http://honda.vf1000.com The data contained in this file is for noncommercial use only. No warranties, express or implied, are given for the accuracy of this material. HONDA SERVICE DIVISION MOTOR CYCLE SERVICE INFORMATION MANUAL VOLUME XXII http://honda.vf1000.com r - - - - -- - -IIMPORTANT SAFETY NOTICE- - -- - - - - , '&2.i;imn; CAUTION : Indicates Q strong possibility of sel'ert personal injury or loss of life if instructions are not followed. Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE : Give helpful information. Detalied descriptions of standard workshop procedures, safety principles and service operations are not included. It is im portant to note that this manual conta ins some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnal or could damage a vehicle or· render it unsafe. Please understand that those w~rnigs could not cover all conceivable ways in wh ich service, whether or not recommended by Honda might be done o r of the possible hazardous consequences of each conceivable way , nor could Honda investigate all sud'! ways. Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughl y that ne igher personal safety nor vehicle safety will be jeopardized by the service method or tools selected . ( HONDA VF1000F HOW TO USE THIS MANUAL GENERAL INFORMATION This shop manual describes the technical features and LU BRICATION servicing procedures for the VF1 0 00F. Throughout the manual, the following abbreviations MAINTENANCE are used to identify individual modules. CODE AREA (TYPE) ED Europe E U.K. F France G Germany U Australia SA South Africa NO FUEL SYSTEM ENGINE REMOVAL/INSTALLATION COOLING SYSTEM CLUTCH SYSTEM w SN Switzerland AR Austria GEARSHIFT LINKAGE 2 Northern Europe (!l 2 ALTERNATOR w Follow the Maintenance Schedule (Section 3) re- CYLINDER HEAD/VALVE commendations to ensure that the vehicle is in peak operating condition. CRANKCASE Performing the first scheduled maintenance is very important. It compensates for the initial wear that PISTON/CRANKSHAFT occurs during the break-in period. Sections, 1 through 3 apply to the whole motorcycle, whi Ie sections 4 through 21 describe parts of the TRANSMISSION motorcycle, grouped according to location . FAIRING Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. CI) FOR NT WHEEL/SUSPENSION ~ ::I: REAR WHEEL/SUSPENSION U HYDRAULIC BRAKES If you don't know the source of the trouble, go to section 23, TROUBLESHOOT I NG. ALL INFORMATION , I LLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING . HONDA MOTOR CO., LTD . RESER V ES THE RIGHT TO MAKE CHANGES AT AN Y TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI GATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION . HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE BATTERY/CHARGING SYSTEM ...J : U NGK ND Standard DPR8EA-9 X24EPR-U9 < X24EP-U9> For cold climate (Below 5° , 41 ° F) DPR7EA-9 < DP7EA-9> X22EPR-U9 < X22EP-U9> For extended high speed riding DPR9EA-9 < DP9EA-9> X27EPR-U9 < X27EP-U9> Spark plug gap Firing order Fuse/ Main fuse LIGHTS left foot operated return system. l - N- 2 - 3 - 4 - 5 Ignition ign ition timing " F" mark Full advance Starting system Alternator Battery capacity Spark plug Headlight (high/ low beam) Tai l/stoplight Front turn signal/ runn ing light Rear turn signal Instrument lights Neutral indicator Turn signal indicator High beam ind icator Posit ion light 0 .S- 0 .9 mm 10.031 - 0.035 in) 1- 4 - 3 - 2 10A, 15A/30A 60/ 55 W 5/21 W 21 W 21 W 3.4 W X 2 3W 3W 3W 4W ~ 1-3 HONDA VF1000F GENERAL INFORMATION TORQUE VALUES ENGINE Q'tv Thread Dia. Imml 8 16 6 8 9 12 12 Clutch lock nut 8 16 1 1 1 22 Crankcase 14 9 2 15 8 6 22 7 10- 14 45- 50 18-20 14.5- 5.0, 32-361 11.8- 2.0, 13 -141 8 7 26-30 16- 20 12.6- 3.0, 19 - 221 11.6 -2.0, 12 - 141 12 21 -2 5 15 - 20 Item Cylinder head cover Cam holder Cylinder head Alternator Primary drive gear Rocker arm shaft 8 Cam sprocket 8 3 1 1 Starter clutch Shift fork center Cam chain guide bolt Oillilter Countershaft bearing holder Drive sprocket 1 3 1 16 6 20 8 10 7 12 To rq ue N·m Ikg·m, It·lbl 8-12 10.8-1.2, 6-91 10- 14 11.0- 1.4,7 -1 01 21 - 25 12. 1- 2.5,15- 181 43 - 4714.3 - 4.7,31 - 341 85 - 10518.5 - 10.5,61 - 76 1 85-10518.5 - 10.5,61 - 761 80 - 90 180-9.0, 58 - 651 38 - 4213.8 - 4.2,27 - 301 21 - 25 21-25 50-54 12.0- 2.5, 14 - 181 11.0- 1.4,7 -101 11 - 141 14- 181 36- 391 15 - 181 1 4 12 12-16 Q'ty Thread Dia. Imml Torque N·m Ikg·m, It·lbl 1 24 90- 120 19.0- 12.0, 65-871 nut 1 26 Top bridge pinch bolt Front axle nut 1 4 1 23-27 20- 30 18-25 55-65 Front lork top pinch bolts 2 8 8 14 7 2 10 Drain plug Connecting rod nuts Drum stopper pivot shaft Oi l pressure switch Spark plugs 1 8 1 8 6 - { Apply LOCTITE 271 to the threads . 12.1-2.5,15- 181 11.5-2.0, 12.0- 2.5, 15.0- 5.4, 12.1 - 2.5, 21 - 25 35 - 40 30- 34 8- 12 10 - 14 Valve adjustment nuts Remark s 13 .513.010.811.0 - 4.0, 25- 291 3.4,22-251 1.2, 6-91 1.4,7 - 101 11.2-1.6,9-121 { Apply 3·8ond Sealant, or its equivalent, to the threads. CHASSIS Item Steering stem nut Steering bearing adjustment Front axle holder 12.3-2.7, 17-201 12.0-3.0, 14-221 11.8-2.5, 13-181 15.5-6.5,40-471 20-30 12.0-3.0, 14-221 Front fork bottom pinch bolts 1-4 45-55 14.5-5.5, 33- 401 Remarks ~HOND.A ~. VF1000F GENERAL INFORMATION Q'ty Item Thread Oia. (mm I Torque N·m (kg·m, ft·lbl Remarks Brake cal iper bracket mount bolts (Rightl ( Left·upperl Anti·dive piston pin bolt Brake caliper mount bolts 2 1 1 10 10 6 3 3 12 30-40 30-40 10-15 20-25 (3.0-4.0, (3.0-4.0, (1.0-1.5, (2.0-2.5, 22 - 291 22-291 7-111 14-181 2 8 12 8 10 Shock link to shock arm bolt 1 10 40-50 (4.0-5.0, 29- 361 Shock absorber mount bolts 2 10 Swing arm 'pinch bolt Swing arm left pivot bolt 1 8 25 40-50 (4.0-5.0, 29- 361 20-30 (2.0-3.0, 14-22)) Brake caliper pivot bolts Front brake discs Shock arm to frame bolts Swing arm right pivot bolt 1 1 25-30 (2.5- 3.0, 18- 221 35-40 (3.5-4.0,25-291 40-50 (4.0-5.0, 29- 361 16 85-105 (8.5-10.5, 61-761 85-105 (8.5-10.5, 61 - 761 8 10 18-25 (1.8- 2.5,13-181 30-40 (3.0-4.0,22-291 12 80-100 (8.0- 10.0, 58-721 8 18 35- 40 (3.5-4.0, 25-291 85 - 105 (8.5-10.5, 61 - 761 35- 45 (3.5-4.5, 25-331 30-40 (3.0-4.0, 22-291 } Front brake calipers } Front and rear brake calipers Rear brake torque rod 8mm 1 10 mm 1 Final driven sprocket Rear brake disc Rear axle nut Sub·frame bolts (upper and lowerl 5 6 1 Rear brake Pedal 4 2 1 Side stand 1 10 8 8 10 (upperl 1 10 (lowerl 1 10 Engine center hanger bolts 6 2 1 8 10 6 Handlebar pinch bolts f--.[ ~PIY bolts oil to lower 30 - 40 (3.0 - 4.0, 22 - 291 35-45 (3.5-4.5, 25-331 Eng ine rear hanger bolts Engine front hanger bolts Gearshift pedal pivot bolt 60-70 (6.0-7.0, 44 - 501 35 - 45 (3.5 - 4 .5 , 25 - 331 24-30 (2.4-3.0, 17-221 35-45 (3.5-4.5, 25-331 35-45 (3.5-4.5, 25-331 Torque specifications listed above are for important fasteners. Others should be tightened to standard torque valves listed below. STANDARD TORQUE VALUES Item Torque Values N·m Ikg·m, ft·lbl Item Torque Values N·m (kg·m, ft·lbl 5 mm bolt and nut 4-6 10.4-0.6, 3-4) 5 mm screw 3- 5 10.3-0.5, 2-41 6 mm bolt and nut 8- 12 (0.8-1.2, 6 - 91 18- 2511.8-2.5,13-181 6 mm screw 6 mm flange bolt and nut 7- 1110.7-1.1,5-81 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 30-40 13.0-4.0, 22- 29) 50-60 15.0-6.0, 36- 431 8 mm flange bolt and nut 24-3012.4- 3.0, 17 - 221 10 mm flange bolt and nut 35-45 13.5- 4.5, 25-331 10- 1411 .0 - 1.4,7 - 101 1-5 (i)HONDA ~ . VF1000F . GENERAL INFORMATION TOOLS SPECIAL TOOL NAME Primary gear holder 4ch Vacuum tester set Oil pressure gauge attachment Compression gauge attachment Pilot screw wrench Tappet lock wrench Snap ring pliers Steering stem socket Lock nut wrench Hollow set wrench 6 mm Needle bearing remover Bearing race remover I Steering stem driver Slider weight . Seal driver attachment Ball race remover Oil seal driver attachment Oil seal dri ver Driver ring attachment Oil seal driver attachment Valve guide reamer Fly wheel cover APPLICATION TOOL NUMBER 07924-ME90000 07404-0030100 07510-4220100 07510-MB0010 1 07908-4220201 07908-MB00100 07914-3230001 07916-3710100 07916·4220000 07917-3230000 07931 -MA 70000 07946-3710500 07946-MBOOOOO 07947-KA50000 07947-KF00100 07953-4250002 07965-MB00100 07965-MC70100 07965-ME70100 07965-MA60100 07984-2000000 07998-MB40000 Primary gear Vacuum Oil pressure Compression Carburetor Tappet lock nut Master cylinder Steering stem Clutch Front fork f- r- Swing arm Lower ball race Steering stem Front fork seal Front fork seal Steering ball race Rear shock absorber REF. SECTION 7 3 2 3 4 3 17 15 7 15 16 15 15 15 15 15 16 fValve guide Timing cover 10 3 COMMON TOOL TOOL NAME Float level gauge Lock nut wrench 30 x 32 mm Extension bar Flywheel holder Rotor puller Valve guide remover 5, 5 mm Valve guide driver Attachment 37 x 40 mm Pilot 17 mm Pilot 20 mm Attachment 32 x 35 mm Attachment 52 x 55 mm Attachment 42 x 47 mm Pilot 15 mm Pilot 25 mm Attachment 62 x 68 mm Driver A Driver C Inner driver 30mm 1-6 TOOL NUMBER 07401 -0010000 07716-0020400 07716-0020500 07725-0040000 07733-0020100 07742-0010100 07743-0020000 07746-0010200 07746-0040400 07746-0040500 07746-0010100 07746-001 0400 07746-0010300 07746-0040300 07746-0040600 07746-0010500 07749-0010000 07746-0030100 07746-0030300 APPLICATION b- P- Carburetor Steering lock nut Fly wheel REF . SECTION 4 15 9 b- Valve guide 10 ~ Swing arm 16 Pb- Swing arm Rear wheel Counter shaft 16 16 13 Front wheel Rear wheel 15 16 P- Main shaft 13 rt ~ ~. HON D A VF1000F TOOL NAME Bearing remover shaft Bea ring remover head 1 5 mm Bearing remover head 20 mm Valve spring compres sor GENERAL INFORMATION TOOL NUMBER 07746-0050100 07 746-0050400 07746-0050600 07757 -0010000 IT APPLICATION REF. SECTION Front wheel Rear wheel 15 16 Valve 10 OPTIONA L TOOL TOOL NAME Compression gaug e Oil pressure gauge Seat cutter 29 mm 45 °I EXI 33 mm 45 ° liN ) Seat cutter 30 mm 3 2 ° (IN, EX ) Flat cutter Interior cutter 30 mm 60 ° liN , EX ) Cutter holder 5.5 mm TOOL NUMBER 07305-0010000 0 7 506 -3000000 07780-0010300 07780-0010800 0 77 80-0012200 07780-0014000 07781 -0010 101 A PPLICATION Compression Oil pressure Va lve V alve Valve Valve Valve seat seat seat seat seat REF. SEC TION 3 3 10 10 10 10 10 1-7 ~ ~ GENERAL INFORMATION HONDA VF1000F CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses. • A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure it is secure. • Do not squeeze wires against the weld or end of its clamp when a weld-on clamp is used. o X Q • Secure wires and wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses. • Route harnesses so they are neither pulled tight nor have excessive slack. • Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. Clean the attaching surface thoroughly before applying tape. • Do not use a wire or harness with a broken insulator. Repair by wrapping them with pro· tective tape or replace them. • Route wire harnesses to avoid sharp edges or corners. • Also avoid the projected ends of bolts and screws. • Keep wire harnesses away from the exhaust pipes and other parts that get hot. • Be sure grommets are seated in their grooves properly. • After clamping, check each harness to be certain that it is not interferring with any moving or sl id ing parts. • After routing, check that the wire harnesses are not twisted or kinked. • Wire harnesses routed along the handlebars should not be pulled taut, have excessive slack, be pinched by or interfere with adjacent or sur· rounding parts in all steering positions. 1-8 ( ~ ~. HONDA VF1000F GENERAL INFORMATION 111 CHOKE CABLE 141 CLUTCH FLUID LINE (2) FRONT BRAKE HOSE /- ( (5) SPEEDOMETER CABLE (6) THROTTLE CABLES 171 FRONT BRAKE HOSE ,r ,\ 1-9 ~ GENERAL INFORMATION ~. HONDA VF1000F (2) CLUTCH HOSE (3) THROTTLE CABLES (5) CHOKE CABLE 111 BRAKEfTA)LLlGHT SENCOR 1-10 (2) SPARK UN)T ~ ~ HONDA . Vf1000F GENERAL INFORMATION III IG NITION COILS (3) FUEL PUMP RELA Y (4 ) TURN SIGNAL RELAY (6) ALTERNATOR WIRE (7) CLUTCH HOSE (1) STARTER RELAY/ MAIN FUSE (2) GROUND CABLE (3) IGNITION COIL (9) PULSE GENERATOR WIRE (4) REAR BRAKE HOSE ~ :: ~ >,-.':~ ~ RESERVE TANK / " BREATHER TUBE _ ............J...- i1> RIo."" Oil pre9Sure (at oil pressure switch) 540 :t 70 kPa (5 .4 :t 0.7 kg/c m', 77:t 10 psi) at 5,000 min-> (rpm) (BooC/ 176 °F) Oil pump delivery 56 .3 liter (59.6 US qt, 49.6 Imp qt) /min . at 5,600 min-> (rpm) Oil pump service data STANDARD SERVICE LIMIT 0.15 mm (0.006 in) 0.20 mm (O.OOB in) Pump body clearance 0.15-0.22 mm (0.006-0.009 in) 0.35 mm (0.014 in) Pump end clearance 0.02- 0.07 mm (0.001-0 .003 in) 0.10 mm 10.004 in) Rotor tip clearance 2- 1 HONDA VF1000F LUBRICATION TORQUE VALUES Engine oil drain plug Engine oil filter Oil pressure switch 35-40 N ·m (3.5-4.0 kg ·m, 25 - 29 ft· lb) 15-20 N·m (1.5-2.0 kg·m, 11 - 14 ft·lb) 10 - 1 4 N·m 11.0- 1.4 kg· m, 7 - 10 ft·lbl TOOLS Special Oil pressure gauge Oil pressure gauge attachment 07506-3000000 07510-4220100 TROUBLESHOOTING Oil level too low 1. External oil leaks 2 . Worn piston rings 3. Worn valv e guide or seal Oil contamination 1. Oil or filter not changed often enough 2. Head gasket faulty 3. Worn piston rings Low oil pressure 1. Oil level low 2. Pressu re relief valve stuck open 3. Plugged oil pick·up sc reen 4. Oil pump worn 5. External oil leaks High oil pressure 1. Pressure relief valve stuck closed 2. Plugged oil filter , gallery , or metering orifice 3. Incorrect oil being used No oil 1. Oil 2. Oil 3. Oil pressure level low pump drive chain broken pump faulty 4 . Internal oil leakage 2-2 r:::iih HONDA. ~ LUBRICATION ENGINE OIL LEVEL (1) OIL FILLER CAP/DIPSTICK Put the motorcycle on its center stand on level ground. Start the engine and let it idle for 2-3 minutes. Turn off the engine. Remove the filler cap/dipstick, wipe it clean and insert it without screwing it in. Remove the tiller cap/dipstick and check the oil level. If the level is below the lower level mark on the dipstick. fill to the upper level mark with recom- mended oil. (2) UPPER Check the oil pressure with the oil pressure warn- ing light after the engine starts. The light should go off after one or two seconds. (3) LOWER If it does not, stop the engine and check the oil pump output and/or oil circuit. ENGINE OIL & FILTER CHANGE NOTE Change engine oil with the engine warm and the motorcycle on its center stand to assure complete and rapid draining. Stop the engine. Remove the oil filler cap/dipstick, oil drain plug and drain the oil. Remove the lower cowl. Remove the oil filter with a filter wrench (079126110001) and let the remaining oil drain out. Dis· card the oil filter. Check that the sealing washer on the drain plug is in good condition and install the plug. Replace the oil filter with a new one. Check that the oil filter O·ring is in good condition, and coat it with oil before installing it. Install and tighten the oil filter. TORQUE: 15-20 N'm (1.5-2.0 kg·m, 11-14 ft·lb) Fill the crankcase with 2.9 liters (3.1 US qt, 2.5 Imp qt) of the recommended oil (page 2·1). Rein· stall the oil filler cap/dipstick. Start the engine and let it idle for 2-3 minutes, then stop the engine. Make sure that the oil level is at the upper level mark on the dipstick. Make sure that there are no oil leaks. I nstall the lower cowl. 2-3 VF1000F (1) OIL FILTER r::iiJ\HONDA ~ VF1000F LUBRICATION Oil STRAINER/PRESSURE RELIEF VALVE NOTE The oil strainer can be removed with the engine mounted in the frame. Remove the lower cowl. Remove the exhaust chamber. Drain the engine oil (page 2-3). Remove the oil pan bolts and oil pan. Remove and clean the oil strainer (1) PRESSURE RELIEF VALVE Check the operation of the pressure relief valve. 2-4 HONDA VF1000F LUBRICATION (1) SPRING SEAT (2) PISTON Disassemble the relief valve by removing the snap ring. Inspect the piston for wear, sticking or damage. Inspect the spring for weak or damage. Assemble the relief valve in the reverse order of disassembly. 0 0 1 (4) SNAP RING (1) RELIEF V Make sure that the a-ring is in good condition and install the relief valve. Make sure the O-ring is in good condition and install the oil strainer aligning its groove with the lug on the oil strainer tube pipe. 2 -5 (3) a -RING ! ' (5) SPRING (6) VALVE BODY (2) a-RING r:::iJ\ HONDA ~ VF1000F LUBRICATION Inst.,,11 the oil pan with a new gasket. Tighten the oil pan bolts in 2·3 steps in a criss cross pattern. Install the exhaust pip·es. Fill the crankcase with the recommended oil Ipage2- 1). Install the lower cowl. OIL PRESSURE CHECK Warm the engine up to normal operating temper- ature (approximately 80°C' 176° F). Stop the engine and disconnect the oil pressure switch wire. Remove the oil pressure switch and connect an oil pressure gauge to the pressure switch hole (page 2-5). Check the oil level. (1) OIL PRESSURE SWITCH (1) OIL PRESSURE GAUGE Start the engine and check the oil pressure at 5,000 rpm. OIL PRESSURE: 540 ± 70 kPa (5.4 ± 0.7 kg /cm', 77 ± 10 psi) at 5,000 min-! (rpm) (80 0 C/17 6 °FI Stop the engine. Apply 3-80ND® sealant or equivalent to the pres- sure switch threads and install. TORQUE: 10-14 N·m (1.0-1_4 kg-m, 7 - 10 ft-Ibl Connect the oil pressure switch wire . Start' the engine. Operate the warning indicator switch. Check that the oil pressure warning indicator goes out after one or two seconds. If the oil pressure warning indicator stays on, stop the engine immediately and determine the cause. ,./ (2) OIL PRESSURE GAUGE ATTACHMENT 07510-4220100 2-6 ~HONDA LUBRICATION ~. VF1000F OIL PUMP REMOVAL NOTE The oil pump can be removed with the engine mounted in the frame. Drain the engine oil. Remove the right crankcase cover. Remove the oil pump driven sprocket by removing the bolt and washer. III OIL PASS PIPE Remove the oil strainer (page 2·4) and the oil pass pipe. Make sure the a-rings are in good condition. Remove the oil pump by removing the mounting bolts. (2) O·RINGS (1) OIL (3)OIL PUMP INER TUBE Straighten and remove the cotter pin holding the oil strainer tube. Remove the oil strainer tube. Remove the oil pump body cover. (2) OIL PUMP BODY 2-7 R (3) COTTER PIN ~HONDA ~. VF1000F LUBRICATION 111 DOWEL PIN Remove the dowel pin. Measure the rotor tip clearance. STANDARD: 0.15 mm (0.006 in) SERVICE LIMIT: 0.20 mm (0.008 in) Measure the pump body clearance. STANDARD: 0.15-0.22 mm (0.006-0.009 in) SERVICE LIMIT: 0.35 mm (0.014 in) 2-8 ~ ~ lUBRICATION HOND.A VF1000F Remove the rotor shaft and measure the pump end clearance. STANDARD: 0.02-0.07 mm (0.001-0.003 in) SERVICE LIMIT: 0.10 mm (0.004 in) (1) OUTER ROTOR ASSEMBLY Install the outer rotor into the body and insert the rotor shaft. Install the washer. Insert the drive pin into the rotor shaft. Align the slots in the inner rotor with the drive pin. (4) DRIVE PIN (1) DOWEL PIN (5) INNER ROTOR (2) O·RINGS Install the dowel pin and oil pump body cover. Make sure the oil strainer tube a-rings are in good condition . (3) OIL PUMP BODY COVER 2-9 (4) OIL STRAINER TUBE ~ HON ~. D A VF1 000F LUBRICATION Install th e oil strainer tube with a new cotter pin. (1) COTTER PIN INSTAL LATIO N Install the orifice, O·ring and dowel pin. (2) DOWEL PINS (1) O IL PASS PIPE (2) BOLTS Install the oil pump and tighten the three bolts. NOT E Make sure that the o il pump shaft rotates freely after tightening the bolts. Make sure the a-rings on the oil pass pipe are in good condition and install the oil pass pipe. Install the oil strainer and o il pan (page 2·5). (3) OI L PUMP 2- 10 ~ ~ lUBRICA TION Place the oil pump driven sprocket into the drive chain. NOTE The "IN" mark on the driven sprocket should face the crankcase. HONDA VF1000F •. ,' .' • •• • , (1) "IN" MARK (1) DRIVE N SPROCKET Install the washer and tighten the bolt. Install the dowel pins and a new gasket. Install the right crankcase cover. Install the exhaust system. Fill the engine with the recommended oil (page 2-11. (3) WASHER CONTROL CABLE LUBRICATION Periodically , disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil. 2- 11 (2) DRIVE CHAIN ~ HON'DA ~ VF1000F LUBRICATION LUBRICATION POINTS (17) ISPECIAL LUBRICANT I SHOCK ABSORBER UPPER MOUNT BUSHING (page 15-11) SUSPENSION LINKAGE NEEDLE BEARINGS (page 15-12) • • I I ~ . iii (11 or ',.IC~AB ~ L=E ~ L ~ U=BR~ICANT THROTTLE AND CHOKE CABLE ~ (5) i i . iii (2) CLUTCH AND BRAKE LEVER PIVOTS "7I(S) (1 0) • LE GRIP or ICABLE LUBRICANT I SPEEDOMETER CABLE ' , , I REAR SHOCK ABSORBER , rtjjjijffi , , BRAKE PEDAL PIVOT / I I I I I I I ", I I I ~)rtjif I (1 2). I FOOT PEG PIVOT SWING ARM PIVOT • rtjjjijffi rtjjjijffi (7) STEERING HEAD ~BEARINGS WHEEL.' BEARINGS (When replaced) (111 _UIJD1 \ GEARSHAFT PEDAL PIVOT (8) SPEEDOMETER DRIVE GEAR (9) FRONT FOR K (13) • SIDE AND CENTER STAND PIVOTS (lS) . ' _ FOOT PEG PIVOT (14) "71 WHEEL BEARINGS (When replaced) DRIVE CHAIN (GEAR OIL SAE #80 - 90) 2-12 ~ MAINTENANCE RADIATOR CORE 3- 1 3-3 3-4 3-4 3-5 3-6 3-6 3-7 3-7 3-8 3 - 11 3-12 3-12 3-13 COOLING SYSTEM HOSES & CONNECTIONS 3-13 SERVICE INFORMATION MAINTENANCE SCHEDULES FUEL LINES FUEL FILTER THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER CRANKCASE BREATHER SPARK PLUGS VALVE CLEARANCE CARBURETOR SYNCHRONIZATION CARBURETOR IDLE SPEED RADIATOR COOLANT ~ , ~ ~ CYLINDER COMPRESSION DRIVE CHAIN BATTERY BRAKE FLUID BRAKE SHOE/ PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SIDE STAND SUSPENSION NUTS, BOLTS, FASTENERS WHEELS STEERING HEAD BEARINGS HON'DA VF1000F 3-13 3-14 3-15 3-16 3-16 3-16 3-17 3-17 3-17 3-18 3 - 18 3-20 3-20 3-20 .. SERVICE INFORMATION ' GENERAL • • See page 2-3 See page 2-3 Eng ine oil Engi ne oil filter SPECIFICATIONS < Engine> Spark plugs : For cold climate (b elow 5° C. 41 ° F) Standard For extended high speed r id ing NGK NO NGK NO NGK NO OPR8EA-9 < OP8EA-9> X24EPR -U9 OPR7EA -9 < OP7EA-9> X22EPR-U9 OPR9EA-9 < OP9EA-9> X27E PR-U9 Spark plug gap: 3-1 0.8- 0.9 mm (0_031 - 0035 in) < >: U HONDA VF1000F Valve clearance Cold IBelow 3S' C, 9S' F): MAINTENANCE .. Intake/Exhaust: 0.12 mm 10.00S in) Idle speed: 1,000 ± 100 min" Carburetor synchronization: All carburetors within 60 mm (2.4 in) Hg 1,300 ± 200 kPa 113.0 ± 2.0 kg/em', lBS ± 28 psi) Cylinder compression: Throttle grip free play: Irpm) 2-6 mm 11 /8-1/4 in) lS-2S mm IS/8-1 in) Drive chain slack: Tire: Front Tire size Rear 120/BOV 16 - V2S0 140/BOV17 - V2S0 Driver only 2S0 12.S0, 36) 290 12.90. 42) Driver and one passenger 2S0 (2.50, 36) 290 12.90, 42) Cold tire pressure, kpa (kg/cm 2 , psi) Tire brand Bridgestone GSll G520 Dunlop K500 K500 Suspension air pressure: Front, 0 - 40 kPa (0 - 0.4 kg/em', 0 - 6 psi) Rear, 0-300 kPa 10-3.0 kg/e m', 0-43 psi) TOOLS Special Vacuum gauge Carburetor pilot screw wrench Valve adjusting wrench Compression gauge attachment 07404-0020000 0790B--4220201 0790B-MBool00 07510-MBool0l Common Valve adjsuting wrench 07708-0030300 3-2 ~HONDA MAINTENANCE ~, VF1000F MAINTENANCE SCHEDULES Perform the PRE·RIDE INSPECTIDN in the Owner's Manual at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE , A: ADJUST, L: LUBRICATE FREQUENCY WHICHEVER COMES FIRST , , , , , , , , , , ITEM .J EVERY FUEL LINES " l&tl~ ",": ~ THROTTLE OPERATION CARBURETOR · CHOKE AIR CLEANER CRANKCASEBREAHTER SPARK PLUGS VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER CARBURETOR · SYNC HRONIZATION CARBURETOR ·IDLESPEED RADIATOR COOLANT ~ ~ I NOTE 1 NOTE 2 C I I YEAR YEAR R R I I I I ::-'''1 oS' *1:1 *1:1' *1:1' I ~:-"! ..... "~ ..... I MONTH MONTH I 2 YEARS' R .fJ I 3·4 3·4 I I I I I I 3·5 3-6 R R R 3-6 C R I 3-7 3-7 C R I R C I I I I I I C R I R R I I I C I 3-8 R R I I 'R 2· 3 2· 3 3-11 I I 3· 13 I I 3-13 I 3-12 3-12 3· 14 I I I I 3· 15 I I I ' R I I 'R 3-16 I I I I I I I I I I I I I 'R 3· 16 I I I 3· 16 3-17 I I 3-17 'R 3·17 I 3-17 i I I I I I I I I I I SIDE STAND NUTS, BOLTS, FASTENERS I R I I SUSPENSION Refer to page I HEADLIGHT AIM CLUTCH SYSTEM 1iP'~ :y I I I MONTH I 2 YEARS ' R *1:l' '##. f . I, L EVERY 1,000 km (600 mil BRAKE PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH CLUTCH FLUID , f ~& R I RADIATOR CORE COOLING SYSTEM HOSES & CONNECTIONS BRAKE FLUID ,, ,, *~l FUEL FILTER BATTERY ~ ~ .~ "" t ll> 1& DRIVE CHAIN , , ODOMETER READING (NOTE 31 I I I 3-18 I I 3· 18 3-20 WHEELS I I I I 3· 20 STEERING HEAD BEARINGS I I I I 3-20 , SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALI FI ED. ,. IN THE INTEREST OF SAFETY , WE RECOMMEND THAT THE SE ITEMS BE SERVICED ONLY BY AN AUTHO · RIZED HONDA DEALER . NOTES: 3-3 - 1. SERVICE MORE FREQUENTLY WHEN RI DING IN DUSTY AR EAS. 2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTT LE . 3. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTER V AL ESTABLI SHED HERE . HONDA VF1000F MAINTENANCE FUEL LINES Remove the seat and left side cover. Check the fuel lines and replace any parts which show deterioration, damage or leakage. ..' ......,,.• Mil""'" '.' (1) FUEL FUEl FIlTER (1) ELECTRIC PANEL ' j , .. INES (2) ARROW Gasoline is flammable and is expwsive under certain conditions. Do not smoke or allow f/Ilmes or sparks in your working area. Replace the fuel filter with a new one when indicat- ed by the maintenance schedule (page 3·3). Remove the left side cover. Remove the electric panel mounting bolts and remove the coolant reserve tank. Unclip the fuel filter holder from the bottom of the electric panel. Disconnect the fuel outlet line from the fuel filter. Pull the fuel filter out then clip the inlet line closed. Disconnect the fuel inlet line. Install the fuel filter with its arrow pointing outlet side. After installing, turn the fuel valve on and check that there are no fuel leaks. 3-4 ~HONDA MAINTENANCE ~ . VF1000F THROTTlE OPERATION Check that the throttle grip opens smoothly to full throttle and fully closes automatically. in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables (page 2-11), if throttle operation is not smooth. Measure throttle grip free play at the throttle grip flange. FREE PLAY, 2-6 mm (1/8- 1/4 in) (1) LOCK NUT Adjustment can be made at either end of the throttle cable. Minor adjustments are made with the upper adjuster and major adjustments are made with the lower adjuster after removing the fuel tank and air cleaner case. Adjust the loosening the lock nut and turning the adjuster. Tighten the lock nut and recheck throttle operation. Install the air cleaner case and fuel tank, and check throttle free play once more. Also check for fuel leaks. (2) UPPE ADJUSTER (3) LOWE R ADJUSTE R rr\RII.,....=f--r (4) LOCK NUT 3-5 ~ HONDA ~ VF1000F MAINTENANCE CARBURETOR CHOKE The choke system uses a fuel enrichening circuit controlled by a bystarter valve . The bystarter valve opens the enrichening circuit via cable when the choke lever on the handlebar is pulled back. Check for smooth operation of the choke lever. Lubr icate the choke cable, if the operation is not smooth. Pull the choke lever on the handlebar all the way back to the fully open. Make sure the choke valve is open by trying to move the choke lever on the carburetor, after removing the fuel tank and air cleaner case. There should be no free play. 111 CHOKE LEVER Adjust if necessary, by loosening the choke cable clamp on the carburetor and moving the choke cable casing so the choke lever is fully open. Tighten the clamp. Push the choke lever up all the way to fully closed. Make sure the choke valve is fully closed by checking for free play in the cable between the lever on the carburetor and cable casing. Reinstall the removed parts in the reverse order of disassembly. 121 CHOKE CABLE AIR CLEANER 111 AIR CLEANER CASE COVER Remove the fuel tank. Remove the air cleaner case cover screws and the cover. 3-6 ~HONDA. MAINTENANCE ~ . VF1000F Remove . the spring clip and the air cleaner element. Discard the element in accordance with the main- tenance schedule. Also , replace the element any time it is excessively dirty or damaged. Install a. new element and secure it with the spring clip . Install the air cleaner cover and fuel tank. CRANKCASE BREATHER (2) AIR CLEANER ELEMENT Remove the plug from the drain tube to empty any deposits . Install the drain plug, NOTE Service more frequently when riding in rain or at full throttle, or if the deposit level can be seen in the transparent section of the drain tube. SPARK PLUGS RECOMMENDED SPARK PLUGS < >. U NGK NO Standard DPR8EA-9 < DP8EA-9> X24EPR-U9 For cold Climate IBelow 5° C. 41 ° F) DPR7EA-9 < DP7EA-9> X22EPR-U9 For extended h igh speed riding X27EPR·U9 DPR9EA-9 < DP9EA-9> Disconnect the spark plug caps. Clean any dirt from around the spark plug bases. Remove the spark plug. Visually inspect the spark plug. Discard the spark plug if the insulator is cracked or chipped. Measure the spark plug gap with a wire-type feeler gauge. SPARK PLUG GAP: 0.8- 0.9 mm 10.031 - 0.035 in) Adju st by bending the side electrode carefull y. With the plug washer attached, thread each spark plug in by hand to prevent crossthreading. Continue tightening by hand until the spark plug bottoms. Then, tighten the spark plugs another 112 turn with a spark plug wrench to compress the plug washer. Connect the spark plug caps. 3-7 III 0 RAIN PLUG (1) CENTER ELECTRODE (2) SIDE ELECTRODE ~ l - i T 0.B-0.9 mm 10.031-0.035 in) HONDA VF1000F VALVE CLEARANCE MAINTENANCE (2) AIR CLEANER CASE (1) BREATHER TUBES MAINTENANCE NOTE Inspect and adjust valve clearance while the engine is cold. (Below 35° C, 95°F) Remove the lower cowl. Drain coolant from engine (page 6·3). NOTE Drain the coolant into a clean container for reuse. Scheduled coolant replacement is every 24,000 miles (38,400 km). (3) No.1 CYLINDER Remove the seat and remove the left and right side covers. Turn the fuel valve off and remove the fuel tank. Remove the lower radiator (page 6·5). Remove the spark plug caps. (4) No . 3 CYLINDER (5)IGNITION COILS (1) FRONT CYLINDER HEAD COVER Disconnect the breather tubes from the rear cylinder head cover and air cleaner case . Remove the air cleaner case (page 4-3). Remove the ignition coils (page 19·4). Remove the front and rear cylinder head cover bolts and both cylinder head covers. Remove the alternator cover. (2) No.4 CYLINDER (3) No. CYLINDER (1) T1.3 MARK )NSPECTION Measure and adjust the intake and exhaust valve clearances as described below. Rotate the crankshaft clockwise to align the T1.3 mark with the crankcase mating surfaces. Make sure the No.1 piston is at TDC (Top Dead Center) on the compression stroke. (2) REAR CRANKCASE MATING SURFACE 3-8 (.j) HONDA ~, VF1000F MAINTENANCE Check the valve clearances for the No.1 cylinder using two feeler gauges for each pair of valves; one for 'each valve that shares a common rocker arm. VALVE CLEARANCE (iN, EX): 0.12 mm (0.005 in) ADJUSTMENT If adjustment is necessary, remove the eight oil pipe bolt and the oil pipe. (1) OIL PIPE (1) VALV E ADJUSTING WRENCH 07908 Loosen the lock nuts and turn the adjusting screws until there is a slight drag on both feeler gauges. Both feeler gauges should re main inserted during adjustment. Hold the adjusting screws and tighten the lock nuts. TORQUE: 21-25 N·m (2.1-2.5 kg·m, 15-18 ft·lb) CAUTION The lock nuts will come loose if not tightelled to the correct torque value. Rech eck the valve clearance. 3-9 00 ~HONDA ~. VF1000F MAINTENANCE (1) T2.4 MARK Rotate the crankshaft 90° counterclockwise to align the T2.4 mark with the crankcase mating surfaces ,......--: and check the valve clearances for the No.4 cylin- der. Adjust using the procedures for the No.1 cylinder. 0 Rotate the crankshaft 270 counterclockwise to align the Tl.3 mark with the crankcase mating sur· faces and check the valve clearances for the No.3 cylinder. Adjust using the procedures for the No.1 cylinder. Rotate the crankshaft 90° counterclockwise to align the T2.4 mark with the crankcase mating surfaces and check the valve clearances for the No.2 cy linder. Adjust using the same procedures as for the No. 1 cylinder. (2) CRANKCASE MATING SURFACE (1)6 mm BOLTS (2) 9 mm BOLTS Install the oil pipes with their shorter pipe ends toward the exhaust sides. Install the 9 mm and 6 mm bolts and tighten the 9 mm bolts first, then the 6 mm bolts. TORQUE: 9 mm - 43-47 N·m (4.3-4.7 kg-m. 31-34 ft·lb) 6 mm - 10-14 N'm (1 .0-1.4 kg·m. 7-10 ft·lb) Install the front cylinder head cover with its insulator grooves facing up and tighten the cover bolts. (2) FRONT CYLINDER HEAD COVER 3-10 ~ MAINTENANCE ~. HONDA VF1000F (1) REAR CYLINDER HEAD COVER Install the rear cylinder head cover and tighten the cover bolts. Install the removed parts in the reverse order of removal. Fill the cooling system (page 6·3). CARBURETOR SYNCHRONIZATION NOTE Synchronize the carburetors with the engine at normal operating temperature, transmission in neutral and motorcycle on the centerstand. Remove the plugs from the No.1, 2, 3 and 4 cylinder head ports and install the vacuum gauge adapters. Connect the vacuum gauges. <':>AlJ~ 07404-0020000 Start the engine and adjust the idle speed. IDLE SPEED: 1,000 ± 100 min -I (rpm) Check that all carburetors are within 60 mm (2.4 in) Hg. (2) ADAPTE RS 3-11 -- ~HONDA ~. VF1000F MAINTENAN CE (2) CAR8URETOR PILOT SCREW WRENCH 07908-4220201 Synchronize to specification by turning the adjusting screws with a carburetor pilot screw wrench (07908-4220201) . NOTE The No.4 carburetor cannot be adjusted; It is the base carburetor. CARBURETOR IDLE SPEED NOTE • Inspect and adjust idle speed after all other engine adjustments are within specifications. • The engine must be warm for accurate adjustment. Ten minutes of stop-and-go riding is sufficient. Warm up the engine, shift to NEUTRAL, and place the motorcycle on its center stand. Turn the throttle stop screw as reQuired to obtain the ~pecifd idle speed. IDLE SPEED: 1,000 ± 100 rpm RADIATOR COOLANT (1) RESERVE TANK CAP Remove the frame left side cover. Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" and "LOWER" levellines. If necessary, remove the reserve tank cap and fill to the "UPPE R" level line with a 50/50 mixture of distilled water and anti-freeze. Reinstall the cap and frame side cover. 3-12 MAINTENANCE HONDA VF1000F RADIATOR CORE Check the air passages for clogging or damage. Straighten bent fins and collapsed core tubes . Remove insects, mud or any obstruction with com- pressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface. COOLING SYSTEM HOSES & CONNECTIONS Inspect the hoses for cracks or deterioration, and replace if necessary. Check the tightness of all hose clamps. CYLINDER COMPRESSION Warm up the engine. Stop the engine, then disconnect the spark plug caps and remove the spark plugs. Insert the compression gauge. Open the throttle all the way and crank the engine with the starter motor. NOTE Crank the engine until the gauge reading stops rising. The maximum reading is usually reach ed within 4-7 seconds. COMPRESSION PRESSURE: 1,300 ± 200 kPa (13.0 ± 2.0 kg/em', 185 ± 28 psi) If compression is low, check for the following: Improper valve clearance Leaky valves Leaking cylinder head gasket Worn piston/ring/cylinder If compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and/or the piston crown. 3-13 111 COMPRESSION GAUGE ANACHMENT 0751O-MB0010l HONDA. Vf1000F MAINTENANCE DRIVE CHAIN Turn the engine off, place the motorcycle on its center stand and shift the transmission into neutr,al. Check slack in the drive chain lower run midway be· tween the sprockets. SLACK: 15- 25 mm (5/8-1 in) CAUTION Excessive chain slack, 50 mm (2 in) or more, may damage the frame. Adj ust as follows : Loosen the axle nut. Loosen the adjusting bolt lock nuts. Turn both adjusting bolts an equal number of turns until the correct drive chain slack is obtained. CAUTION Make sure that th e same alignment marks on both adjustillg plates align with the ends oj the swingann. Tighten the adjusting bolt lock nuts. Tighten the rear axle nut. TORQUE: 85-105 N·m (8.5 - 10.5 kg·m, 61-76 ft·lb) (4) ADJUSTING BOLT (5) LOCK NU~T .:J'Tt( 6 5i)~'u"STm: PLATE Recheck chain slack and free wheel rotation . Lubr icate the drive chain wit h SAE 80 or 90 gear oil. Check the chain wear label. If the red zone on the label align, or is beyond, the rear end of the swing· arm after the chain has been adjusted , the chain must be replaced. REPLAC EMENT CHAIN: 0.1.0. 50V or RK50MO 3- 14 ~HONDA MAINTENANCE VF1000F ~_ Inspect the drive chain and sprockets for damage or wear . A drive chain with damaged rollers, loose pins, or missing O-rings must be replaced. Replace any sprocket which is damaged or excessively worn. (1) DAMAGED NOTE .- ~ - (2) WORN Never install a new drive chain on worn sprochets or a worn drive chain on new sprockets. Both chain and sprockets must be in good condition or the replacement chain or sprockets will wear rapidly. Lubrication and cleaning: (3) NORMAL The drive chain on this motorcycle is equipped with small O-rings between the link plates. The O-rings can be damaged by steam cleaner, high pressure washers, and certain solvents. Clean the chain with kerosene. Wipe dry and lubri- cate only with SAE 80 or 90 gear oil. Commercial chain lubricants may contain solvents which CQuid damage the rubber O-rings. (1) UPPER LEVEL (2) HOLDE R BOLT BATTERY Remove the right frame side cover and inspect the. battery fluid level. When the fluid level nears the lower level , remove the battery and add distilled water to the upper level line as follows: Remove the battery holder bolt, then swing the holder out of the way. (3) LOWER LEVEL Disconnect the negative cable at the battery. then disconnect the positive cable. Disconnect the battery breather hose from the (1) POSITIVE TERMINAL (2) FILLER CAPS battery. Pull the battery out, remove the filler caps and add distilled water to the upper level line. Reinstall the filler caps and the battery. NOTE Add only distilled water. Tap water will shorten the service life of the battery. The banery electrolyte contains sulphuric acid. Protect your eyes, skin, and clothing_ If electrolyte gets in your eyes, flush them thoroughly with water and get prompt medi· cal attention. 3-15 (3) BREATHER HOSE (4) NEGATIVE TERMINAL ~HONDA ~. VF1000F BRAKE flUID MAINTENANCE (l)UPPER LEVE (31 FRONT Check the front brake fluid reservoir level. If the level nears the lower level mark, fill the re o servoir with DOT 4 BRAKE FLUID to the upper level mark . Check the entire system for leaks, if the level is low. CAUTION Do not remove the cover until the handlebar has been turned so that th e reservoir is level. Avoid operating the brake lever with the cap removed. Brake fluid will squirt out if the lever is pulled. Do not mix different types of fluid, as they are not compatible. (21 LOWER LEVEL Refer to section 17 for brake bleeding procedures. BRAKE PAD WEAR (2ILOWER LEVEL Check the brake pads for wear by looking through the slot indicated by the arrow cast on the caliper assembly. Replace the brake pads if the wear line on the pads reaches the edge of the brake disc (page 17-51. CAUTION Always replace the brake pads in pairs to assure even disc pressure. BRAKE SYSTEM I nspect the brake hoses and fittings for deterioration, cracks and signs of leakage . Tighten any loose fittings. Replace hoses and fittings as required. (3) BRAKE DISC (4) ARROW (61 BRAKE DISC (5) ARROW 3-16 ~HONDA MAINTENANCE BRAKE LIGHT SWITCH ~. (1) BRAKE LIGHT SWITCH VF1000F 121 ADJUSTING NUT Adjust the brake light switch so that the brake light will come on when the brake engagement begins. Adjust by holding the switch body and turning the adjusting nut. Do not turn the switch body, Turn the adjusting nut clockwise if the brake light comes on too late. HEADLIGHT AIM Adjust vertically by turning the vertical adjusting III HDRIZONTAL ADJUSTING SCREW screw. Turn the adjusting screw clockwise to direct the beam down . Adjust horizontally by turning the horizontal adjusting screw. Turn the adjusting screw clockwise to direct the beam toward the right side of the rider. NOTE Adjust the headlight beam as specified by local laws and regulations. An improperly adjusted headlight may blind oncoming drivers, or it may fail to light the road for a SIlfe distance. CLUTCH 121 VERTICAL ADJUSTING SCREW III UPPER LEVEL MARK Check the clutch fluid reservoir level. If the level nears the lower level mark, fill the reservoir with DOT 4 BRAKE FLUID until the level is between the upper and lower level mark . Check the entire system for leaks, if the level is low. CAUTION Do not remove the cover until the handlebar has been turned so that the reservoir is level. Avoid operating the clutch lever with the cap removed. Fluid will squirt out if the lever is pulled. Do not mix different types of fluid, as they are not compatible. 3-17 121 LOWER LEVEL MARK (jf)HONDA ~ . VF1000F MAINTENANCE SIDE STAND Check the rubber pad for deterioration or wear. Replace if any wear extends to wear line as shown. Check the side sta nd spring for damage and loss of tension, and the side stand asse'mbly for freedom (1) GOOD (2) NO GOOD of movement. Make sure the side stand is not ben t. NOTE When rep la cing, use a rubbe r pad with the mark "Over 260 Ibs ONLY". Spring tension is correct if the measure· ments fall within 2-3 kg (4.4-6.6 Ib), when pulling the side stand lower end with o x a spring scale. SUSPENSION Do not ride a vehicle with faulty suspension. Loose. worn or damaged suspension parts impair vehicle stability and control. FRONT Check the action of the front forks by compressing them several times. Check the entire fork assembly for leaks or damage. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Check the front fork air pressure when the forks are cold. Place the ·vehicle on its center stand. Remove the air valve cap and measure the air pressure. AIR PRESSUR E: 0-40 kPa (0- 0.4 kg/em' ,0-6 psi) (l)AIRVALVE 3-18 ~HONDA MAINTENANCE ~, VF1000F ANTI·DIVE SYSTEM INSPECTION Select a sofe ploce away from traffic 10 perform this inspection. Check the operation of the anti-dive system by riding the motorcycle and firmly applying the brakes. Position Anti-dive damper force 1 LIGHT ANTI·DIVE MEDIUM HARD MAXIMUM ANTI·DIVE 2 3 4 Inspect and if necessary, repair the system (Refer to section 15). 11) ADJUSTE R REAR Place the motorcycle on its center stand. Move the rear wheel sideways with force to see if the 5wingarm bearings are worn. Replace the bearings if there is any looseness (page 16·141Check the shock absorber for leaks or damage. Tighten all rear suspension nuts and bolts. Remove the frame left side cover. Remove the valve cap and measure the shock absorber air pressure. REAR SHOCK ABSORBER AIR PRESSURE: 0-300 kPa 10 - 3.0 kg/em'. 0-43 psi) NOTE Check the air pressure when the shock absorber is cold. 3-19 (1) AIR VALVE ~HON'DA. ~ VF1000F MAINTENANCE NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (Section 1) at the intervals shown in the Maintenance Schedule (Page 3·31. Check all cotter pins, safety clips, hose clamps and cable stays. WHEELS NOTE Tire pressure should be checked when tires are COLD. Check the tires for cuts , imbedded nails, or other sharp objects. RECOMMENDED TIRES AND PRESSURES: T Ire size Front Rear 120 /80V1S V250 140/80Vl 7 V250 25012.5.36) 29012.9,42) Up to 90 kg 1200 1b,) Cold tire load pressure psi kPa, (kg/cm 2 psi) 90 kg 1200 lb, I load to , 250 12.5, 36) 29012.9,42) 8RIDGE· STONE G511 G510 DUNLOP K500 K500 veh Icle capacitY load T ire bra nd Check the front and rear wheels for trueness (Section 15 and 16). Measure the tread depth at the center of the tires. Replace the tires if the tread depth reaches the following lim it : Minimum tread depth : Front: 1.5 mm 11/16 in) 2.0 mm 13/32 in) Rear: STEERING HEAD BEARINGS NOTE Check that the co nt rol cables do not interfere with handlebar rotat ion . Raise the front wheel off the ground and check that the handlebar rotates freely. If the handlebar moves unevenly, binds, or has vert ical movement, adju st the steering head bearing by turning the steering head adjust ing nut (page 15· 33). 3-20 ~ FUEL SYSTEM 4-0 ~, HON'DA VF1000F ~ ~. HONDA VF1000F FUEL SYSTEM LJ~ f i 'i LJ f i' t'l • t'l 4-0 HONDA VF1000F FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING CARBURETOR REMOVAL VACUUM CHAMBER FLOAT CHAMBER PILOT SCREW CARBURETOR SEPARATION 4- 1 4-2 4-3 4-4 4- 6 4-8 4-9 CARBURETOR ASSEMBLY CARBURETOR INSTALLATION PILOT SCREW ADJUSTMENT FUEL TANK AIR CLEANER FUEL PUMP 4-11 4-14 4-15 4-16 4-17 4-18 SERVICE INFORMATION GENERAL Gasoline is extremely flammable and is explosive under certain conditions. Work in a well venrilated area. Do not smoke or aI/ow flames or sparks in the work area. • • • • The front cylinders use down draft carburetors. When disassembling fuel system parts, note the locations of the O·rings. Replace them with new ones on reassembly. The float bowls have drain screws that can be loosened to drain residual gasoline. Fuel pump inspection is in section 20. • The No.1 and No.3 carburetors use different jet needles (thinner) and shorter springs than the No.2 and No.4 carburetors Do not interchange these parts. TOOLS Common Float level gauge 07401-0010000 SPECIFICA TIONS Item ~. arbueto ~ type Throttle bore Venturi bore I I Primary Secondary Identification No. Float level Main jet Idle speed Throttle grip free play Pilot screw initial opening 4-1 1 J: SWI Specifications KEIHIN VD 36 mm 11.42 in) 12.2 mm 10.48 in) 34 mm (1.34 in1128.8 mm 11.13 in)J 131.5 mm (1.24 in)) VD82A IVD82BJ (VDB2D) 7.5 mm 10.30 inl Front: #150, Rear: #145 [Front: #138, Rear: #135J 1,000 ± 100 rpm 2 - 6 mm 10.08 0.24 in} See page 4 - 1 5 ). G HONDA VF1000F FUEL SYSTEM TROUBLESHOOTING Engine cranks but won't start 1. No fuel in tank 2. No fuel to carburetors 3. 4. 5. 6. 7. 8. Engine flooded with fuel No spark at plug (ignition system faulty) Air cleaner clogged Intake air leak Improper choke operation Improper throttle operation Lean mixture 1. Clogged fuel jets 2. Faulty float valve 3. Float level low 4. Fuel cap vent blocked 5. Fuel strainer screen clogged 6. Restricted fuel line 7. Air vent tube clogged 8. Intake air leak 9. Restricted or faulty fuel pump Hard starting or stalling after starting 1. 2. 3. 4. 5. 6. Improper choke operation Ignition malfunction Carburetor faulty Fuel contaminated Intake air leak Idle speed incorrect Rich mixture 1. Clogged air jets 2. Vacuum piston stuck closed 3 . Faulty float valve 4. Float level too high 5. Choke stuck or clogged 6. Dirty air cleaner Rough idle 1. Ignition system faulty 2. Idle speed incorrect 3. Incorrect carburetor synchronization 4. Carburetor faulty 5. Fuel contaminated Misfiring during acceleration 1. Ignition system faulty Backfiring 1. Ignition system faulty 2. Carburetor faulty Poor performance (driveability) and poor fuel economy 1. Fuel system clogged 2. Ignition system faulty 4-2 ~ FUEL SYSTEM CARBURATOR REMOVAL ~, HONDA. VF1000F (1) AIR CL EANER CASE Turn the fuel valve off. Remove the left and right side covers. Remove the seat and fuel tank. Remove the fairing. Disconnect the breather hose and remove the air cleaner case by removing five screws, Remove the heat insulator plate. (2) BREATHER HOSE Remove the spark plug caps from the plugs. Disconnect the ignition coil primary wires from the coils. Remove the three ignition coil bracket bolts and the coils/brackets from the air chamber. (4) BOLTS (3) PRIMARY WI RES (1) FUEL LINE Disconnect the fuel line from the carburetor and remove it from the clamp on the carburetor. (2) CLAMP 4-3 ~HON'DA ~. VF1000F FUEL SYSTEM (1) CARBURETOR BANDS Loosen all carburetor bands and remove the car- buretor assembly from the intake pipes. (2) INTAKE PIPES (1) CHOKE CABLE Lift, the carburetors out of the frame and discon- nect the choke and throttle cables from the carburetor. (2) THROTTLE CABLES VACUUM CHAMBER REMOVAL Remove the four vacuum chamber cover screws and cover. CAUTION: Do not interchange vacuum chamber covers, springs, pistons or jet needles between car- buretors. (2) COVER 4-4 HONDA VF1000F FUEL SYSTEM (1) COMPRESSION SPRING Remove the compression spring, diaphragm and vacuum piston. Inspect the vacuum piston for wear, nicks, scratches or other damage. Make sure the piston moves up and down freely in the chamber. NOTE No. 1 and No.3 carburetors use thinner jet needles and shorter springs than the No.2 and No.4 carburetors. (2) DIAPHRAGM (3) VACUUM PISTON Push the needle holder in and turn It 60 degrees with an 8 mm socket. Then remove the needle holder, spring and needle from the piston. (1) NEEDLE HOLDER (1) DIAPHRAGM (2) SPRING Inspect the needle for excessive wear at the tip and for bending, or other damage. Check for a torn diaphragm or other deterioration. (3) NEEDLE 4-5 f (4) NEEDLE HOLDER ~HOND.A ~, VF1000F FUEL SYSTEM INSTALLATION Installation is essentially the reverse of removal but to keep from distorting the diaphragm, install the vacuum piston/diaphragm as follows: Insert the vacuum piston into the carburetor. Stick your finger into the carburetor bore and hold the vacuum piston in the full throttle position, then turn down the diaphragm so its lip fits into the carburetor groove. Install the chamber cover, aligning its cavity with the hole in the carburetor, and secure with at least two screws before releasing the vacuum piston. NOTE Be sure the thinner jet needles and shorter springs are installed in the No. 1 and No.3 carburetors. flOAT CHAMBER 111 FLOAT CHAMBER REMOVAL Remove the four float chamber screws and the float chamber. (2) SCREWS (1) FLOAT FLOAT LEVEL Measure the float level with the carburetor inclined 0 15° _45 from vertical and the float tang just contacting the float valve. FLOAT LEVEL: 7.5 mm (0.30 in) Adjust the float level by carefully bending the float tang. 12) FLOAT LEVEL GAUGE 07401-0010000 4-6 ~HONDA FUEl SYSTEM ~, VF1000F (1) FLOAT PIN FLOAT AND JETS Remove the float pin, float and float valve. (1) VALVE SEAT Inspect the float valve for grooves and nicks. Inspect the operation of the float valve. (2) FLOAT VALVE (1) MAIN JET (2) FLOAT VALVE SEAT Remove the starter jet, main jet and slow jet. Remove the float valve seat and filter. (3) STARTER JET 4-7 (4) SLOW JET ~ HONDA ~ VF1000F FUEL SYSTEM (l) FILTER (2) V VE SEAT Inspect the float valve seat and filter for grooves, n icks or deposits. ASSEMBLY Assemble the float chamber components in the reverse order of disassembl y. PILOT SCREW REMOVAL NOTE The pilot sc rews are factory pre-set and should not be removed unless the ca rburetors are overhauled. Turn each pilot screw in and carefu lly count the number of turns before it seats lightly. Make a note of this to use as a reference when reinstalling the pi lot screws. CAUTION Damage to the pilot screw seat will occur if the pilot screw is tigntelled against the seat. (2) PILOT SCREW Remove the pilot screws and inspect them. Replace they are worn or damage. INSTALLATION Install the pilot screws and return them to their original position as noted during removal. Perform pi lot screw adjustment if a new pi lot screw is installed (page 4-151_ NOTE If you replace the pilot screw in one carburetor, you must replace the pilot screws in the other carburetors for proper pilot screw adjustment. 4-8 ~HONDA FUEL SYSTEM CARBURETOR SEPARATION ~ . VF1000F (1) AI R CHAMBER Remove the screws attaching the air chamber to the carburetors and separate the chamber and carburetors. (1) CHOKE LEVERS AND RODS Remove th e nuts, and remove the choke levers and rods. Remove the cotter pins and washers, and remove the choke rod. (2) CHOKE ROD ( 1) (2) (3) FUEL SYNCH RONIZATION No. 1 CARBURETOR JOINT PIPE SPRINGS (4) No.3 CARBURETOR Carefully separate the No .1 carburetor from the assembly. Then se parate the No.2 carburetor. CAUTION Separate the carburetors horizontally to prevent damage to the joint pipes. IS) No. 2 CARBURETOR 4-9 (6) THRUST (7) AIR JOINT (8) No.4 SPRINGS PIPES CARBURETOR HONDA VF1000F FUEL SYSTEM (1) THROTTLE LINK Disconnect the throttle link from the No.3 and 4 caburetors by removing the cotter pins. (1) FUELJOINT PIPE (2) No.4 CARBURETOR Carefully separate the No.3 and No.4 carbureto". (3) No.3 CARBURETOR (1) CHOKE ARM (2) SPRING (3)COLLAR Remove the choke arm collar and remove the choke arm and spring. Remove the choke valve nut, spring and valve. (4) NUT 4-10 ~HONDA FUEL SYSTEM ~ . VF1000F III CHOKE VALVE Check the choke valve and spring for nicks. grooves, or other damage. ~ '__ ffl\V \ # (2)SPRING CARBURETOR ASSEMBLY (1) ARM (2)VALVE Install the choke valve, valve spring and nut and tighten the nut. Install the choke arm and spring while hooking the arm to the groove in the choke valve. Install the choke arm collar. (5) NUT (1) FUEL JOINT PIPE Coat the new a-rings with oil and install them on the fuel joint pipe for NO.3 and No.4 carburetors. Install the fuel joint pipe to the No.3 and No. 4 carburetors. (2) O·RINGS 4-11 (3)SPRING (4)COLLAR ~HONDA ~. VF1000F FUEL SYSTEM (1)THROTTLE LINK Reconnect the throttle linkage between the No.3 and NO.4 carburetors, using new cotter pins. (2) No.3 (3) COTTER PINS CARBURETOR (4) No.4 CARBURETOR III FUEL JOINT PIPE Coat new O-rings with oil and install them on the fuel and air joint pipes. Put the No.1 and No .2 carburetors together with the joint pipes. (2) AIR JOINT PIPES II) No.4 CARBURETOR (2) THRUST SPRING (3) No.2 CARBURETOR Loosen the synchronization adjusting screws until there is no tension. Install the synchronization springs. Install the thrust springs between the throttle valve shafts. (4) No.2 SYNCHRONIZATION SPRING 4-12 ~ FUEL SYSTEM (11 No.1 SYNCH RON IZATION SPRING ~ HONDA VF1000F (2) No.3 SYNCH RONIZATION SPRING Make sure the fuel joint and air joint pipes are securely installed. (3) No.1 CARBURETOR (4) THRUST (5) No.3 CARBURETOR SPRING (1) CHOKE RODS AND LEVERS Install the choke rods and levers, using the nuts and new cotter pins. (2) CHOKE ROD (1) FUNNELS (2) GROMMETS Make sure the air chamber funnels, grommets and dowel pins are in place. (4) DOWELPINS 4-13 (3) FUNNELS ~ HOND.A ~, VF1000F FUEL SYSTEM Place the air chamber over the carburetors aligning the dowel pins with the carburetor holes. Attach the air chamber to the carburetors with the eight screws. (1) SCREWS (1) BY·PASS HOLE Turn the throttle stop screw to align the No.4 throttle valve with the edge of the bY'pass hole. Align each throttle valve with the bY'pass hole edge by turning the synchronization adjusting screws. Inspect throttle operation as described below: Open the throttle slightly by pressing the throttle linkage. Then release the throttle. Make sure that it returns smoothly. Make sure that there is no drag when opening and closing the throttle. Make sure that choke valve operation is smooth by moving the choke linkage. (2) No.4 CARBURETOR (3)THROTTLE STOP SCREW Close the choke valve by turning the choke linkage. Release the choke linkage and make sure that it returns smoothly. (2) No.3 ADJUSTING SCREW CARBURETOR INSTALLATION Installation is essentially the reverse of removal. NOTE Route the throttle and choke cables properly (page 1- 9 to 1 - 11) Perform the following inspections and adjustments. Throttle operation (page 3·5). Carburetor choke (page 3·6). Carburetor idle speed (page 3·12). Carburetor synchronization (page 3- 11). (3) No.1 ADJUSTING SCREW (1) No.2 ADJUSTING SCREW 4-14 ~HOND.A FUEL SYSTEM ~. PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE NOTE The pilot screws are factory pre-set and no adjustment is necessary unless the pilot screws are replaced (page 4-8) . Use a tachometer with graduations of 50 rpm or smaller that w ill accurately indicate a 50 rpm change. 1. Turn each pilot screw clockwise until it seats lightly and back it out to the specification given. This is an initial setting prior to the final pilot screw adjustment. INITIAL OPENING: 2·1 /2 turns out CAUTION Damage to th e pilo t screw seat will occur if the pilot screw is tightened against the seat. 2. Warm up the engine to operating temperature. Stop and go driving for 10 minutes is sufficient. 3. Attach a tachometer according to its manufacturer's instructions. 4. Adjust the idle speed with the throttle stop screw. IDLE SPEED: 1,000 ± 100 rpm 5. Turn each pilot screw 112 turn out from the initial setting. 6. If the engine speed increases by 50 rpm or more, turn each pilot screw out by successive 112 turn until engine speed drops by 50 rpm or less. 7. Adjust the idle speed with the throttle stop screw. 8. Turn the No.1 carburetor pilot screw in until the engine speed drops 50 rpm. 9. Turn the No. 1 carburetor pilot screw 1 turn out from the position obtained in step 8. 10. Adjust the idle speed with the throttle stop screw. 11. Perform steps 8, 9 and 10 for the No.2, 3 and 4 carburetor pilot screws. 4-15 (2 ) THROTTLE STOP SCREW VF1000F ~ ~. HONDA VF1000F FUEL SYSTEM (1) FUE L LEVEL FUEL TANK SENSOR COUPLER Do not aI/ow flames or sparks near gasoline. Wipe up spilled gasoline at 01lce. Remove the both frame side covers and seat. Tu rn the fuel valve OF F and disconnect the fuel line at the fuel tank outlet tube. Disconnect the fuel level sensor wire coupler. Remove the two fuel tank mounting bolts and fuel tank. Turn the fuel valve ON and drain the fuel into a clean container. Check the vent hole of the filler cap for blockage. Check that fuel is flowing out of the fuel valve freely. (3) FUEL LINE Make sure that there are no fuel leaks. ~ \8 "~:= ~ 4-16 ~ FUEL SYSTEM ~, HONDA VF1000F AIR CLEANER CASE/ CHAMBER Check the air cleaner case seal rubbers for deterioration. CRANKCASE VENTILATION SYSTEM Check that the breather tube is not restricted. (1) AIR CLEANER COVER J (4) (5) BREATHER HOSES (7) ::::,......-_ SEAL RUBBER (9)INLET AIR DUCTS 4-17 (8) AI R CLEANER CASE ~ HON ~. D .A VF1000F FUEl PUMP FU EL SYSTEM (1 I FU EL PUMP REL AY IN SPECT ION (21 JAMPER WIRE Remove the left frame side cover. Turn the fuel valve and ignition switch off. Disconnect the fuel pump relay coupler and short the white and black wire terminals with a jam per wire. (1 I FUEL LINE Disconnect the fuel line at the fuel line joint and hold a graduated beaker under the tube. Turn the ignition switch on and let fuel flows into the beaker for 5 seconds, then turn the ignition switch off. Multiply the amount in the beaker by 12 to determine the fuel minute. pump flow capacity per FUEL PUMP FLOW CAPACITY: 900 cc (30 US OZ, 32 Imp ozi :t 10%/minute (1) COOLANT RESERVE TANK (2) BOL TS REMOVAl/INSTALLATION Do not allow flames or sparks near gasoline. Wipe up spilled gasoline at once. Remove the seat and left frame side cover. Remove the coolant reserve tank and electric panel from the frame by removing the two mount bolts. 4-1 8 HONDA VF1000F FUEL SYSTEM (1) COUPLER Disconnect the fuel pump wire coupler . Disconnect the fuel inlet and outlet tubes from the fuel pump. Remove the two fuel pump mounting bolts and the pump. (2) FUEL PUMP (3) OUTLET TUBE Install the fuel pump in the reverse order of reo moval. 4-19 (4)INLET TUBE {;;jp, ~ HONDA VF1000F ENGINE REMOVAU INSlALLAliON 5-0 ~HOND.A ENGINE REMOVAL/INSTALLATION ., ~, VF1000F 60-70 N'm (6.0-7.0 kg·m, 43-51 ft·lb) 35-45 N·m (3.5-4.5 kg·m, 25-33 ft·lb) ., 35-45 N·m (3.5-4.5 kg·m, 25-33 ft·lb) ~ 35-45 N'm (3.5-4.5 kg·m, 25-33 ft ·lb) " 10-15N·m (1.0-1.5 kg·m, 7-11 ft·lb) 35-45 N·m (3.5-4.5 kg·m, 25-33 ft·lb) 30-40 N·m (3.0-4.0 kg·m, 22-29 ft·lb) 5-0 ~HOND.A ~. VF1000F ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 5-1 ENGINE REMOVAL 5-2 ENGINE INSTALLATION 5-6 SERVICE INFORMATION GENERAL • A floor jack or other adjustable support is required to support and maneuver the engine . • The following parts or components can be serviced with the engine installed in the frame: A l t e r n a t o r ' Cooling system Clutch • Gearshift linkage • Starter motor • Front cylinder head • Carburetors The muffler of the VF1000F is black chromeplated. To clean the muffler, use a soft sponge and flush with sufficient water. After washing, let it dry and coat with non-compounded silicon wax. Apply a heat-resist and black paint if the black chrome plating is scratched or scored . • SPECIFICATIONS Engine dry weight Oil capacity 92.5 kg 12041b) 3.5 liters 13.7 U.S. qt) TORQUE VALUES Engine rear upper hanger bolt 50-54 N·m (5.0 - 5.4 kg-m, 36-39 ft-Ib) 60-70 N·m (6.0- 7.0 kg-m, 43-51 ft-Ib) Engine rear lower hanger bolt Engine center hanger bolts Engine front hanger bolts Sub-frame bolts Exhaust chamber mount bolts Gearshift arm bolt 35-45 N·m 24-30 N·m 35-45 N·m 35-45 N·m 30-40 N-m 10- 15 N·m Drive sprocket bolt (3.5-4.5 kg-m, 25-33 ft-Ib) (2.4-3.0 kg-m, 17-22 ft-Ib) (3.5 - 4.5 kg-m, 25-33 ft-Ib) (3_5-4.5 kg-m, 25-33 ft-Ib) (3.0-4.0 kg-m, 22-29 ft-Ib) (1.0-1.5 kg-m, 7-11 ft-Ib) 5-1 ~ ENGINE REMOVAL/INSTALLATION ~, HONDA VF1000F ENGINE REMOVAL Place the motorcycle on its center stand. Remove the seat, right and left fram e side covers. Remove the fairing and fuel tank. Drain the engine oil (page 2·3) and coolant (page 6 ·31. Remove the following components: lower radiator (page 6 -5 1. - carburetors (page 4·3). (1) STARTER MOTOR CABLE (2) TERMINAL NUT Disconnect the starter motor cable at the starter motor by removing the terminal nut. (3) STARTER MOTOR (1) MUFFLER MOUNT BOLT Loosen the muffler clamp bolts and remove the muffler mount bolts and right and left mufflers. 5-2 ~ ~ HONDA VF1000F ENGINE REMOVAL/INSTALLATION Remove the front ex haust pipe joint nuts. (1) REAR EXHAUST PIPE CLAMP BOLTS -.} Loosen the rear exhaust pipe clamp bolts. (1) STARTER MOTOR CABLE Remove the exhaust chamber mount bolts and exhaust chamber/ pipes from the engine. Remove the starter motor cable from the clamps on the right crankcase cover. (2) ~") CHAMB ER (3) MOUNT BOL T 5-3 ~HONDA ENGINE REMOVAL/INSTALLATION ~, VF1000F Remove the thermostat housing by loosening water hose bands and removing the mount bolt . (31 MOUNT BOLT (11 CLUTCH SLAVE CYLINDER (21 CRANKCASE BREATHER TUBE Remove the clutch slave cylinder by removing three mount bolts. NOTE Do not operate the clutch lever after removing the clutch slave cylinder; It will cause difficulty when reinstalling the slave cylinder. Remove the gearshift arm from the shift spindle. Remove the drive sprocket cover by removing two bolts. Loosen the two water hose bands and remove the hose. (31 WATER HOSE Loosen the tube bands and remove the crankcase breather tube. (11 REAR AXLE NUT Loosen the drive chain adjusting lock nuts and bolts. Loosen the rear ax Ie nut and push the rear wheel forward. L (21 ADJUSTING BOLT 5-4 (31 LOCK NUT HONDA VF1000F ENGINE REMOVAL/INSTALLATION Rem ove the drive sprocket bolt and sprocket from the countershaft and drive chain. (2) DRI VE SPROCKET (3) DRIVE CHAIN (1) ALTERNATOR WIRE COUPLER Di sconnect the alternator wire coupler and neutral switch wire connector. (2) NEUTRAL SWITCH WI RE CONNECTOR 111 CRANKCASE (2) PULSE GENERATOR BREATHER TUBE CONNECTOR D isconnect the pulse generator wire coupler. Disconnect the battery ground cable at the battery negati ve (-) terminal. Disconnect the crankcase breather tube from the rear cylinder head cover. 5-5 ~HONDA. ENGINE REMOVAl/INSTAllATION ~. VF1000F Place the floor jack or other adjustable support under the engine. NOTE The jack height must be continuously adjust· ed to relieve stress from bolts that are being removed. Remove the engine hanger bolts from the right side. Remove the frame-to-sub-frame bolt. (1) SUB·FRAME Disconnect the crankcase breather hose. Remove the engine hanger bolts and nuts from the left side. Remove the sub-frame bolts. Carefully lower the engine and remove it from the left side. ENGINE INSTAllATION Check the engine mount rubbers for damage and replace if necessary. Install the engine mount rubbers. Engine installation is essentially the reverse of removal. Use a floor jack or other adjustable support to carefully manuever the engine into place. CAUTION Carefully align mounting points with the jack to prevent damage to mounting bolt threads ~ . ( 11 SUB·FRAME Ii BO TS (2) CENTER -,;;.., " -, (3) REAR UPPER ER BOLTS HANGER BOLT and wire harness and cables. Tighten all fasteners to the torque values given on page 5·1. NOTE Route the wires and cables properly (pages 1-9 thru 1-11!. Fill the crankcase to the proper level with the recommended oil (page 2·1). Fill the cooling system (page 6·3). Perform the following inspection and adjustments; Throttle operation (page 3·5). Clutch (page 3- 171. 5 -6 (4) FRONT HANGER (5) REAR LOWER HANGER (6) SUB·FRAME BOLTS BOLTS BOL T HONDA VF1000F COOLING SYSTEM ----------------. 6-0 ~ COOLING SYSTEM 6-0 ~. HONDA VF1000F ~HONDA ~. VF1000F SERVICE INFORMATION TROUBLESHOOTING SYSTEM TESTING COOLANT REPLACEMENT COOLING SYSTEM 6-1 6-1 THERMOSTAT RADIATOR/COOLING FAN 6-4 6-5 6-2 6-3 WATER PUMP 6-10 SERVICE INFORMATION GENERAL Do not remove the radiator cap when the engine is hOI. The coolant is under pressure and severe scalding could result. The engine must be cool before servicing the cooling system. • Use only distilled water and ethylene glycol in the cooling system. A 50 - 50 mixture is recommended for max imum corro- • • sion protection, Do not use alcohol-based antifreeze. Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. All cooling system service can be done with the engine in the frame. • Avoid spilling coolant on painted surfaces. • • After servicing the system, check for leaks with a cooling system tester. Refer to Section 20 for fan motor thermostatic switch and temperature sensor inspections. SPECIFICATIONS Radiator cap rel ief pressure 75-105 kPa (0.75-1.05 kg/cm', 10.7-14.9 psi) F reezing point (Hydrometer test): 55% Distilled water + 45% ethylene glycol: _32°C (_ 25° F) 50% Distilled water + 50% ethylene glycol: _ 37°C I_34° F) 45% Distilled water + 55% ethylene glycol: -44. 5°C (_48°F) Coolant capacity: Rad iator and engine Reser ve tank Total system 3.0 liters 13.18 US qt, 2.64 imp qt) 0.4 liters 10.42 US qt, 0.35 imp qt) 3.4 liters 13.6 US qt, 2.99 imp qti Thermostat 8egins to open: 80° to 84°C (176° to 183°F) Valve lift: Minimum of 8 mm at 95°C (0.315 in at 203°F) 80iling point (with 50 - 50 mixture): Unpressurized: 107.7°C (226°F) Cap on , pressurized: 125.6°C (258°F) TROUBLESHOOTING Engine temperature too high Engine temperature too. low 1. 2. 3. 4. 5. 6. 7. 1. Faulty temperature gauge or gauge sensor 2. Thermostat stuck open Faulty temperature gauge or gauge sensor Thermostat stuck closed Faulty radiator cap Insufficient coolant Passages blocked in radiator, hoses, or water jacket Fan blades bent Faulty fan motor Coolant leak, 1. Faulty pump mechanical seal 2. Deteriorated O-rings 6-1 ~ COOLING SYSTEM ~. HONDA VF1000F SYSTEM TESTING COOLANT Remove the frame left side cover and reserve tank 111 ANTIFREEZE TESTER cap. Test the coolant mixture with an antifreeze tester. For maximum corrosion protection, a 50-50% solution of ethylene glycol and distilled water is recommended . 111 COOLING SYSTEM TESTER RADIATOR CAP INSPECTION Remove the fairing and radiator cap. The engine must be cool before removing the eap. Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low . It must hold specified pressure for at least six seconds. NOTE Before installing the cap on the tester , apply water to sealing surfaces. 121 RADIATOR CAP RADIATOR CAP RELIEF PRESSURE: 75-105 kPa (0.75-1.05 kg/em', 10.7-14.9 psi) SYSTEM PRESSURE TEST Remove the fairing and radiator cap. Pressurize the radiator, engine and hoses, and check for leaks. CAUTION Excessive pressure can damage the radiator. Do not exceed J.05 kg/em' (J 4.9 Psi) Repair or replace components if the system will not hold specified pressure for at least six seconds. 111 COOLING SYSTE.M TESTER 6-2 HONDA VF1000F COOLING SYSTEM COOLANT REPLACEMENT The engine must be cool before serpicing the cooling system, or severe scalding may result. Remove the fairing. Remove the radiator cap. Remove the lower cowl. Drain the coolant from the front cylinders by removing the drain bolts. I (1) LOWER COWL Drain the coolant from the rear cylinders and water pump by removing the drain bolt at the water pump cover. Drain the coolant from the radiators by removing the drain bolt on the sub·frame. Replace the drain bolts after making sure their sealing washers are in good condition. Fill the system with a 50-50 mixture of distilled water and ethylene glycol. Bleed air from the cooling system. • Start the engine and run until there are no air bubbles in the coolant, and the level stabilizes. • Stop the engine and add coolant up. to the proper level if necessary. • Reinstall the radiator cap. • Check the level of coolant in the reserve tank and fill to the correct level if the level is low. • Install the lower cowl. (3) SUB ·FRAME (4) DRAIN BOLT 6-3 ~HONDA COOLING SYSTEM THERMOSTAT ~. VF1000F '''''''''''-"T HOUSING COVER REMOVAL Remove the fairing. Drain the coolant (page 6·3). Remove the thermostat housing cover by loosening the water hose band and removing the two cover bolts. (3)BOLTS Remove the thermostat from the housing. """"'-- (11 THERMOSTAT (2) HOUSING INSPECTION Inspect thermostat visually for damage. Suspend the thermostat in heated water to check its operation. NOTE If the thermostat or thermometer touches the pan, you'll get a false reading. Replace thermostat if valve stays open at room temperature, or if it responds at temperatures other than those specified. Technical Data Start to open 80° to 84°C (176° - 183° F) Valve lift 8 mm minimum (0.31 in) when heated to 95°C (203°F) for five minutes. 6-4 ",:=~jI;-(2)TH E RMOM ETE R HONDA. VF1000F COOLING SYSTEM (1) THERMOSTAT INSTALLATION Install the thermostat into the housing. (1) BOLTS (2) WATER HOSE BAND Install the thermostat housing cover into the water hose. Install a new O-ring onto the cover and the cover onto the housing and tighten the two cover bolts and water hose band. Fill the cooling system (page 6·3) . Install the fairing. (3) T HERMOSTAT HOUSING COVER RADIATORS/COOLING FANS (1)HOSE BANDS LOW ER RADIATOR REMOVAL Turn the ignition switch off and disconnect the battery negative cable from the battery. Remove the fairing and lower cowl. Drain the coolant Ipage 6·3). D isconnect the fan motor wire couplers. Loosen the water hose bands and disconnect the water hoses from the lower radiator. Remove the three radiator mount bolts and the lower radiator. 6-5 ~HOND.A COOLING SYSTEM ~ . VF1000F LOWER RADIATOR/ COOLING FAN DISASSEMBLY Remove the radiator grille and side covers by removing the screws. Remove the cooling fan / motors by removing the mount nuts. ( 11 Remove the fan from the motor by removing the nut. 6-6 LING FAN ~HOND.A VF1000F ~. COOLING SYSTEM (1) FAN MOTOR Remove the washer from the motor shaft. Remove the fan motor from the fan shroud by reo moving the th ree screws. LOWER RADIATOR INSPECTION Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off with low pressure water. LOWER RADIATOR ASSEMBLY/ INSTALLATION Assemble and install the lower radiator in the reverse order of disassembly and removal. NOTE Apply a locking agent to the fan motor shaft threads before installing the fan mount nut. Install the fan motor with longer wire onto the left side of the radiator. After installation, fill the cooling system Ipage 6·3). 6-7 ~HONDA COOLING SYSTEM ~ . VF1000F (1) UPPER RADIATOR LOWER COVER UPPER RADIATOR REMOVAL Remove the fairing and lower cowl. Drain the coolant (page 6·3). Remove the radiator lower cover by removing the two screws. (2) SCREWS (l)OVERFLOWTUBE Disconnect the coolant overflow tube from the filler neck. Loosen the hose band and remove the filler neck from the upper radiator. r (2) HOSE BAND (3) FILLER NECK Remove the horn mount bolt and horn. Remove the upper radiator shroud by re moving two bolts. (3) UPPER RADIATOR SHROUD 6-8 (4) BOLTS ~HON'DA ~, VF1000F COOLING SYSTEM (1) BOLTS (2) HOSE BANO Disconnect the wire coupler from the thermostatic switch on the upper radiator . Loosen the hose bands and disconnect the water hoses from the radiator. Remove the two upper radiator mount bolts and the radiator from the frame. (3) HOS E BANO (4) THERMOSTATIC SWITCH WIRE COUPL ER UPP ER RADIATOR INSPECTION Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air . If insects, etc ., are clogging the radiator, wash them off with low pressure water. UPPER RA DI ATOR INSTALLATION Install the upper radiator in the reverse order of removal. 6-9 ~HOND.A COOLING SYSTEM ~ . VF1000F WATER PUMP MECHANICAL SEAL INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. Replace the water pump as an assembly if the mechanical seal is leaking. (2) TELLTALE HOLE REMOVAL Drain the coolant Ipage 6-3). Remove the clutch slave cylinder. NOTE Do not operate the clutch lever after removing the clutch slave cylinder. To do so will cause difficulty in reinstalling the slave cylinder. Remove the gearshift arm from the shift shaft. Remove the drive sprocket cover. ER BOLTS Disconnect the water hose from the water pump cover. Remove the water pump cover bolts and cover. 6-10 (2)WATER COVER ~HONDA ~. VF1000F COOLING SYSTEM Remove the water pipe clamp bolt. Loosen the water hose bands. Pull off the water pump from the crankcase. Remove the water pipe from the water pump. INSPECTION Check the water pump for mechanical seal leakage and bearing deterioration. Replace the water pump as an assembly if necessary. (3) O·RING @~ (4) WATER PUMP COVER INSTALLATION Apply a coat of clean engine oil to a new a-ring and install it in the water pump groove. Align the water pump shaft groove with the oil pump shaft and insert the water pump in the crankcase. (3) O·RING 6-11 ~HOND.A COOLING SYSTEM Insert a new O-ring over the end of the water pipe. Connect the water pipe to the pump hose and water pipe cap. Install the dowel pins and install a new O-ring in the groove of the water pump cover. Install the water pump cover and torque the bolts. Connect the water inlet hose. Install the drive sprocket cover, gearshift arm and clutch slave cylinder. Fill the cooling system (page 6-3). 6-12 ~, VF1000F ~ ~. HON'DA VF1000F CLUTCH SYSTEM .. 7-0 ~HONDA CLUTCH SYSTEM 4-7 N·m 140-70 kg·em, 35-61 in·lb) . ~ 7-0 ' - ~. VF1000F HONDA. VF1000F CLUTCH SYSTEM 7- 2 7-3 SERVICE INFORMATION TROUBLESHOOTING CLUTCH FLUID REPLACEMENT! AIR BLEEDING CLUTCH COVER REMOVAL STARTER CLUTCH DISASSEMBLY CLUTCH DISASSEMBLY 7-4 7-5 7-8 CLUTCH MASTER CYLINDER CLUTCH SLAVE CYLINDER CLUTCH ASSEMBLY STARTER CLUTCH ASSEMBLY CLUTCH COVER INSTALLATION 7-10 7-10 7-12 7-17 7-20 7-22 ) 80-90 N'm ~ a;' -~ . .. <90- 18.5 - 10.5 kg-m, I!\ ' 61 - 76 ft-Ib) • W ~ \ 9" • ~. ' . (i1$i .:? ~J DDcR ARM Install the drum stopper arm, cottar, spring, washer and nut over the arm bolt. Tighten the nut securely. Rotate the gearshift spindle and check the linkage for smooth operation . 8 -5 VF1000F ~HONDA ~ VF1000F GEARSHIFT LINKAGE (1101 L PUMP ORIVE CHAIN (2IDRIVE SPROCKET Install the oil pump drive and driven sprockets with drive chain and tighten the driven sprocket bolt securely. NOTE The driven sprocket has an "IN" mark that must face the crankcase. Install the clutch assembly and cover (section 7). Align the punch marks on the gearshift arm and gearshift spindle and install the gearshift arm on the shift shaft. Fill the crankcase with recommended oil (page 2·31. 8-6 ~ ALTERNATOR 9-0 ~, HONDA VF1000F ~ ~. HONDA Vf1000F ALTERNATOR D 85 - 105 N·m 18.5-10.5 kg-m, 61 - 76 ft-Ibl 9-0 ~HONDA ALTERNATOR ~ . SERVICE INFORMATION 9-1 FLYWHEEL REMOVAL 9- 2 STATOR REMOVAL 9-3 STATOR INSTALLATION 9- 3 FL YWHEEL INSTALLATION 9-3 SERVICE INFORMATION GENERAL • This section covers removal and installation of the alternator. Refer to section 18 for troubleshooting and inspection of the alternator. TORQUE VALUE Alternator rotor/ Flywheel bolt 85 - 105 N·m (8.5 - 10.5 kg -m, 61 - 76 ft-Ibl TOOLS Common Flywheel holder Rotor puller 9-1 L VF1000F 07725-0040000 07733-0020001 ~ ~ HONDA VF1000F ALTERNATOR flYWHEEL REMOVAL Place a container under the alternator cover to catch engine oil. Remove the alternator cover. (1) FL YWHEEL HOLDER 07725-0040000 (2) F Hold the flywheel with the flywheel holder and remove the flywheel bolt . (1) ROTOR PULLER 07733- 0020001 Remove the flywheel with the rotor puller. Remove the woodruff key from the crankshaft. /' (2) FLYWHEEL HOLDER 07725- 0040000 9-2 ~ ALTERNATOR ~ HON'D.A VF1000F STATOR REMOVAL Remove the frame left side cover. Disconnect the alternator wire coupler and free the alternator wire from the clamp . (1) ALTERNATOR WI RE COUPLER Remove the stator by removing the bolts and wire clamp. STATOR INSTAllATION In stall the stator and wire clamp. Route the al ternator wire properly, secure it with clamp and connect the alternator wire coupler t o the main harness. Install the fram e left side cover. flYWHEEL INSTALLATION Install the woodruff key into the crankshaft. Install the flywheel by aligning its keyway with the key in the crankshaft. Hold the flywhee l with the flywheel holder and torque the flywheel bolt. TORQUE: 85 - 105 N·m (8.5-10.5 kg-m, 61 - 76 ft-Ibl Install the alternator cover. Check engine oil level and add if necessary (page 2-3). 9-3 ~ ~ . HONDA VF1000F CYLINDER HEAD/VALVE iii] 10- 0 ~ CYLINDER HEAD/VALVE ~ HOND.A . VF1000F 8-12 N·m (0.8- 1.2 kg.m\, 6-~ ft·lb) ~@ @ ~!J ~ @ @~ :;lrm 10-14 N·m ~ - ~ 21-25 N·m (2.1 - 2.5kg·m, 15-18ft·lb) 43 - 4 7N·m 14.3-4.7 kg-m, 31 - 34 ft -Ibl ~' P.1~, 13-0 a_., @ ~HOND.A ~ VF1000F TRANSMISSION SERVICE INFORMATION 13-1 TROUBLESHOOTING 13-2 TRANSMISSION DISASSEMBLY 13-3 SHIFT FORK AND SHIFT DRUM 13-5 TRANSMISSION ASSEMBLY 13-6 SERVICE INFORMATION GENERAL • The gearshift linkage can be serviced with the engine in the frame (Section 8). • For internal transmission repairs, the crankcase must be separated (Section 11). SPECIFICATIONS Transmission Gear 1.0 . Gear bushing 0.0 . Gear bushing 1.0. STANDARD SERVICE LIMIT M4 , M5 gear 31.000- 31.016 mm 11.2205- 1.2211 in) 31.04 mm 11 .222 in) Cl gear 26.000- 26.013 mm 11.0236- 1.0241 in) 26 .04 mm 11.025 in) C2 , C3 gear 31.000-31.016mm 11 .2205-1.2211 in) 31 .04 mm 11.222 in) M4, M5 gear 30.950-30.975 mm 11.2185-1.2195 in) 30.94 mm 11 .218 in) Cl gear 25.959-25.980 mm 11.0220- 1.0228 in) 25.94 mm 11.021 in) C2, C3 gear 30.950-30.975 mm 11.2185- 1.2195 in) 30.93 mm 11.218 in) M4 27.995-28.016 mm 11.1022- 1.1 030 in) 28.04 mm 11.104 in) Cl 22.020-22.041 mm 10.8669-0.8678 in) 22.06 mm 10.869 in) 27.977-27 .990 mm 11.1015-1.1020 in) 27.92 mm 11.099 in) Mainshaft 0.0. lat M4) Countershaft 0.0. lat ClI 21.979-22.000 mm 10.8653- 0.8661 in) 21.96 mm 10.865 in) M4,M5 0.025- 0.066 mm 10.0010- 0.0026 in) 0.10 mm 10.004 in) Cl 0.020-0.054 mm 100008-0.0021 in) 0.10 mm 10.004 in) C2,C3 0.025-0.066 mm 10.0010-0.0026 in) 0.11 mm 10.004 in) Bushing-to- M4 0.005-0.039 mm 10.0002-0.0015 in) 0.06 mm 10.002 in) shaft clearance Cl 0.020-0.062 mm 10.0008-0.0024 in ) 0.10 mm 10.004 in) 6.43-6.50 mm 10.253-0.256 in) 6.1 mm 10.24 in) 14.000-1 4.021 mm 10.5512-0.5520 in) 14.04 mm 10.553 in) 13.966- 13.984 mm 10.5498-0.5505 in) 13.90 mm 10.547 in) Gear -to- bushing clearance Shift fork Claw thickness 1.0. Fork shaft 0.0. Left and right 13-1 ~HONDA TRANSMISSION TORQUE VALUES Countershaft bearing holder Shift fork center 21-25 N·m (2.1-2,5 kg·m, 15-18 ft·lbj 16- 20 N·m (1.6- 2.0 kg·m, 12- 14 ft·lbl TOOLS Special Driver 07949- 3710000 Common Attachment, 52 x 55 mm 07746-0010400 Driver 07746-0030100 07746-0030200 Attachment, 25 rnm TROUBLESHOOTING Hard to shift 1. Clutch slave cylinder sticking 2. Shift fork bent 3. Shift shaft bent 4. Shift claw bent 5. Shift drum cam grooves damaged Transmission jumps out of gear 1. Gear dogs worn 2. Shift shaft bent 3. Shift drum stopper broken 4. Shift forks bent 13-2 ~. VF1000F ~HON'DA ~ VF1000F TRANSMISSION DISASSEMBLY TRANSMISSION (1) MAINSHAFT Separate the crankcase (Section 11). Remove the dowel pins from the crankcase. Remove the mainshaft. (1) COUNTERSHAFT BEARING HOLDER (2) C1 GEAR Remove the countershaft bearing holder bolts. Pull the countershaft out of the crankcase while removing C1, C4, C2, C3, and the spline washers and bushings. (3) C3 GEAR (4) C2 GEAR (5) C4 GEAR TRANSMISSION INSPECTION Check gear dogs, dog holes and gear teeth for excessive or abnormal wear, or evidence of insufficient lubrication. Measure the 1.0. of each gear. SERVICE LIMIT: M4, M5 gear: 31.04 mm (1.222 in) C1 gear: 26.04 mm (1.025 in) C2, C3 gear: 31,04 mm (1.222 in) 13-3 CiJJ\ HONDA ~ VF1000F TRANSMISSION Measure the D.D. of the gear bushings. SERVICE LIMIT: M4. M5: 30.94 mm (1.218 in) Cl : 25.94 mm (1.021 in) C2. C3: 30.93 mm (1.218 in) • Calculate the clearance between the gear bushings and the gears. • SERVICE LIMIT: M4. M5: 0.10 mm (0.004 in) Cl: 0.10 mm (0.004 in) C2. C3: 0.11 mm (0.004 in) Measure the I.D. of the gear bushings. SERVICE LIMIT: M4 gear bushing: 28.04 mm 10.986 in) Cl gear bushing: 22.06 mm 10.869 in) Measure the 0.0. of the mainshaft and countershaft. SERVICE LIMIT: Mainshaft (at M4 bushing): 27.92 mm 10.981 in) Countershaft (at Cl bushing): 21.96 mm (0.865 in) Calculate the clearance between the bushing and shaft. SERVICE LIMIT: M4 bushing-to-shaft: 0.06 mm (0.002 in) Cl bushing-to-shaft: 0.10 mm (0.004 in) 11) ATTACHMENT.52x55mm 07746-0010400 COUNTERSHAFT BEARING REPLACEMENT Drive the countershaft bearing out of the lower crankcase. Drive a new countershaft bearing into the crankcase using the special tools. 121 DRIVER 07949-3710000 13-4 • ~HON'DA ~ VF1000F SHIFT FORK AND SHIFT DRUM TRANSMISSION (1) SHIFT FORKS (2) LOCK WASHER AND BOLT REMOVAL Bend the lock washer tab down and remove the center fork mounting bolt. Remove the shift fork shaft and shift forks. Remove the bearing stopper plates. Remove the shift drum. (3) SHIFT FORK (4) SHIFT DRUM (5) BEARING STOPPER PLATE SHAFT GEAR SHIFT DRUM AND SHIFT FORK INSPECTION Inspect the shift drum end for scoring, scratches, or evidence of insufficient lubrication. Check the shift drum grooves for damage . Inspect the shift drum hole and shift fork shaft hole in the upper crankcase for scoring or scratches. Measure the shift fork shaft O.D . at right and left sh itt fork surfaces. Check for scratches, scoring or evidence of insufficient lubrication . SE RVICE LIMIT: 13.90 mm (0.547 in) Measure the right and left shift fork I.D. SERVICE LIMITS: I.D. (right and left fork): 14.04 mm 10.553 in) Measure the shift fork claw thickness. SERVICE LIMIT: 6.1 mm (0.24 in) INSTALLATION Install the shift drum. Install the shift fork shaft so that the oil hole .nd is toward the right. Install the shift forks onto the shaft. (1) LEFT SHIFT FORK (2) OIL HOLE (3) SHIFT FORK SHAFT 13-5 (i) HONDA ~ TRANSMISSION , VF1000F Install a new lock washer and the bolt to the center shift fork and tighten the bolt. TORQUE: 16- 20 N·m (1.6- 2.0 kg-m, 12- 14 ft-Ib) Bend up the lock washer's tabs. Apply a locking agent to the screw threads and install the bearing stopper plates. ~ (3) BEARING STOPPER PLATES (1) DRIVER TRANSMISSION ASSEMBLY 114b-(JUJIJ100 MAINSHAFT Install the mainshaft bearing with the special tools. (2) ATTACHMENT, 25 mm 1.0. 07746-0030200 Check the gears for freedom of movement or rota· tion on the shaft. Check that the snap rings are seated in the grooves. (1) MAINSHAFT/ M1 (15T) M4 (25T) 13-6 ~ HONDA ~ VF1000F TRANSMISSION COUNTERSHAFT Before installing the countershaft in the crankcase, install the C5 gear and snap ring. C1 (41T) C5 (28T) (1) C3 GEAR Install the C3 gear and spline collar. Install the stopper washer while aligning the tab of the stopper washer with the groove in the spline collar. Assemble the C2, C4 and C1 gears, washers and collars. (2) SPLINE COLLAR (3) STOPPER WASHER CAUTION Align the oil holes in the splined bushings with the oil holes in the countershaft. 13-7 ri!J HONDA ~, VF1000F TRANSMISSION Install the countershaft bearing holder bolts and tighten them. TOROUE: 21-25 N'm (2.1-2.5 kg.m, 15-18 ft·lb) Check that the oil orifice is clear. (2) OIL ORIFICE (1) MAINSHAFT Install the mainshaft, then reassemble the upper and lower crankcase (see Section 11). 13-8 ~ ~. HON'DA VF1000F FAIRING m 14-0 HONDA VF1000F FAIRING /' \\ ,/ <~ , i Il J S 14-0 J ' ~ ~. HONDA VF1000F FAIRING SERVICE INFORMATION 14 - 1 LOWER COWL 14- 2 FAIRING 14-2 14 - 3 FAIRING BRACKET SERVICE INFORMATION GENERAL • The fairing bracket can be removed without removing the upper radiator. 14-1 HONDA VF1000F FAIRING LOWER COWL (1) SCREWS RE MOV A L/I NSTALLATION Remove the fou r lower cowl attaching screws and the lower cowl. Install the lower cowl in the reverse order of removal. 1"""-' U [;J (2) LOW ER COWL FAIRING REMO VA L/IN STALLATION Remove the two fairing mount bolts and fairing . (2) MOUNT BOLT 14-2 HOND A VF1 000F FAIRING Install the fairing aligning its grooves with the rub· ber mounts on the fairing bracket and fuel tank. T ighten the two fairing mount bolts. (1) GROOVES FAIRING BRACKET REMOVAL Remove the fairing (page 14·1). Remove the headlight (page 14· 12). Drain an amount of coolant for filler neck into '8 clean container by removing the drain bolt on the sub·frame (page 6·3). Remove the filler neck from the upper radiator by disconnecting the overflow tube and loosening the hose band. (3) HOSE BAND 14-3 ~ FAIRING 111 HORN 121 BOLT ~. HOND.A VF1000F 131 INSTRUMENTS Remove the horn by removing the bolt. Remove the two radiator grille mount bolts and grille. Remove the instruments (page 21-14). 111 WIRE COUPLERS/ CONNECTORS Disconnect all wire couplers and connectors at the fairing bracket. 111 FAIRING BRACKET Remove the fairing bracket mount bolts and bracket from the frame. 14-4 HONDA VF1000F FAIRING INSTALLATION Install the fairing brack et in the reverse order of removal. NOTE After installation, fi ll the filler neck with coolant. • 14-5 ( j J HONDA ~ . VF1000F FRONT WHEEL/SUSPENSION 15-0 HONDA VF1000F FRONT WHEEL/SUSPENSION """'- _ ~ 30-40 N·m (3.0-4.0 kg·m, 22-29 ft·lb) 90-120 N'm (9.0-12.0 kg·m, 65-87 ft·lb) 45-55 N·m (4.5-5.5 kg·m, 33-40 ft ·lb) ----irir\7 30-40N·m / (3.0-4.0 kg·m, 22-29 ft·lb) ~ ~ 55-65 N·m / (5.5-6.5 kg·m, 40-47 ft·lb) I!EJ "" ell 18-25 N'm / (1.8-2.5 kg·m, 13- 18 ft·lb) o 10-15N·m (1.0-1.5 kg.m, 7-9 ft·lb) 15-0 ~ FRONT WHEEL/SUSPENSION ~ . HONDA VF1000F SERVICE INFORMATION 15-1 FRONT WHEEL 15-7 TROUBLESHOOTING 15-2 FRONT FORKS 15-15 HANDLEBARS 15-3 STEERING STEM 15-28 SERVICE INFORMATION GENERAL • A jack or other support is required to support the front of the motorcycle when you are worki ng on the front wheel or fork. SPEC) F)CAT)ONS Axle shaft runout Front wheel rim runout Radial Axial SERVICE LIMIT - 0.2 mm 10.Q1 in) - 2.0 mm 10.08 in) 2.0 mm 10.08 in) 413.8 mm 116.29 in ) Fork spring free length - Fork tube runout Front fork flu id capacity STANDARD 0.2 mm 10.01 in) Right 380 cc 112 .9 US OZ, 13.4 Imp) Left 400 cc 113.5 US OZ, 14.1 Imp) Front fork air pressure 0- 40 k?a 10- 0.4 kg/cm ', 0-6 psi ) TORQUE VALUES Steering stem nut Steering bearing adjustment nut Top bridge pinch bolt Front axle holder Front axle nut Fork top pinch bolts Fork bottom pinch bolts Handlebar pinch bolts Front brake caliper bracket mount bolts Anti -dive piston pin bolt Front brake disc Front fork cap Front fork socket bolt Anti -dive case socket bolts 15 -1 405.5 mm 115.9 in) 90-120 N'm 19.0-12.0 kg·m, 65-87 ft·lb) 23-27 N·m 12.3-2.7 kg·m, 17-20 ft·lb) 20-30 N·m 12.0-3.0 kg·m, 14-22 ft·lb) 18-25 N·m 11 .8-2.5 kg·m, 13-18 ft·lb) 55-65 N·m 15.5-6.5 kg·m, 40- 47 ft·lb) 20-30 N·m 12.0-3.0 kg·m, 14- 22 ft·lb) 45-55 N·m 14.5- 5.5 kg·m, 32-40 ft·lb) 30-40 N'm 13.0-4.0 kg·m, 22-29 ft·lb) 30-40 N·m 13.0-4.0 kg·m, 22-29 ft·lb) 10-15 N·m 11.0-1.5 kg·m, 7-9 ft·lb) 35-40 N'm 13.5- 4.0 kg·m, 25-29 ft·lb) 15- 30 N·m 11.5-3.0 kg·m, 11-22 ft·lb) 15-25 N·m 11.5-2.5 kg·m, 11-18 ft·lb) 6-9 N·m 10.6-0.9 kg·m, 4-7 ft ·lb) - ~ ~. HO ND A VF 1000F FRONT WHEEL/SUSPENSION TOOLS Special Hex. wrnech, 6 mm Snap ring pliers Fork seal driver Fork seal driver attachment Steering stem socket Bearing race remover Ball race remover Steering stem driver 07917 07914 07947 07947 07916 07946 07953 07946 - 3230000 3230001 KA50000 KF00100 3710100 371 0500 4250002 MBOOOOO Common Driver Attachment, 42 x 47 mm Pilot, 15 mm Lock nut wrench, 30 x 32 mm Extension Attachment, 52 x 55 mm Bearing remover shaft Bearing remover head, 15 mm 07749 07746 07746 07716 07716 07746 07746 07746 - 0010000 0010300 0040300 0020400 0020500 0010400 0050100 0050400 TROUBLESHOOTING Hard steering 1. Steering bearing adjustment nut too tight 2. Faulty steering stem bearings 3. Damaged steering stem bearings 4. Insufficient tire pressure Steers to one side or does not track straight 1. Bent forks 2. Bent front axle 3. Wheel installed incorrectly Front wheel wobbling 1. Bent rim 2. Worn front whee l bearings 3. Faulty tire 4. Axle nut tightened improperly Soft suspension 1. Weak fork springs 2. Insufficient fluid in forks 3. Fork air pressure incorrect Hard suspension 1. Incorrect fluid weight in forks 2. Fork air pressure incorrect 3. Bent fork tubes 4. Clogged fluid passage 5. Clogged anti-dive orifice Front suspension noise 1.. Worn slider or guide bushings 2. Insufficient fluid in forks 3. Loose front fork fasteners 4. Lack of grease in speedometer gearbox 15-2 ~ FRONT WHEEL/SUSPENSION HANDLEBARS REMOVAL Disconnect the front brake switch wires. Remove the front brake master cylinder. HONDA ~. VF1000F (1) FRONT BRAKE MASTER CYLINDER I (1) RIGHT HANDL EB AR SWITCH Remove the right handlebar switch. J CLUTCH MASTER CYLINDER Disconnect the clutch switch wires. Remove the clutch master cylinder. 15-3 j r;j) HONDA. ~. VF1000F FRONT WHEEL/SUSPENSION (1) LE FT HAND LEBAR SWI T CH Remove the left handlebar switch . I Disconnect the choke cable from the choke lever. (2 ) CHOKE CABLE Remove the left and right handlebar retainer rings. Loosen the left and right handlebar pinch bolts. Remove the handlebars from the fork tubes. Remove the throttle grip from the right handlebar. (2) HAND LE BAR PINCH BOLT 15-4 ~ FRONT WHEEL/SUSPENSION INSTALLATION Apply grease to the throttle grip sliding surface and -- ~ . HOND.A VF1000F slide the throttle grip over the handlebar. (1) RETAINER RING Install the handlebars onto the lork tubes, aligning the pin on the bottom of the handlebar with the cut-out in the top bridge. Tighten the handlebar pinch bolts. TOROUE: 30-40 N'm (3.0-4.0 kg·m, 22-29 It·fb) Install the handlebar retainer rings. (2) PINCH BOLT (1 J HOLE Align the right handlebar switch locating pin with the hole in the handlebar and install the right handlebar switch. Install the top portion of the switch and tighten its screws. Tighten the forward screw first , then tighten the rear screw. (2) LOCATING PIN 15-5 r;t) HONDA VF1000F ~. FRONT WHEEL/SUSPENSION (1) FRONT BRAKE MASTER CYLINDER Place the front brake master cyl inder on the handle· bar and install the master cylinder holder with the "UP" mark facing up. Align the index mark on the holder with the punch mark on the handlebar, and tighten the upper bolt first then tighten the lower bolt. (3) PUNCH MARK (4)IN DEX MARK (5) LDER (1) HOLE Connect the choke cable to the choke lever. Align the left handlebar switch locating pin with the hole in the handlebar and install the left handlebar switch. Tighten the upper screw first, then tighten the lower screw. (2) LOCATING PIN (1) "UP" MARK (2) CLUTCH MASTER CYLINDER Place the clutch master cylinder on the handlebar and install the master cylinder holder with the "UP" mark facing up, Align the index mark on the holder with the punch mark on the handlebar, and tighten the upper bolt. Connect the clutch switch wires. (3) INDEX MARK (4) PUNCH MARK 15-6 ~HONDA FRONT WHEEL/SUSPENSION ~ . VF1000F FRONT WHEEL REMOVAL Remove the right front brake caliper from the fork leg. Remove the right axle holder. NOTE If you squeeze the front brake lever after the caliper is removed, the caliper piston will move out and make reassembly difficult. (1) LEFT FRONT CALIPER Remove the speedometer cable set screw and dis connect the speedometer cable. Remove the left front caliper from the fork leg and anti -dive piston case. Remove the left axle holder. (2) AXLE HOLDER (1) AXLE NU T DISASSEMBL Y Remove the front axle nut and axle. 15-7 (3) SPEEDOMETER CABLE ~ HONDA ~ VF1000F FRONT WHEEl/SUSPENSION _ _...;.('-'.) SPACE Remove the spacer from the right side. Remove the speedometer gear box from the left side. > :. R~_ ..._ ,," (1) BRAKE DISC Remove the left and right brake disc mOlmting bolts and discs. Remove the dust seal from both sides. Remove the speedometer ratainer from the left side. WHEEL BEARING INSPECTION Check w heel bearing play by placing t he wheel in a truing stand and spinning the wheel by hand. Replace the bearings with new o nes if they are noisy or have excessive play. (1) PLAY 15-8 HONDA V F1000F FRONT WHEEL/SUSPENSION WH EE L INSPECTION Check the rim runQut by placing the wheel in a truing stand . Spin the wheel slowly and read the runout using a dial indicator. SERVICE LIMITS: RADIAL RUNDUT: 2.0 m m (0 .08 in) AXIAL RUNOUT: 2.0 mm (0.08 in) NOTE The wheel cannot be repaired and must be replaced with a new one if th e service limits are exceeded . AX LE INSP ECT ION Set the axle in V blocks and measure the runout. SE RVI CE LIMIT: 0.2 mm (0.01 in) (1) BEARING REMOVER SHAFT 07746-0050100 WHEEL BE ARING REMOVAL If the bearing need replace ment, remove the bear- ings and distance collar. NOTE Never reinstall old bearings; once the bearings are removed, they must be replaced with new ones. 15-9 ~ HOND.A ~ VF1000F FRONT WHE EL/SUSPENSION ASSEMBLY Do not get grease on the brake disc or stopping power will be _ reduced. _ _ _ _ _ _--1 NOTE The cast wheel has no rim band . The front wheel uses a tubeless tire. For tubeless tire repair, refer to the Honda Tubeless Tire Manual. (1) DRIVER 07749-0010000 Pack all bearing cavities with grease. Drive in the right bearing first, sealed side facing out, then press the distance collar into place. NOTE Be certain the distance collar is in position before installing the left bearing. Drive in the left bearing squarely, making sure that it is fully seated and that the sealed side is facing out. (2) ATTACHMENT, 42 x 47 mm 07746-0010300 (3) PILOT, 15 mm 07746-0040300 15-10 ~ HONDA ~ FRONT WHEEL/SUSPENSION VF1000F Install the speedometer gear retainer in the left side of the wheel hub, aligning its tangs with the slots in the hub. Install the left dust seal. (21 ALIGN (1) "L" MARK (2) BRAKE DISC Place new gaskets on the disc mounting flange, then install the left disc with its "L" mark facing out. Tighten the disc mounting bolts. TORQUE: 35- 40 N·m (3.5 - 4.0 kg·m, 25-29 ft·lb) Install the right dust seal. (1) "R" MARK . . . ._ _ (21 SPAI :C E~R_ Place new gaskets on the disc mounting flange, then install the right disc with its "R" mark facing out. Tighten the mount ing bolt to the same torque as left side. In stall the spacer. (3) DUST SEAL 15-11 ... ~ HON ~. D A VF1000F FRONT WHEEL/SUSPENSION (1) DRIV E GE AR Fill the speedometer gearbox with grease and install the plain washer and drive gear. (1) SPEEDOMETER GEAR BOX Install the speedometer gearbox in the wheel hub, aligning the tangs with the slots. (1) AXLE NUT Install the front axle and axle nut. Tighten the axle nut. TOROUE: 55-65 N'm (5.5-6.5 kg·m, 40-70 ft·lb) NOTE There are flats on the opposite end of the axle, so you can hold the axle while torquing the axle nut. Clean the brake discs with a high quality degreasing agent. 15-12 ~ FRONT WHEEL/SUSPENSION ~, HONDA VF1000F (1) TIRE BALANCE MARK WHEEL BALANCE CAUTION Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Always check balance when the tire has been removed from the rim. NOTE For optimum balance, the tire balance mark (a paint dot on the side wall) must be located next to the valve stem. Remount the tire if necessary. Remove the dust seal and speedometer gearbox from the wheel. (2) INSPECTION STAND Mount the wheel, tire and brake disc assembly in an inspection stand. ·Spin the wheel, allow it to stop, and mark the lowest (heaviest) part of the wheel with chalk. Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop con- sistently in the same position. To balance the wheel, install wheel weights on the highest side of the rim, the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it's spun. Do not add more than 60 grams to the front wheel (rear wheel: 70 grams). (3) WHEEL WEIGHT (1) TANG INSTA LLATION Position the wheel between the fork legs. Lower the engine so the fork legs rest on the top of the axle . Position the tang on the speedometer gear box against the lug on the left fork leg. Install the axle holders with the arrow pointing forward. (3)ARROWMARK 15-13 (2) LUG ~ ~ . HOND.A VF1000F FRONT WHEEl/SUSPENSION (1 ) CALIPER BRACKET MOUNT BOLTS Install the right front caliper and tighten the bracket mount bolts. TORQUE: 30- 40 N'm (3.0-4.0 kg·m, 22-29 ft·lb) Tighten the right axle holder nuts to the specified torque, starting with the forward nut. TORQUE: 18-25 N'm (1.8-2.5 kg·m, 13-18 ft·lb) (1) CALIPER BRACKET MOUNT BOLT Install the left front caliper. Tighten the anti -dive piston pin bolt. TORQUE: 10-15 N'm (1.0-1.5 kg-m, 7-9 ft·lb) Tighten the caliper bracket mount bolt. TORQUE: 30-40 N'm (3.0-4.0 kg-m, 22-29 ft·lb) Connect the speedomete r cable and secure it with th e screw. (2 ) ANTI·DIVE PIVOT BOLT Measure the clearance between each surface of the left brake disc and the left caliper holder with a 0.7 mm (0.028 in) feeler gauge. If the gauge inserts easily, tighten the forward left axle holder nut to the specified torque, then tighten the rear nut. If the feeler gauge cannot be inserted easily, pull the left fork out or push it in unti r the gauge can be inserted. After installing the wheel, apply the brake several times, then recheck both discs for caliper holder to disc clearance. Failure to provide adequate disc to caliper holder clearance may damage the brake disc and impair brake efficiency. 0.7 mm (0.028 in) 11 ) CALIPER HOLDER 1 11 f[ I ,~ ~ (2) II - BRAKE DISC ,- 15-14 ~ FRONT WHEEL/SUSPENSION ~ . HONDA VF1000F FRONT FORKS REMOVAL Remove the following parts: - fairing. - headlight. - instruments. - handlebars. - front wheel. - front fender and fork brace. (2) FRONT FENDER (1) UPPER PINCH BO LTS Loosen the fork upper and lower pinch bolts. (2) LOWER PINCH BOLTS Pull each fork tube out of the top bridge . NOTE Because of the friction caused by the air joint O·rings, you'll have to turn the tubes while pulling down. Remove the fork stop rings Pull each fork tube out of the for bottom bridge . (1) FORK STOP RING 15-15 ~HONDA ~, VF1000F FRONT WHEEL/SUSPENSION If replacement of the joint is necessary, remove the two screws which attach the fork air joint to the top bridge. (1) FORK CAP DISASSEMBL Y Hold the fork tube in a vise, with soft jaws or shop towel and remove the fork tube cap. CAUTION Do not damage the sliding surface. (2) SPACER Remove the fork spring, space and washer. Drain the fork fluid by pumping the fork up and down several times. (3) WASHER 15-16 ~ FRONT WHEEL/SUSPENSION ~ . HONDA VF1000F (1) HEX WRENCH 6 mm 07917 - 3230000 Hold the fork slider in a vise with soft jaws or a shop towel. Remove the socket bolt with a hex wrench . NOTE Temporarily install the spring and fork cap if difficulty is encountered in removing the socket bolt. The piston and rebound spring can be removed from the right fork . (1)WASHER (2)GREASE SEAL (3)DUSTSEAL Remove the dust seal, grease seal and washer. (1) SNAP RING PLIERS 07914-3230001 Remove the snap ring. (2) SNAP RING 15-17 ~HONDA ~. VF1000F FRONT WHEEL/SUSPENSION Pull the fork tube out until resistance from the slider bushing is felt. Then move it in and out, tapping the bushing lightly until the .fork tube separates from the slider. The slider bushing will be forced out by the fork tube bushing. Remove the oil lock piece from inside the slider. (2) FORK SLIDER (1) FORK TUBE (1) OIL (2) BACK-UP RING (3) SLIDER BUSHING Remove the oil seal, back-up ring and slider bushing from the fork tube. NOTE Do not remove the fork tube bushings unless it is necessary to replace it with a new one. (4) FORK TUBE BUSHINGS (1) SPRING SEAT (2) PISTON On the left fork, remove the circlip, oil lock valve, spring, and spring seat from the piston. Remove the piston and rebound spring from the fork tube. (3) SPR (4) OIL LOCK (5) CLIP VALVE 15-18 HONDA VF1000F FRONT WHEEL/SUSPENSION INSPECTION FORK SPRING FREE LENGTH Measure the fork spring free length. SERVICE LIMIT: 405.5 mm 115.9 in) ~I FORK TUBE/ FORK SLIDER / PISTON Check the fork tube, fork slider and piston for score marks, scratches, or excessive or abnormal wear . Replace any components which are worn or damaged. Check the fork piston ring for wear or damage. Check the rebound spring for fatigue or damage. (1) REBOUND SPRING FORK TUBE Set the fork tube in V blocks and check its runout. SERVICE LIMIT: 0.20 mm (0.008 in) 15-19 ~HOND.A ~. VF1"OOOF FRONT WHEEL/SU SPE NSION BUSHING/ BACK-UP RING Visually inspect the slider and fork tube bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire (3) BACK-UP RING (11 BUSHING surface. Check the back-up ring; replace it if there is any distortion at the points shown. ".... - 4 -- (4)C HECK POINTS -" (2) COPPER SURFACES (1) CASE ANTI-DIVE CASE Remove the four socket bolts and remove the antidive case. (2) (1) SPRING PISTON (3) PISTON PI N BOLT COLLAR Remove the piston and spring. Remove the boots, piston pin bolt collar and stop rubber. Check the spring and pistion for wear or damage. "~'I (4)O-R INGS 15-20 (fj!)HONDA ~ . VF1000F FRONT WHEEL/SUSPENSION (2)SETTING SCREW Remove setting screw, adjuster and orifice . Remove the check valve setting screw, valve spring and check ball. (3) CHECK VALVE SETTING SCREW 11) 12) CHECK BALL ORIFICE (3) SPRING Check the orifice for clogging by applying com· pressed air. Also check the orifice for damage and replace if necessary. Assemble the anti-dive case in the reverse order of disassembly. NOTE Apply a Thread Lock Agent to the th reads of the screws and socket bolts before assembly. Apply ATF to the piston and piston O· ring. Apply silicone grease to the pivot bolt collar. \, I ."" (4) ADJUSTER Check the operation of the collar and piston. 15-21 (5) SETTING SCREW , (6) SETTING SCREW ~ ~ HONDA VF1000F FRONT WH EEL/SUSPENSION ASSEMBLY Befo re assembly, wash ali parts with a high flash point or non-flammable solvent and wipe them off completely . (9) DUST SEAL 111FORK CAP 12I SPACE~ 1 \§ "" 1141 SLIDER "'" <:;) ~ ©~ J. IJ !! @ W / @)~ ®<::D c::w = 115I ANTI·DIVE CASE /J P OIL LOCK VALVE 1131 LOCK PIECE 111 SPRING SEAT 121 CIRCLIP Insert the rebound spring and piston into the for k tube. On the left fork, install the spring seat, valve spring, oil lock valve and circlip on the piston. . / 131 PISTON / 141 SPRING 151 0lL LOCK V ALVE 15-22 ~HONDA FRONT WHEEl/SUSPENSION ~. (1) (2) LEFT RIGHT VF1000F (3) OIL LOCK Place the oil lock piece on the end of the piston. NOTE On the right fork, install the oil lock piece, aligning the flats of the oil lock piece and piston end. l\~ ~' ..f) '.'. '1 · ..... .., r .. t. I • 1 (4)0IL LOCK PIECE (1) DRAIN BOLT Insert the fork tube into the slider. NOTE On the right fork, align the cutout of the oil lock piece with the drain bolt in the slider. (2)CUTOUT Place the fork slider in a vise with soft jaws or a shop towel. Apply a locking agent to the socket bolt and thread it into the piston. Tighten with a 6 mm hex wrench. NOTE Temporarily install the fork spring and fork cap bolt to tighten the socket bolt. TORQUE: 15-25 N·m (1.5-2.5 kg·m,11 - 18 ft·lb) 15-23 (5) FLATS ~HONDA. ~ VF1000F FRONT WHEEl/SUSPENSION 11) FORK SEAL DRIVER 07947 - KA Place the slider bushing over the fork tube and rest it on the slider. Put the back-up ring and an old bushing or equivalent tool on top. Drive the bushing into place with the seal driver and remove the old bushing or equivalent tool. Coat a new oil seal with ATF and install it with the seal markings facing up, Drive the seal in with the seal driver. 12) ATTACHMENT 07947-KF0010 11 )SNAP RING PLIERS 07914-3230001 Install the snap ring with its radiused edge facing down and install the washer, oil felt and dust cover. / 12) DUST SEAL SNAP RING OIL SEAL (7) BACK·UP RING Pour the specified amount of ATF into the fork tube. CAPACITY: Right fork: 380 cc 112.9 US oz, 13.4 Imp) Left fork: 400 cc 113.5 US oz, 14.1 Imp) :£ o ~ Compress the front fork and measure the oil level from the top of the tube. E E SPECIFIED LEVEL: Right fork: 230 mm 19.0 in) Left fork: 230 mm 19.0 in) '" o N AT' 15-24 Ci!JHONDA ~, VF1000F FRONT WHEEL/SUSPENSION fRr~ fork spripg, spring seat apd spacer in the Ipstal! t~e tube. ,,!OTE Note th~ spring pir~cto; t~e small coil end must face toward the bpttqm· (1 ) (2) TOP BOTTOM 1]) FORK TUBE CAR Instal! and torque the fqrk tube cap. NOTE On the right fork, align tpe cavity on the damping adjuster rod with the flat side in the piston. ' TORQUE: 15 - 30 N'm (1.5-3.0 kg-m, 11 - 22 t-'~If .. ~ (1) O·flINGS INSTALLATION Make sure the air joi~t O-rings are in good condition and apply grease to them. (2) AI R JOINT 15-25 C(j\ aONDA ~ VF1000F FRONT WHEEL/SUSPENSION Install the air joint onto the fork top bridge and tighten the two screws . • Install the forks and temporarily tighten the bottom pinch bolts . Install the fork stop rings in the grooves in the fork tube. Push the fork tubes up Until the stop rings contact the air joints. Tighten the bottom pinch bolts. TORQUE: 45-55 N·m (4.5-5.5 kg-m, 33-40 ft-Ib) 15-26 ~HONDA FRONT WHEEL/SUSPENSION ~_ (1) TOP PINCH BOLTS Tighten the top pinch bolts. TOROUE: 20-30 N·m (2.0-3.0 kg·m, 14-22 ft·lb) 11I FRONT FORK BRACE Loosely install the fork brace. Install the removed parts in the reverse order of removal. front fender. - handlebars. front wheel. fairing. With the front brake applied, pump the forks up and down several times. Tighten the front fork brace mounting bolts. TOROUE: 24-30 N'm (2.4-3.0 kg-m. 17 - 22 ft·lb) (2) FRONT FENDER Fill the fork tubes with air. RECOMMENDER PRESSURE: 0-40 kPa (0-0.4 kg/em ' , 0- 6 psi) CAUTION Use only a hand-operated air pump to fill the fork tubes. Do not use compressed air. Maximum pressure is 300 kPa (3 kg/em' , 43 psi). Do not exceed this or fork tube component damage many occur. With the front brake applied, pump the forks up and down several times. Place the motorcycle on its center stand. Check the air pressure and adjust if necessary. 15-27 VF1000F ~ ~HOND.A VF1000F FRONT WHEEL/SUSPEN SION STEERING STEM REMOVAL Remove the following components. - fairing, fuse box. handlebars. - front wheel. - brake hose 3-way joint. 111LOCK NUT WRENCH, 30 x 32 mm 07716-0020400 Loosen and remove the steering stem nut. Remove the forks. Loosen the top bridge pinch bolt and remove the top bridge with the fork air joint. 121 EXT ENSION 07716-0020500 OR EQUIVALENT U.S.A. 121LOCK NUT Straighten the lock washer tabs and remove the lock nut and lock washer. 111 LOCK WASHER 15-28 HONDA VF1000F FRONT WHEEL/SUSPENSION 111 STEERING STEM SOCKET 07916-3710100 Loosen the bearing adjustment nut and remove the steering stem. Check the steering stem bearings for damage or wear. BEARING REPLACEMENT NOTE Replace the bearing and bearing race as a set, Remove the grease retainer. Remove the bearing inner race and dust seal from the steering stem. 111 DUST SEAL 121 BEARING INNER RACE Remove the upper bearing race with the special tool. 111 BALL RACE REMOVER 07953 - 4250002 15-29 HONDA VF1000F FRONT WHEEl/SUSPENSION 11 I BALL RACE REMOVER 07953 - 4250002 Remove the lower bearing race with the special tool. NOTE If the motorcycle has been involved in an accident, examine the area around the steering head for cracks. (21 BEARING RACE REMOVER 07946-3710500 • ~ (1) LOCK NUT (2) LOCK WASHER (3) BEARING ADJUSTMENT _ NUT . ~ ~ ~ (4) UPPER BEARING INNER RACE ~ ®' ~ (5) UPPER BEARING OUTER RACE ~ (10) DUST SEAL (11) UPPER BEARING (6) GREASE RETAINER _ _~. (7) LOWER BEARING OUTER RACE ~ ~ (8) LOWER BEARING INNER RACE -. (9) DUST SEAL ~ ~ ______ (12) LOWER BEARING • ~ (1 I DRIVER 07749-0010000 (2) ATTACHMENT, 52 x 55 mm 07746-0010400 Orive the upper bearing outer race into the steering head. Dri ve the lower bearing outer race into the steering head. (3) ATTACHM , 42 x 47 mm 07746-0010300 15-30 ~ FRONT WHEEl/SUSPENSION ~_ HONDA VF1000F Install a dust seal onto the steering stem and press the lower bearing inner race over the stem with the special tool. (11 STEERING STEM DRIVER 07946-MBOOOOO INSTALLATION Pack the bearing cavities with bearing ease. Install the lower bearing and grease retainer onto the steering stem, then insert the steering stem into the steering head. Install the upper bearing and inner race. (2) LOWER BEARING (11 STEERING STEM SOCKET 07916-3710100 Install and tighten the adjusting nut to the specified torque. TORQUE: 23-27 N-m (2.3-2.7 kg·m. 14-22 ft-Ibl 15-31 ~ HONDA ~ VF1000F FRONT WHEEl/SUSPENSION Turn the steering stem lock-ta-Iock 4-5 times to seat the bearings, then tighten the nut to the same torque. Install a new bearing adjustment nut lock washer aligning the tabs with th e grooves in the nut. Bend two opposite tabs down into the grooves. NOTE ~ (1) LOCK NUT IDa ------------------------NOT install a used bearing adjustment t lock washer . Hand tighten the lock nut. Hold the adjustment nut and further tighten the lock nut only enough to align its grooves with the lock washer tabs. NOTE If the lock nut grooves cannot be easily aligned with the lock washer tabs, remove the nut, turn it over and reinstall it. Bend two lock washer tabs up into the lock nut grooves. (2) LOCK WASHER (1) E XTEI~SON 077 16-0020500 Install the top bridge with the fork air joint. Install the front forks (page 15·25). Install and tighten the steering stem nut. TORQUE: 90-120 N'm (9.0-12.0 kg·m, 65-87 ft·lb) (2) LOCK NUT WREI~Cli. 07716-0020400 15-32 ~ FRONT WHEEL/ SUSPENSION ~, HONDA (1) SPR IN G SCAL E (commercially available) STE ER ING HE AD BEA RIN G PREL OAD Install the front wheel (page 15·13). Place a stand under the engine and raise the front wheel off the ground. Position the steering stem to the straight ahead position. Hook a spring scale to the fork tube and measure the steering head bearing preload. NOTE ake sure that there is no cable and wire interference. [harness ; ~ The preload should be within 1.0-1.6 kg (2.21 - 3.53Ib) for right and left turns. If the readings do not fall within the range, lower the front wheel and adjust the bearing adjustment nut. After making sure the bearing preload is acceptable, im:tall the removed parts in the reverse order of removal. 15-33 VF1000F ~ ~ HONDA VF1000F REAR WHEEL/SUSPENSION 16-0 ~ REAR WHEEL/SUSPENSION ~. HOND.A VF1000F 40-50 N·m (4.0-5.0 kg-m, 29-36 ft-Ib) 40-50 N·m (4.0-5.0 kg·m, 29-36 ft-Ib) ~- \.A--'-"<' 85-105 N·m (8.5-10.5 kg·m, 61-76 ft-Ib) 40-50 N·m (4.0-5.0 kg-m, 29-36 ft-Ib) 80-100 N·m (8.0-10.0 kg-m, 58-72 ft-Ib) 18-25 N·m (1.0-2.5 kg,m, 13- 18 ft -Ib) 20 - 30 N'm 12.0 - 3.0 kg -m, 14 - 22 ft -Ibl 85-105 N·m (8.5-10.5 kg-m, 61-76 ft,lb) 16-0 HONDA VF1000F REAR WHEEL/SUSPENSION SERVICE INFORMATION 16-1 TROUBLESHOOTING SHOCK ABSORBER 16-2 16-3 16-9 SWINGARM 16-15 REAR WHEEL SERVICE INFORMATION GENERA L • The rear wheel uses a tubeless tire. For tubeless tire repairs, refer to the TUBELESS TIRE MANUAL. SPEC I F ICATIONS STANDARD SERVICE LIMIT I Radial - 0.2 mm (0.01 in) 2.0 mm (O.OB in) I Axial - 2.0 mm (0.08 in) Axle runout Rear wheel rim runout Shock absorber air pressure - 0 - 300 kPa 10 - 3.0 kg /cm', 0 - 43 psi I TORQUE VALUES Shock arm-te-frame bolts Shock link ·to-shock arm bolt Rear shock absorber mount bolts Swingarm pinch bolt Swingarm pivot bolts Rear brake torque rod 8 mm 10 mm Final driven sprocket Rear brake disc Rear axle nut 40-50 N·m 14.0-5.0 kg·m, 29 - 36 ft-Ib) 40- 50 N·m 14.0- 5.0 kg -m, 29- 36 ft -Ib) 40- 50 N·m 14.0-5.0 kg·m, 29-36 ft·lb) 20-30 N·m 12.0- 3.0 kg-m, 14-22 ft-Ib) 85 - 105 N·m 18.5- 10.5 kg·m, 61 -7 6 ft·lb) lB- 25 N.m 11.8-2.5 kg-m, 13- 18 ft·lb) 30 - 40 N·m 13.0-4.0 kg·m, 22 - 29 ft-Ib) 80 - 100 N·m 18.0- 10.0 kg-m, 58 - 72 ft ·lb) 35 - 40 N·m 13.5- 4.0 kg-m, 25-29 ft-Ib) 85 - 105 N·m 18.5- 10.5 kg -m , 61 - 76 ft·lb ) TOOLS Special Needle bearing remover Oil seal driver attachment Oil seal driver attachment ring Oil seal driver 07931 07965 07965 07965 - MA 70000 MB00100 ME70100 MC70100 Common Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm Attachment, 62 x 68 mm Pilot, 17 mm Pilot, 20 mm Pilot, 25 mm Driver Bearing remover shaft Bearing remover head, 20 mm 07746-0010100 07746- 0010200 07746-00 10300 07746-0010400 07746-0010500 07746-0040400 07746-0040500 07746 - 0040600 07749- 0010000 077 46- 0050100 077 46 - 0050600 .. , . 16-1 ~ REAR WHEEL/SUSPENSION TROUBLESHOOTING Oscillation 1. 2. 3. 4. 5. 6. 7. Bent rim Loose wheel bearings Faulty tire Loose axle Tire pressure incorrect Swingarm bearings worn Worn tires Soft suspension 1. Weak spring 2. Insufficient fluid in shock absorber 3. Shock absorber air pressure incorrect Hard suspension 1. Incorrect fluid weig ht in shock absorber 2. Bent shock absorber 3. Shock absorber air pressure incorrect Suspension noise 1. Shock case binding 2. Loose fasteners 16-2 ~ HONDA VF1000F ~ HONDA ~ VF1000F REAR WHEEL/SUSPENSION REAR WHEEl REM OVA L Place the motorcycle on its center stand. Loosen the drive chain adjusting bolts lock nuts and the adjusting bolts. Remove the axle nut and axle. Push the wheel forward and remove the drive chain from the driven sprocket and remove the rear wheel. NOTE If you depress the brake pedal after the rear wheel is removed the caliper piston will move out and make reassembly difficult. (3) DR IV E CHA IN ADJUST ING BOLT (1) REA R BRAKE DI.:SC DISA SSEMBL Y ~_ Remove the rear brake disc. Remove the dust seal. (1) FINAL DR IV EN SP ROCK ET Remove the final driven sprocket and driven flange ....:oiII-- together. NOTE Do not separate the driven sprocket and flange, unless replacement of the driven sprocket or flange is necessary. Remove the dust seal from the final driven flange . (2) DUST SE A L (3) FI NAL DR IV EN FL AN GE 16-3 ~ REAR WHEEL/SUSPENSION HOND.A VF1000F INSPECTION AXLE Set the axle in V blocks and read the axle runout with a dial indicator. SERVICE LIMIT : 0.2 mm (0.01 in) REAR WHEEL BEARING Check the wheel bearing play by rotating th e whee l by hand. Replace the bearings with new ones if they are noisy or have excessive play. REAR WHEEL RIM RUNOUT Check the rim for runout by placing the wheel in a truing stand. Spin the wheel slowly, and read the runout using a dial indicator. SERVICE LIMITS: RADIAL RUNOUT: 2.0 mm (0.08 in) AXIAL RUNOUT: 2.0 mm (0.08 in) NOTE The wheel cannot . be serviced and must be replaced if the above limits are exceeded. 16-4 C~3= ~(1) PLAY HONDA. VF1000F REAR WHEEl/SUSPENSION FINAL DRIVEN SPROCKET Check the condition of the final driven sprocket teeth. Replace the sprocket if worn or distorted. NOTE (2) REPLACE (1) GOOD If the final driven sp rocket requires replace ment, inspect the drive chain and drive sprocket. (1) DAMPER RUBBER DAMPER RUBBERS Replace the damper rubbers if they are damaged or deteriorated. (1) BEARING REMOVER SHAFT 07746-0050100 BEARING REPLACEMENT Remove the wheel bearings. Drive the driven flange side bearing out. NOTE Never reinstall old bearings; once the bearings are removed, they must be replaced with new ones. (2) BEARING REMOVER HEAD, 20 mm 07746-0050600 16-5 ~ REAR W HEEL/SUSPENSION ~. HONDA V F1000F (1) AXL E SL EE VE Remove the rear axle sleeve. Remove the snap ring. Drive the driven flange bearing out. (2) DRIVEN FLANGE BEARING (2) ATT ACHMENT, 52 x 55 mm (3) ATTACHMENT, 42 x 47 mm 07746-00 10400 07746- 0010300 PI LOT, 20 mm PILOT, 20 mm 07746-0040500 Pack all bearing cavities with grease. Press distance collar into place from the left side. Drive the right bearing in first, then the left bearing. CAUTION Drive the bearings in squarely with the sealed end [acing out, making sure they are fully seated. (1) DRIVER 07749- 0010000 16-6 ~ HOND.A ~ VF1000F REAR WHEEL/SUSPENSION (11 DRIVER 07749-0010000 Drive the driven flange bearing in. DRIVER ATTACHMENT, 62 x 68 mm PILOT, 25 mm 07749- 0010000 07746-0010500 07746-0040600 CAUTION Drive tire bearings in squarely with tire sealed elld facing out, making sure they are fully sealed. Install the snap ring and rear axle sleeve. (21 ATTACH MENT , 62 x 68 mm 07746-0040500 PI LOT, 25 mm 07746- 0010500 ASSEMBLY NOTE The rear wheel uses a tubeless tire. For tube· less tire repairs, refer to the Tubeless Tire Manual. -- Do 1101 get grease Oil the brake disc or stop· pillg power will be reduced. ----------------- 35-40 N·m (3.5-4.0 kg-m, 25- 29 ft-Ibl .. "" (11 FINAL DRIVEN FLANGE 80-100 N·m (8_0-10_0 kg-m, 58-72 ft-Ibl (31 DISC 16-7 HONDA VF1000F REAR WHEEL/SUSPENSION (1) DRIVEN FLANGE (2) DRIVEN SPROCKET Install the rear axle sleeve, final driven flange and driven sprocket. If the driven sprocket was removed from the flange, tighten the driven sprocket nuts to the specified torque. TORQUE: SO-100 N'm (S.0-10.0 kg-m, 5S-72 ft·lb) Install the dust seal. (3) DUST SEAL (1) REAR BRAKE DISC Install the brake disc and tighten the bolts. TORQUE: 35-40 N'm (3.5-4.0 kg-m, 25-29 ft·lb) Install the dust seal. (2) DUST SEAL Install the left and right side spacers. 16-8 ~ HONDA. ~ VF1000F REAR WHEEL/SUSPENSION INSTALLATION Install the rear wheel in the reverse order of removal. NOTE When installing the wheel, carefully fit the brake disc between the brake pads. After installing the wheel, apply the brake several times. Then check that the wheel rotates freely. Recheck wheel installation if the brake drags or if the wheel does not rotate freely. Tighten the rear axle nut. TORQUE: 85-105 N·m (8.5-10.5 kg·m, 61-76 ft·lb) Adjust the drive chain slack (page 3·13). (1) BREATHER SEPARATOR SHOCK ABSORBER REMOVAL Place the motorcycle on its center stand. Remove the seat and left frame side cover. Remove the breather separator and the electric panel. (2) ELECTRI C PAN EL (1) LOCK NU T (2) BATT ER Y Remove the battery. Remove the rear shock abso rbe r damping force knob from the frame by loosening th e lock nut. (3) OAMPING FORCE KNOB 16-9 HONDA VF1000F REAR WHEEL/SUSPENSION (1) UPPER MOUNTING BOLT Remove the shock absorber lowl1r mounting bolt. Remover the shock absorber upper mounting bolt, tilt the shock absorber rearward and remove it from the frame by pulling it up . • (2) LOWER MOUNTING BOLT (5) STOP RING REAR SHOCK ABSORBER 01 L SEAL REPLACEMENT Remove the rear shock absorber (page 16-91. Remove the boot band and boot. (1) 01 L SEAL DRIVER • To remove the stopper ring, press down on the 07965-MC70100 (2) STOP RING BACK-UP (3)RING back-up plate and oil seal. Remove the stopper ring and back-up plate. (4) OIL SEAL Release air pressure and remove the air valve from the hose. • (1) AIR VALVE 16-10 Q \ HONDA ~ VF1000F REAR WHEEL/SUSPENSION (1) OAMPER OIL (ATF OR EQUIVALENT) Place about 300 em' (10.1 oz) of damper oil (ATF or equivalent) in a clean container. Place the shock absorber in a hydraulic press with an OIL SEAR ORIVER ATTACHMENT positioned as shown. Place the air hose in the oil and press the shock absorber several times until the damper is filled with the oil. - "'!I NOTE 00 not over-press the shock. This shock absorber's store is 42.5 mm (1.67 in). (2) 01 L SEAL ORIVER ATTACHMENT 07965 - MB00100 Place the shock absorber up right in an oil drain pan. Let the shock stand for 5 minutes to allow air to escape. (1) OIL SEAL ORIVER ATTACHMENT 07965 - MB00100 (1) SHOP TOWEL Reinstall the air valve in the air hose. Place the shock absorber in the hydraulic press using the oil seal driver attachment. Wrap a shop towel around the shock absorber. Press the oil seal out by compressing the shock absorber . • I (2) OIL SEAL DRIVER ATTACHMENT (4) 07965 - MB00100 16-11 ~ REAR WHEEL/SUSPENSION ~. HONDA VF1000F Leave the shock absorber for another 5 minutes to let any remaining ATF drain out. NOTE Do not tilt the shock absorber or ATF will flow out of the damper case. Turn the shock absorber upside down as soon as all the ATF has drained from the outer case. Fill the damper case with the specified amount of ATF. SPECIFIED AMOUNT: 120 cc (4.06 US OZ., 3.38 Imp. oz.) Install the guide bushing into the damper case. Wrap a piece of tape around the groove at the end of the shock absorber. Dip the oil seal in damper oil and install it on the damper. CAUTION Be careful not to damage the oil seal during installation. (2) TAPE 16-12 ~ HON'DA ~. VF1000F REAR WHEEL/SUSPENSION (1) ATTACHMENT 07 00 Press the oil seal into the shock absorber with a (2) OIL SEAL DRIVER 07965-MC701oo hydraulic press until the oil seal driver and oil seal driver ring stops at the edge of the outer case. (3) DRIVER ADAPTOR 07965-ME70001 ~ (4) OIL SEAL ~ lID ~ ~ (2) 01 L SEAL DRIVER 07965-MC70100 Install the back-up ring. Install the stop ring, being certain that it is seated in (1) STOP RING the ring groove in the outer case. NOTE Be sure stop ring is seated in the ring groove all the way around. Install the boot and boot clip. ...----- (2) BACK-UP RING INSTALLATION Apply paste grease (containing more than 45% of molybdenum) to the upper mounting bushings. NOTE Use paste grease (containing more than 45 % of molybdenum) as follows: MOL YKOTE G-n PASTE manufactured by Dow Corning, U.S.A. Local Paste manufactu red by Sumi co Lubricant, Japan. Other lubricants of equivalent quality. Install the shock absorber in the frame and tighten the upper and lower mounting bolts. TORQUE: 40-50 N-m (4.0-5.0 kg-m. 29-36 ft-Ib) (2) LOWER MOUNTING BOLT 16-13 HONDA VF1000F REAR WHEEL/SUSPENSION Install the battery. Install the damping force knob onto the knob bracket on the frame. (2) DAMPING FORCE KNOB Install the electric panel and crankcase breather separator. NOTE Route the wires, hoses and tubes properly (pages 1-9 thru 1 1 I. Install the left frame side cover and seat. Adjust the air pressure (page 3-18). (1)SW INGAR M LT PINCH (2) SHOCK LINK (3) SHOCK ABSORBER SHAFT LOWER MOUNTING BOLT SHOCK ABSORBER LINKAGE REMOVAL Remove the left and right mufflers. Remove the shock link by removing the shock absorber lower mounting bolt, shock link-te-shock arm bolt, swingarm pinch bolt, and shock link shaft. Remove the shock arms from the frame. (4) SHOCK LINK " 16-14 (5) LlNK -TO-ARM BOL T (6) SHOCK ARM ~ ~ HOND.A VF1000F REAR WHEEL /SUSPENSION LINKAGE PIVOT INSPECTION Check the linkage needle bearings and collars for wear or damage. Inspect the dust seals for damage . Replace parts as necessary. SHOCK LINKAGE INSTALLATION Apply molybdenum disulfide grease to the needle bearings and dust seals. Install the shock arms and shock link and tighten each bolt in the order listed. TORQUE: SHOCK ARM·TO·FRAME: 40-50 N·m 14.0-5.0 kg·m. 29-36 ft·lb) SHOCK LlNK·TO·SHOCK ABSORBER 40-50 N·m 14.0-5.0 kg·m. 29-36 ft·lb) SHOCK LlNK·TO·SHOCK ARM: 40-50 N·m (4.0-5.0 kg·m. 29-36 ft·lb) SWING ARM PINCH BOLT: 20-30 N·m (2.0-3.0 kg·m. 14-22 ft·lb) Install the mufflers. . SWING ARM 131 SHOCK LlNK·TO· ARM BOLT (4) SHOCK ARM·TO· FRAME BOLT (1) SHOCK LINK PINCH BOLT (2) SHOCK LINK SHAFT REMOVAL Remove the rear wheellpage 16·3). Remove the right muffler. Remove the drive chain cover. Remove the shock link pinch bolt and shock link shaft. 16-15 ~H REAR WHEEL/SUSPENSION (1) LEFT PIVOT BOLT ~ . ONDA VF1000F (2) RIGHT PIVOT BOLT Remove the left and right swing arm pivot bolts. Remove the lock pin from the rear brake torque rod bolt and remove the torque rod bolt. Remove the swing arm from the frame. (1) LOCK PIN (2) TORQUE ROD BOLT Remove the drive chain slider from the swingarm. -' • (1) DRIVE CHAIN SLIDER 16-16 ~HONDA ~, VF1000F REAR WH EEL/ SUSPENSION (1) DUST SEAL PIVOT BEARING REPLACEM ENT Remove the pivot collar from the swingarm's right pivot. Remove the dust seal. Remove the snap ring and drive out the right pivot bearings. (2) PIVOT COLLAR (3) SNAP RING 111 NEEDLE BEARING REMOVER 07931 - MA 70000 Remove the dust seal from the swingarm's left pivot. Remove the left pivot needle bearing with the sped aI too I. (1) DRIVER 07749-0010000 (2) WOODEN BLOCK Drive a new needle bearing into the 5wingarm left pivot. CAUTION To prevent swingarm damage, support tlze swingarm as shown. r (3) ATTACHMENT, 32 x 35 mm 07746-0010100 PILOT, 20 mm 07746-0040500 16-17 HONDA VF1000F REAR WHEEL/SUSPENSION (1) DRIVER 07749-0010000 Drive new ball bearings into the swingarm right pivot. (2) ATTACHMENT, 37 x 40 mm 07746-0010200 PILOT, 17 mm 07746-0040400 Install the snap ring in the right swingarm pivot . Install the oil seals both pivots. Install the pivot collar into the right pivot. (1) SNAP RING (2) PIVOT COLLAR (1) DRIVE CHAIN SLIDER INSTALLATION Install the drive chain slider. Install the swingarm in the frame. 16-18 ~HOND.A ~. VF1000F REAR WHEEL/SUSPENSION 11) LOCK PIN 12) BOLT Make sure that the rear brake torque rod's flanged washer is installed in the swingarm pivot. Connect the rear brake torque rod to the 5wingarm and tighten the pivot bolt. TORQUE : 18-25 N·m 11.8-2.5 kg·m. 13-18 fUb) Secure the bolt with the lock pin. Install the left and right pivot bolts. Tighten the right pivot bolt. TORQUE: 85-105 N'm 18.5-10.5 kg·m. 61-76 ft·lb) Tighten the left pivot bolt. TORQUE: 85-105 N·m 18.5-10.5 kg·m. 61-76 ft·lb) 16-19 HONDA VF1000F REAR WHEEl/SUSPE NSION Connect the swingarm and shock link and install the shock link shaft and shock link pinch bolt. T ighten the shock li nk pinch bol t . TORQUE: 20-30 N·m (2.0-3.0 kg·m. 14-22 f t·lb ) (1) DRIVE CHAIN COVER Install the drive chain cover onto the swing arm. Install the right muffler. Install the rear wheel (page 16-8), 16-20 HONDA VF1000F HYDRAULIC BRAKE m 17-0 ~HOND.A HYDRAULIC BRAKES . VF1000F 30-40 N·m (3.0-4.0 kg·m, 22-29 ft ·lb) 30-40 N·m (3.0 - 4.0 kg·m, 22-29 ft ·lb) ~ ir$ o ~ ," ~; I ~ Q ~ tb 25-35 N·m (2.5-3.5 kg·m, 18-25 ft·lb) , 18- 22 ft·lb) - - a ~<>i 'N~h /. ~ 20-25 N·m (2.0-2.5 kg·m, 14-18 ft·lb) 17-0 .~ ~ 20-25 N·m (2.0-2.5 kg·m, 14-18 ft·lb) ~ ~HOND.A ~_ VF1000F HYDRAULIC BRAKES SERVICE INFORMATION 17-1 TROUBLESHOOTING 17-2 BRAKE FLUID REPLACEMENT/AIR BLEEDING 17-3 BRAKE PAD/DISC 17-5 FRONT MASTER CYLINDER 17-8 BRAKE CALIPERS 17-10 REAR MASTER CYLINDER 17-14 SERVICE INFORMATION GENERAL • The brake calipers can be removed without disconnecting the hydraulic system. • • Bleed the hydraulic system if it is disassembled or if the brake feels spongy. Do not allow foreign material to enter the system when filling the reservoir. • Avoid spilling brake fluid on painted surfaces or instrument lenses, as severe damage can result. • Always check brake operation before riding the motorcycle. SPECIFICATIONS Front disc thickness 4.0 mm (0.157 in) 4.5-5.2 mm (0.177-0.205 in) - Front disc runout Front master cylinder 1.0. SERVICE LIMIT STANDARD ITEM 0.30 mm (0.012 in) 15.870-15.913 mm (0.6248-0.6265 in) 15.925 mm (0.6270 in) Front master piston 0.0. 15.827- 15.854 mm (0.6231-0.6242 in) 15.815 mm (0.6226 in) Front caliper piston 0.0. 31.948-31.998 mm (1.2578-1.2598 in) Front caliper cylinder 1.0. 32.030-32.080 mm (1.2610-1.2630 in) 14.000-14.043 mm (0.5512-0.5529 in) 13.957-13.984 mm (0.5495-0.5506 in) 31.940 mm 32.090 mm 14.055 mm 13.945 mm Rear master cylinder 1.0. Rear master piston 0.0. Rear caliper cylinder 1.0. Rear caliper piston 0.0. Rear disc thickness 32.030 - 32.080 mm (1.2610 1 .2630 inJ 31.948 - 31.998 mm (1.2578-1 .2598 in) 6.5- 7.2 mm (0.256-0.283 in) Rear disc runaut - (1.2575 (1.2634 (0.5533 (0.5490 in) in) in) in) 32.090 mm (1.2634 in) 31.940 mm 11.2575 inJ 6.0 mm (0.236 in) 0.30 mm (0.012 in) TORQUE VALUES Front brake caliper bracket mount bolt (Right) Front brake caliper bracket mount bolt (Left-upper) Anti·dive piston pin bolt Brake caliper mount bolt Brake caliper pivot bolt Brake hose oil bolt Rear brake actuating arm 30 30 10 20 25 25 10 - 40 N·m 40 N·m 15 N·m 25 N·m 30 N·m 35 N·m 15 N·m (3.0 13.0 (1.0 12.0 12.5 12.5 (1.0 - 4.0 kg -m, 4.0 kg -m, 1.5 kg -m, 2.5 kg -m, 3.0 kg -m, 3.5 kg -m, 1.5 kg -m, 22 29 22-29 7 - 11 14 - 18 18 - 22 18 - 25 7 - 11 ft-lbJ ft -lbJ ft -Ib) ft -lbJ ft-lbJ ft -lb J ft IbJ 17-1 ~HONDA HYDRAULIC BRAKES TOOL Special Snap ring pliers 07914 -3230001 TROUBLESHOOTING Brake lever/pedal soft or spongy Brakes grab 1. Air bubbles in hydraulic system 1. Pads contaminated 2. Low fluid level 2. Disc or wheel misaligned 3. Hydraulic system leaking Brake lever/pedal too hard Brake chatter or squeal 1. Sticking pistonlsl 2. Clogged hydraulic system 3. Pads glazed or worn excessively 1. Pads contaminated 2. Excessive disc runout Brake drag 1. Hydraulic system sticking 2. Sticking piston lsi 17-2 3. Caliper installed incorrectly 4. Disc or wheel misaligned ~ . VF1000F ~ HONDA ~. VF1000F HYDRAULIC BRAKES (2) (4) BRAKE flUID REPLACEMENT! AIR BLEEDING Check the fluid level with the fluid reservoir parallel to the ground. CAUTION Install the cover on the reservoir whenever operating the brake lever or pedal. Failure to do so will allow brake fluid to squirt out of the reservoir during brake operation. Avoid spilling fluid on painted surfaces. Place clean shop towels over the fuel tank whenever the system is being serviced. (3) LOWER LEVEL BRAKE FLUID DRAINING 111 Connect a bleed hose to the bleed valve to avoid spilling fluid. FRONT A brake fluid contaminated brake disc or pad reduces SlOpping power. Discard pads alld clean a contaminated disc with a high quality brake degreasing agent. Loosen the caliper bleed valve and pump the brake lever or pedal. Stop operating the lever or pedal when fluid stops flowing out of the bleed valve. BRAKE FLUID FILLING Fill the reservoir with DOT4 brake fluid from a sealed container. NOTE ( 1) FRONT (2) BRAKE BLEEDER Check the fluid level oftern while bleeding the brakes to prevent air from being pump· ed into the system. When using the Brake Bleeder, follow the manufacturer's instructions. CAUTION "- ," Use only DOT4 brake fluid from a sealed container. Do not mix brake fluid types and never re· use the contaminated fluid which has been pumped out during brake bleeding, because this will impair the efficiency of the brake system. Connect the Brake Bleeder or equivalent to the bleeder valve. (3) RUBBER HOSE (4) BLEEDER VALVE 17-3 ~ HYDRAULIC BRAKES ~. (1 ) REAR (2) BRAKE BLEEDER Pump the brake bleeder and loosen the bleeder valve. Add fluid when the fluid level in the master cylinder reservoir is low. Repeat above procedures until air bubbles do not appear in the plastic hose. NOTE If air is entering the bleeder from around the bleeder valve threads, seal the threads with teflon tape. Close the bleeder valve and operate th e brake lever or pedal. If it feels spongy, bleed the system by performing the air bleeder procedure. If a Brake Bleeder or equivalent not available, fill the system as follows: Pump up the system pressure with the lever or pedal until there are no air bubbles in the fluid flowing out of the reservoir hole and lever or pedal resistance is felt. AIR BLEEDING Bl eed the system as follows: 1) Connect a bleeder tube to the bleeder va lve. 2) Squeeze the brake lever or depress th e brake pedal, open the bleed valve 1/2 turn and then close the va lve. NOTE Do not release the brake lever or pedal unti l the bleed valve has been closed . 3) Release the bra ke lever or pedal slowly and wait several seconds after it reaches the end of its travel. Repeat steps 1 and 2 until bubbles cease to appear in the fluid at the end of the hose. Fill the flu id reservoir to the upper level ma rk. A brake fluid contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. 17-4 (1) (2) FRONT REAR HONDA VF1000F ~ HON'DA ~ VF1000F BRAKE PAD/DISC HYDRAULIC BRAKES 121 LEFT CALIPER FRONT PAD REPLACEM ENT NOTE Always replace the brake pads in pairs to assure even disc pressure. Remove the pad pin retainer bolt. Right caliper: Remove the caliper bracket mount bolts and caliper mount bolt. Left caliper: Remo ve the caliper bracket mount bolt, anti-dive piston pin bolt and caliper mount bolt. Remove the caliper from the bracket. Remove the pad pin retainer and pull the pad pins out of the caliper. Remove the brake pads. ___ 111 PAD SPRING Position the pad spring in the caliper as shown. Push the caliper pistons in all the way. 17-5 ~H HYDRAULIC BRAKES ~. OND.A VF1000F Install the new pads in the caliper. Install the pad pins, one pad pin first, then install the other pin by pushing the pads against the caliper to depress the pad spring. (1) RETAINER Place the pad pin retainer over the pad pins. Push the retainer down to secure the pins. Install the pad pin retainer bolt. (1) CALIPER BRACKET (2) PIVOT BO LT BOOT Apply silicone grease to the inside of the pivot bolt boot and pivot bolt and install the caliper onto the bracket. (4) 51 LlCONE 17-6 ~HOND.A ~. VF1000F HYDRAULIC BRAKES (1) RIGHT CALIPER (2) BRACKET MOUNT BOLTS Install the caliper bracket onto the fork leg so the disc is positioned between the pads, being careful not to damage the pads. (3) CALIPER MOUNT BOLT .. Right caliper: Tighten the caliper bracket mount bolts and caliper mount bolt. Left caliper: Tighten the caliper bracket mount bolt, anti-dive piston pin bolt and caliper mount bolt. TOROUE: Caliper bracket mount bolt: 30-40 N'm (3.0-4.0 kg·m, 22-29 ft·lb) Anti-dive piston pin bolt: 10-15 N'm (1.0-1.5 kg-m, 7-9 ft-Ib) Caliper mount bolt: 20-25 N'm (2.0-2.5 kg-m, 14-18 ft-Ib) (3) ANTI-DIVE PISTON PIN BOLT (4) CALIPER MOUNT BOLT REAR BRAKE PAD REPLACEMENT Loosen the caliper mount bolt and remove it from the caliper bracket. Pivot the caliper up out of the way. Replace the rear brake pads using the same method as used for front brake pad replacement . (1) CALIPER MOUNT BOLT 17-7 ~ HYDRAULIC BRAKES DISC THICKNESS Measure the thickness of each disc. SERVICE LIMIT: FRONT: 4.0 mm (0.16 in) REAR: 6.0 mm (0.24 in) BRAKE DISC WARPAGE Measure brake disc for warpage. SERVICE LIMIT: 0.30 mm (0.012 in) FRONT MASTER CYLINDER DISASSEMBL Y Dra in brake fluid from the hydraulic system. Remove the brake lever and rear view mirror from the master cylinder. Disconnect the brake hose. CAUTION Avoid spilling brake fluid on painted surfaces. Place a rag over the fuel tank whenever the brake system is being serviced. NOTE When removing the fluid hose bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out. Disconnect the front Drake switch wires. Remove the front brake master cylinder. 17-8 ~ HOND.A VF1000F ~ ~, HONDA VF1000F HYDRAULIC BRAKES Remove the piston boot and the snap ring from the master cyli nder body. 11) SNAP RING PLIERS 07914 - 3230001 Remove the secondary cup and piston. Then remove the primary cup and spring. Remove the brake light switch from the master cylinder body, if necessary. Clean the inside of the master cylinder and reservoir with brake fluid. INSPECTI ON Measure the master cylinder I.D. Check the master cylinder for scores, scratches or nicks. SERVICE LIMIT: 15 .925 mm (0.6270 in) 17-9 ~ HYDRAULIC BRAKES HONDA ~, VF1000F Measure the master piston 0 .0. SERVICE LIMIT: 15.815 mm (0.6226 in) Check the primary and secondary cups for damage before assembly. ASSEMBLY CAUTION Keep the master cylinder piston, cylinder and spring as a set; don't substitute individual parrs. Assemble the master cylinder. Coat all parts with clean brake fluid before assembly. Install the spring and primary cup together. Dip the piston cup in brake fluid before assembly. CAUTION When illStallillg the cups, do not allow the lips to turn inside out and be certain the snap ring is firmly seated in the groove. (l ) PISTON ~ (2) BRAKE FLUID DOTA " ~ f~_ ~ ~ 19 U ~ Install the piston and snap ring. Install the boot. Place the front master cylinder on the handlebar an and install the holder with its "UP" mark facing up. Align the index mark on the holder with the punch mark on the handlebar. Tighten the upper bolt first, then tighte n the lower bolt. Install the fluid hose with the bolt and two sealing washers. Install the brake lever. Install the rear view mirror. Connect the front brake switch wires. Fill the reservoir to the upper level and bleed the brake system according to page 17·4. (1) ALIGN 17-10 U ... (3) FRONT BRAKE LIGHT SWITCH ~HON'DA. ~ VF1000F BRAKE CALIPERS HYDRAULIC BRAKES ( 1) RIGHT CALIPER (2) LEFT CALIPER FRONT BRAKE CALIPER REMOVAL Place a clean container under the caliper and disconnect the brake hose from the caliper. CAUTION A void spilling brake fluid on painted surfaces. Right caliper: Remove the caliper bracket mount bolts and caliper mount bolt and remove the caliper from the bracket. Left caliper: Remove the caliper bracket mount bolt, anti-dive piston pin bolt and caliper mount bolt and remove the caliper from the bracket. REAR BRAKE CALIPER REMOVAL Place a clean container under the caliper and disconnect the brake hose from the caliper. CAUTION A void spilling brake fluid on the painted surfaces to prevent paint damage. Remove the caliper mount bolt, pivot up and remove the caliper from the bracket. (1) BOOTS (2) PAD SPRING DISASSEMBLY Remove the brake pads (p,ge 17·5). Remove the pad spring. . Remove the caliper pivot collar and boots. Remove the pistons from the caliper. (2) PIVOT COLLAR 17-11 HYDRAULIC BRAKES If necessary, apply compressed air to the caliper fluid inlet to get the piston out. Place a shop rag Under the caliper to cushion the piston when it is forced out. Use the air in short spurts. Do nor bring rhe nozzle too close to rhe inlet. Examine the pistons and cylinders for scoring, scratches or other damage and replace if necessary. Push the piston seals in and lift them out, then discard them. Clean the piston seal grooves with brake fluid . CAUTION Be careful nor to damage the piston sliding surfaces. PISTON INSPECTiON Check the pistons for scoring, scratches or other damage. Measure the piston diameter with a micro - meter . SERVICE LIMIT: FRONT: 31,940 mm (1.2575 in) REAR: 31.940 mm (1 .257 5 Inl 17-12 {;;jj\ HONDA ~ VF1000F (jJ)HONDA ~. VF1000F HYDRAULIC BRAKES CYLINDER INSPECTION Check the caJiper cylinder for scoring, scratches or ot~er darpage. fV1easure the caliper cylinder bore. SERVICE LIMIT: FRONT: 32.090 mm (1.2634 in) REAR: 32.090 mm 11.2634 inl ASSEMBLY If the collar boots are hardened or deteriorated, replace them with new ones. The piston seals rTlust be replaced with new ones (1) COLLAR BOOTS whenever they are removed. Coat the seals with brake fluid before assembly (2) PISTON SEALS '\, (\IOTE I~stal the piston seals with their sma!! dia· meter erds facing in. Install the pislons with the dished ends toward the pads. Apply midium grade of t-ii-TefT1perature silicon inside of the collar grease. grease to the co!!ar a~d Install the collar boots and collar makin g sure that the boots are seated in the collar and caliper grooves properly. Install the pad sprirg· Install the pads (page 17-51. (3) COLLAR (4) PAD SPRING (5) PISTONS (1) BUSHING FRONT BRAKE CAL!PER INSTALLATION Check the left caliper ~lracket collar, O-rings and busilings for excessive wear or damage, and replace if necessary. Apply paste grease (page 16-131 to the collar and bushing. install it into t~e (2) COL __ PASTE GREASE 17-13 r:::iJ\ HONDA ~ HYDRAULIC BRAKES (1) ANTI-DIVE PISTON Install the anti-dive piston collar into the hole in the piston and secure it with the clip. (2) CLIP (3) COLLAR (1) CALIPER PIVOT BOOT Make sure that the retainer clip is in position on the caliper bracket. ~- Inspect the condition of the caliper pivot boot. Apply silicone grease to the caliper pivot bolt. Assemble the caliper and bracket. (2) RETAINER CLIP Install the caliper assembly over the brake disc so that the disc is positioned between the pads. CAUTION I Be careful not to damage the pads. Right caliper: Tighten the caliper bracket mount bolts and caliper mount bolt. Left caliper: Tighten the caliper bracket mount bolt, anti-dive piston pin bolt and caliper mount bolt. TORQUE: Caliper bracket mount bolt: 30- 40 N'm 13.0-4.0 kg.m, 22-29 ft·lb) Anti-dive piston pin bolt: 10- 15 N·m 11.0-1 .5 kg·m, 7- 9 ft·lb) Caliper mount bolt: 20-25 N·m 12.0-2.5 kg·m, 14-18 ft·lb) 17-14 (3) RIGHT CALIPER VF1000F r::iiJ\ HONDA ~ VF1000F HYDRAULIC BRAKES (11 LEFT CALIPER Connect the brake hose to the caliper with the bolt and two sealing washers. TORQUE: 25-35 N'm (2.5-3.5 kg·m, 18-25 ft·lb) Fill the brake fluid reservoir and bleed the brake system (page 17·4). 111 CALIPER PIVOT BOOT REAR BRAKE CALIPER INSTALLATION Make sure that the retainer clip is in position on the caliper bracket. Inspect the condition of the caliper pivot boot. Apply silicone grease to the caliper pivot bolt. 131 SI LlCONE 111 HOS E BOLT Insert the caliper pivot bolt on the caliper into the pivot boot and pivot the caliper assembly over the brake disc so that the disc is positioned between the ".. 121 BRAKE HOSE '"-'"""'- pads, being careful not to damage the pads. Install and t ighten the caliper mou nt bolt. TORQUE : 20-25 N'm (2.0-2.5 kg-m, 14-18 ft-Ib) Connect the brake hose to the caliper with the bolt and two sealin g washers. TORQUE: 25-35 N'm (2.5-3.5 kg·m, 18- 25 ft·lb) Fill the brake fl uid reservoir and b leed t he rear brake sy stem (page 17·4). , (3) SE A LING WASHERS (4) CA LIPER MOUNT BOLT 17- 15 ~ HYDRAULIC BRAKES REAR MASTER CYLINDER HONDA ~. V F1000F (11 B RAKE RE MOVAL. Drain the rear brake hydraulic system (page 17·31. Remove the brake hose bolt and disconflect the brake hose. Loosen the rear master cylinder mount bolts. Remove the right footpeg bracket. Unhook the rear brake switch spring from the rear brake actuating arm. (11 MASTER SYLINDER HOSE Remove the hose connector screw and disconnect the master cylinder hose. Remove the rear brake actuating arm bolt and the arm. Remove the cotter pin, washer and joint pin, and disconnect the brake actuating arm from the master cylinder push rod. Remove the rear master cylinder from the footpeg bracket. (21 ACTUATING ARM (31 COTTER PIN (11 SNAP RING OISASSEMBL Y I Remove the rubber boot. Remove the snap ring and push rod from the master cylinder body. Remove the master piston, primary cup and spring. It may be necessary to apply a small amount of air pressure to the fluid outlet to remove the master piston and primary cup. Clean all parts with brake fluid. (21 SNAP RING PLIERS 07914-3230001 17-16 ~ HOND.A ~ VF1000F HYDRAULIC BRAKES CYLINDER 1.0. INSPECTION Measure the inside diameter of the master cylinder bore, SERVICE LIMIT: 14.055 mm (0.5533 in) Check for scores, scratches or nicks. PISTON 0.0. INSPECTION Measure the master piston 0.0. SERVICE LIMIT: 13.945 mm (0.5490 in) Check the primary cup and piston cup fur damage. ASSEMBLY CAUTION Keep the master cylinder piston, cylinder and spring as a set; do not substitute individual parts. Assemble the master cylinder. Coat all parts with clean brake fluid . Dip the piston cup in brake fluid before assembly. CAUTION When installing the cups, do not allow the lips to tum inside out and be certain the snap ring is seated firmly in the groove. Install the primary cup and piston. Install the push rod and snap ring. Install the rubber cover. 17-17 ~ HYDRAULIC BRAKES ~. HONDA V F1000F 111 MASTER CYLINDER HOSE INSTALLAT IO N Install the master cylinder to the right footpeg bracket. Connect the rear brake actuating arm to the master cylinder push rod with the joint pin, and secure the joint pin with the washer and a new cotter pin. Install the actuating arm onto the rear brake pedal shaft, aligning the punch marks on the arm and shaft. Tighten the actuating arm bolt. TORQUE: 10-1 5 N·m 11.0- 1.5 kg-m. 7- 11 ft-Ibl Connect the master cylinder hose to the master cylinder with a new a-ring and screw. 121 PUNCH MARKS 111 BRAKE HOSE Hook the rear brake switch spring to the actuating arm. Install the right footpeg bracket. Tighten the bracket bolt. Tighten the rear brake master cylinder mount bolts, Connect the rear brake hose with the fluid bolt and two sealing washers. TORQUE:..25-35 N·m 12.5-3.5 kg-m. 18- 25 ft-Ib) Fill and bleed the rear brake system (page 17-4). 17-18 131 COTTER PIN 121 BRAKE SWITCH SPRING HONDA VF1000F BATTERY /CHARGING SYSTEM 1 8-0 HONDA VF1000F BATTERY/CHARGING SYSTEM (l)I GNITION SWITCH (2 ) BATTERY (4) REGULATOR/RECTI (3) ALTERNATOR (5) BATTERY /CHARGING SYSTEM (6) RED/WHITE ~ . ~ i (12) RED ~ ~ ~ 1>-=- ~ Ol -_ « ;;: o...J ~ ...J >W ~ (7) ALTERNATOR A~ ~ ~ ~ (9 ) GREEN -- 18-0 .. ~, ~ r \ "- ~ r (1 1) VOLTAGE SENSOR IC (10) REGULATOR / RECTIFIER Uj a: (13) w _ fFUSE 30Af- :~ITON ~ SWITCH (15) BL ACK I co HONDA VF1000F BATTERY/CHARGING SYSTEM SERVICE INFORMATION 18-1 TROUBLESHOOTING 18-2 BATTERY 18-3 CHARGING SYSTEM 18-4 SERVICE INFORMATION GENERAL • Battery fluid level should be checked regularly. Fill with distilled water when.necessary. • • Quick charge a battery only in an emergency; slow-charging is preferred. Remove the battery from the motorcycle for charging. If the battery must be charged on the motorcycle, disconnect th e battery cables. Do not smoke or allow f/Ilmes near a charging battery. The gas produced by a battery will explode if f/Ilmes or sparks are brought near. • • All charging system components can be tested on the motorcycle. Alternator removal is in Section 9 . SPEC I FICATIONS Battery Capacity 12V 16AH Specific gravity 1.2B0 /20° C (6SoF) Charg ing rate 1 .6 amperes ma ximum Alternator Capacit y Voltage regulator 5,000 rpm 1,000 rpm 10.2A min. (No load) 25.0A min . (No load) Transistori zed non·adjustable regulator 18-1 HONDA VF1000F BATTERY/CHARGING SYSTEM TROUBLESHOOTING No power - key turned on : 1. Dead battery Low fluid level - Low specific gravity - Charging system failure 2. Disconnected battery cable 3. 4. Main fuse burned out Faulty ignition switch low power - key turned on: 1. Weak battery Low fluid level - Low specific gravity - Charging system failure 2. Loose battery connection Low power - engine running: 1. Battery undercharged - Low flu id level - One or more dead cells 2. Charging system failure 18-2 Intermittent power: 1. Loose battery connection 2. Loose connection or short circuit charging system 3. Loose connection or short circuit starting system 4. Loose connection or short circuit in ignition system 5. Loose connection or short circuit in lighting system Charging system failure: 1. Loose, broken or shorted wire or connection 2. Faulty voltage regulator/rectifier 3. Faulty alternator ~ HON'D.A ~ VF1000F BATTERY/CHARGING SYSTEM BATTERY REMOVAL Remove the battery holder bolt, then swing the holder out of the way. Disconnect the negative cable at the battery, then disco nnect the positive cable. Disconnect the battery br eather hose from the battery. Remove the battery. (3).BATTERY HOLDER TESTING SPECIFIC GRAVITY BATTERY TEMPERATURE VS SPECIFIC GRA VITY 131 1 304 Test each cell with a hydrometer. SPECIFIC GRAVITY : 1.270-1.290 (20° C, 6SoF) 1.270-1.290 Fully charged Below 1.260 Undercharged NOTES The battery must be recharged if the spe· cific gravity is below 1.230. The specific grav ity varies with the temperature as shown in the accompanying table. Replace the battery if sulfation is evident or if the space below the cell plates is filled with sediment. 1 256 125 1 24 c· o· F' 32 ' 5' 41 ' 10' 50' IS' 59' 20' 68' 25' 77" 30' 86' 35' 95' 40' 104 ' ELECTROL YTE TEMPERATURE Specific gfavity c~a nges by 0.007 for every 1Q° C. The battery contains sulfuric acid. A poid contact with skin, eyes, or clothing. Antidote: Flush with ""ter and get prompt medical attention. 18-3 ~HONDA BATTERY/CHARGING SYSTEM ~. VF1000F CHARGING Remove the battery cell caps. Fill the battery cells with distilled water to the upper level line, if necessary. Connect the charger positive (+) cable to the battery positive (+) terminaL Connect the charger negative (-) cable to the battery negative (-) terminal. Charging current: 1,6 amperes max. Charge the battery until specific gravity is 1.2701.290 at 20°C (68°F). Before charging a battery, remove the cap from each cell. Keep flames and sparks away from a charging bauery. Turn power ON/OFF at the charger, not at the battery terminals 10 prevent sparks. Discontinue charging if the electrolyte temperature exceeds 45°C (113°F). (11 C AUT ION (2) PIPING AS SHOWN BELOW (3) BATTERY CAUTION ElBOW Quick'charging should only be done in an emergency; slow-charging is preferred. Route the breather tube as shown on the battery caution label. (4)TUBE CLAMP (5) BATTERY After installing the battery. coat the terminals with BREATHER TUBE clean grease. CHARGING SYSTEM (61 INSERT BREATHER SECURElY. CURRENT TEST THE TUBE BATTERY MB2-670 NOTE Be sure the battery is in good condition before performing this test. rs:J Warm up the engine. Remove the frame left and right side covers and V seat. coupler. Disconnect the headlight. Open the main fuse cover and remove the mainfuse. Connect a voltmeter and ammeter as shown. e Allow engine to idle. Increase engine speed slowly. Charging amperage should be a minimum of 10.2 amperes at 1,000 rpm and should be a minimum of 25.0 amperes at 5,000 rpm. Check the stator (page 18·5) and then the regulator/ rectifier (page 18·5). if the charging specifications are not met. 18-4 (1) MAIN FUSE TERMINALS (21 BATTERY HONDA VF1000F BATTERY/CHARGING SYSTEM 111 REGULATOR /RECTIFIER COUPLER STATOR CONTINUITY TEST Remove the left side cover. Disconnect the alternator and regulator/ rectifier coupler. Check for continuity between the leads, and between the leads and ground. Replace the stator if there is no continuity between the leads, or if there is continuity between the leads and ground. VOLTAGE REGULATOR / RECTI FIER T EST Remove the left side cover. Disconnect the regulator/rectifier couplers. Check for continuity between the leads wi th an ohmmeter. NOTE The test results shown are for a positive ground ohmmeter and the opposite results will be obtained when a negative ground ohm· meter is used. NORMAL DIRECTION: CON TINUITY ~ probe (3) REDIWHITE e probe I YELLOW GREEN II RED/WHITE YELLOW z o z ,- [-~ 0 fU w REV ERSE DIRECTION: NO CONTINUITY ~ I II probe GREE N YELLOW e probe a: 0 ..J ..: YELLOW ::;; a: RED/WHITE z 0 f- - ,~ ~ ~ U w a: o w N [- w > w ; [- '" - ' ~ a: ~~ .n (4)G REEN 18-5 (j)HONDA ~ , VF1 000F BATTERY/CHARGING SYSTEM VOLTAGE REGULATOR PERFORMANCE TEST BLACK Connect a voltmeter across the battery. Check regulator performance with the engine funning . The regulator must divert current to ground when battery voltage reaches 14.0 ..... 15.0 V. -~ .. , ~ ~ F- 1\ 1\ ,r I\. IC -- --~ -'- 18-6 V ~ ~ HONDA VF1000F IGNITION SYSTEM m 19-0 ~H IGNITION SYSTEM ~ , ONDA VF1000F III IGNITION SWITCH 121 ENGINE STOP SWITCH 141 SPARK UNITS 161 PULSE 191 WHITE COUPLER 181 1.3 CYLINDER SPARK UNIT 1111SPARK PLUG r I I I I I '- 1151 PULSE GENERATORS ' - - - . - - - ' (17) RED COUPLER 11612.4 CYLINDER SPARK UNIT 19-0 ID---III ~HONDA ~, VF1000F IGNITION SYSTEM SERVICE INFORMATION 19-1 TROUBLESHOOTING 19-2 IGNITION COIL 19-3 TRANSISTORIZED IGNITION SYSTEM 19-4 IGNITION TIMING 19-5 SERVICE INFORMATION GENERAL • A TRANSISTORIZED IGNITION SYSTEM is used and no adju stments can be made . SPECIFICATIONS < >: U NGK ND Spark plu g Standard X24EPR-U9 DPR8EA-9 < DP8EA-9> For cold cl imate Selow 5°C (41 ° FI X22EPR -U9 DPR7EA-9 < DP7EA-9> Fo r extended high speed drivin g X27EPR -U9 DPR9EA-9 < DP9EA-9> Spark plug gap 0.8- 0.9 mm (0.031-0.035 inl Ignition tim ing A t idle 10 BTDC 0 Full advance 37" BTDC /3,800 rpm 0.3-0.9 mm (0.012-0.035 inl Pulse generator air gap TOOL Special Timing inspection cover 07998 - M840000 19-1 ~ IGNITION SYSTEM TROUBLESHOOTING The ignition system has two sub-systems; one for the No.1 and No.3 cylinders and one for th e No.2 and No .4 cylinders. Determine which sub-system is faulty. then proceed to the detailed tests below. Engine cranks but will not start Engine stop switch OFF No spark at plugs Faulty transistor ized spark unit Faulty pulse generator No spark at plug Eng ine stop switch OFF Poorly connected, broken or shorted wires Between ignition switch and engine stop switch Between spark unit and engine stop switch Between spark un it and ignition coil Between ignition coil and plug Between spark unit and pulse generator F aulty ignition coil Faulty ignition switch Faulty spark unit Faulty pu lse generator Engine starts but runs poorly Ignitio n primary circuit Faulty ignition coil L oose or bare wire Interm ittent short circuit Secondary circuit Faulty plug Faulty high tens ion wire Timing advance incorrect Faulty pulse generator - Faulty spark unit 19-2 ~ , HONDA VF1000F ~ ~. HONDA VF1000F IGNITION SYSTEM IGNITION COIL Remove the seat and fuel tank. CONTINUITY TEST Disconnect the colis primary leads. Measure the primary coil resistance. RESISTANCE: 2.8 n Measure the secondary coil spark plug caps in place. RESISTANCE: 21-28 k resistance with the n 19-3 ~ IGNITION SYSTEM ~ . HONDA V F1000F Remove the high tension wire and measure the secondary coil resistance. RESISTANCE 13.6- 15.5 k!1 TRANSISTORIZED IGNITION SYSTEM PULSE GENERATOR TEST Remove the right side cover. Disconnect the pulse generator coupler and measure the coil resistance. RESISTANCE: Approximately 480!1 Between white/yellow and yellow leads 11 , 3 cy· linders) Between white/ blue and blue leads 12,4 cy· linders) (1) 1-3CYLINDER PULSE GENERATOR (2)2-4 CYLINDER PULSE GENERATOR PULSE GENERATOR REPLACEMENT Remove the clutch cover Ipage 7·10) . Remove the pulse generator mounting bolts, and pulse generators . Install new pulse generators. Measure the air gap between the pulse generator and rotor. AIR GAP: 0.3-0.9 mm 10.012-0.035 in) Install the clutch cover Ipage 7·221. Recheck the ignition timing (page 19-51. (3)FEE LER GAUGE 19-4 ~HONDA ~, VF1000F IGNITION SYSTEM SPARK UNIT If the pulse generators, ignition coils, and wiring are good, and the ignition timing is not in specification; replace the spark units with new ones and recheck the ignition timing. Remove the rear cowl by removing the four bolts. 111 REAR COWL 111 SPARK UNIT Replace the spark units with new one. Install the rear cowl in the reverse order of removal. 121 SPARK UNIT IGN ITION TIMING Warm up the engine and remove the alternator cover. Alig n t he F mark on the flywheel with the rear crankcase mating surface. (1) FULL A D VANC E MARK i!!) -;:::-~ ~ '-- ~ -= Use a felt pen to mark a dark line and "1-3F " in line with the F mark on the end surface of the flywheel. 19-5 ~ ~ IGNITION SYSTEM Install the timing inspection cover. Connect the timing light to the high tension wire of the No.1 or No . 3 cylinder. Start the engine and check the ignition timing. AT IDLE SPEED: The HON'D.A dark line (1·3F) (1)TIMING INSPECTION COVER 07998 - M840000 should align with the index mark on the timing cover. 1,300- 1,750 rpm: The advance starts. 3,100-3,500 rpm: The advance ends VF1000F (3) "F" MARK and the index mark should be between the full advance marks. Connect the timing light to t he high tension wire of the No.2 or No.4 cylinder and check the igni· tion timing for No.2 and NO.4 cylinders. (4) INDEX MARK (5) AT 3,100-3,500 rpm ~ (6 ) AJ- FULL ADVANC E MARKS NOTE The ignition system is transistorized and cannot be adjusted. If the ignition timing is incorrect, check the spark units and pulse generators. Replace parts as required . After timing inspection, check the engine oil level and add if necessary . 19-6 ~ ~. HONDA VF1000F ELECTRIC STARTER 20-0 ~H ELECTRIC 8T ARTER ~ ONDA . VF1000F (1) (3 ) STARTER RELAY SWITCH (2) ~ ~ _______ STARTER BUTTON (4) STA R MOTOR 15) NEUTRAL SWITCH I ll) STARTER RELAY SWITCH (7) STARTER MOTOR (14) GREEN / RED (15) DIODE f- STARTER BUTTON ~ - -0 10 0 .. "" •• /. ... ,:'&, &",/y • • • , OG $ToUITtR EW.INE STOP UGHlIHG SWITCH C.llrltw ill ..... ,011_•. turf! .. ..c....1 (k\ai.1Cf 00.'1: STeP s.'lTQI C.lltlnr 1\lIiN SIGNAl. SWITCH UGHTlI'IG SWITCH C.llrl... lkloi.... . .m i~ I r~ l ' l . . TI. BATS ~, () -0 () Ol o-K m DltAIIJI S"TC)! C.. tarlnr Ihlai .... '" • ~, Co . " 11 0 fOK IOIH SI'lTCH C..1I<1nr .. 1' .... 1. . . _ . ~ """ , ... u" WIRING DIAGRAM QUE _ot,,, $T.+JITVI ItAGNETlC SWITQ.I l"If~ h"'1Lf fVSI: (M.t.IN) f';W. 1";..;_1 EB amERY ,,"u.rio e IZVIIAH - ST.utTING M01011 DII........ SWITCH III.,. ~I.HT ,II. lilt... .. . r.-~ , , It II£AA TURN 5ICiIW. Tn tilool ...i ..... "rth••• 11 "" ""'- r'i~ ," P Cw) (lIIIf11 ) (I' , " ~ I " ...!.,., I" ) (WI ) STCP. TAIL SEHSOR Dr,"1fw f,.)I" , at,i... L O~ ~ L- IItI.R TUIIN SHiHA1. 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