUIDE, VALVE (OS) 008 $16.15 14 BOLT, FLG (6X39.5) 008 $2.25
12204-MT4-305 90019-MA6-000
03 GASKET, CYL HD 001 $46.67 15 BOLT, STUD (6X22) 004 $4.29
12251-MT4-014 (replaces 12251-MT4-004) 90036-MZ5-000
04 FIN A, CYLINDER HEAD 001 $113.93 16 WASHER (9MM) 008 $2.82
12350-MZ5-000 90445-MM4-000
05 RUBBER, SEAT 002 $2.44 17 WASHER (5MM) 002 $0.85
12352-MZ5-300 90452-323-000
06 FIN B, CYLINDER HEAD 001 $73.62 18 SCREW, PAN (5X8) 002 $0.45
12360-MZ5-000 93500-05008-0A
07 INSULATOR, CARB 002 $38.78 19 PIN, DOWEL (8X14) 008 $1.00
16211-MZ5-000 94301-08140
08 JOINT, BOOSTER 002 $3.51 20 PIN, DOWEL (12X20) 002 $1.17
16214-MB0-000 94301-12200
09 BAND A, INSULATOR 002 $8.07 21 BOLT, FLANGE (6X30) 002 $0.83
16219-MM4-000 95701-06030-00
10 BAND B, INSULATOR 002 $8.07 22 SPARK PLUG (CR9EH9) 002 $8.14
16220-MM4-000 98059-59916 (replaces 98059-58926,
11 BOLT, FLANGE (9X93) 008 $7.85 98059-59910)
90007-ML7-920
23-43
Rear Fender

01 REFLECTOR, REFLEX 001 $10.55 14 SUB-FRAME, RR. 001 $149.92
33741-MS6-921 80125-MZ5-000
02 RUB, METER CUSHION 002 $2.33 15 GROMMET, SIDE COVER 001 $2.25
37215-MA6-008 83601-MN5-000
03 GROMMET, ENG HGR 003 $1.51 16 RUBBER 002 $3.11
50370-HA2-770 84702-MF2-670
04 RUBBER, BATTERY 002 $3.24 17 BOLT (8X56) 004 $3.55
50383-GB6-300 90064-KK3-830
05 GROM, SPEAKER PANEL 001 $2.45 18 BOLT 002 $1.60
64266-MG9-770 90215-ML0-000
06 COLLAR, ROTO-STOP 002 $2.58 19 NUT 002 $3.65
75133-960-000 90305-SH3-000
07 GRAB RAIL, R. 001 $105.00 20 NUT, CAP (8MM) 004 $2.30
77330-MZ5-000 90443-107-000
08 GRAB RAIL, L. 001 $105.00 21 WASHER, PLAIN (8MM) 004 $1.12
77340-MZ5-000 90518-921-000
09 FENDER B,REAR 001 $164.39 22 PLUG, CONE TYPE 003 $1.45
80100-MZ5-000YB (replaces 80100-MZ5- 90899-422-610
000ZC) 23 CLIP, WIRE 002 $2.93
09 FENDER B *Y124P* 001 $180.00 91406-166-000
80100-MZ5-000ZD 24 BOLT, HEX. (6X10) 002 $0.67
09 FENDER B, RR. *R201* 001 $154.24 92101-06010-0G
80100-MZ5-000ZE 25 NUT, HEX. (6MM) 002 $0.55
10 BRKT, NUMBER PLATE 001 $40.85 94002-06070-0S
80101-MZ5-670 26 NUT, FLANGE (5MM) 001 $0.60
11 STAY, RR. REFLECTOR 001 $17.82 94050-05000
80102-MM8-010 27 NUT, FLANGE (6MM) 002 $0.73
12 GROM, ENGINE COVER 002 $1.55 94050-06070
80103-GJ5-000 28 BOLT, FLANGE (6X12) 002 $0.72
13 FENDER A, RR. 001 $66.36 95701-06012-00
80105-MZ5-000
23-44
Rear Shock Absorber

01 SHOCK ABSORBER, RR. 002 $306.24 05 BOLT, FLANGE (8X16) 002 $3.18
52400-MZ5-672 (replaces 52400-MZ5-671) 90106-MB2-000
02 BUSH, RR. SHOCK 002 $3.76 06 WASHER, PLAIN 002 $1.91
52485-KR3-003 90501-MZ5-000
03 COLLAR, RUBBER BUSH 002 $2.91 07 BOLT, FLANGE (10X35) 002 $1.23
52486-GA7-003 95817-10035-00 (replaces 95801-10035-00)
04 BUSH, RUBBER (UPPER) 002 $3.58
52489-GS3-003
23-45
Rear Wheel

01 SPROCKET (40T) 001 $127.81 08 WEIGHT, BALANCE (30) AR $10.36
41200-MZ5-770 (replaces 41200-MA3-000, 42706-MCF-D60 (replaces 42706-MB0-000)
replaces 41200-MZ5-670) 09 TIRE, RR. 001 $152.63
02 ARRESTER, NOISE 001 $8.29 42711-MZ5-024 (replaces 42710-MZ5-004,
41212-MK4-010 (replaces 41212-MK4-000) 42711-MZ5-004)
03 DAMPER, RR. WHEEL 005 $10.47 11 VALVE, RIM 001 $9.67
41241-MM5-000 42753-ML7-004
04 SLEEVE, RR. AXLE 001 $15.93 12 NUT, FLANGE (12MM) 005 $3.15
42606-MS2-000 90306-KF0-003
05 FLANGE, FINAL DRIVEN 001 $243.35 13 OIL SEAL (34X62.2X7) 001 $9.20
42610-MS2-000 90753-MG5-670
06 COLLAR, RR. 001 $19.36 14 BEARING,BALL RADI 001 $23.11
42620-MZ5-000 91051-MBT-611 (replaces 91051-MAT-003,
07 WHEEL SET, RR. 001 $705.94 91051-MM5-003)
42650-MZ5-305 15 BEARING (6204UU) 001 $23.13
08 WEIGHT (10G) AR $9.07 91052-MM5-003
42704-MB0-000 16 BEARING (6304UU) 001 $24.36
08 WEIGHT (20G) AR $10.36 91053-MM5-004
42705-MB0-000 17 O-RING (69X2) 001 $3.07
08 WEIGHT, BALANCE (20) AR $10.36 91302-MS2-003
42705-MCF-D60 18 BOLT, STUD (12X28) 005 $2.15
92918-12028-0E
23-46
Right Crankcase Cover

01 COVER, R. CRANKCASE 001 $405.03 09 BOLT, FLANGE (6X28) 011 $2.16
02 CAP (45MM) 001 $25.67 10 BOLT, FLANGE (6X32) 002 $2.96
11332-MZ5-000 90001-GHB-690
03 PLATE, R. COVER 001 $14.84 11 O-RING (48.1X3.6) 001 $3.11
11333-MV8-900 91301-ML7-003
04 RUB, R. COVER DAMPER 001 $31.35 12 O-RING (22X3.0) 001 $1.47
11334-MT7-300 91307-425-003 (replaces 91301-250-000)
05 GASKET, R. 001 $18.08 13 O-RING (8.4X2.4) 001 $1.87
11394-MY7-000 91316-MJ8-003
06 CAP, OIL FILLER 001 $7.36 14 PIN, DOWEL (8X14) 002 $1.00
15611-MB0-000 94301-08140
07 DIPSTICK, OIL 001 $10.67 15 BOLT, FLANGE (6X10) 001 $0.75
15650-ML7-000 95701-06010-00
08 CLAMP, SWITCH WIRE 004 $2.93
35211-443-760
23-47
Seat

01 RUB, SEAT MOUNTING 002 $3.96 05 RUBBER B 002 $3.96
77110-KA3-730 77215-GC2-000
02 SEAT ASSY. 001 $308.50 06 SEAT ASSY., RR. 001 $188.28
77200-MZ5-000 77300-MZ5-000
03 STAY A, RR. SEAT 001 $15.89 07 BOLT (8X12) 003 $3.07
77206-MZ5-000 90125-KR3-000
04 STAY B, RR. SEAT 001 $12.82 08 NUT, FLANGE (6MM) 006 $0.23
77207-MZ5-000 94050-06080
23-48
Side Cover

01 RUBBER B, STOPPER 002 $2.09 04 CVR, R. SIDE *R201* 001 $142.83
50354-428-000 83650-MZ5-000ZE
02 CAP, STEP HOLDER END 002 $2.16 05 COVER, L. SIDE *NH1* 001 $84.82
50713-ML0-720 83750-MZ5-000ZC
03 GROMMET, A/CLNR HSG 004 $2.96 05 CVR, L. SIDE *Y124P* 001 $84.82
83551-300-000 83750-MZ5-000ZD
04 COVER, R. SIDE *NH1* 001 $95.47 05 CVR, L. SIDE *R201* 001 $152.19
83650-MZ5-000ZC 83750-MZ5-000ZE
04 CVR, R. SIDE *Y124P* 001 $84.82
83650-MZ5-000ZD
23-49
Speedometer Tachometer
23-50

01 BULB (12V3W) 006 $1.68 25 CUSHION, RUBBER 002 $2.44
34908-KM1-671 37255-MZ5-008
02 BULB (12V1.7W) 001 $1.95 26 GROMMET, TACHOMETER 001 $5.13
34908-MB9-871 37257-MK4-601
03 BULB (12V1.4W) 002 $2.27 27 SOCKET 001 $43.49
34908-MN8-700 37562-MZ5-008
04 METER, COMBINATION 001 $974.79 28 BOX ASSY., PILOT 001 $80.14
37100-MZ5-671 37600-MZ5-008
05 SPEEDOMETER ASSY. 001 $363.85 29 COLLAR 002 $4.00
37200-MZ5-671 37606-MR1-008
06 COVER, SPEEDOMETER 001 $58.98 30 RUBBER, SETTING 002 $4.62
37202-MZ5-008 37607-MZ5-008
07 RUBBER, SPEEDOMETER 001 $7.15 31 CAP 001 $1.60
37204-MK4-611 37618-MB2-008
08 BRKT, METER (LOWER) 001 $65.47 32 SOCKET, METER 001 $117.14
37211-MZ5-008 37619-MZ5-671
09 BRKT, METER (UPPER) 001 $57.34 33 CABLE, SPEEDOMETER 001 $23.23
37212-MZ5-008 44830-MT3-000
10 RUBBER 001 $7.27 34 CABLE (INNER) 001 $4.46
37213-MW3-671 44831-MM5-000 (replaces 44831-443-720)
11 COVER, METER BRACKET 001 $70.22 35 SCREW, TRUSS (4X12) 004 $1.51
37214-MZ5-008 90106-KN8-008
12 CLAMP 001 $1.53 36 SCREW-WASHER (3X10) 002 $1.65
37215-KM1-670 90108-GN2-008
13 RUB, BRACKET SETTING 003 $1.60 37 SCREW, TAP (4X14) 002 $3.24
37215-MW3-671 90109-MZ5-008
14 GUIDE, R. CABLE 001 $8.82 38 SCREW, PAN (2X6) 001 $1.42
37216-MZ5-000 90158-KM7-911
15 GUIDE, L. CABLE 001 $10.78 39 O-RING (6.8X1.9) 001 $1.43
37217-MZ5-000 91306-PJ4-000 (replaces 91301-027-000,
16 KNOB, TRIP METER 001 $10.04 91310-MC7-003)
37220-MB4-671 40 SCREW, OVAL (5X20) 001 $0.35
17 SOCKET 001 $35.71 93700-05020-0G
37224-MZ5-008 41 SCREW-WASHER (4X16) 002 $0.37
18 BAND, SELF-LOCK 002 $2.35 93891-04016-07
37226-MZ5-008 42 SCREW, TAP (4X12) 001 $0.47
19 WASHER, PLAIN 003 $1.60 93903-24310
37244-MA6-008 43 NUT, HEX. (6MM) 003 $0.55
20 TACHOMETER ASSY. 001 $409.83 94002-06070-0S
37250-MZ5-671 44 WASHER, PLAIN (8MM) 003 $0.45
21 COVER, TACHOMETER 001 $59.10 94101-08700
37252-MZ5-008 45 BOLT, FLANGE (8X16) 002 $0.85
22 RUBBER 002 $2.33 95701-08016-08
37253-MK4-611
23 RUBBER, TACHOMETER 001 $7.15
37254-MK4-611
24 RUBBER 002 $2.33
37255-MK4-611
23-51
Stand

01 SWITCH, SIDE STAND 001 $41.75 04 BOLT 001 $6.31
35070-MZ5-A80 (replaces 35700-MZ5-305) 90108-MR5-000
02 BAR, SIDE STAND 001 $69.70 05 BOLT, SPECIAL (6X16) 001 $1.84
50532-MZ5-000 90147-MCE-950 (replaces 90147-MK6-671)
03 SPRING, SIDE STAND 001 $6.04 06 NUT, SIDE STAND 001 $2.84
50541-KV3-830 90203-MF9-710
23-52
Starting Motor

01 MOTOR ASSY., STARTER 001 $455.40 06 RING 002 $2.58
31200-MZ5-003 31207-KS5-901
02 TERMINAL SET, BRUSH 001 $17.73 07 NUT-WASHER (6MM) 002 $1.53
31201-KS5-901 90071-MB0-000
03 SPRING, CARBON BRUSH 002 $2.20 08 O-RING 001 $2.93
31204-KS5-901 91309-MA6-000
04 BOLT, SETTING 003 $3.93 09 O-RING 001 $1.82
31205-MN0-008 91320-MB0-000
05 HOLDER SET, BRUSH 001 $18.91 10 BOLT, FLANGE (6X25) 002 $0.93
31206-KW1-901 96001-06025-00
23-53
Steering Stem

01 CLAMP A, BRAKE HOSE 001 $10.53 08 SCREW (6X12) 002 $1.25
45131-MZ5-000 90164-028-000
02 CLAMP 001 $6.60 09 THREAD 001 $16.51
53105-MZ5-000 90302-425-830
03 STEM, STEERING 001 $320.76 10 WASHER, LOCK 001 $5.67
53200-MZ5-000 90506-425-830
04 DUST SEAL 001 $9.20 11 BEARING, HEAD PIPE 001 $30.15
53213-MB4-771 91015-KT8-005
05 DUST SEAL 001 $9.56 12 BEARING, HEAD PIPE 001 $30.15
53214-371-010 91016-KT8-005
06 THREAD (UPPER) 001 $24.84 13 BOLT, FLANGE (6X12) 001 $0.72
53220-422-000 95701-06012-00
07 LOCK, HANDLEBAR 001 $34.24 14 BOLT, SOCKET (10X25) 002 $1.48
53600-086-007 (replaces 53600-126-921) 96700-10025-10
23-54
Step

01 PIN, STEP BAR JOINT 002 $2.55 11 BAR, PILLION STEP 002 $25.25
50603-033-010 50715-MN0-000
02 BAR, R. STEP 001 $21.58 12 BOLT, HEX. (6X12) 002 $0.53
50612-MR1-000 92101-06012-0A
03 BRACKET, R. STEP 001 $88.37 13 BOLT, CAP (6X12) 002 $1.75
50615-MZ5-000 92501-06012-0A
04 SPRING, STEP RETURN 002 $4.55 14 WASHER, PLAIN (6MM) 002 $0.30
50617-MB1-700 94101-06800 (replaces 94101-06000,
05 STOPPER, STEP RUBBER 002 $13.18 94101-06080)
50619-MN0-000 15 WASHER, PLAIN (8MM) 002 $0.40
06 BRACKET, L. STEP 001 $91.59 94101-08000
50625-MZ5-000 16 PIN, SPLIT (1.6X12) 002 $0.43
07 BAR, L. STEP 001 $21.58 94201-16120
50642-MR1-000 17 PIN, SPLIT (2.0X15) 002 $0.35
08 RUBBER, MAIN STEP 002 $8.16 94201-20150
50661-MN0-000 18 PIN A, PILLION STEP 002 $1.58
09 RUB, PILLION FOOTPEG 002 $10.78 95015-81000
50716-371-660 (replaces 50710-377-000) 19 BOLT, FLANGE (8X18) 004 $0.83
10 WASHER 002 $2.62 95701-08018-00
50712-413-000
23-55
Swingarm @ Drive Chain

01 CHAIN SET, DRIVE 001 $168.18 17 BOLT, FLANGE (6X12) 002 $1.67
06405-MZ5-P20 (replaces 06405-MZ5-405) 90154-ML0-000
01 CHAIN SET, DRIVE 001 $307.34 18 NUT, U (14MM) 001 $3.05
06405-MZ5-407 90305-GE8-003
01 CHAIN SET, DRIVE 001 $168.18 19 WASHER A 001 $1.04
06405-MZ5-P20 90524-030-000 (replaces 90505-425-000)
02 CASE, DRIVE CHAIN 001 $102.29 20 WASHER (6X20) 001 $2.33
40510-MZ5-000 90512-KF9-900
03 MASTER LINK 001 $5.18 21 WASHER (6X9) 001 $0.98
40535-MW0-305 90513-405-000 (replaces 90513-428-900)
03 MASTER LINK 001 $5.18 22 BEARING (22X29X30) 001 $27.96
40535-MW0-306 91071-MJ0-003
04 AXLE, RR. WHEEL 001 $26.85 22 BEARING, NEEDLE 001 $27.96
42301-KBG-000 91071-MJ0-004
05 ARM, RR. 001 $12.65 23 OIL SEAL (22X31X5) 001 $4.71
43431-MZ5-000 91205-965-003
06 RUBBER, STOPPER ARM 001 $2.73 24 DUST SEAL (22X35X7) 001 $5.87
43434-ME1-670 91213-MB2-003 (replaces 91213-MB2-006)
07 COLR, PIVOT DISTANCE 001 $24.15 25 SCREW, TAP (5X12) 002 $0.47
52102-MM5-000 93901-25280
08 COLLAR B, SWINGARM 001 $8.11 26 NUT, HEX. (8MM) 004 $0.52
52105-MM2-670 94001-08000-0S
09 COLLAR B, PIVOT 001 $16.45 27 NUT, HEX. (8MM) 002 $0.48
52106-ML4-000 94030-08000
10 COLLAR 002 $42.35 28 WASHER, PLAIN (8MM) 001 $0.40
52120-MJ0-010 (replaces 52120-MJ0-000) 94101-08000
11 PLATE 002 $15.93 29 WASHER (10MM) 001 $0.60
52121-MJ0-000 94111-10000
12 SLIDER, CHAIN 001 $36.36 30 PIN, COTTER (2.0X35) 002 $0.65
52170-MZ5-000 94201-20350 (replaces 94201-20180,
13 WASHER, CHAIN SLIDER 002 $1.87 94201-20200, 94201-20250, 94201-20280,
52171-KR6-000 94201-20320)
14 SWINGARM SET 001 $627.52 31 CIRCLIP (35MM) 001 $1.00
52200-MZ5-305 94520-35000
15 BOLT, RR. 001 $3.82 32 BEARING (6202) 001 $8.90
90127-393-000 96100-62020-10
16 BOLT, RR. 001 $3.51
90133-286-000
23-56
Taillight

01 TAILLIGHT UNIT 001 $103.47 06 COLLAR 002 $9.98
33701-MZ5-671 80135-MZ5-000
02 LENS, TAILLIGHT 001 $22.96 07 SCREW, TAP (4X40) 002 $3.87
33702-MC4-671 90105-GAM-000
03 SOCKET, TAILLIGHT 001 $51.15 08 WASHER (5MM) 002 $2.33
33703-MZ5-671 91409-VM0-770
04 GSKT, TAILLIGHT LENS 001 $3.31 09 BOLT, HEX. (5X35) 002 $1.28
33709-KB7-003 92101-05035-0A
05 BULB (12V27/8W) 001 $3.18 10 WASHER, SPRING (5MM) 002 $0.50
34906-425-771 94111-05000
23-57
Tools

01 BAG, SERVICE BOOK 001 $3.38 09 SCREWDRIVER 1 (NO.2) 001 $1.75
77251-GR1-000 99003-10000
02 TOOL SET 001 $52.58 10 SCREWDRIVER 3 (NO.2) 001 $0.82
89010-MZ5-000 99003-30000
03 WRENCH, PLUG (16.5) 001 $19.29 11 GRIP 001 $1.80
89216-MT3-000 99003-50000
04 WRENCH, HEX. (5MM) 001 $4.22 12 HANDLE (12MM) 001 $2.60
89221-429-000 99006-12000
05 WRENCH, PIN 001 $15.98 13 WRENCH, EYE (22MM) 001 $3.31
89230-MB1-000 99006-22000
06 WRENCH (8MM) 001 $1.89 14 WRENCH, EYE (27MM) 001 $3.49
99001-08000 99006-27000
07 SPANNER (10X12) 001 $1.72 15 BAG, TOOL (160MM) 001 $1.51
99001-10120 99008-01600
08 SPANNER (14X17) 001 $2.75
99001-14170
23-58
Transmission

01 MAINSHAFT (13T) 001 $146.95 21 WASHER (20X1.00) 001 $2.02
23211-ML7-920 90454-428-000
02 PLATE 001 $8.73 22 WASHER B (22MM) 002 $3.89
23212-ML7-000 90455-ML7-000
03 COUNTERSHAFT 001 $223.89 22 WASHER A (22MM) 002 $3.89
23220-MT4-000 90456-ML7-000
04 GEAR (37T) 001 $110.83 22 WASHER C (22MM) 002 $3.89
23421-ML7-000 90457-ML7-000
05 GEAR (17T) 001 $40.44 23 WASHER (25MM) 001 $2.02
23431-MV8-900 90456-MA6-000
06 GEAR (32T) 001 $92.55 24 WASHER (10.2MM) 001 $4.67
23441-MV8-900 90459-438-000
07 COLLAR (28MM) 001 $19.96 25 WASHER (28MM) 001 $7.71
23442-ML7-000 90463-MR7-000
08 GEAR 001 $110.83 26 WASHER, LOCK (28MM) 001 $7.71
23451-MZ5-000 90464-MR7-000
09 GEAR (29T) 001 $101.60 27 CIRCLIP (25MM) 002 $2.91
23461-MV8-900 90601-107-000
10 GEAR (27T) 001 $98.99 28 SET-RING (68MM) 001 $6.36
23481-MV8-900 90602-MR7-000
11 COLLAR (28X13.5) 002 $22.11 29 CIRCLIP (28MM) 003 $2.91
23482-MR7-000 90602-MM5-000 (replaces 90603-MN4-000)
12 GEAR 001 $99.68 30 BEARING (20MM) 001 $30.56
23491-MZ5-010 91022-MT4-000
13 COLLAR (25X12) 001 $18.78 31 BEARING (22MM) 001 $40.07
23495-MB0-000 91023-MZ5-003
14 GEAR 001 $112.42 32 BEARING (22X26X11) 001 $22.58
23501-MZ5-010 91026-MB4-003
15 COLLAR (25X18.4) 001 $21.00 33 OIL SEAL (40X68X7.2) 001 $11.24
23512-MZ5-000 91207-MR7-003
16 SHIFTER 001 $65.32 34 PIN B, DOWEL (8X10) 001 $1.03
23521-MV8-900 94302-08100
17 SPROCKET (16T) 001 $48.18 35 *95701-06016-08 003 $0.73
23801-MCJ-000 (replaces 23801-ML7-920) 95701-06016-00
18 BOLT, SPECIAL (10MM) 001 $5.78 36 BEARING (6305) 001 $11.98
90037-422-003 96100-63050-00
19 WASHER (25X31X1.5) 002 $3.89
90451-MR7-000
20 WASHER (28X34X1.5) 003 $4.58
90452-MR7-000
23-59
Turn Signal

01 SUB-WIRE, R. RR. 001 $14.73 13 TURN SIGNAL ASSY. 001 $49.11
32360-MZ5-000 33600-MR1-000
02 SUB-WIRE, L. RR. 001 $10.69 14 REFLECTOR, R. RR. 001 $27.04
32365-MZ5-000 33605-MR1-000
03 WINKER LIGHT ASSY 001 $49.09 15 TURN SIGNAL ASSY. 001 $49.11
33400-MK7-P00 (replaces 33400-MN0-003) 33650-MR1-000
04 LENS, FR. 004 $8.46 16 REFLECTOR, L. RR. 001 $27.04
33401-MK7-672 33655-MR1-000
05 BASE, R. FR. 002 $34.20 17 STAY, RR. 002 $23.75
33402-MK7-671 33690-MZ5-000
06 REFLECTOR, R. RR. 001 $18.04 18 BULB (12V23W32CP) 002 $1.67
33405-MN0-003 34905-268-671
07 GASKET 004 $3.07 19 BULB (12V23/8W) 002 $4.33
33407-MK7-671 34905-425-671
08 TURN SIGNAL, L. FR. 001 $38.04 20 COLLAR 002 $4.00
33450-MN0-003 84702-KV0-670
09 BASE, L. FR. 002 $34.20 21 SCREW, SPECIAL (6X8) 004 $3.58
33452-MK7-671 90380-MZ5-000
10 REFLECTOR, L. RR. 001 $15.69 22 SCREW, TAP (4X25) 008 $0.20
33455-MN0-003 93901-34610
11 STAY, R. FR. 001 $39.56 23 NUT, FLANGE (8MM) 002 $0.25
33490-MZ5-000 94050-08080
12 STAY, L. FR. 001 $39.56 24 BOLT, FLANGE (6X30) 002 $1.15
33491-MZ5-000 96001-06030-07
23-60
Water Pipe

01 CLIP B, TUBE 001 $2.38 09 BOLT, FLANGE (6X12) 001 $2.33
16106-KW7-900 90004-GHB-610 (replaces 90001-GHB-610)
02 PIPE, CONNECTING 001 $17.71 10 GSKT, CONNECTING CAP 002 $3.05
19507-MB0-000 91301-MB0-000
03 CAP A 001 $32.62 11 O-RING (18.3X2.3) 002 $1.42
19508-MZ5-000 91301-147-023
04 CAP B 001 $41.04 12 SEAL, WATER PIPE 001 $1.95
19509-MZ5-000 91315-MB0-013
05 CLAMP (24-32MM) 002 $10.95 13 O-RING (21.2X2.4) 002 $1.95
19516-ML7-691 91331-PC9-003
06 PIPE A, WATER 001 $72.16 14 BOLT, FLANGE (6X22) 005 $0.91
19521-ML7-000 96001-06022-00
07 JOINT, WATER 002 $24.76 15 BOLT, FLANGE (6X35) 003 $1.00
19523-MT4-000 96001-06035-00
08 HOSE A, WATER 001 $6.31
19525-ML7-000
23-61
Water Pump

01 COVER, L. CRANKCASE 001 $360.59 17 BOLT (6X95) 002 $8.53
11340-MZ5-000 90025-MZ5-000
02 RUBBER, L. 001 $33.87 18 BOLT, FLANGE (6X25) 002 $2.11
11342-MZ5-300 90121-MV9-670
03 GASKET, L. 001 $4.57 19 WASHER (6.5MM) 003 $2.25
11343-MZ5-000 90463-ML7-000
04 GUIDE, DRIVE CHAIN 001 $16.04 20 WASHER, TANK RUBBER 002 $2.06
11365-MZ5-000 90503-898-000
05 COVER, CHANGE 001 $64.40 21 WASHER, BRAKE ARM 001 $1.73
11630-MZ5-000 90525-GC4-700
06 GASKET, SHIFT COVER 001 $9.47 22 OIL SEAL (12X20X6) 001 $3.91
11632-MY7-000 91201-427-003
07 WATER PUMP ASSY. 001 $185.14 23 OIL SEAL (13X22X5) 001 $2.58
19200-MZ5-010 (replaces 19200-MZ5-000) 91204-KE8-003
08 COVER, WATER PUMP 001 $57.43 24 O-RING (10.5X6.5) 001 $2.07
19220-MZ5-000 (replaces 19221-MZ5-305) 91301-ML0-781
09 GASKET 001 $3.53 25 O-RING (32.95X2.62) 001 $2.07
19226-ML7-000 91302-MB0-013
10 LEVER, CLUTCH 001 $31.58 26 PIN, DOWEL (8X14) 004 $1.00
22710-MZ5-000 94301-08140
11 SPRING, CLUTCH LEVER 001 $3.09 27 BOLT, FLANGE (6X32) 001 $0.95
22815-MZ5-000 96001-06032-00
12 PIECE 001 $5.40 28 BOLT, FLANGE (6X35) 001 $1.00
22852-ML0-780 96001-06035-00
13 BOLT, FLANGE (6X16) 002 $2.75 29 BOLT, FLANGE (6X40) 002 $1.02
90004-GHB-630 (replaces 90001-GHB-630) 96001-06040-00
14 BOLT, FLANGE (6X10) 002 $1.67 30 BOLT, FLANGE (6X60) 002 $1.18
90011-HB9-000 96001-06060-00
15 BOLT (6X12) (CT200) 001 $1.34 31 BOLT, FLANGE (6X75) 001 $1.47
90013-883-000 96001-06075-00
16 BOLT (6X75) 001 $6.78
90021-MZ5-000
23-62
Wire Harness

01 RUBBER 001 $4.22 16 SUSPENSION 001 $3.71
30401-GB6-000 38306-GE7-000
02 RUBBER, SPARK UNIT 001 $19.40 17 INDICATOR UNIT 001 $66.65
30405-MT6-000 38710-MZ5-003
03 MODULE, IGN CONT 001 $502.46 18 BRACKET, RR. 001 $21.73
30410-MZ5-671 50333-MZ5-000
04 COIL, IGNITION 002 $89.99 19 BRACKET, FR. 001 $21.58
30510-KT7-023 50334-MZ5-000
05 SPACER 004 $2.89 20 PLATE 001 $8.09
30520-ML7-000 50336-MR1-000
06 CAP ASSY. 004 $25.56 21 STRAP, CABLE (105MM) 001 $2.75
30700-KAF-010 90672-SB2-003
07 WIRE 1, IGNITION 001 $19.87 22 BOLT, HEX. (6X22) 002 $2.33
30731-MZ5-000 92101-06022-4J
08 CORD,HIGH/T 001 $19.87 23 BOLT, HEX. (6X28) 002 $1.82
30731-KEA-505 (replaces 30732-MZ5-000) 92101-06028-4J
09 CORD,HIGH/T 001 $19.87 24 NUT, FLANGE (6MM) 002 $0.73
30731-KEA-505 (replaces 30733-MZ5-000) 94050-06070
10 CORD,HIGH/T 001 $19.87 25 NUT, FLANGE (6MM) 002 $0.23
30731-KEA-505 (replaces 30734-MZ5-000) 94050-06080
11 RECTIFIER, REGULATE 001 $203.22 26 BOLT, FLANGE (8X12) 001 $0.75
31600-MZ5-003 95701-08012-07
12 RECTIFIER, SILICON 001 $20.76 27 BOLT, FLANGE (6X12) 002 $0.78
31700-196-000 96001-06012-00
13 WIRE HARNESS 001 $409.25 28 FUSE, BLADE (10A) 004 $0.67
32100-MZ5-670 98200-31000
14 HORN (LOW) 001 $48.47 29 FUSE, BLADE (15A) 002 $0.67
38120-MZ5-003 98200-31500
15 RELAY, TURN SIGNAL 001 $46.75
38301-KK9-952
23-63
MEMO
24. Appendix: Gasket Diagrams
Alternator Cover Gasket 24-2
Cam Chain Tensioner Gaskets 24-3
Oil Pan Gasket 24-4
Right Crankcase Cover Gasket 24-5
Shift Cover Gasket 24-6
Sprocket Cover Gasket 24-7
NOTE
Diagrams must be printed without using any scaling to fit paper.

Some of the diagrams must be printed on larger than letter sized paper, or must be pieced together using the guides
included on the images
24-1
Appendix B: Gasket Diagrams
Alternator Cover Gasket
Description Part Number

Alternator Cover Gasket 11636-MY7-000
Material Thickness
Paper 0.0218
NOTE
Grey area is a thin bead of sealant
24-2
Cam Chain Tensioner Gaskets

Cam Chain Tensioner Gasket - Front 12194-KW3-880
Cam Chain Tensioner Gasket - Rear 12194-HC5-740
Material Thickness
Paper 0.0218
24-3
Oil Pan Gasket

Oil Pan Gasket 11315-MY7-000
Material Thickness
Paper 0.0218
24-4
Right Crankcase Cover Gasket

Right Crankcase Cover Gasket 11394-MY7-000
Material Thickness
Paper 0.0218
24-5
Shift Cover Gasket

Shift Cover Gasket 11632-MY7-000
Material Thickness
Paper 0.0218
24-6
Sprocket Cover Gasket

Sprocket Cover Gasket 11343-MZ5-000
Material Thickness
Paper 0.0218
24-7
,,1
6 1 MZ509 D RC 3750 .03.08
H O N DA M OTO R CO. , LTD. TOKYO, JAPAN P R I NT E D I N U SA
M A D E F R O M 5 0 % RECYCLED PAPER
M I N I M U M 1 0% POST-CONSUMER CONTENT

1994-2003 HONDA Service Manual - Magna VF750C-CD - With Parts Fiche - V3

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1994-2003 HONDA Service Manual - Magna VF750C-CD - With Parts Fiche - V3

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Copyright:

Verfügbare Formate

1994-2003

HONDA MOTOR CO., LTD. 1994

N OTE: G ives helpful i nformation .

This Model S pecific Manual includes every service proce

If y o u a re n o t familiar with this motorcycle, read Tech Charging System/Alternator

Electric Starter/Starter Clutch

HONDA MOTOR CO ., LTD .

This manual is devided into sections which cover each of the

An index of the entire book is p rovided in the last chapter

N ote On the Explanation M ethod Of This M anual

Part name N u m ber of parts Extra notes or precaution

- Replace the part(s) with new one(s) before assembly.

ls.TOOl! Use special too l .

, Use recommended engine oil , unless otherwise specified .

- Use multi-purpose g rease ( Lithium based m ulti-purpose g rease N LG I # 2 or equivalent) .

Use molybdenum disulfide g rease (containing more than 3% molybdenum disulfide , N LG I # 2 o r

Use silicone g rease .

... Use Fork or Suspension Fluid .

General Safety 1-1 Lubrication & Seal Points 1-17

Specifications 1-4 Emission Control System (U.S.A. Only) 1-27

Torque Values 1-12 Emission Control Information Labels

Run the engine in an open a rea or with an exhaust evacua

Coolant Nitrogen Pressure

(1) FRA M E SERIAL N U M BE R

( 1) The frame serial number is stamped on the r i g h t side o f

( 2 ) E N G I N E SERIAL N U M BE R (3) V E H I C LE I DE N T I F I CATI O N N U MBER

Dlmel..... Overall length '94-'00 2,332 mm (91.8 in)

Frame Frame type Double cradle

Engine Bore and stroke 70 .0 x 48.6 mm (2.76 x 1.91 in)

Carburetor Carburetor type CV (Constant Velocity) type,with flat valve

Final reduction 2.500 (40/16)

Gear ratio reverse --

Gearshift pattern Left foot operated return system 1-N-2-3-4-5

Engine oil capacity at draining 3. 0 lit ( 3. 2 US qt, 2. 6 Imp qt) --

at disassembly 3.8 lit ( 4. 0 US qt, 3 , 3 Imp qt) --

at oil filter change 3. 1 lit ( 3. 3 US qt, 2. 7 Imp qt) --

Recommended engine oil Use Honda GN4 4-stroke Oil or equivalent

Other viscosities shown in the chart may

Oil pressure at oil pressure switch 490 - 588 kPa ( 5 - 6 kg/cm2, 7 1 . 1 - 8 5 . 3

--, FueiSystem ------.----

--, Cooling System --------.---,.--,

Cylinder compression 1,275 kPa (184.9 psi, 13.0 kg/cm2)/

Camshaft journal O . D . 24.949-24.970 (0.9822-0.9831) 24.94 (0.982)

Before guide installation:

Valve seat width 1.0 (0.04) 1.5 (0.06)

Clutch lever free play 10-20 (0.4-0.8) --

[OJ ( 1'--<'l (0] H

Cylinder-to-piston clearance 0.010-0.035 (0.0004-0.0014) --

Crankpin oil clearance 0.030-0.052 (0.0012-0.0020) 0.08 (0.003)

Transmission gear I . D . M 5 2 8 . 000 - 28 . 021 (1.1024 - 1.1032) 2 8 . 04 (1.104)

Countershaft O . D . at C 2 gear bushing 2 7 . 967 - 2 7 . 980 (1. 1011 - 1 . 1016) 2 7 . 96 (1.10 1 )

Minimum tire tread depth (FR) -- 1.5 (0.06)

Up to 90 kg (200 l b ) load ( R R ) 250 kPa (2.50 kg/cm2, 36 psi) --

Up to maximum weight capacity (FR) 250 kPa (2.50 kg/cm2, 36 psi) --

Up to maximum weight capacity (RR) 290 kPa (2.90 kg/cm2, 42 psi) --

Front and rear axle runout -- 0.2 (0.01)

Drive chain size/link ( D I D) D I D 50V4/118 --

r- Front Suspension -------.---.---,

r- Rear Suspension ----------

Shock absorber spring free length 241.8 (9.52) 237.0 (9.33)

Alternator/charging coil resistance (at 20C/68F) 0.1-1.0 0 --

Regulator/rectifier regulated voltage/amperage 14-15.5 V/below 0.5 A/3,000 rpm --

Battery capacity 12 V-10 Ah --