http://honda.vf1000.com The data contained in this file is for non- commercial 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 \VFIOOO.COII'I http://honda.vf1000.com IMPORTANT SAFETY NOTICE Indicates a strong pouibiliry of severe personal inlury or lost ofllje if instructions are not founwed. cumou: Indicate: a possibility of personal injury or equipment damage if instruction: are not followed. NOTE: Give help'ul information, Dntalied descriptions of standard workshop procedures, safety principles and service operations ere not included, It is important to note that this manual contains some warnings and cautions against some specific service method: which could cause PERSONAL INJURY to service personnal or could dermal I vehicle or render it unsafe. Nelle undermnd that those warnings could not cover all conceivable weys in which service, whether or not recommended by Honda minht be dcna or of the possible hazardous consequences of each conceivable way, nor could Honda investigate III sud'i ways. Anyone using service procedures or tools, whether or not recommended by Honda Inuit ztidy himself thorougth that naigher personal safety nor vehicle safety will be ieopardiud by the service method or tools selected. HONDA VFI 00°F HOW Tl] USE THIS MANUAL This shop manual describes the technical features and servicing procedures for the VF‘lOOOF Throughout the manual, the following abbreviations are used to identify individual modules. CODE AREAlTYPEl ED Europe E V V u.l<. ‘ .L;. ’: G Germanv U iAustTallai 7 7 7 ‘ SA South Africa 7 7 ‘ ND Northern Europe 7 W, SN 7 Switzerland iAR— 7;” AusItAla‘W 7’ ~ Follow the Maintenance Schedule (Section 3) re- oommendations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections] through 3 apply to the whole motorcycle, while sections 4 through 21 describe parts of the motorcycle, grouped according to location. Find the section you want on this page] then turn to the table of contents on 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. If you don't know the source of the trouble, go to section 23, TROUBLESHOOTING, ALL INFORMATION, ILLUSTRATIONS, DlREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUELICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE ‘ TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NO- TICE AND WITHOUT INCURRING ANY OBLI- GATION WHATEVER. No PART OF THIS PUBLICATION MAY BE RE~ PRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE GENERAL INFORMATION LUBRICATION n MAINTENANCE J ENGINE i FUEL SYSTEM 7 T ENGINE REMOVAL/INSTALLATION iCOOLING SYSTEM —C|1JTCH SYSTTENIT igr‘n *figmma‘ 4—wn- ALTERNATOR V —_CRANKCASE W 7 PISTON/CRANKSHAFT 7 4 TRANSMISSION CHASSIS l ELECTRICAL FAIRING m TEORNTVWHIEE‘KETTKNTVe REAR WHEEL/SUSPENSIBAT HYDRAULIC BRAKES I‘l BATTERyicHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER >iswnc+ms WV—Viil WIRING DIAGRAM TROUBLESHOOTING !i()IhIIJJL VFIOOOF é GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES TOOLS CABLE & HARNESS ROUTING 1 GENERAL INFORMATION 1—1 171 1—2 1—3 1—5 1—7 1—9 GENERAL SAFETY (IZEEME If (he Higin mm! [m run/mtg m :10 write wurk. make sure lllt‘ arm n wellq'mIl/ull'll \m'Pr mll Ilu’ engine in a t'llnet/ area. lllt‘ nlluull (‘lNIlu/IH [ml'mlulln rurhml mmmxlllr gas. IZZEEH! Gum/luv LI (Urn/rely flammuhlr and l,\ l‘,\'/)llul'l'l' urn/er n-uum r-mnmmm. Du Im! ,wmlu‘ wallow 11mm or warm in mm war/(mg urea. SERVICE RULES I'llr Imam Ammo-w ('mllul'm Atlljllrl't' uml, I'm/m rum firm, Vklll IIIIII rllrrlll‘llg, Ill mw nft'mzmrl, flmh Illumughly Wll/I walrr and call u l/IIl'llU l'] rlet'lrllllvlr gel) in yllur 41y“. alumna llw I'm/wry xl‘numm hydrogen gas which um be highly m’plnsll'ln [)0 Nu] mmkl‘ ur allow [11mm ur spark» near the [ml/My. l‘.\[7l’l'lulll‘ wlll'lv l'lmrglllg ll I. Use genulne HONDA or HONDA-recommended parts and lubrlcanls or thelr equlvalem. Parts that do not meel HONDA'S design specrflcatlons may damage the motorcycle. 2. Use the speClal tools dESlgl’led fur (hls product. 3. Use only metric tools when servicing this motorcycle. MEUIE bolts, nuts, and screws are not Interchangeable with English fasteners The use 01 lncorrect tools and fasteners may damage the motorcycle. 4. Install new gaskets, O (lngs. cotter DlnS, lack plates, etc. when reassemblmg. 5. When tightenmg bolts or nuts, begun wnh larger-diameter or lnner bolts hrst, and trghten to the speclfied torque dlagonally, unless a particular sequence is specriled 6. Clean parts lI’I cleamng solvent upon dlsassembly. Lubricate any slldlng surlaces belure reassembly. 7 After reassembly, check all parts lor proper lnslallanon and operatlon. 1-1 é HONDA. GENERAL INFORMATION VFI OOOF SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS OveralI lengm 2210 mm187,01nl 21 so mm 1850 in) SA 2270 min 159.3 in) sw, so, Fl Overall width 765 mm 130 0 in] Ovevall )rergnl 1.240 mm 140.5 in) thSIbsSa 1.505 mm I59.3 IHI Seat heiehr 820 mm 1323 in) Gmund clearance 135 mm 15 3 In) Dry weienr 233 kg 1514111) euro weigh: 255 kg 1570115) FRAME Type Double cradIe reerangler pipe From suspension. navel Telescopic (01k 155 mm 16.1 in) Rear suspension, IraveI Swingarm/Shock absorhver, 120 mm 14.7 in) From suspension air pressure 0e. 40 We (0—0.4 kglcm‘, 0—5 psri Rear suspension air pressure 07300 We 107 3.0 kg/cm', 0743 psrl Front rire size 120/aov1 671/250 Rear lire size 140/90v17—v250 D _ I From 250 sz12.50 kg/cm‘. as psi) Cale we "W m” Rear 290 kPa 12 so kg/cm‘, 41 psi) pressures pm, and From 250 kPa 12.50 kglcm’, 30 psi) one Passenger Rear :90 kPa 12.90 kglomi. 41 psi) From brake, lining swapr area DoubIe disc 904 cm‘ 1140 so in) Rear brake, Iining swept area Single disc 452 cm‘ (70 sq In) Fuel capacin 23 litevs 15 1 us gal, 5.0 Imp gaI) Fuel reserve capacilv 3.5 Iiiers10.9 us gal, 0.5 Imp pan CasIeI angle 28° Trsrl 98 mm 13.9 in) Fvom Iork oil capecin Right: 3150 :m’ 112.9 us oz. 134 lrnp 01), LeIr: 400 cm’113,5 us oz. 141 Irnp oz) ENGINE Type wisIer cooled ¢~stwke, DOHC englne CyIindeI arrangemem 4 cylinders 90°v Bore and mm 77 x 53.5 mm 13.03 x 2.11 in) Displacement 953 cm’I50.5 ou in) Compression ratio 10.5 1 Valve nain Silem, multI-Ilnk chaln dIlve end DOHC wrm woke! arms Maximum horsepower lDlNl as kw 1116 psI/I0.000 mm“ IDIN) 74 kw 1100 psi/10.000 in" : G, SD, AR (DIN) as kw 192 psl/7.5oo min sw Maximum Iproue as N-m 19.0 kg-mll7.500 mm" 79 N-m 15.5 kp-mli7.500 mm" : G, 90, AR as Nrm 19.0 kgsmll7.000 rrrin-I . sw oil cauaeily 3.5 liters 13.7 US qr, 3.1 Imp on aim disassemblv 2.9 lirers (31 us or, 2.5 Imp mi sner draining Coolsni capacily 3 lirers 13.2 us ei, 1.5 Imp qll Lubrication system Forced pressure and wax sump Air IIlualion Pepe) Iiner CyIIndaI complasslun 1300 s 200 kPa 113 z 2 kglcm’, 155 e 25 psi) Intake valve Opens 10° (3100) Closes 40° 14901:) . Exhaust valve Opens 40“ 19900) 3‘ I ’“m "" Closes 10“ (ATDC) Valve clearance ICoId) 0.12 mm (0.005 in] é HONDA VF'I 00°F GENERAL INFORMATION I :G a eSW ITEM SPECIFICATION ENGINE Enginu weight (Dry) 92.5 kg (203.92 loI Idle speed moo : loo rpm Cylinder numbering . —Lalt realt —Leh "out inlflhl tear -nght lront CARBURETION type/throttle oera KEIHIN VD136 mm 11.44 in] ldantrlication numbar VDBZA was» t rvoazs Film screw initial setting 2412 Turn counterclockwise Float level 75 mm (0.30 inl DRIVE TRAIN Clutch Wet, nulti»plale Tlansmlssion 5-speed with over drive Primary reduction l.971 Final reductian 2.529 Gear ratio I 2.733 Gear ratio ll 1.894 Gear ratio lll 1.500 Gear ratio lv 1.240 Gear ratio v 1.027 Gear sl'llft pattern Lult 100! operated Tatum system. 1 —N—~2—37 A—S ELECTRICAL Ignition Full transistm ignition Ignitinn timing “F mavk 10" BTDC at idle Full advance 37° BTDC at 3,800 rpm Starting system Starting motor Alternator 350w15,000 rprn Battery capacity 12V—16AH . Spark plug < “J NGK ND Standard DPREEA»9 X24EPR-US fgglgsjdsfit'flflfi) DPR7EA79 XZZEPR-US :fghsgég'a‘fv‘i’ding DPRsEA-s x27EPR-u9 Spark plug gap 0.8—0.9 mm (0.031~0.035inl Filing order 1444 Fuse/Main full 10A, ISA/30A LIGHTS Headlight thigh/low beam] 60/55 w Tail/stoplight 5/2l w Flam turn signal/lunnmg light 21 w Rear turn signal 21 w lnatrumant lights 3 a w x 2 Neutral indicator 3 w Turn rignal indicator 3 w High beam indicator 3 w 4 w Position light HONDA. GENERAL INFORMATION VF'I OOOF TDRUUE VALUES ENG IN E Item O’ty Thread Dia. (mm) Torque N-m (kgrm, Vt-lbl Remarks Cylinder head cover 8 6 8—1210.8—1.2,6—91 Cam holder 16 6 10e14 (1.0-114, 7—10) Cylinder head 3 8 21—25 (2.1—2.5, 15—13) 16 9 43*4714,3~4t7, 31734) Alternator 1 12 85710518157101617761 Primary drivegear 1 12 8571051857105617761 Clutch lock nut 1 22 80#9018.0—9.0, 587651 crankcase 14 9 38742 (3.8 -4. , 277301 2 8 21—25 110715147181 15 6 10—14 11.0—14.7—101 Rocker arm shaft 8 22 4540 14.57 o, 3246) 2931‘: (fig? 271 Cam sorocket 3 7 18—20 (1.8—2.0, 13—14) Starter clutch 3 8 26—30 [2.6730, 19*22) Shift fork center 1 16‘20 (1.6—2.0, 12—14) Cam chain guide bolt 1 12 21v25 (2.1—2.5l 15—18] Oil filter 1 20 15720 (1.57 ,0, 11~14l Countershaft beefing holder 3 8 21—25 (2.0—2.5, 14718) Drive sprocket 1 10 50—54 (5,075.4,367391 Valve adjustment nuts 16 7 21725 [2.1— 5, 15718) Drain plug 1 12 35740 13574.0, 25429) Connectlng rod nuts 8 8 30—34 (3.0~3 4, 22—25) Drum stopper pivot shalt 1 6 8712 (0.84 ,2, 6—91 Apply 3,50,“, Sealant, Oil pressure switch 1 — 10—14110—114, 7710) -|: or 1ts equivalent, to the Spark plugs 4 12 12—16 11.2—16.9—12l “"95” CHASSIS Item O’ty Thread Dia. (mm) Torque N-m (kg-m, ft-lbl Remarks Steering stem nut 1 24 90—120 19.0—12.0,65—87) Steering bearmg adjustment nut 1 26 23—27 (2.3—2.7, 17—20) Top bridge pinch bolt 1 8 20—30 (2.04310, 14—221 Front axle holder 4 8 18—25 (1.8725, 13718) Front axle nut 1 14 55—65 (55—65, 40—47) Front fork top pinch bolts 2 7 20—30 (20—30, 14722) Front fork bottom pinch bn|ts 2 10 45755 (4575.5, 33740) 1-4 HONDA GENERAL INFORMATION Item O’ty Thread Dialmm) Torque N~rn (kg-m, ft-lbl Remarks Brake caliper bracket mount bolts (Right) 2 10 30—40 (3.0—4.0, 22—291 (Left-upper) l 10 30—40 (CLO—4.0, 22-291 } Front brake calipers Anti-dive piston pin bolt 1 6 10—15(1.041.5,7—11) Brake caliper mount bolts 3 a 204512.045, 14—18) A Front and rear Brake caliner pivot bolts :4 12 25—30 (Zia—3.0, 13-22) brake calipers Front brake discs 12 8 35—40 (3.5—4.0, 25—29) Shock arm to frame bolts 2 10 40—50 (4.0—50, 29—36) Shock link to shock arm bolt 1 10 40—50 (4.0—5.0, 29A36) Shook absorber mount bolts 2 10 40—50 (4.0—5.0, 29—36) Swing arm pinch bolt 1 8 20730 (2.0—3 0, 14—221) Swing arm left pivot bolt 1 25 85-105 (ES—10.5, 61—76) Swing arm right pivot bolt 1 16 85—105[3.5~10t5,61—761 Rear brake torque rod 8 mm 1 B 18—25 (1.8725, 13—181 10 mm 1 10 30—40 (30—40, 22—29] Final driven sprocket 5 12 80—100 (ELI—10.0, 58—721 Flour brake disc 6 8 35740 (35—413, 25—29) Rear axle nut 1 18 85—105 18.5—10.5] 61-761 Sub-frame bolts (upper Apply oil to lower and lower) 4 10 35745 (3.5-4 5 25—33) bolts Handlebar pinch bolts 2 8 30—40 (10—40, 22-29) FEET brake Pedal 1 8 30740 (3.07413, 22729) Side stand 1 10 35—45 (B‘s—4.51543) Engine rear hanger bolts (upper) 1 10 60—70 [6.0—7,0, 44450] (lower) 1 10 35—45 (3.5 —4.5, 25733) Engine center hanger bolts 6 B 24—30 [24—313, 17—221 Engine front hanger bolts 2 10 35—45 (3.5—4.5, 25—331 Gearshift pedal pivot bolt 1 6 35—45 (3.5—4.5, 25v331 Torque specifications listed above are for important lastencrs‘ Others should be tightened to standard torque valves listed below. STANDARD TORQUE V ALUES Torque Values Torque Values 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 18—25 (1.5— 5.13718) 30—40 [SD—4.0, 22—291 50—60 (5.0—60, 36—43) "9'" N-rn (kg-m, ft-Ibl "em N-m (kg-m, tt-lb) 5 mm bolt and nut 476 (0.0-0.6, 3—4) 5 mm screw 3—5 (0.3—0.5, 2—4) 6 mm bolt and nut 8—12i0t8—1.2,6—9) 6 mm screw 7711 (OJ—11578) 6 mm flange bolt and nut 8 mm flange bolt and nut 10 mm llange bolt and nut 10714 (1071.4, 7—10) 24—30 (2.4—3.0, 17—221 35—45 (3.5—4.5, 25—33) HONDA GENERAL INFORMATION TIJIlLS SPECIAL TOOL NAME TOOL NUMBER APPLICATION REF. SECTION Primary gear holder 07924-ME90000 Primary gear 7 4ch Vacuum tester set 07404-0030100 Vacuum 3 Oil pressure gauge attachment 075104220100 Oil pressure 2 Compression gauge attachment 0751 OvMBOO101 Compression 3 Pilot screw wrench 079084220201 Carburetor 4 Tappet lock wrench 07908—MBOO100 Tappet lock nut 3 Snap ring pliers 07914-323000l Master cylinder 1'] Steering stem socket 07916-3710100 Steering stem 15 Lock nu! wrench 079164220000 Clutch 7 Hollow set wrench 6 mm 07917-3230000 Front lork 15 Needle bearing remover 07931-MA70000 Swing arm 16 Bearing race remover 07946-3710500 Lower ball race 15 Steering stem driver 07946-M800000 Steering stem 15 Slider weight 07547-KA50000 Front fork seal 15 Seal driver attachment 079477KF00100 Front fork seal 15 Ball race remcrver ’ 0795374250002 Steering ball race 15 Oil seal driver attachment 07965~MBOO100 Rear shock absorber 16 Oil seal driver 07965-MC70100 Driver ring attachment 07965-ME70100 Oil seal driver attachment 07965-MA60100 Valve guide reamar 07954-2000000 Valve guide 10 Fly wheel cover 07993-MB40000 Timing cover 3 COMMON TOOL TOOL NAME TOOL NUMBER APPLICATION REF. SECTION Float level gauge 07401-0010000 Carburetor 4 Lock nut wrench 30 x 32 mm 07716-0020400 Steering lock nut 15 Extension bar 077160020500 :— Flywheel holder 07725-004000!) Fly wheel 9 Rotor puller 07733-0020100 j Valve guide remover 5,5 mm 07742-0010100 :— Valve guide 10 Valve guide driver 07743-002000!) Attachment 37 x 40 mm 07746-0010200 :- Swing arm 16 Pilot 1 7 mm 07746—0040400 Pilot 20 mm 07746-0040500 Swing arm 16 Attachment 32 x 35 mm 07746-0010100 _|E Rear wheel 16 Attachment 52 x 55 mm 0774643010400 Counter shaft 13 Attachment 42 x 47 mm 07745-0010300 l Pilot 15 mm 07746-0040300 Front wheel 15 Pilot 25 mm 0774670040600 :— Rear wheel 16 Attachment 62 x 68 mm 07746-0010500 Driver A 077490010000 Driver C 07746-0030100 :— Main shaft 13 Inner driver 30 mm 077450030300 HON DA GENERAL INFORMATION 7 7 W TOOL NAME TOOL NUMBER APPLICATION 7 REF. SECTION Bearing remover shaft 07745-0050100 From wheel 15 Bearing remover head 15 mm 077460050400 Rear wheel 16 Beanng remover head 20 mm 0774643050600 Valve spring compressor 07757-0010000 Valve 10 OPTIONAL TOOL TOOL NAME TOOL NUMBER APPEEAIION REE SECTION Compression gauge 07305-0010000 Campression 3 Oil pressure gauge 07506-3000000 Oil pressure 3 Seal cutter 29 mm 45°[EX) 07780—0010300 Valve seat 10 Seat Cuner 33 mm 45°HN) 07750-0010800 Valve seal 10 Flat cutter 30 mm 32°(IN, EX) 07780-001220!) Valve seal 10 Interior Cutler 30 mm 80°(IN, EX) 0773043014000 Valve sea! 10 Cutter holder 55 mm 07781-0010101 Valve seal 10 1-7 GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses. 0 A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure it is secure. 0 Do not squeeze wires against the weld or end of its clamp when a weldon clamp is used. 0 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. 0 Route harnesses so they are neither pulled tight nor have excessive slack. 0 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. 0 Do not use a wire or harness with a broken insulator. Repair by wrapping them with pro» teetive tape or replace them. 0 Route wire harnesses to avoid sharp edges or corners. 0 Also avoid the projected ends of bolts and screws. 0 Keep wire harnesses away from theexhaust pipes and other parts that get hot I Be sure grommets are seated in their grooves properly. I After clamping] check each harness to be certain that it is not interferring with any moving or sliding parts. I After routing, check that the wire harnesses are not twisted or kinked. I 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. ‘9 HONDA VF'I OOOF We 0 X k..@_ OXX HONDA V" 00°F GENERAL INFORMATION (1) CHOKE CABLE (3) RADIATOR OVERFLOW TUBE (5) SPEEDOM ETE Fl CAB LE (6) TH ROTTLE CABLES 1-9 HONDA GENERAL INFORMATION VF'I 00°F 11) FRONT (2) CLUTCH B RAKE Hose (3) TH ROTTLE CAB LES (4) RADIATOR OVERFLOW TUBE (1] BRAKE/TAILLIGHT SENCOR (2) SPARK UNIT 1-10 GENERAL INFORMATION (I) IGNITION COILS (2) COOLANT (3) FUEL PUMP RESERVE RELAY REGULATOR] RECTIFIER (6) ALTERNATOR WIRE ‘7’ CLUTCH HOSE [1) STARTER RELAY/ (3| IGNITION MAIN FUSE [2) GROUND COIL \‘ OILPRESSURE ‘ Q‘swrrcn ‘\\\ / (9] " PULSE V GENERATOR / WIRE (a) ‘ , REAR BRAKE W I I HOSE (51 CODLANT -,,. ‘ -_ RESERVE ' ;_ TANK <6) aATTERv BREATHER BREATHEB / TUBE / / TUBE (71 STARTER MOTOR CABLE 1-11 HONDA. VF 'IOOOF LUBRICATIUN 2-0 HONDA VF'I 00°F (1} FRONT CYLINDER EX. CAMSHAFT (2] FRONT CYLINDER IN‘ CAMSHAFT "'*1 18) OIL PUMP (6) OIL FILTER (7) OIL STRAINER (3) (TO REAR CYLINDER) (5] SHIFT FORK SHAFT L (4) OIL ORIFICE (10! MAINSHAFT (9) COUNTERSHAFT LUBRICATION HON DA LUBRICATION VFI OOOF SERVICE INFORMATION 2—1 OIL PRESSURE CHECK 2—6 TROUBLESHOOTING 2—2 OIL PUMP 2—7 ENGINE OIL LEVEL 2—3 CONTROL CABLE LUBRICATION 2—11 ENGIE OIL & FILTER CHANGE 2—3 LUBRICATION POINTS 2—12 OIL STRAINER/PRESSURE RELIEF VALVE 2—4 SPECIFICATIONS Engine oil Oil capacity 2.9 liter (3.1 US qt, 2.5 Imp qt) after draining 3.5 liter (3.7 US at, 3.1 Imp an after disassemny W Oil recommendation OIL VISCOSITIES Use HONDA 4~STROKE OIL or equivalent. . API SERVICE CLASSIFICATION: SE or SF. VISCOSITY: SAE row—40 Other VlSCOSItIeS shown in the Chan may be used when the average temperature in your riding area is withln lhe indicaxed range. 0“ “I‘m” . 540 z 70 kPa (5.4 t 0.7 kg/cm’, 77 1 10 psi) at 5,000 min" (rme (EOUC/176°Fl (ll ml pressure svmchl Oil pump delivery 56.3 liler (59,6 US at, 49.6 Imp all/min. a! 5.600 min" (rpm) Oil pump service data STANDARD SERVICE LIMIT Romr (in clearance 0.15 mm (0.006 in) 0.20 mm (0.008 in) Pump body clearance 0.15—0.22 mm [0.006—0.009 in) 0.35 mm (0.014 in) Pump and clearance 0.02—0.07 mm [0001—0003 in) 0.10 mm (0.004 in) HONDA VF'I OOOF TORQUE VALUES Engine oil drain plug 35—40 N»m (3.5—4.0 kg-m, 25—29 ft-lb) Engine Oil filter 15—20 N-m (1.5—2.0 kg-m, 11—14ff-lb) Oil pressure switch 10—14 N-rn (1071.4 kgrm, 7—10 h>lbl TOO LS Special Oil pressure gauge 07506—3000000 Oil pressure gauge attachment 0751074220100 TRflllBlESHllllTlllli Oil level two low 1. External oil leaks z. Worn piston rings 3. Worn valve guide or seal Oil contamination 1. Oil or filter not changed often enough 2. Head gasket faulty 3. Worn piston rings Low oil waser 1. Oil level low 2. Pressure relief valve stuck open 3. Plugged oil pick-up screen 4. Oil pump Warn 5. External ail 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 prluure 1. Oil level low 2. Oil pumpdrive chain broken 3. Oil pump faulty 4. Internal oil leakage LUBRICATION LUBRICATION ElllilllE lJIL lEVEL Put the motorcycle on its center stand on level ground. Start the engine and let it idle for 2—3 minutes. Turn oi! the engine. Remove the tiller cap/dipstick, wipe it clean and insert it without screwing it in. Remove the filler cap/dipstick and check the oil level. H the level is below the lower level mark on the dipstick, (III to the upper level mark with recom- mended oil. Check the ml pressure with the oil pressure warn- ing light after the engine starts, The light should go off after one or two seconds. If it does not, stop the engine and check the oil pump output and/or oil circuit. ENEINE UIL & FILTER EHANGE NOTE Change engine oil with the engine warm and the motorcycle on its center stand to assure camplete 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 (07912— 6110001) 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 0er 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 h-lb) Fill the crankcase With 2.9 liters (3.1 US qt, 2.5 Imp nt) of the recommended oil {page 271). Rain stall the oil hller cap/dipstick. Start the engine and let it idle for 23 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. Install the lower cowl. 2-3 l2) UPPER (3) LOWER I f‘ (ll OIL DRAIN PLUG (ll OIL FILTER HON DA VF 'l 000 F OIL STRAINER/PRESSURE RELIEF VALVE NOTE The oi‘ strainer can be removed with the engine mounted in the frame. Remove the lower cowl. Remove the exhaust chamber. Drain the engme oil (page 2—3). Remove the oil pan boils and or! pan. Remove and clean the ui‘ strainer Check the operation of the pressure relief valve. LUBRICATION H) PRESSURE RELIEF VALVE HONDA VF'I OOOF LUBRICATION (“SPRING SEAT (2JPISTON (3) O-RING 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 disr assembly. \ i (“SNAP RING 15) SPRING [6l VALVE BODY (2| OrRlNG lilHELlEF VALVE Make sure that the O-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. l4) LUG l3lGROOVE HONDA VF'I OOOF LUBRICATION Ill OIL PAN GASKET 1 |nst1l| the oil pan with a new gasket. Tighten the ail pan bolts in 23 steps In a criss cross pattern. Install the exhaust pipes. Fill the crankcase wlth Ihe recummended oil (page2-1 I. Install the lower cowl. IIIL PRESSURE CHEEK Warm the engine up to normal operating temper- ature (approximately 80°C/176°F). Stop the englnE 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. III OIL PRESSURE SWITCH ll] OIL PRESSURE GAUGE Start the engine and check the oil pressure at 5pm) 07506—3000000 rpm. OIL PRESSURE: 540 x 70 kPa 15.4 1 0,7 kg/cm‘, 77 :10 psi) at 5,000 min“ (rpm! (80°C/176°F) Stop the engine. Apply SVBONDer sealant or equivalent to the pres- sure switch threads and install. TORQUE: 10A14 N-m (1 .O— 1 .4 kg-m, 7710 il-ib) Connect the oil pressure switch wire. Start the engine. Operate the warning indicator switch. Check that the oil pressure Warnlng indicator goes nut after one or two seconds. If the oil pressure warning Indicator stays on, stop the engine immediately and determine the cause. ‘ I‘ / (2i OIL PRESSURE GAUGE ATTACHMENT 07510—4220100 LUBRICATION ll". PUMP REMOVAL NOTE The oil pump can be removed with the engine mounted in the frame. Drain the engine oili Remove the right crankcase cover. Remove the oil pump driven sprocket by remaving the bolt and washer. Remove the oii strainer (page 2-4) and the oil pass pipe, Make sure the O-rings are in good condition. Remove the oii pump by removing the mounting bolts. Straighten and remove the cotter pin holding the oil strainer tube‘ Remove the oil strainer tube. Remove the oil pump body cover. (2)O|L PUMP BODY COVER HON DA VF'I 00°F 1 ) OIL PUMP DRIVEN SPROCKET (1i OIL PASS PIPE (2) O-RINGS l3) OIL PUMP (1] OIL STRAINER TUBE (3) COTTER PIN 2-7 HONDA VF'I OOOF LUBRICATION IIIDOWEL PIN Remove ‘he dowel pin, Measure the rotor tip clearance. STANDARD: 0.15 mm (0.006 in) SERVICE LIMIT: 0.20 mm 10.003 in) Measure ‘he pump body clearance. STANDARD: 0.15—0‘22 mm ((1006—0309 in) SERVICE LIMIT: 0.35 mm (0.014 in) LUBRICATION HONDA VF'I OOOF Remove the rotor shaft and measure the pump end clearancel STANDARD: 0.02—0.07 mm (0301—0003 in) SERVICE LIMIT: 0.10 mm (0.004 in) ASSEMBLY Install the outer rotor into the body and Insert the rotor shaft. Install the washer. Insert the time pin into the rotor shaft‘ Atign the sIots In the Inner rotor with the drive pin. InstaH the dowel pin and owl pump body cover. Make sure the oil strainer tube O-n'ngs are in good candltian, 11) OUTER ROTOR I4) DRIVE PIN (I) DOWEL PIN \. l3) OIL PUMP BODV COVER (ZIWASHER IBIROTOR SHAFT 6%. I5 INNER ROTOR 12) OVRINGS (AI OIL STRAINER TUBE 2-9 HONDA VF'I OOOF LUBRICATION Install the oil strainer tube with a new cotter pin. l1) COTTER PIN lllORIFICE INSTALLATION Install the orifice, O-ring and dowel pin, IZlDOWELPlNS lSlO-RING (llOlL PASS PIPE l2) BOLTS Install the oil Pump and tighten the three bolls. V ‘H NOTE Make sure that the oil pump shalt rotates freely after tightenlng the bolts. Make sure (he Orrlngs on the oil pass pipe are in good condition and install the all pass pipe. Install the oil strainer and oil pan (page 25), l3) OIL PUMP 2-10 HONDA VF'I OOOF LUBMCAHON Place the oil pump driven sprocket into the drive chain. NOTE The "IN" mark on the driven sprocket should face the crankcase. (1) "IN" MARK (1i DRIVEN SFROCKET (2) DRIVE CHAIN Install the washer and tighten the bolt, l 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“. (3] WASHER EIJNTRDL CABLE LUBRICATIIJN Periodically, disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially avail- able cable lubricant or 3 light weight oil. 2-11 HONDA VF'I OOOF LUBRICATION LUBRIEATIIIII PflINTS WW I SHOCK ABSORBER UPPER MOUNT BUSHING (Page 15-11) C SUSPENSION LINKAGE NEEDLE BEARINGS (page IE-IZI I III a or CABLE LUERjIcANT - II THROTTLE AND IEI i I CHOKE CABLE 7% m REAR SHOCK / / CLUTCH AND BRAKE ABSPRBER I LEVER PIVOTS In» E I [I . BRAKE I I I {3) PEDAL PIVOT ’6“ l I 1/ THROTTLE GRIP 7% (m or CABLE LUBRICANT , l SPEEDOMETER I L I CABLE \ (4, l [I (12) ,fi \ v—fifl , FOOT PEG \ (7I STEERING | I I | SWING ARM ' I / PIVOT | 1 HEAD I / WHEEL/ BEARINGS (When replaced] GEARSHAFT Mew-fin PEDAL PIVOT 'fi FOOT PEG WHEEL I8I SPEEDOMETER “35-611 PIVOT BEARINGS DRIVE GEAR SIDE AND (When repIaCedl CENTER I9I FRONT FORK STAND r14I :% PIVOTS DRIVE CHAIN IGEAR OIL SAE #80»90I 2-12 3 HONDA. MAINTENANCE vnoooF SERVICE INFORMATION 3—1 CYLINDER COMPRESSION 3—13 MAINTENANCE SCHEDULES 3—3 DRIVE CHAIN 3—14 FUEL LINES 3—4 BATTERY 3—15 FUEL FILTER 3—4 BRAKE FLUID 3—16 THROTTLE OPERATION 3—5 BRAKE SHOE/PAD WEAR 3—16 CARBURETOR CHOKE 3—6 BRAKE SYSTEM 3—16 AIR CLEANER 3—6 BRAKE LIGHT SWITCH 3—17 CRANKCASE BREATHER 3—7 HEADLIGHT AIM 3—17 SPARK PLUGS 3—7 CLUTCH 3—17 VALVE CLEARANCE 3—8 SIDE STAND 3—18 CARBURETOR SYNCHRONIZATION 3* 11 SUSPENSION 3— 18 CARBURETOR IDLE SPEED 3*12 NUTS, BOLTS, FASTENERS 3—20 RADIATOR COOLANT 3—12 WHEELS 3—20 RADIATOR CORE 3—13 STEERING HEAD BEARINGS 3—20 COOLING SYSTEM HOSES 81 CONNECTIONS 3—13 SERVICE INFUIIMIITIIJN‘ GENERAL 0 EngInEOII See 93992-3 I Engan ouI finer See page 23 SPECIFICATIONS < Engine > Spark plugs: Standard For cold climate [below 5°C, 41°F) For exxended hlgh speed rxdmg NGK ND NGK ND NGK ND DPRBEA-Q X24EPR-U9 DPR7EA-Q XZ’ZEPRUQ DPR9EA-9 X27EPR-U9 : U Spark pIug 939’ 0370.9 mm [003170035 In) HONDA. VF'I OOOF Valve clearance Cold (Below 35"c, 95°F): Idle speed: Carburetor synchronization: Cylinder compression: Throttle grip free play: < CHASSIS > Drive chain slack: Tire: Intake/Exhaust: 012 mm (0.005 in) 1,000i 100 min" (rpm) All carburetors within 60 mm (2.4 in] Hg 1,300 i 200 kPa (13.0 t 2,0 kg/cm2,135 t 28 psi) 2—6 mm [1/5—1/4ini 15—25 mm (5/8—1 in) MAlNTENANCE Tire size From Rear l20/80V157V250 140/80V177V250 Driver only 25012.50, 36) 290 [2.90, 42) Cold tire pressure, kpa (kg/sz, psi) Driver and one passenger 250 (2,50. 36) 290 (190, 42) Bridgeslane (5511 (3520 Tire brand Dunlnu K500 K500 Suspension air pressure: From, 0 40 kPa (0—0 4 kg/cm‘, 0 —6 psi) Rear, 07300 kPa (0—3.0 kg/cml, 0—43 psil TOOLS Spatial Vacuum gauge Carburetor pilot screw wrench Valve adjusting wrench Compression gauge attachment Common Valve adjsuting wrench 07404—0020000 079084220201 07mS—M 800100 07510—Ml300101 07708—0030300 HONDA MAINTENANCE v“ 00°F MAINTENANCE SCHEDULES Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE WHICHEVER ODOMETER READING [NOTE 3) FREQUENCY COMES \ F'RSTJ 5‘ 3-5: fig 32? $§ $5 $5 _ I?“ 3:8 3i? Ii? «i? $6.? fine.“ ITEM EVERY "s “’k“ ‘3" '93“ vi? "K '83 page ' FUEL LINES I I I 3-4 ' FUEL FILTER R 3.4 ' THROTTLE OPERATION I I I I 3.5 ' CARSURETOR-CHOKE I I I 3-6 ' AIR CLEANER NOTE 1 R R R 3-6 CRANKCASE BREAHTER NOTE 2 c c c C c I: 3-7 SPARK PLUGS I R I R I R 3-7 ‘ 7 VALVE CLEARANCE I I I I 3-3 ENGINE OIL YEAR R R R R 2-3 ENGINE OIL FILTER YEAR R R R R 2-3 ' CARBURETOR-SYNCHRONIZATION I I I I 3-11 ' CARBURETOR-IDLE SPEED I I I I I I I 3-12 _ RADIATOR COOLAWT I I 'R 3-I2 ' RADIATOR CORE I I I 3-13 ' COOLING SYSTEM HOSES B I I I I 3‘13 cONNECTIoNSi I, L EVERY DRIVE CHAIN moo km (600 mi) 314 BATTERY MONTH I I I I I I I 3-15 BRAKE FLUID £221.?“ I I I 'R I I 'R 3-16 _7 BRAKE in WEAR i I I I I I I 3.16 7 BRAKE SYSTEM 7 I I I I 3-16 ' BRAKE LIGHT SWITCH I I I I 3-17 " HEADLIGHT AIMV ‘7 7 I I I I 3-17 CLUTCH FLUID flag: .'R I I I 'R I I 'R 3-17 CLUTCH SYSTEM I I I I 3-17 SIDE STAND #¥ I U I 3-13 I7 fiNSTON 777 7 7 I I I I 3-18 7 7' 7 7 NEEOLTS, FASTENERS I I I I 3-20 " WHEELS I I I I 320 7'7 7STEEEN7GWADTB7EARRS 777 7’ I 1 7 I I 3-20 ‘7 SHOULD BE SERVICED EV AN AUTHOHIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. " IN THE INTEREST OF SAFETY, WE RECOMMEND THAT THESE ITEMS BE SERVICED ONLY BY AN AUTHO- RIZED HONDA DEALER, NOTES: 1. SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS. 2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE. 3. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE, 3-3 HON DA VF 1 00°F FUEL LINES Remove the seat and left side cover. Check the fuel lines and replace any parts which show deterioration, damage or leakage. FIIEL FILTER Gasoline is flammable and is explosive under certain candifians. Do not make or allow flame: or spark: in your wnrking area. Replace the fuel fiiter with a new one when indicatr ed by the maintenance schedule (page 33), Remove the ieft side cover. Remnve the electric panei mounting bolts and remove the caaiant reserve tank. Unclip the fuel filter holder from the bottom of the electric panei. Disconnect the fuel outiet line from the fuei filter Puil the fuel filter out than clip the inlet line closed. Disconnect the fuel lnIEl line. Instail the fuel filter with its arrow pointing outlet side. After installing, turn the fuel valve on and check that there are no fuel leaks 'mFuEL LINES (1 i ELECTRIC PANEL I3] FUEL FILTER MAINTENANCE MAINTENANCE THROTTLE flPEllllTlflN Check that the throttle grip opens smoothly to full throttle and lully closes automatically, in all steer- ing posltions. check the throttle cables and replace them If they are deteriorated, kinked or damaged, Lubllcale the throttle cables (page 2 ll), lf throttle uDEratlon ls not smooth. Measure throttle grip free play at the throttle gnp flange. FREE PLAV: 2—6 mm (1/8—1/4 in) Adjustment can be made at either end of the throttle cable. Mlnor adjustments are made wlth 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 oneratlon. Install the air cleaner case and fuel tank, and check throttle free play once more. Also check for fuel leaks. VF'I OOOF ' 2—6 mm (1/8—1/4 ln) (‘ll LOCK NUT (2) UPPER ADJUSTER (3] LOWER ADJUSTER (4l LOCK NUT 3-5 HONDA VF'I OOOF CARBIJRETDR CHOKE The choke system uses a fuel enrichenlng 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, Lubricate 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 trylng to move the choke lever on the carburetor, after removing the fuel tank and air cleaner case. There should be no free play. Adlust it necessary, by loosening the choke cable clamp on the carburetor and moving the choke cable casmg so the choke level rs tully open Tighten the clamp. Push the choke lever up all the way to fully closedr Make sure the choke valve is lullv closed nv check» mg for free plav In the cable between the lever on the carburetar and came casung. Reinstall the removed parts W the reverse order of disassemblv. Alli CLEANER Hemcve the luel tank. Remove the air cleaner case cover screws and the cover. MAINTENANCE (ll CHOKE LEVER l1lCABLE CLAMP (2) CHOKE CABLE ll) AIR CLEANER CASE COVER HONDA VF'I OOOF MAINTENANCE (ll SPRING CLIP Remove,the spring clip and the air cleaner elements 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 Remove the plug lrum the main tube to empty any deposits l2l AIR CLEANER ELEMENT |n5tali the dram pluq Service more frequenth when rldlng in ram or at lull throttle or ii the deposrt level can be seen in the transparent Section 07 the dram tube SPARK PLUGS RECOMMENDED SPARK PLUGS H < >:u N§K >N_D DPRBEA»B X24EPR-U9 " S‘W‘W’ l” DRAW PLUG For cold Climate DPR7EA»9 X22EPH-U9 (Below 5°C441nF) HlCENTER meende“ DPRQEA'Q X27EPR'U9 ELECTRODE (ZlSIDE ELECTRODE high speed riding Disconnect the spark plug caps. 0.84.9 mm Clean any dirt from around the spark plug bases. -:(0.03iv0.035 inl Remove the spark plug Visually inspect the spark plug. Discard the spark plug if the insulator is cracked pr chipped, Measure the spark plug gap with a wirertvpe feeler gauge. SPARK PLUG GAP: 0.8—0.9 mm [0.031~0.035 in) Adjust by bending the Side electrode carefully With the plug washer attached, thread each spark plug in by hand to prevent crossthreading. Continue tightening by hand until the spark plug bottoms. I Then, tighten the spark plugs another 1/2 turn with a spark plug wrench to compress the plug washer. Connect the spark plug caps. 3-7 ".34. e. , V a.“ HONDA VF'I OOOF MAINTENANCE l‘IIBREATHER TUBES V (ZIIR CLEANER CASE MAINTENANCE NOTE Inspect and adjust valve clearance while the engine is cold. (Below 350C, 95°F) Remove the lower cowl, Drain coolant from engine (page 673). NOTE Drain the coolant into a clean container for reuse Scheduled coolant replacement is every L24,000 miles [33,400 km), (3) Not 1 CYLINDER M) No. 3CYL|NDER [SIIGNITION Remove the seat and remove the left and right side COILS covers. Turn the fuel valve off and remove the fuel tank. Remove the lower radiator (page B-Elr Remove the spark plug caps. l1] FRONT CYLINDER HEAD COVER Disconnect the breather tubes from the rear cylinder head cover and air cleaner case. Remove the air cleaner case (page 473). Remove the ignition coils lpage 1974Il Remove the front and rear cylinder head cover bolts and both cylinder head covers. Remove the alternator cover. [2) Na, 4 CYLINDER l3l No, 2 CYLINDER lllT‘l.3MARK INSPECTION Measure and adjust the intake and exhaust valve clearances as described below. Rotate the crankshaft clockwrse to align the T13 mark with the crankcase mating suriaces. Make sure the Na. 1 piston is at TDC (Top Dead Center) on the compression stroke. I l2) REAR CRANKCASE MATING SURFACE 3-8 MAINTENANCE HONDA VF'I OOOF Check the valve clearances Ior the No, 1 cylmder 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. Loosen the lock nuts and turn the adjusting screws unth there is a shght drag on both feeIEr gauges. Both feeIer gauges shouId remam Inserted during adjustment. Hold the adjusting screws and tighten the Iock nuts. TORQUE: 21—25 N‘m (2.1—25 kgm,15—‘IB ft-lb) CAUTION The lack nu]: will come 101mI ifm)! tightened [0 the correct lurque value. Recheck the MM clearance. (I) FEELEH GAUGE \ HIOILPIPE III VALVE ADJUSTING WRENCH 07908 MBOOIOO HONDA V F1 OOOF Rotate the crankshaft 9t]w counterclockwise to align the Tz.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. ‘l cvlinder. Rotate the crankshaft 270° counterclockwise to align the T1.3 mark With the crankcase mating surr faces and check the valve clearances for the No. 3 cvlinderv Adjust Using the procedures for the No 1 cylinder. Fiotate the crankshaft 90° counterclockwise to align the T24 mark with the crankcase mating surfaces and check the valve clearances for the No. 2 Cy in- der. Adjust using the same procedures as Ior the No. l cylinderr Install the oil pipes with their shoner 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-lh) 6 mm —10—14 N~m (1.0-1.4 kg-m, 7—10 firlbl Install the front cylinder head cover with its in sulatur grooves facing up and tighten the cover bolts. MAINTENANCE H) T2.4 MARK ‘A l2) CRANKCASE MATING SURFACE IllGrnm BOLTS l2l9mm BOLTS l3lOlL PIPE (1) GROOVES (2) FRONT CYLINDER HEAD COVER 3-10 HONDA V F 'l 000 F MAINTENANCE (1) REAR CYLINDER HEAD COVER Install the rear cylinder head cover and tighten the l caver bolts‘ Install the removed parts in the reverse order of removal. Fill the cooling system [page 6-3). l1)N0.ZCYL|NDER l2) N0.1CYL|NDEFl HEAD PORT HEAD PORT CARBURETOR SYNCHRIJNIZATIDN NOTE Synchronize the carburetors with the englne at normal operatlhg temperature, transmission in neutral and motorcycle on the centerstand. Remove lhE plugs from the No. 1, 2, 3 and 4 cylinder head ports and install the vacuum gauge adapters. Connect the vacuum gauges. ll 1 VACUUM GAUGE 0740470020000 Start the engine and adjust the ldle speed, - IDLE SPEED: 1,000 2100 min" (rpm) Check that all carburetors are Wlthln 50 mm 12.4 in] H9 , _,l [2) ADAPTERS 311 HONDA VF'I 00°F MAINTENANCE lZl CARBURETOR PILOT SCREW (1] No.2 ADJUSTING scnew WRENCH 079084220201 Synchronize to specificanon by turning the ad lustlng screws wlth a carburetor pilot screw wrench (07908—4220201]. NOTE The No. 4 carburetor cannot be a Juste It IS the base carburetcrt (3W0 Cl ADJ STlNG (4lNo.1 ADJUSTING SCREW SCREW CARBURETDR IDLE SPEED NOTE r ,fi , W - Inspect and mum idle speed after all othe ‘ engine adjustments are WIthin speclhcatlons. IThe engme must be warm for accurate adjust- ment. Ten minutes at stop-and-go rlding is suflicienL 4 Warm up the engine, shIft to NEUTRAL, and place the motorcycle on its center stand, Turn the throttle stop screw as requlred m obtain the syecifled Idle speed. IDLE SPEED: 1,000 :100 rpm l‘l l THROTTLE STOP SCREW RADIATUR EflflLANT Remove the frame left side cover, Check the coblant level of the reserve tank with the engIne running at normal operatlng temperature. The level shculd be between the "UPPER" and “LOWER” level llnes. If necessarvl remove the reserve tank cap and fill to the “UPPER” level line with a 50/50 mixture of distilled water and anti-freeze. Reinstall the can and frame side cover. [2) “UPPER” MARK lSl "LOWEFl” MARK 3-12 MAINTENANCE RADIATUR CflRE Check the air passages for clogging or damage. Straighten bent fins and coliapsed 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. ClillLINii SYSTEM HUSES & CONNECTIUNS Inspect the hoses for cracks or deterioration, and repiaoe if necessary. Check the tightness of all hose clamps. CYLINDER BflMPRESSiflN 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 2 200 ItPa (13.0 x 2.0 kg/cml, 185 z 28 mil If compression is low, check for the following: 7 Improper valve clearance — Leaky valves Leaking cyiinder head gasket — Worn piston/ring/cylinder It compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and/or the piston crown. 3-13 HONDA VF‘I OOOF (‘Il COMPRESSION GAUGE ATTACHMENT O751U—MB00101 HONDA VF'I 00°F MAINTENANCE DRIVE CHAIN Tum me englne off, place me motorcycle on lts center stand and shift lhe transmission inm neutral. Check slack In me dlive Chain lower Hm midway be» tween the sprockets, SLACK: 15—25 mm (5/8—1 in) CAUTION —. . . i *l IL.\'A‘L’SSII c ('lmln slack, 30 mm (1 m) w more, may damage I/IL’ frame ‘ (II REAR END OF SWINGARM (2I GRADUATED SCALE (3) AXLE NUT Adjusl as follows. Loosen the axle nm. Loosen the adjusting boll lock nuts. Turn both adjusnng bolls an equal number of turns untll the correct drlve chain slack IS obtainedl CAUTION Make sure that Illersimm' ultgnmerl! riarkslorl bath adjusting plates align with the ends of I the swingann. Tighten the adjusting bolt lock nuts. Tighten the rear axle nul. TORQUE: 85—105 N-m (BS—10.5 kg-m, w' . A . A 61—76 fl-Ih) (4)ADJUST|NG BOLT [5) LOCK NUT (6) ADJUSTING PLATE Rechka chain slack and free wheel romion Lubricate me drive chain with SAE 80 or 90 gear °“v (1) RED ZONE (2l REAR END OF SWINGARM Check the chain wear label. II the red zone on aha label align, or is beyond, (he rear end of xha swmg- arm afler the chain has been adjusted, the chain must be replaced. REPLACEMENT CHAIN: D.|.D. 50V or RKSDMO é HONDA MAINTENANCE 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 rocket which is dama ad or excessivel worn. so 9 y (1) DAMAGED l2) WORN NOTE Never install a new drive chain on worn spru- chets or a worn drive chain on new sprockets. Both chain and sprockets must be in good condition or the replacement chain or spro- ckets will wear rapidly. V Lubrication and cleaning: The drive chain on this motorcycle is equipped with i3l NORMAL small O-rings between the link plates The Orings 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 9!] gear oil. Commercial chain lubricants may contain solvents which could damage the rubber O-rlnes. llluPPER LEVEL (2) HOLDER 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 negatlve cable at the battery, then disconnect the positive cable. Disconnect the battery breather hose from the 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. l‘l] POSITIVE TERMINAL (2) FILLER CAPS NOTE an oandiEtlllea water. Tap water will Lshorten the service life of the battery file battery electrolyl: contains sulphuric acid, Protect your eyes, skin. and clathing. If electrolyte gets in yaw eyes, flush [hem thoroughly with water and get prompt medi- cnlarlenn'vn. l3] BREATHEH HOSE l4lNEGATlVE TERMINAL 3-15 HONDA VF1 OOOF BRAKE FLUID Check the front brake fluid reservoir level. If the level nears the lower level mark, fill the re- servoir with DOT 4 BRAKE FLUID m the upper level mark. Check the entire system for leaks, if the level is low, CAUYION [1' Do not remove the cover until [he handle- bar ha been turned so that (he reservairix level ~ Avoid npemtihg (he bmke lever with the rap removed. Brake fluid will squirt out if the lever is pulled. ~ [)0 no! mix different types o/fluid, 0: [hey L are (mt compatible. Refer to section 17 for brake bleedlng procedures, BRAKE PAII WEAR 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 oi the brake disc (page 17-5). CAUTION Always replace the brake pad: in pairs to mime hd ressure. BRAKE SYSTEM Inspect the brake hoses and fittings far datevio- ration, cracks and signs oi leakage. Tighten any loose fittings. Replace hosesand fittings as required. (SIBRAKE DISC MAINTENANCE (“UPPER LEVEL (SI FRONT "v r' (2) LOWER LEVEL (IIUPPEH LEVEL (4, HEAR l2) LOWER LEVEL [1) BRAKE PADS (8i REAR (2) BRAKE PADS l (MARROW IGIBRAKEDISC I5IARROW 3-16 HONDA VF'I OOOF MAINTENANCE BRAKE LIEHI SWITCH l‘llBRAKE LIGHT SWlTCH l2) 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 ii the brake light COMES On [00 late. HEADLIGHT lllM Adjust vertically by turning the vertical adjusting 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 Slde of the rider. NOTE Adjust the headlig local laws and regul beam as specified by on ._—_l An impmperly lilijumd headlight may blind oncoming drivers, in it may fail to light the road far a sife diilerie. if l2) VERTICAL ADJUSTING SCREW CLUTCH ll) 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, ii the level is low. CMJYIOH [)0 nor remove the cover until [he haml- char has been turned so that the reservoir is level. Avoid operating the clutch lever with the cap removed. Fluid will squirt out if ihe lever is pulled. Do not mix different [ypm of fluid. as they are not compatible. 12) LOWER LEVEL MARK 3'17 HONDA. VF‘I OOOF SIDE STAND Check the rubber pad tor deterioratron or wear Replace If any wear extends to wear lme as shcwn Check the srde stand sprmg tar damage and ‘05: of tension, and the sude stand assembly for treedom of movement. Make sure the stde stand ts not bent. ' When replacing, use a rubber pad wlth the mark “Over 2601bs ONLY". Spring tenston is correct it the measure- menls ran within 2‘3 kg (4,476.6 lb), when pulling the side stand lower end with a sprmg scale SUSPENSION Du not ride a vehicle with faulty suspenxr’an. Loose, worn or damaged surpension parts impair vehicle stability and control, FRONT Check the action of the tram forks by compressing them several times. Check the entire fork assembly for leaks or damage. Replace damaged components which cannot be repaired. Tighten aH nuts and bolts. Check the front fork air pressure when the forks are cord. Place the vehicle on its center sland. Remove the air valve cap and measure the air pressure. AIR PRE$URE: 0—40 kPa (0-0.4 kg/cmz, 0—5 psi) MAINTENANCE 1HGOOD (2) NO GOOD {HAIR VALVE MAINTENANCE ANTLDIVE SYSTEM INSPECTION m We Selecl a safe place away fram traffic In perform [his inspern'an. Check the operation of the anli»dive system by riding the momrcycle and firmly applying the brakes. Pofiion Ann-(live Qaimflr rgrce 7 7 1 LIGHT ANTLDIVE 2 MEDIUM 3 HARD L 4 MAXIMUM ANTI-DIVE Inspect and if necessary, repair the system (Refer to section r5r REAR Place the mororcycle on lIS center stand. Move rhe rear wheel sideways wlrh force to see il rhe swinqarm bearings are worn. Replace the bearlngs If rhere ls any looseness [page 1 6-14]. Check the shock absorber for Ieaks or damage. Tlgmen all rear SUSDEHSIOH 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 “’3 (0—3.!) kg/cm’, 0—43 psi) NOTE HONDA. VF‘I 00°F (1| ADJUSTER Check the air pressure when (he shock ab- sorber iscold. l1lAlR VALVE 3-19 HONDA VF'I 00°F NUTS, BllLTS, FASTENERS Check that all Chassls nuts and bolts are tightened ta their correct torque values (Section 1) at the intervals shown in the Maintenance Schedule (Page 3-3]. Check all cotter pins, safety clips, hose clamps and cable stays. WHEELS NOTE Tlre pressure should be checked when ttres are COLD. Check the mes for cuts, Imbedded nails, or other sharp objects. RECOMMENDED TIRES AND PRESSURES: 7 ’ Fran: > héar l20/EOV16 rao/auvne T” “"1 V250 vzso un m 7 ‘ 90 kg Sleek: ‘ (20mm 250 (2.5.36) 290 (19,42) presr fl? , ,i ,7, fi sure ‘ 90 k9 ‘ p5: (200 lbs) kpa‘ load to [kg/cm,“ mm 250125.36] 290 (23,42; p,” canacttv ,i l law Tlm ‘BH'DGE' cart 5510 brand “ONE , 7 , JDUNLOP K500 K500 Check the front and rear wheels for trueness (Sec- tion 15 and 16), Measure the tread depth a! the center of the tires. Replace the mes if the tread depth reaches the followmg limit: urn trend depth: From: 1.5 mm 11/16 in) Rear: 20 mm (3/32 in) STEERING HEAD BEARINGS NOTE Check that the control cables do not inter- fere wrth handlebar rotatron. Raise the from wheel all the ground and check that the handlebar rotates lveelv. If the handlebar moves unevenly, blnds, or has vertical movement, adjust the steering head bearan by turmng the steermg head adjusting nut (page 1533). MAINTENANCE HONDA é vnooor FUEL SYSTEM 4-0 FUEL SYSTEM ; HONDA é VF'IOOOF 4-o HONDA. FUEL SYSTEM V“ 00°F SERVICE INFORMATION 4—1 CARBURETOR ASSEMBLY 4—11 TROUBLESHOOTING 4—2 CARBURETOR INSTALLATION 4—14 CARBURETOR REMOVAL 4—3 PILOT sanw ADJUSTMENT 4-15 VACUUM CHAMBER 4.4 FUEL TANK 4—16 FLOAT CHAMBER 4—6 AIR CLEANER 4—17 PILOT sanw 4—8 FUEL PUMP 4-13 CARBURETOR SEPARATION 4—9 SERVICE INFIJRMATIUN GENERAL Catalina ix exiremely flammuhle and u explnsivr under certain Candi-IIIIIIIL Work in a well ventilated area, [10 run smoke I)! allu w flames m xparks in the work area. The front cylinders use down draft carburetors. When dIsassemblIng fuel system pans, note the locations of the O-rings. Replaoe them with new ones on reassembly. The float bowls have dram screws that can be loosened to drain residual gasoline, Fuel pump Inspection is In sectIOn 20. The N17. 1 and NO. 3 carburetors use different iet needles (thinner) and shorter springs than the No. 2 and No.4 carburetors 00 not interchange these parts. TOOLS Common FlOat level gauge 0740170010000 SPECIFICATIONS I I: SW l l: G Item Specifications # 7 '7CaibureTor type 7 7 KEIHIN \LD E Throttle bore i r 36 mm (7.42 in) Venfibm J» Primary 12.2 mm (0.43 in) Secondary 34 mm (1,34 in) [28.8 mm (1.13 inll (31.5 mm [1.24 In)! IdeEtiIicatmn No. i win lVDBZB] 0/0320) Float level 7’ 7 ' 705 mm 40.30 in) Main)? 7 ’ W ’ ' Front: #150, Rear: #145 Iant: #130, Rear: #1351 E Idle’speed ' 7 fl 1,000 2 100 rpm _ Throttle grip free play 7 2~s mm [0.087024 in] EiEt’E'crew iiitiaTapenifig ’ See page 4-15 é HONDA VF'I OOOF TRflflBLESHflflTINE Engine cranks but won't start , No fuel In tank . No fuel to carburetors , Engine flooded with luel . No spark at plug (ignition system Iaultyl . Arr cleaner clogged . Intake alr leak . Improper choke operation , Improper throttle Operatmn muchmsum_. Hard starting ar stilling after starting . Improper choke operation . Ignition mallunnion . Carburetor faully . Fuel contaminated . Intake air leak . Idle speed incorrect mmbmnfl Rough idle . Ignition system faulty . Idle speed Incorrect Incorrect carburetor synchronization I Carburetor laulty , Fuel contaminated manna—- Misiiring during acceleration 1 ignlllal’l system faulty Backliring 1. Ignition system taulty 2. Carburetor laulty Poor partarmanoa (drivuhility) and poor Incl economy 1. Fuel system clogged 2r Ignition system faulty FUEL SVSTEM Lean mixture t Clogged fuel jets t Faulty float valve . Float level low . Fuel cap vent blocked . Fuel strainer screen clogged . Restricted fuel line . Air vent tube clogged . Intake air leak . Restricted or faulty fuel pump wmumwuum— Rich mixture . Clogged air jets I Vacuum piston stuck closed . Faulty float valve . Float level ton high t Choke stuck or clogged . Dirty air cleaner mmbmmd FUEL SYSTEM BARBURATIIR REMflVAl 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. Remove the spark plug caps from the plugs. Disconnect the ignition coll primary wires from the coils, Remove the three ignition coil bracket bolts and (he coils/brackets from the air chamber, Disconnect the iuel line from the carburetor and remove ii from the clamp on the carburetar, III IGNITION COILS 12) CLAMP be HONDA VFI 00°F (1) AIR CLEANER CASE IZI BREATHER HOSE I2) AIFI CHAMBER i4) BOLTS HONDA VF'I OOOF Loosen all carburetor bands and remove Khe car- burekor assembly from the intake pipes, Lift «he carbureiors out of the frame and discon- "act the choke and \hroule cables from the car- burexor, VACUUM CHAMBER REMOVAL Remove the four vacuum chamber cover screws and cover. CAUYLON: r 7 { Do nut inlen‘hange vacuum chamber Coven. :pn'ngs pix/am or in needle: between cur- hurelurx. (H CAHBURETOR BANDS FUEL SYSTEM (2) \NTAKE PIPES (1) CHOKE CABLE (2) THROTTLE CABLES 11) SCREWS (2! COVER 4-4 HONDA VF'I OOOF 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 let 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. (ll NEEDLE HOLDER (“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, cl (3) NEEDLE l4) NEEDLE HOLDER HON DA V“ 00°F FUEL SYSTEM INSTALLATION Installation is essentially the reverse of removal but to keep from distorting the diaphragm, install the vacuum piston/diaphragm as iollows: Insert the vacuum piston into the Carburetors 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. i‘ll CAVITY (2| HOLE Ill FLOAT CHAMBER FLIIAT CHAMBER REMOVAL \ Remove the four float chamber screws and the float chamber. iZI SCREWS Ill FLOAT FLOAT LEVEL Measure the float level with the carburetor inclined 15°45" from vertical and the float tang just con- tacting the float valve. FLOAT LEVEL: 75 mm (0.30 in) Adjust the float level by carefully bending the float tang. l2) FLOAT LEVEL GAUGE 07401—0010000 FUEL SYSTEM FLOAT AN D JETS Remove the float pin, float and float valve. Inspect the float va‘ve for grooves and nicks. Inspect the operation of the float valve. Remove the starter Jet, main jet and s‘ow jet. Remuve the float valve seat and filter. (H FLOAT PIN (2) FLOAT VALVE (1) MAIN JET (3) STARTER JET HONDA VF'I OOOF [2) FLOAT VALVE (4) SLOW JET HONDA VF 1 00°F inspect the float valve seat and filter for grooves, nicks or deposits. ASSEMB LY Assemble the float chamber components in the reverse order of disassembly. Pllfll SCREW REMOVAL NOTE The pilot screws are factory preset and should not be removed unless the carburetors are overhauled. Turn each pilot screw in and carefully count the number oi turns before it seats lightly. Make a note of this to use as a reference when reinstalling the pilot screws, CAUTION Damage to the the pilot screw Remove the pilot screws and inspect them. Replace they are worn or damage. INSTALLATION Install the pilot screws and return Ihem to their original position as noted during removal. Perform pilot screw adjustment if a new pilot screw is installed (page 4-15). NOTE [—li you replace the pilot screw in one carbu- retor4 you must replace the pilot screws in the other carburetors for proper pilot screw ad- iustment. (llFILTER FUEL SYSTEM (2) VALVE SEAT (2) PILOT SCREW FUEL SYSTEM CARBURETHR SEPARATIUN HWRCHAMBER Remove the screws attachmg Xhe arr chamber to the carburetors and separate the chamber and carbu- retors. (2) SCREWS [1) CHOKE LEVERS AND RODS Remove the nuts, and remove lhe choke levers and rods. Remove the coner pins and washers, and remove the choke rod. (ZlCHOKE ROD In ‘2’ 131 (4) SYNCHRONIZATION No.1 FUEL No,3 SPRINGS CARBURETOH JOINTPIPE CARBURETOR Carefully separate the No1 carburetor from the assembly Then separate the No. 2 carburetor. CAUTION Separate [he carburetors horizontally to pm rent damage 10 the [aim pipex. l (El No. 2 l6) THRUST (7) AIR JOINT (El No. 4 CARBURETOR SPRINGS PIPES CAREURETOR HONDA v" 00°F FUEL SYSTEM [1) THHOTTLE LINK Discannect the throttle link from the No. 3 and 4 caburetors by removing the cutter pins. (HFUELJOINT PIPE (2)No.4CARBUHETOR 5L 133i Nov 3 CARBUHETOR Carefullv separate the No. 3 and No. 4 carburetors, R (HCHOKE ARM 12)SPHING (3)COLLAR Remove the choke arm coilar and remove the choke aim and spring. Remove the choke valve nut, spring and valve. — i, (4] NUT FUEL SYSTEM Check the choke valve and Spring [or nicksl groovest or uther damage. EARBURETOR ASSEMBLY Install the choke valve, valve spring and nut and tlghten the nut. Install me choke arm and spnng while hooking the arm to the groove in the choke valve. Install the choke arm collar. Coat the new Orrings with oil and install them on the fuel jolnt pipe tor N04 3 and No.4 carburetors. Install the fuel joint pipe to the Note and No.4 carburetors. ’ HONDA VF'I 00°F (ll CHOKE VALVE “WW/r -i \ . (ZlSPRING (ZlVALVE 13) SPRING l4lCOLLAR (5| NUT (llFUEL JOINT PIPE ti? (2) O-RINGS 4-11 HONDA VF'I 00°F Reconnect the throttle linkage between the N03 and No. 4 carburetors, uslng new cotter pins. Coat new O-rings with oil and install them on the fuel and air joint pipesl Put the No. 1 and No. 2 carburetors together Wlth the joint pipes. Loosen the synchronixatiun adjusting screws until there is no tension, Instal| the synchronization springs. Install the thrust spnngs between the throttle valve shafts. FUEL SYSTEM (“THROTTLE LlNK 13) COTTER PINS (4) No. 4 CARBURETOR CARBURETOR l1) FUEL JOINT PIPE .L .L (2| AIR JOINT PIPES (2| THHUST (1 D No. 4 CARBURETOR SPRING (3) No. 2 CARBURETOR 4-12 FUEL SYSTEM Make sure lhe lual joint and air join! pipes are securely ins‘alled. Install the choke rods and levers, using the nuts and new cotter pinsi Make sure me an chamber funnels, grommets and dowel pins are in piece. (i)No.1SYNCHHONIZATION SPRING [3] No‘ 1 CARBURETOR SPRING HONDA VF‘I OOOF (WM). 3 SYNCHRONIZATION SPRING (4) THRUSY (5| No.3 CARBURETOH [1] CHOKE RODS AND LEVERS (1i FUNNELS (2) CHOKE ROD 12) GHOMMETS (MDOWEL PINS (3)FUNNELS 4-13 HONDA. VF'I OOOF 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. Turn the throttle stop screw to align the No.4 throttle valve with the edge of the bvvpass 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. Close the choke valve by turning the choke linkage. Release the choke linkage and make sure that it returns smoothly. CARBURETUR INSTALLATIUN installation is essentially the reverse of removal. NOTE Route the throttle and choke cables properly (page 1 9m1711l Perform the following inspections and adiustments. - Throttle operation (page 3-5li - Carburetor choke (page 3-6). - Carburetor idle speed (page 3-12). - Carburetor synchronization (page 371 1 l. FUEL SYSTEM \ l (1; scasws ill BY-PASS HOLE _ .4 .llllllllllllll l2lNo.4CARBURETOR l3lTHRO‘I'l'E STOP SCREW l2l No. 3 ADJUSTING SCREW (H No. 2 ADJUSTING SCREW (3l No. ‘l ADJUSTlNG SCREW 4-14 FUEL SYSTEM PILflT SCREW ADJUSTMENT IDLE DROP PROCEDURE NOTE - The pilot screws are lactory 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 will accurately indicate if a 50 rpm change. J 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 l Damage to the piIoI screw seat will occur L if the pilot screw is tightened against rhe seat. 2. Warm up the engine to operating temperature. Stop and go driving Ior 10 minutes is sufficient. 3. Attach a tachometer according to its manufac- turer’s instructions. 4. Adjust the idle speed with the throttle stop screw. IDLE SPEED: 1,000 1100 rpm 5. Turn each print screw 1/2 turn out from the initial setting, 6. If the engine speed increases by 50 rpm or more, turn each pilot screw out by successive 1/2 turn until engine speed drops by 50 rpm or less. . 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 Na. 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. N HONDA VF1 00°F 12) THROTTLE STOP SCREW 4-15 HONDA VF'I OOOF FUEL SYSTEM [H FUEL LEVEL (2] SENSOR COUPLER MOUNTING BOLT Do not 1”sz flEes In Tray/«s near nga Wipe up willed gasoline at am Remove the both frame side covers and seat. Turn the fuel valve OFF and disconnect the fuel line at the fuel tank outlet tube. Disconnect the fuel level sensor wire coupler. Remove the two fuel tank mountth bolts and fuel tank. Tum the fuel valve ON and drain the fuel into a clean container. Check the vent hole of the ttller cap for blockage. Check that fuel rs flnwmg out oi the fuel valve ‘3, FUEL LINE freely. Make sure that there are no fuel leaks. 4-16 HONDA VF‘I 00°F FUEL SYSTEM AIR CLEANER CASE/CHAMBER Check the air cleaner case seal rubbers For deteriora~ tiun. CHANKCASE VENTILATION SYSTEM Check that the breather tube is not restricted. (1 I AIR CLEANER COVER (6)5REATHER SEPARATOR (3) AIR CLEANER ELEMENT (9} INLET AIR DUCTS (NAIR CLEANER CASE 4-17 HONDA VF'I 00°F FUEL PUMP INSPECTION 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 er9 terminals with a iamper WIFE. Disconnect the fuel line at the fuel line joint and hold a graduated beaker under the tube. Dr: not allo flame: or :park: near gay/line, Turn the ignition switch cm and let fuel flows ll'llD the beaker for 5 seconds, then turn the ignition switch off. Multiply the amount in the beaker bv12 tu detelmlne the fuel pump flow capacity per minute. FUEL PUMP FLOW CAPACITV: 900 an (30 US 02, 32 Imp ozl : 10%lminute REMOVAL/INSTALLATION Do rm! allow flames or xpark: near gatoline. Wipe up spilled gum/int a! once. Remove the seat and left frame side Cover Remove the coolant reserve tank and ElECtrlC panel from the frame by removing the two mount bolts FUEL SYSTEM (ll FUEL PUMP FlELAV l2) JAMFEFl WIRE 13) BLACK l4) WHlTE ll) FUEL LINE (l) COOLANT RESERVE TANK (2) BOLTS I 4-18 HONDA VF'I OOOF FUEL SYSTEM [IlCOUPLEFl Disconnect the fuel pump wire coupler. Disconnecl (he fuel inlet and ouxlet tubes from the fuel pump. Remove the two fuel pump mounting bolts and the pump‘ l (2lFUEL PUMP ISlOUTLETTUBE (4)|NLETTUBE Install (he fuel pump in the reverse order of re- moval, 4-19 HONDA % vnooor ENGINE REMOVAU INSTALLATION 5-0 é HONDA VF‘I OOOF ENGINE REMOVAL/INSTALLATION 73 60—70 N‘m (6.0—7.0 kg-m, 43—51 fl-Ib) (3 \k 35—45 N-m N (3.5—4‘5 kg-m, 25—33 mm m, V 24—30 N‘m (24—31) kg-m, 17—22 h-lb) V \ (3.5—4.5 kg-m, 25—33 hvlb) z. 50~54 N-m (53-5.4 kg-m, 35—39 frlb) 10—15 N-m (1.0—1.5 kg-m, 7—11 fi-lb) 35445 N-m (35—45 kgAm, 25—33 mm) x 30—40 N>m (3.0—4.0 kgrm, 22—29 fl-lb) HONDA VF'I 00°F ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE REMOVAL ENGINE INSTALLATION 5—1 5—2 5—6 SERVICE INFIIRMAI'ION GENERAL 0 A floor jack or other adjustable support is required to support and maneuver the engine. I The followmg parts or components can be serviced with the engine installed in the frame: Clutch Alternator Gearshift linkage - Starter motor ' Front cylinder head - Carburetors Cooling system C The muffler of the VFiOODF 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 TORQUE VALUES Drive sprocket bolt Engine rear upper hanger bolt Engine rear lower hanger bolt Engine center hangar bolts Engine front hanger bolts Sub-Irame bolts Exhaust chamber mount bolts Gearshift arm bolt 92.5 kg 1204 lb) 35 liters [3.7 US. qt) 50—54 N«rn (5.0—5.4 kg»m, 35—39 ft-lb) 60—70 N-m (Geo—7,0 kg-m, 43—51 ft-Ib) 35—45 N-m (35—45 kg-m, 25—33 ft-lb) 24—30 N~rn (211—10 kg-m, 17—22 ft-lb) 35—45 Nrm (35—4.!) kg-m, 25—33 ft-lb) 35—45 N-m (35—45 kg-m, 25—33 ft-ib) 30—40 N-m (3.0—4.0 kg-m, 22—29 ft-lb) 10—15 N-rn (LO—LS kg-m,7—-1‘lft-lb) ENGIN E REMOVAL/INSTALLATION ENGINE REMflVAL mace the motorcycle an its center stand. Remove the seal, right and Ten frame side covers. Remove (he fairing and fue‘ \ank‘ Drain the engine oil (page 2-3) and coolant (page 6 3!. Remove the foHowmg components: — lower radiator {page 675}. 7 carburetors (page 4-3). Disconnect the starter motor cable at the staner motor by remowng (he terminal nut Loosen the muffler cTamp buns and remove the muffler mount bolts and right and left mufflers. f1) STARTER MOTOH CABLE HONDA VF1 OOOF (2) TERMINAL NUT (3) STARTER MOTOR [H MUFFLER MOUNT BOLT (2) MUFFLER l3] CLAMP BOLTS HONDA VFI OOOF Remove the from exhaus‘ pipe [pint nuxs. Loosen the rear exhaust pipe clamp bolts. Remove the exhaust chamber moum bolts and Exhaust chamber/pipes from the engine. Remove the starter motor cable from the damp: on the right crankcase cover. ENGINE REMOVAL/INSTALLATION (1) REAR EXHAUST PIPE CLAMP BOLTS n) (1) STARTER MOTOR CABLE (21 EXHAUST CHAMBER (3)MOUNT BOLT HONDA VF'I OOOF ENGINE REMOVAL/INSTALLATION (1) THERMOSTAT HOUSING (2] HOSE BANDS Remove the thermostat housing by loosening water , hose bands and removing the mount bolt. (3lMOUNT BOLT (1| CLUTCH SLAVE CYLINDERl2)CRANKCASE BREATHER TUBE Remove the clutch slave cylinder by removing three I mount bolts. “03, , ,, _ _ A. Do not operate the clutch lever alter remove mg the clutch slave cylinder; It will cause dlfr llculty when reinstalling the slave cyllnder. Remove the gearshift arm from the shiit spindle, Remove the drive sprocket cover by removing two boltsi Loosen the two water hose bands and remove the hose. (3) WATER HOSE l4] GEARSHIFT ARM (5| DRIE SPROCKE'I" COVER Loosen the tube bands and remove the crankcase b'“‘""“"e‘ lllREAR AXLE NUT Loosen the drive chain adjusting lock nuts and bolts. Loosen the rear axle nut and push the rear wheel forward. '(2) ADJUSTING BOLT HONDA VF'I 00°F ENGINE REMOVAL/INSTALLATION (1) DRIVE SPROCKET BOLT Remove the drive sprocket bolt and sprucket from the Cnunlershah and drlve chain, ('3 _ ~ (2| DRIVE SPROCKET <3) DRIVE CHAIN (1) ALTERNATOR WIRE COUPLER Disconnect the alternatar wure coupler and neutral switch wrre connectorv 12D NEUTRAL SWITCH WIRE CONNECTOR (fl CRANKCASE (2) PULSE GENERATOR BREATHER TUBE CONNECTOR Disconnect the pulse generator wire coup‘er. Disconnect the battery ground cable at the battery negative (—) terminal. Disconnect the crankcase breather tube from the rear cylrnder head cover. (3r BATTERY GROUND CABLE 5-5 ENGINE REMOVAL/INSTALLATION Place the floor Jack or other adjustable support under the engine NOTE The jack height must be continuously adjust- ed to relieve stress lrorn bolts that are being removed. Remove the engine hanger bolts from the right side. Remove the framertorsubrframe bolt. Disconnect the crankcase breather hose. Remove the engine hanger bolts and nuts from the lelt 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 tf necessary. Install the engine mount rubbers Engine Installation is essentially the reverse of removal. Use a floor lack or other adjustable support to carefully manuever the engine into place, CA 110" iii Litre/i110! align mnuming point: with Ihe jack to prevent damage tn Innunling bolt lhread: and wire harness and cables. Tighten all fasteners to the torque values given on page 54. NOTE - Route the Wires and cables properly lpages 179thru171'l]. - Fill the crankcase to the proper level with the recommended oil lpage 2-1). ‘ Fill the cooling system (page 673), ‘ Perlorrn the following inspection and ad» iustments' ThrOttle operation (page 36), Clutch [page 3-17]. HONDA VF'I OOOF (‘IlSUB-FRAME l1) SUE-FRAME (3) REAR UPPER BOLTS (2| CENTER HANGER BOLTS HANGER BOLT 4 x a i ‘ d (4) FRONT HANGER l5) REAR LOWER HANGER ISISUB-FRAME BOLTS EOLT BOLTS 5-6 HONDA vn ooor CUULING SYSTEM COOLING SYSTEM HONDA VF'I OOOF 6-0 HONDA VF'I 00°F COOLING SYSTEM SERVICE INFORMATION 6—1 THERMOSTAT 5—4 TROUBLESHOOTING 6—1 RADIATOR/COOLING FAN 6-5 SYSTEM TESTING 6—2 WATER PUMP 6—10 COOLANT REPLACEMENT 6-3 SERVICE INFDRMATIDN GENERAL 00 MI remove rile radiarar can when the engine is hot. The (MIan is under pressure and severe IMMng could result. The engine must be um] before Inviting [he roofing system. Use only distilled water and ethylene glycol in the cooling system. A 50—50 mixture is recommended for maximum 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. AVOld spilling coolant an painted surfaces. After servicing the system, check for leaks with a cooling system tester. Refer to Section 20 for lan motor thermostatic switch and temperature sensor inspections. SPECIFICATIONS Radiator cap relief pressure 75—105 kFa (0.75—105 kg/cm’, 10.7—14.9 psi) 55% Distilled water + 45% ethylene glycol 50% Distilled water + 50% ethylene glycol 45% Distilled water 0 55% ethylene glycol: ‘44.5°C (48°F) Freezing point (Hydrometer test): Coolant capacity: Radiator and engine Reserve tank Tutal system 3.0 liters (3.18 US qt, 2.64 Imp qt) 0.4 liters (0.42 US at, 0.35 imp qt] 3.4 liters 13.6 US cit, 2.99 imp qtl Begins to open: 30° to 34°C (176° to 183°Fi The'mosm Valve lift: Minimum of 8 mm at 95°C (0.315 in at 203°Fl Unpressurized: 107.7%: (225”F) .l. . . 7 . : BOI mg DOIM (With 50 50 mixture) cap on, pmssuriud: 125‘6oc ‘zsecF) TRUUBLESHUHTINE Engine temperature too high . Faulty temperature gauge or gauge sensor . Thermostat stuck closed . Faulty radiator cap , Insuificient coolant . Passages blocked in radiator, hoses, or water jacket . Fan blades bent . Faulty fan motor ummaond Enpina tampontur: too.|uw 1. Faulty temperature gauge or gauge sensor 2. Thermostat stuck open Coolant leaks 1. Faulty pump mechanical seal 2. Daterioratad O-rings COOLING SVSTEM SYSTEM TESTING COOLANT Remove the frame left side cover and reserve tank 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. RADIATOR CAP INSPECTION Remove the fairing and radiator cap. The engine must be moi before remuving the cap, Pressure test the radiator cap Replace the radiator can if it does not hold pressure, or ii relref pressure is (on 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. RADIATOR CAP RELIEF PRESSURE: 75—105 kPa (015—105 kg/cmz, 10.7—143 psi) SYSTEM PRESSURE TEST Remove the fairing and radiator cap Pressurize the radiator, engine and hases,and check for leaks bx;;ssivr pressure can damage (he mdiarur. 00 Hill mm 1,05 kg/cm’ (14.51 Fri} Repair or replace components if the system will not hold specified pressure for at least six seconds HONDA é vn ooor (1) ANTIFREEZE TESTER I1) COOLING SYSTEM TESTER IZI RADIATOR CAP ii) COOLING SYSTEM TESTER HONDA VF'I OOOF CflfllANT REPLACEMENT The engine must be cool before ten/icing the cooling Aystem, 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 boltst Dram 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 subrlrame. Replace the drain bolts aiter making sure their seal» mg washers are in good condition. Fill the system Wilh a 50'50 mixture of distilled water and ethylene glycol. Bleed air from the cooling system. 0 Start the engine and run until there are no air bubbles in the coalant. and the level stabilizsst 0 Stop the engine and add coolant unto the proper level if necessary. 0 Reinstall the radiator cap. I Check the level of coolant in the reserve tank and lill to the correct level if the level is low, t Installthe lower cowl. COOLING SYSTEM (“RADIATOR CAP . I ‘v t (1] LOWER COWL (3lSUB»FRAME l2lDRA|N BOLT 12) WATER PUM? COVER lllDRAIN BOLT (4) DRAIN BOLT COOLING SYSTEM THERMUSTAT REMOVAL Remove the fairing. Drain the coolant (page 63). Remove the thermostat housing cover by loosening the water hose band and removing the two cover boits. Remove the thermostat from the housing INSPECTION Inspect thermostat visually for damage. Suspend the thermostat in heated water to check its operation. NOTE If th; thermostat or thermometer touches the pan, yuu'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 30° to B4°Cl176° A 133°?) 8 mm minimum (0.31 in) when heated to 95°C (203°Fl for live minutes. Start to open Vaive lift (1i WATER HOSE BAND HONDA VF'I OOOF [21THERMOSTAT HOUSING COVER i2)HOUSING i‘llTHERMOSTAT i2iTHERMOMETER 6-4 HONDA VF 'I 000 F COOLING SYSTEM INSTALLATION Install the thermostat into the houslng. Install the thermostat housmg cover into the water hose. lnstall a new O-ring onto the cover and the cover unto the houslng and tighten the two cover bolts and water hose band. Flll the cooling system (page 6-3). Install the fairing‘ RADIATORS/CIJIJLING FANS LOWER RADIATOR REMOVAL Turn the ignitlon switch off and disconnect the battery 71993th5 cable from the battery. Remove the falrmg and lower cowl. Drain the coolant (page 6-3). Disconnect the fan motor wire couplers, Loosen the water hose hands and disconnect the water hoses from the lower radiator, Remove the three radlator mount bolts and the lower radratora THE Fl MOSTAT l.» (3)THERMOSTAT HOUSING COVER IllHOSE BANDS IZJBOLS HONDA VF'I OOOF COOLING SYSTEM (“SCREWS 12)LEFT5|DE COVER LOWER RADIATO R/COOLING FAN DISASSEMBLY Remove me radiator gnHe and Slde covers by remov~ my me screws, (3D RIGHT SIDE COVER 14) RADIATOR GRILLE (“FAN/MOTORS Remove (he cuoling fan/motors by removing the mourn nuts (HCOOLING FAN Remove the fan from the mater by removing me nut. HONDA VF'I OOOF Remove the washer from the motor shaft. Remove the fan motor from the fan shroud by re- moving the three screws. LOWER RADIATOR INSPECTION Inspect the radiator soldered joints and seams lor leaks. Blow dirt out from between core fins with com- pressed air. If insects, etc., are clogging the radiator, wash them OH with low pressure water. LOWER RADIATOR ASSEMBLY/ INSTALLATION Assemble and install the lower radiator in the reverse order of disassemblv 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 ' tor. After installation, fill the cooling system (page 6-3), (H FAN MOTOR COOLING SYSTEM (3) FAN SHROUD HONDA VF'I OOOF COOLING SYSTEM [1] UPPER RADIATOR LOWER COVER UPPER RADIATOR REMOVAL Remove the Iamng and lower cowl. Drain the coolant [page 6-3]. Remove the radiator lower Cover bv removing the two screws. Disconnect the cou‘ant overflow tube from the filler neck. Loosen the hose band and remove the filler neck from the upper radiator. (Z) HOSE BAND (3) FILLER NECK (“HORN (ZIBOLT Remove the horn mount bolt and ham. Remove the upper radiator shroud by removing two ‘ a bum. (3IUPPER RADIATOR SHROUD (4) BOLTS HONDA. VFI OOOF 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. UPPER RADIATOR INSPECTION Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with com pressed air. If insects, etc” are clogging the radiator, wash them off with low pressure water. UPPER RADIATOR INSTALLATION Install the upper radiator in the reverse order of removal. COOLING SYSTEM @ I2) HOSE BAND HONDA VF'I OOOF COOLING SYSTEM III WATER PUMP 12) TELLTALE HOLE . r .e r ' MECHANICAL SEAL INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. Replace the waler pump as an assembly if the mechanical seal is leaking. IZI TELLTALE HOLE III CLUTCH SLAVE CYLINDER REMOVAL . . Dram the coolant [page 6 . Remove the clutch slave cv under. NOTE Do not operate the clutch lever alter removing the clutch slave cylinder. To do so wxll cause difficulty in reinstalling the slave Cylinder. Remove the gearshift arm from the shift shaft. Remove the drive sprocket cover, I2)GEARSHIFT ARM I3! DRIVE SRROCKET COVER IQIWATER IIICOVER BOLTS PUMP COVER Disconnect the waler hose from the water pump cover. Remove the water pump cover bolts and cover. (4IDRAIN RCLT I3)WATER HOSE 6-10 HONDA VF'I OOOF COOLING SVSTEM (1) P1PE CLAMP (2) HOSE BANDS .- Remove the water pipe clamp ban. Loosen the water hose bands. Pull off the water pump from the crankcase. Remove the warer pipe from the water pump. (3} WATER PIPE (AJWATEH PUMP INSPECTION (1) O-RING Check she water pump for mechanical seal leakage (2) WATER pUMP ASSEMBLy and bearing deterioration Replace the water pump as an assembly if necessary, (3, CHUNG INSTALLATION App‘y a coat of clean engine oil to a new O-ring and instal‘ it in the water pump groove Nign the water pump shaft groove with the oil pump shaft and insert rhe water pump in the crankcase (3D 0~R|NG COOLING SVSTEM Insert a new O-ring over the end of the water pipe. Connect the water pipe ta 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). HONDA VFI OOOF l1) O-RING l2lWATERPIPE CAP l3l WATER PIPE l4lHOSE ill DOWEL PINS (“WATER INLET HOSE 6-12 HONDA VF'IOOOF CLUTCH SYSTEM HONDA CLUTCH SYSTEM VF'I OOOF HONDA V“ 000' CLUTCH SYSTEM SERVICE INFORMATION 7—2 CLUTCH COVER REMOVAL 7710 TROUBLESHOOTING 7—3 STARTER CLUTCH DISASSEMBLV 7—10 CLUTCH FLUID REPLACEMENT/ cLUTcH DISASSEMBLY 7—12 A'“ BLEED'NG 7‘4 CLUTCH ASSEMBLY 7-17 CLUTCH MASTER "UNDER 7—5 STARTER CLUTCH ASSEMBLY 7—20 CLUTCH SLAVE CVL'NDER 7—8 CLUTCH COVER INSTALLATION 7-22 80—90 N-m (8.0—9.0 kg-m. 53—65 h-lb) 0 (8.5—105 kg-m, 61— 76 ith v 4 & V\ 26—30 N‘m (2.6—3.0 kg-m, 19—22 ft-lb) O HONDA VF'I 00°F CLUTCH SYSTEM SERVICE lIlFlIlIIMTlIIII GENERAL 0 This section covers removal and installation of the clutch hydraulic system, clutch and starter clutch, I DOT-4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in the section. Do not use ather types of lluid as they are not compatible. 0 Clutch maintenance can be done with the engine in the frame, SPECIFICATIONS STANDARD SERVICE LIMIT Clutch master cylinder Cylinder LD. 14.000—14043 mm (0.5512—05524 in) 14.05 mm (0.553 in) Pistan 0.0. 13357711954 mm (05495—05506 in) 13,94 mm (0.549 in) Clutch slave cylinder Cylinder LD. 33500—31622 mm (13228—13253 in) 33.63 mm (1.326 in) Plfl‘m 03- 31550—31575 mm [I 3209—13218 in) 33.53 mm (1.320 in) Clutch Outer guide LD, 29355—30012 mm (1.13097 1 .1315 in) 30.08 mm (1.184 in) Spring free height 4‘4 mm (0.17 in] 4.2 mm (0.165 in) Clutch center B LD. 74.414—74440 mm (19297—19307 in) 74.47 mm (2.932 in) | t h 3:33;. ” c 57.755—57.768 mm (22738—22743 in) 57.72 mm (2.272 in) Disc thickness 3.72—3.38 mm (0.147—0.153 in) 3,1 mm (0.12 in) Plate warpage 7 0.30 mm (0.012 in) Starter clutch Driven gear O.D. 41175—47200 mm (18573-13553 in) 47.16 mm (1.857 in) TORQUE VALUES Primary drive gear 85— 105 Mm (8.5—10.5 kg-m, 61—76 ft-lbl Clutch lock nut 50—90 N-rn (8.0—9.0 kgvm, 58765 fl-lbl Starter clutch 26—30 N‘m (2.6—3t0 kg—mv 19722 hrlb) TOOLS Special Snap ring pliers 07914—3230001 Gear holder 07924— MESOOOO Lock nut wrench 07916’4220000 Common Extension 07716—0020500 Driver 07749—0010000 Attachment, 37 x 40 mm 07746—001020!) Pilot, 40 mm 07746—0040900 Universal holder 07725-0030000 HONDA VF'I 00°F lRllllBlESHfllJTINE Clutch lover soft or spongy 1. Air bubbles in hydraulic system 2. Low fluid level 3. Hydraulic system leaking Clutch lever too hard 1. Sticking pistonlsl 2. Clogged hydraulic system Clutch clip: 1. Hydraulic system sticking 2. Discs worn 3. Springs week Clutch will not disengage 1. Air bubbles in hydraulic system 2. Low fluid level 3. Hydraulic system leaking 4, Hydraulic system sticking 5. Plates warpad CLUTCH SYSTEM Motocyclo creeps with clutch diungnged 1. Air bubbles in hydraulic system 2. Low fluid level 3. Hydraulic system leaking 4. Hydraulic system sucking 5. Plales warped Exocssivl layer pressure 1. Hydraulic system sticking 2. Lifter mechanism damaged Clutch operation fnls rough 1. Outer drum slots rough 2. Sticking pistonls) CLUTCH SYSTEM CLUTCH FLUID REPLACEMENT/ AIR BLEEDING Check the Iluid level with the fluid reservoir parallel tn the ground. CAUTION Install the diaphragm on the reservoir when operating the clutch lever. Failure ta do :0 will allow clutch fluid It) squirt out af the reservoir during clutch operation. ~ Avoid spilling fluid an painted mrfncrs. Place a rug aver the five] tank whenever the system it serviced CLUTCH FLUID DRAINING Connect a bleed hose to the bleed valve, Loosen the slave cvlinder bleed valve and pump the clutch Invert Stop Operating the lever when no fluid flows out of the bleed valve CLUTCH FLUID FILLING Connect the Brake Bleeder m the bleed valve. Puma the brake bleeder and loosen the bleed valve. Add the clutch fluid when the fluid level in the master cylinder reservoir is low. Repeat above prooedure until air bubbles do not appear in the brake hose NOTE I1 air is entering the bleeder from around the bleed valve threads, seal the threads with tetron taoe, II the brake bleeder not available, fill the system as iollow: Close the bleed valve, fill the reservoir, and install the diaphragm. Pump up the system pressure with the lever until there are no air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is ielt. Then bleed the system, 3 HONDA VF'I OOOF (I) LOWER LEVEL (II BLEED HOSE l2) BLEED VALVE m BRAKE BLEEDEIR 7-4 HONDA VF'I OOOF CLUTCH SYSTEM lll BLEED HOSE l2) BLEED VALVE AIR BLEEDING NOTE Check the clutch fluid level often while bleed- ing clutch to prevent air from being pumped into the system. 1) Squeeze the clutch lever, open the bleed valve 1/2 turn then close the bleed valve. NOTE Do not release the clut lever until the bleed valve has been closed 39 2) Release the clutch lever slowly and wait several seconds after it reach: the end of its travel. Repeat the above until bubbles cease to appear in the fluid at the end of the hose. Tighten the bleed valve. TORQUE: 4—7 Nrm (40—70 kflm, 35—51 in-lhl Fill the clutch fluid reservoir to the upper level. CLUTCH MASTER CYLINDER DlSASSEMBLY Drain clutch fluid from the hydraulic system. Remove the rear view mirror and clutch lever. Disconnect the clutch switch wires and remove the clutch hose CAUTION Avoid spilling dun-h fluid an painter] surfaces. place a rag over Ihe fuel tank whenever the clutt'h system is serviced. NOTE When removing the oil bolt, cover the end of the hose to prevent contamination and secu'e the hose, Remove the master cylinder. Remove the push rod, boat and snap ring from the master cylinder bodv. ll) SNAP RING PLIERS 07914-3230001 HON DA CLUTCH svsnsm VF'I 00°F Remove the fullnwing: — piston and secondary cup. — primary cup and spring. (2) — clumh switch, if nmesavy. CLUTCH MASTER CVLINDER (1 I CLUTCH SWITCH I4I PRIMARY CUP (5) SECONDARY / %@ MASTER CYLINDER |.D. INSPECTION Measure the master cylinder |.D. ,Check the masxer cylinder Var scores, scratches or nicks. SERVICE LIMIT: 14.06 mm (0.553 in] MASTER PISTON O.D. INSPECTION Measure the master DISIO" OD. SERVICE LIMIT: 13.54 mm (0.549 in) Check me pnmarv and secondary cups for damage before assemblv. HONDA VF'I OOOF ASSEMBLY CAUTION Handle the master piston, spring, primary cup and Secondary cup [It a se[, Coat all parts with clean brake fluid be90re assemb- Iv. Install the spring, primary cup and piston. CAUTION when installing the cups, do not allow the lips to turn inside out. Install the snap ring making sure it is seated firmly In the groove. Then install the boot and push rod. lnstall the clutch switch, ii It was removed. Place the master cylinder on the handlebav and install the holder with the "UP" mark facing up and the two mounting bolts. Align the mark of the holder with the handlebar punch mark‘ Tighten the top bolt first, then the bottom bolt. Install the oil hose with the bolt and its two sealing washers. Install the push rod end niece into the clutch lever hole and install the clutch levers Connect the clutch swltch wires to the switch terminals, Fill the reservoir and bleed the clutch system lpage 7-4lv CLUTCH SYSTEM (‘IIRESERVOIR COVER l2) DIAPHRAGM (3) HOLDER 4—(4l CLUTCH LEVER PIVOT BOLT l SISPHING l6) PRIMARY CUP (7) PISTON AND SECONDARY CUP / (SISNAP RING % /(9)BOOT l12l CLUTCH SWITCH no, PUSH ROD G III] PUSH ROD END PIECE l‘ll PUNCH MARK l?) OIL BOLT l3l "UP" MARK l4] MARK l5] CLUTCH HOSE 7-7 CLUTCH SYSTEM CLUTCH SLAVE CYLINDER DISASSEMBLY Place a container under the slave cylinder, remove the oil bolt and disconnect the clutch hose. NOTE Avoid spilling clutch fluid on painted sur- laces. Remove the slave cylinder. Remove the piston from the cylinder. ll piston removal is hard, place a shop towel over the piston to cushion the piston when it is expelled, and position the cylinder with the piston down. Apply compressed air to the iluid inlet to remove the piston Use the air in short spurts. Remove the spring from the slave cylinder. Remove the ml and piston seals. Clean the piston groove with clutch lluid. Check the piston spring for weakness or damage. HONDA VF'I OOOF Ii) SLAVE CYLINDER I2) OIL BOLT i \ (1] AIR NOZZLE (1! SPRING (2) OIL SEAL (3) PISTON SEAL 7-8 HONDA VF'I OOOF PISTON 0.0. INSPECTION Check the piston for scoring or scratches. Measure the outside diameter oi the piston with a micrometer. SERVICE LIMIT: 33.53 mm (1.320 In) CYLINDER l.D. INSPECTION Check the sieve cylinder for scoring or scratches. Measure the inside diameter of the cylinder bore. SERVICE lIMIT: 33.63 mm (1.326 in) ASSEMBLY Assemble the slave cylinder in the reverse order of disassembly. The oil seals must be replaced with new ones whenever they have been removed. Lubricate the piston and piston seal with a medium grade at Hi-Temoereture silicone grease or brake fluid before assembly. Be certain the piston seal is seated in the piston groove. Place the piston in the cylinder with the seal end facing out. CLUTCH SYSTEM (1)0IL SEAL (6) SILICONE GREASE (2) p (4) ISTON SEAL SLAVE CYLINDEFI BODY 7-9 CLUTCH SYSTEM InstaH the insulator and slave cylinder Connect the Clutch hose with the 0“ bolt and the two sealing washers. Fill the dutch fluid reservoir and bleed the clutch system (page 74L CLUTCH CCVER REMOVAL Drain the engine orl. Remove the dutch cover, gasket and dowe‘ puns‘ STARTER CLUTCH DISASSEMBLY Remove the pulse generator (page 19-4}. Remove the starter idle gear shaft and gear. Remove the idler gear by rotating the starter clutch cLockwwse with a wrench, or by rotating the id‘er gear clockwrse to turn the starter motor shalt countevclockwlse, 11) SLAVE CYLINDER HONDA VF'I OOOF (2) OIL BOLT \ 4 r [2) IDLEH GEAR SHAFT 7-10 HONDA. VF'I OOOF Hold the primary gear with the gear holder and remove the bolt. Remove the starter clutch. Shift the primary driven sub gear with a screw driver to take preload off the primary drive gear and remove the primary drive gear. Remove the starter driven gear and needle hearing from the starter clutch. Inspect the rollers for smooth operation. Remove the starter clutch cover by removing the three bolts. Remove the clutch rollers] plungers and springs. Check the rollers for excessive wear. CLUTCH SYSTEM (H GEAR HOLDER 079247ME90000 [1i PRIMARY DRIVEN SUB GEAR (2iPRIMARY DRIVE GEAR WSTARTER DRiVEN GEAR 13) NEEDLE BEARING (2)3TARTER CLUTCH m spar G mnouen g A * \‘8Q , (6i PLUNGER 15) STARTER CLUTCH COVER 7 11 HONDA VF'I OOOF CLUTCH SYSTEM STARTER DRIVEN GEAR INSPECTION Inspect the driven gear for damage or excessive wear Measure the driven gear D.D. SERVICE LIMIT: 47.16 mm (1.857 in) CLUTCH DISASSEMBLY Remove the snap ring, clutch lifter plate, bearing, lifter guide and lifter rod. Shift the transmission into 5th gear and apply the rear brake. NOTE If the engine is not in the frame, shift the transmission into gear and use the universal holder (07725—0030000I to hold the drive sprocket, Remove the lock nut and lock washer. Remove the clutch spring set plate, clutch spring and two washers. I3] LOCK NUT WRENCH 079167422000 7-12 HONDA VF'I OOOF Remove the clutch pressure plate, Remove the clutch plates and discsl Remove crutch center B and the one-way clutch as an assembly. Remove clutch cemer A and washer. Remove the srarrer clurch (page 7-10). (HDISCS AND PLATES CLUTCH SYSTEM (2’ CLUTCH PRESSURE PLATE 7-13 COOLING SYSTEM Remove the clutch outer and outer guide. INSPECTION CLUTCH SPRING Measure rhe hElght of the clutch spring. SERVICE LIMIT: 4.2 mm (0.165 in) Replace the spring if ii is shorter than the service limit. CLUTCH DISC Replace rhe clutch dlscs lf they show signs aI scorlng or dlscolorahon. Measure the ihickness OI each disc. SERVICE LIMIT: 3.1 mm (0.12 in) Replace any discs that are thinner than the service limit. 7-14 HONDA VF'I OOOF CLUTCH SYSTEM CLUTCH PLATE Check for plate warpage on a surface plata, using a feeler gauge, SERVICE LIMIT: 030 mm (0.012 in) ONE WAY CLUTCH INSPECTION Inspect the one way clutch for smooth operation. Check the rollers for excessive wear. Measure the ID. of clutch center B. SERVICE LIMIT: 74‘47 mm (2,932 in) 7-15 CLUTCH SYSTEM Measure the OD. of the one way clutch innur, SERVICE LIMIT: 57,72 mm (2.272 In) INSPECTION CLUTCH OUTER Check the slots in the clutch outer for nicks, cuts or Indentations made by the friction discs. Check thl clutch outer needle bearing Iar damage or excessive play If the needle bearing Is difl-cult to remove from the clutch housing, us. the foIluwing tools: Drivev: 0774943010000 Attachment, 42 x 47 mm: 07746—0010300 Film, 40 mm: 07746—0040900 CLUTCH OUTER GUIDE Maasuve the LD. ol the clutch auter guidel SERVICE LIMIT: 30.03 mm (1.184 in) IIISLOT HONDA VF'I 00°F Q (2) NEEDLE BEARING 7-16 HONDA VF‘I OOOF CLUTCH ASSEMBLY Install the clutch outer guide over the mainshaft. Install the needle bearing lnlo the clutch outer. Align the holes In the clutch outer with the pins on the Oil pump drive sprocket and install the clutch mner over the guide. Install clutch center A and the washert Install the starter clutch (page 7-20). Place the clutch center B with the grooved side facing down‘ Install the one-way clutch into the clutch center 8 with its flanged cage facing up. Install the clutch inner inta the anevway clutch with its grooves lacing up. Turn it counterclockwise as you install it. (“OIL PUMP DRIVE SPROCKET (3] CLUTCH OUTER 11 l CLUTCH CENTER A (HGROOVES (3l0NE»WAY CLUTCH CLUTCH SYSTEM (ZJPINS l4) CLUTCH OUTER GUIDE (2) WASHER 1 l4) CLUTCH INNER l2) CLUTCH CENTER E 7-17 HONDA VF‘I 00°F CLUTCH SYSTEM lllCLUTCH CENTER 3 (Turns clockwise) Install th: one-way clutch/clutch center 5 assembly over the mainshaft. NOTE M-ke sure the one way clutch assembly is installod correctly by turning the clutch center 8. The clutch center should turn clock- wise freely and should not turn counter- clockwise. Coat the discs and plates with clean engine oil, and install them, Install the clumh pressure platet 7-18 HONDA V" 00°F CLUTCH SYSTEM Install the clutch spring set plate, clutch spring, and washer. NOTE Install the cl towards the h spling with the dished face (2| CLUTCH SPRING (3iWASHER (i) LOCK WASHER lnstail the lock washer with its dished face towards the insidet Place the transmission in 5th gear. NOTE If servicing the clutch with the engine out of the frame, shift the transmission into gear and hold the drive sprocket With the HOLDE R 07725—0030000, TORQUE: 50—90 N-m (8.0—9r0 kg-m, 58~65 ft-Ihl (1) LOCK NUT WRENCH 0781674220000 HONDA VF'I OOOF CLUTCH SVSTEM Install the clutch liked rod Install the clutch liner plaxe, lifter guide and bear- ing. Install the snap ringi l1] SNAP RING (IIPRIMARlDRlVEN GEAR lZIPRIMARY DRIVE GEAR STARIEII CLUTCH ASSEMBLY \A ,L Install the primary drive gear onto ‘he crankshafl while moving the primary driven gear with a screw» driver. Install the thrust washer on Ihe crankshaft. (3i THRUST WASHER 7-20 HONDA V" 00°F CLUTCH SYSTEM (“ROLLER (2|PLUNGER (3lDOWEL PIN Install the springs, plungers and rollers into the starter clutch. Install the dowel pin. Install the starter clutch cover aligning the dowel pin hole with the dnwal pin and tighten the bolts. TORQUE: 26—30 N‘m (ZS—3.0 kl'm, 19-22 lt-lb) NOTE Apply a lock ng agent to the bolt thread . (A) CLUTCH COVER (1 lSTARTER DRIVER GEAR Install the starter driven gear by turnmg It clockwise Align the punch marks on the starter clutch and crankshaft and install the starter clutch. CLUTCH SYSTEM Hold the primary gear with the gear holder 107924— MC7DODZ) and tighten the primary gear boil TORQUE: 85—105 N-ml8r5—10r5 kg-m, 61 —76 M-lb) Instali (he slaner idler gear and shaft. CLUTCH COVER INSTALLATIDN Install me dowel pins and a new gasket. HONDA VF'I OOOF (1) GEAR HOLDER 07924—ME90000 (HIDLER GEAR SHAFT 12) STARTER IDLER GEAR (1) GASKET [2! DOWEL PINS 7-22 HONDA. VF'I OOOF CLUTCH SYSTEM (HOLUTCH COVER Install me dutch cover. F‘Il the cvankcase wuh on [page 23!. 7-23 HONDA “é vnooor GEARSHIFT LINKAGE 8-0 é HONDA ’ VF'I OOOF GEARSHIFT LINKAGE 8-0 HONDA GEARSHIFI’ LINKAGE V" 00°F SERVICE INFORMATION a_1 TROUBLESHOOTING 8—1 GEARSHIFT LINKAGE REMOVAL 8—2 GEARSHIFT LINKAGE INSTALLATION 8—4 SERVICE INFORMATIIJN GENERAL 0 The gearshift spindle and smnncr Irms can be serviced with the engine in Ihe frame. 0 If Ihe shift forks, drum and transmission require servicing, remove (he engine and sepame the crankcase. TllllllBLESllllDTlllli led to shift 1. Air bubbles in me clutch hydraulic system 2‘ Shin forks bent 3. Shift claw ban! 4. Shih drum cam grooves damaged Tr-mminiou jumps out of em 1. Gear dogs worn 2. Shift shah ban! 3, Shift drum stopper broken 4. Shift forks bent HONDA VF'I OOOF GEARSHIFT LINKAGE EEARSHIFT lINKAGE REMUVAI. Dvain ‘he engine oil (page 2-3)4 Remove the gearshift arm from the shift sham Remove the clutch cover and mumh assemb‘v [Semion 7). Remove the ow] pump dnven spwcket bolt. Remove “15 ml pump dnve chem, drrve and driven snvockets. ‘, (3’OIL PUMP DRWEN SPHOCKET (4} BOLT (HDRUM STOPPER ARM Remove the drum stopper arm nut, washer, spnng, collar, and arm. HON DA. GEARSHIFT LINKAGE VFI OOOF Remove the lab washer. (HTAB WASHER Pu|l the gearshm spindle assembly out of khe crank~ case. Remove [he neutral stopper arm hon, arm and spring and washen {2] ARM BOLT HONDA. V“ 00°F GEARSHIFT LINKAGE (“SHIFT DRUM CAM PLATE Remove the smfl drum cam plate bull and cam plake. (1) DOWEL PIN GEARSHIFT LINKAGE lNSTAllATIflN Inml! the dcwel pin in ‘he hole of the shin drum. Insert (he five pms in the holes of the cam plate, Ahgn the cam plate hole with (he dowel pin on ‘he shift drum and ins‘al! the cam plate. Tighten the bolt securew. (2} CAM PLATE (3)HOLE (4) PIN (“NEUTRAL STOPPER ARM Install the washer, neutral stopper arm, spring and arm bolL Tighten me arm boll securely. 12>5PFiING 13)ARM BOLT HONDA VF'I OOOF GEARSHIFT LINKAGE Assemble the gearshift spindle and return spring and install as shown. i1) RETURN SPRING (2) GEARSHIFT SPINDLE Install the tab washer onto the stopper arm boll. (HTAB WASHER Install (he drum stopper arm, collar] spring, washer I “ l .7 and nut over the arm bolt. Tighten the nm securely. Relate the gearshift spindle and check the linkage for smooth operarion. (1) DRUM STOPPEH ARM v HONDA VF'I OOOF GEARSHIFT LINKAGE InsraH [he oil pump drwe and driven sprockets with drive chain and tighten the driven sprocket bol: secure‘v. 9 ve 9 must face the crankcase. InsraH (he dutch assembly and cover (section 7). Align the punch marks on me gearsmn arm and gearshift spindle and mstaH the gearshih arm on rhe shift shafL FiH the crankcase whh recommended oil (page 2-3! , r , k / 12lGEAHSH FTARM (SISHIFTSHAFT HONDA VF 'IOOOF ALTERNATOR 9-0 ALTERNATOR HONDA VF'I OOOF 85—105 N-m [SE—10.5 kg-m, 51776 h-lb) 9-0 HONDA ALTERNATOR SERVICE INFORMATION 9—1 FLYWHEEL REMOVAL 9—2 STATOR REMOVAL 9—3 STATOR INSTALLATION 9—3 FLYWHEEL INSTALLATION 9—3 SERVICE lNFflRMATIflN GENERAL I This secxion covers removal and installation of the alternamv. Refer to section 18 for troubleshooting and inspection of the alternamr. TORQUE VALUE Altarnatm rotor/Flywheel bolt 85— 105 Nm (35710.5 kg-m, 61—76 't-lb) TOOLS Common Flywheel holder 07725—0040000 Rotor puller 0773370020001 HONDA VF'I OOOF FLYWHEEL REMOVAL Place a container under the anemator cover to each engine oil. Remove ‘he alternator Coven Hold ‘he flywheel with (he flywheel holder and remove (he flywheel bolt, Remove me flywheel wi‘h me ralur puller. Remove the woodruff key from [he C(ankshafi. ALTERNATOR Hi ALTERNATOR COVER [1! FLYWHEEL HOLDER 0772541040000 12) FLYWHEEL BOLT I1] ROTOR FULLER 0773370020001 (2} FLYWHEEL HOLDER 0772570040000 ALTERNATOR STATlJR REMDVAL Remove the Irame left side cover. Disconnect the alternator wire coupler and lree the alternator wrre from the clamp. Remove the stator by removlng the bolts and Wm: clamp. STATDR INSTALLATIIIN Install the stator and wne clamor Route the alternator wire properly, secure It wlth clamp and connect the alternator wire coupler to the main harness. Install the Irame lelt side cover. FLYWHEEL INSTALLATION Install the woodrull key rnto the crankshaft. Install the Ilywheel by aligning trs keyway with the key m the crankshaft, Hold the flywheel with the flywheel holder and torque the flywheel bolt. TORQUE: 85—105 Ntm (BE—10.5 kg-ml 61—76 ft-lbl Install the alternator cover. Check engrne all level and add If necessary (page 2-3). HONDA VF'I OOOF (1 l ALTERNATOR WIRE COUPLER lllSTAOR (lelRE CLAMP lll FLYWHEEL HOLDER 07725 0040000 1:21:02? 10 CYLINDER HEAD/ VALVE 10-0 CYLINDER HEAD/VALVE 8—12 N»m (0,8-12 kg-m, 6—9 fl-Ib) 10-14 N‘m [LO—1,4 kg-m, 7—10k-lb) 21—25 N~m (2.1—2.5 kg-m, 15—18fl-Ib) 4347 Nm " (A‘s—4,7 kg»m, 31—34mm K (1 .8A2D kg-m, 13—14 ft-lb) g7 K 43—47 N-m (4.374] kgrm, 31734f1-lb) 10-0 3 HONDA 4 V“ OOOF cVLINDER HEAD/VALVE SERVICE INFORMATION 10—1 VALVE GUIDE REPLACEMENT 10—13 TROUBLESHOOTING 10—2 VALVE SEAT INSPECTION/ REFACING 10—14 CAMSHAFT REMOVAL 10—3 CYLINDER HEAD ASSEMBLY 10—15 CYLINDER HEAD REMOVAL 10—7 CVLINDER HEAD INSTALLATION 10—16 CYLINDER HEAD DISASSEMBLV 10—9 CAMSHAFT INSTALLATION 10—19 SERVICE INFIJRMATION GENERAL 0 The front cylinder head can be removed wuh the engine in the frame. 0 The rear cylinder head cannot be removed with the engine in the frame; however ('ts Camshafts and rocker arm: can be serviced with the engine in the frame, 3 If the cam sprockets of either from or rear cylinder are removed, the valve timing of both cylinders must be checked during reinslallatinm I Camshaft iuhricating oil is fed through the external oil lines. Be sure the oil lines are not clogged. During assembly, apply moiybdenum disulfIde grease to the camshaft holder surfaces to provide initial lubrication. I The cylinder numbering is given below: F RONT ® ® ‘— SPECIFICATIONS LEFT r STANDARD SERVICE LIMIT i Compression pressure 1,300 2 200 kPa _ ., 3 i (13t2kg/cm1,184228mi) ’ ’1 Camshaft Cam helghl IN 35459—35519 mm (13900—14023 in) 35.40 mm {7.394 in) EX 35.459-35.519 mm (13960—1 .4023 in) 35.40 mm (1.394 in)" f Runout — 003 mm (0.001 in) ( Oil clearance [Center 0.131 —o.191 mm (00052—00075 in) 0.20 mm (0.000 in) v . [sum ends 0027—0088 mm (00011—00035 in) 010 mm (0.004 in) Rocker arm Rocker arm (.0. 12000—12018 mm (04724—04731 in) 12.05 mm (0.474 in) Shaft 0.0. 11366—11384 mm (04711-04710 ini 11.93 mm (0.470 in) Valve Valve stem 00. IN 5475—5490 mrn (02156-02161 In) 5.47 mm (0.215 in) Ex sass—5.470 mm (02143—02154 in) 5.44 mm (0.214 in) Valve guide |.D. 5.500—5.515mm (0.2165—0217lin) 5.55 mm (0.21%) Stem-ro-guide clearance IN 0310—0040 mrn (03004—00016 in) 008 mm (0.003 in) I Ex 0030—0060 mm (00012—00024 in) 0.10 mm (0.004 in) Valve seal width A 10 mm (0.04 in) 1.3 mm (0.05 in) 10-1 CYLINDER HEAD/VALVE HONDA VF'I 00°F Free lerigrh 373 mm (1,48 in) Valve spring Inner 39.01 mm (1.536 in) Outer 44.94 mm (1.769 in] 43.5 mm (1.71 in) Preload/Ienslh Inner 574—634 kg/34‘2 mm (12.65—15.30 5,38 kg/34.2 mm lb/1‘35 in) (11.86Ib/1.35in) Outer 14.75—16.97 icy/37.7 mm (3252—37141 14.15 k9/37e7 mm lb/1i48 in) (31.20 III/1‘48 in) Cylinder head Warpage _ 0.1 mm (0,004 in) TORQUE VALUES Cylinder head cover bdlr Camshaft holder 5 mm bolt Cam chain guide A bolt Cylinder head 9 mm bolt Cylinder head 8 mm bolt Rocker arm shaft Cam sprocket bolt T00 LS Special Valve guide reamer, 5.5 mm Common Valve guide remover] 515 mm Valve guide driver Valve spring compressor TRIJUBLESHI] MINE 8v]? N-m (0.8—1.2 kg~m, 6—9 “~le 10—14 N-rn (LO—1,4 qum, 7—10ft-lb) (The camshah holder bolts in each corner of the cylinder head are longer than the others.) 21—25 N~m (2.1—25 kg-m,15—18 1141.!) 43—47 Nrm 143—4] kgm, 31—34 ft-Ib) 21—25 N-m (2.1—2.5 kgrm,157181trlb) 45—50 N-m (415—5.!) kg-m, 33—46 ft-lb) 18720 N~m(1.8—2ID kg-m,13—141t-lb) 07936—200000!) 07742—0010100 07743—0020000 07757—0010000 Engine lop~end prublems usually arrest engine performance. These can be diagnosed by a compression test, or by tracing noises with a sounding rod or stethoscope, \ Low cumpression 1. Valves — Incorrect valve adjustmenl — Burned or bent valves 7 Incorrect valve tlming — Broken valve spring 2‘ Cylinder head — Leaking or damaged head gasket — Warped or cracked cylinder head 3, Cylinder and DISIOH (Refer in Section 12] Compression me high 1. Excesswe carbnn build-up on piston or cambustion chamber Excessive noise V Incorrect valve adjustment , Sticking valve or broken valve spring ‘ Damaged or worn camshaft Lease or Worn cam chain . Worn or damaged cam chain tensioner Worn cam sprocket teem Worn rocker arm and/or slith \lmu‘buN— 10-2 HONDA VF'I OOOF CAMSHAFT REMflVAL NOTE The Camshafts can be remo engine in the frame. Drain the coolant and remove the inwer radiatnrt Remove the from cylinder head Coven Remove the seat, frame side covers, iuel tank and ignitiun coils. Disconnect the crankcase breather tubes from the rear cylinder head cover and air chamber cover. Remove the rear cylinder head coveri Remove the oil line and cam chain guide mounting bolts, and the cam chain guide. Remove the alternator cover and rotate the crank- shaft counterclockwise until the cam chain has free play. Remove the oil line by pulling up the middle 01 the chain. Remove the alternator cover. CYLINDER HEAD/VALVE ll) FRONT CY (Zl BREATHER TUBES (1) CAM CHAIN GUIDE LINDER HEAD COVER / (3l IGNITION COILS CYLINDER HEAD/VALVE Turn the crankshaft counterclockwise until the T13 mark aligns with the rear crankcase mating surfaces‘ Place rags or shop towels in the rear cylinder head to prevent parts from being dropped into the crankcase. Remove the rear cylinder intake and exhaust cam sprocket bolts. Turn the crankshaft counterclockwise one turn (360°) and remove the other rear cylinder cam sprocket bolts. Turn the crankshaft counterclockwise until the T2.4 mark aligns with the rear crankcase mating surface Remove the front cylinder intake and exhaust cam sprocket bolts. Turn the crankshaft counterclockwise one turn (360°) and remove the other cam sprocket bolts. Slide the cam sprockets and chains off the camshaft sprocket flanges Remove the cam chain from the sprockets and remove the camshaft holders. Mark the camshaft holders so that they can he reinstalled in their original locations, ii lT1.3 MARK (2) REAR MATING SURFACE (‘1) CAM SPRDCKETS (l ) CAMSHAFT HOLDERS (2} CAM CHAlN 10-4 HONDA v" 00°F CYLINDER HEAD/VALVE (HINTAKE CAMSHAFT (2)DOWEL PINS Remnve the camshaft holder dowe‘ pms and (he ‘ intake and exhaust camshaft Remove the cam sprockets from the Camshafts. CAMSHAFT/CAM HOLDER INSPECTION Inspect the camshaft and hmder journal surfaces for seormg scraches, or evidence of Insufficrenl lubrication, CAMSHAFT RUNOUT Check camshafl mnout wlth a dlal indrcatort Support both ends of the camshaft wuth V-blccks. Use 1/2 of the tom Indvcator reading to determine runout. SERVICE LIMIT: 0.03 mm (0.001 in) 10-5 HONDA VF'I OOOF CYLINDER HEAD/VALVE CAM INSPECTION Using a micrometer, measure each cam lobe‘ SERVICE LIMITS: IN, EX: 35.40 mm (1.394 in) Check for wear or damage. [1) PLASTIGAUGE W1pe any oil from Ihe juumals. Lay a strip of plastigauge lengthwise on top of each camshaft iouvna‘ Install the camshah holders and ugmen m a crisscross panern. NOTE Do not rmate the camshaft when using plastigauge. The camshaft holder bulls in each curner of the CVIIndEl’ head are longer than the others. TORQUE: A: 6mm BOLT: 10—14 N-m (LO—1.4 kg-m,7—10fl-lb) B: 3 mm BOLT: 21—25 Nam (2.1—2.5 kg-m,15—1Bft~lh) C: 9 mm BOLT: 43—47 N-m (4.3—4.7 kg-m, 31—34 ft-Ih) 10-6 HONDA. VF'I OOOF Remove the camshaft holders and measure the width of each strip 0f plastigauge. The widest thickness determines the oil clearance. SERVICE LIMIT: CENTER: 020 mm (0.008 in) BOTH ENDS: 0.10 rum (0.004 in) When the service limits are exceeded, replace the camshth and recheck the oil clearance. Replace the cylinder head and camshaft haiders if the ciearance still exceeds service limits. CYLINDER HEAD REMIJVAL NOTE The front-:viinder hgd can be remtfl with the engine installed. But to remove the rear cylinder head, you must remnve the engine. Remove the rear exhaust pipe protector and exhaust Dives. Remove the water pipes and Orrings. Remove the oil pipe and sealing washers. Remove the hunt and rear cam chain tensioner base mounting baits. Pull the cam chain tensiuner base up HI END (2) CENTER CYLINDER HEAD/VALVE 10-7 HONDA VF'I OOOF CYLINDER HEAD/VALVE IIITENSIONER SLIPPER (2) CLIP (3) PIN Remove the slipper clip. washer and pin and remove the Iensioner base. we! l4) WASHER Remove the cylmder head bolts Remuve the cyIinder heads using a screw driver ax (he pry points. (IIPRV POINT I1 I GASKET Remove the from and rear cyImdar head gaskets and dowel pins. l2) DOWEL PINS 10-8 HONDA CYLINDER HEAD/VALVE I1) FRONT CYLINDER CAM IZIREAH CYLINDER CAM CHAIN SLIPPER BASE CHAIN GUIDE Remove the from cylinder cam chain slipper base, and remove the rear cylinder cam chain guide by removing the clip and washer. Remove the from cylinder cam chain guide boils and guide. NOTE Du nm dEp the clip, washer and bolts into the crankcase. I3I FRONT CYLINDER CAM CHAIN GUIDE [IITENSIONER GUIDE IZITENSIONEH SLIPPER CAM CHAIN GUIDE AND CAM CHAIN TENSIONER INSPECTION Inspect the cam Chain guide and tensioner for damage or excessive wear. I 0 Inspect the cam Chain iensioner slipper for damage or excessive wear. Inspem the spring for good tension, replace if necessary. I3I TENSIONER SPRING (2) ROCKER ARM (IIROCKER ARM SHAFT BOLT CYLINDER HEAD DISASSEMBLY 1 I, ‘ Remove the rocker arm shaft and rocker arms. I I Remove the rocker arm spring and Orring from the shaft bolt. \ . f \ I3) ROCKER ARM I4)SPRING ISIO-RING SHAFT BOLT 10-9 CYLINDER HEAD/VALVE To keep the valve spring compressor from interfer~ ing with the cylinder head, remove the large retainer from the compressor attachment. Remave the valve spring cutters, retainers, springs and valves, CAUTION To prevent a (he valve 5p rigs more than her Bar; to remove the Callers. NOTE Mark all disassembled parts to ensure correct reassembly. Remove the valve stem seals, Remove carbon deposits irom the combustion chamber and clean off the head gasket surfaces‘ NOTE 7 77 if Gaskets will come off easier if soaked in solvent. CAUTION Du m)! damage the gaskel surfaces. CYLINDER HEAD INSPECTION Check the spark plug hole and valve areas lor cracks. Check the cylinder head for warpage WlIh a straight edge and ieeler gauge. SERVICE LIMIT: 0.1 mm (0004 in) (H‘VALVE PRING COMPRESSOR 07757—0010000 HONDA VF'I OOOF 10-10 HONDA VF'I OOOF ROCKER ARM INSPECTION Inspect the rocker arms Ior wear or damage tn the camshaft centact surface or for a clogged oil hoIa. Measure the ID, of each rockar arm. SERVICE LIMIT: 12.05 mm (0.474 in) ROCKER ARM SHAFT AND SPRING INSPECTION Measure each rocker arm shaft OD. SERVICE LIMIT: 11.93 mm (0.470 inI Inspect the shaft Ior wear or damage and calculata the shaft to rocker arm cIearance, SERVICE LIMIT: 0.12 mm (0.005 in) Inspect the rocker arm shah spring Ior wear or damage. VALVE SPRING INSPECTION Measure the fraa Iength of the inner and autervalve springs. SERVICE LIMIT: INNER IIN, EX): 37.7 mm (1.48 in) OUTER (IN, EX): 43.5 mmI1.71inI CVLINDER HEADIVALVE 10‘11 CYLINDER HEAD/VALVE VALVE STEM-TO-GUIDE CLEARANCE Inspect each valve for bending, burning, scratches or abnormal stern wear Check valve movement lrl the guide and measure and record each valve stem O.D. SERVICE LIMITS: IN: 5.47 mm (0.215 in) EX: 5.44 mm 10.214 in) NOTE Ream the guides to remove any carbon hulld~ up before checklng clearances. Measure and record each value guide |.D. using a ball gauge or inside micrometer. SERVICE LIMIT: 555 mm (0,219 in) Subtract each valve stem OD from the corres- ponding guide ID. to obtain the stem to guide clearance. SERVICE LIMIT: IN: 008 mm (0003 in) EX: 0.10 mm (0.004 In) NOTE If the stem-to-gmde clearance exceeds the service limits, determine if a new guldE would bring the clearance WlIhln tolerance If so, replace any guides as necessary and ream to fit. II the stern togulde clearance exceeds the serwce limits with new guides, replace the valves, NOTE Reface the valve seats whenever the valve guides are replaced [page 10 3) HONDA VFI OOOF (1) VALVE GUIDE REAMER 07984—2000000 10-12 HONDA v" a a or CYLINDER HEAD/VALVE (IIVALVE GUIDE FlEMOVEFl, 5.5 mm VALVE lilllllE REPLACEMENT 07’7‘42—ooimoo Heal ‘he cylinder head to 100°C (212°F) with a hot plate Dr oven, CAUTION ' Do not use a torch to heat the cylinder; it may cause warping. To avoid bums, wear hazvy gloves when handling the healed cylinder head. Supper! the cylinder head and drive am the old guidls from (ha combustion chamblr side of the cylinder head. (1) VALVE GUIDE DRIVER 07743—0020000 Drive new guxdes in from the rocker arm side of me cvllndev head. NOTE Cylinder head heat should sgm be a! 100°C (ZIZDFI for installation of the new guides. (I) VALVE GUIDE REAMER 07994—2000000 Let the cylinder head cool (0 room temperature and ream the new valve guides. NOTE Use cumng oil on the reamar during this operatian. Rotate the reamer in the same direction when inserting and removing. Reiace ihe valve seats (page 10-14) and clean me cylinder head (homughlv to remove any metal particles. 10-13 CYLINDER HEAD/VALVE VALVE SEAT INSPECTIUN/ REFACINE Ciean all intake and exhaust valves thoroughiy to romove carbon deposits. Apply a light coating of valve Prussian blue to each valve face. Lap each valve and seat using a rubber hose or other hand-lapping tooi. Remove the valve and inspect the face. CAUTION The valve: cannot be ground. If the valve fizre is rough, wam unevenly. or CHIIMCIS the sea! improperly, the wzlve must be replaced, Inspect the valve seat. If the seat is too wide, too narrow, or has low spots, the seat must be ground. NOTE Follow the refacar manu'acturer's operating instructions. After cutting the seat, apply lapping compound to the valve face, and iap the valve using light pressure. After lapping, wash any residual compound off the cylinder head and valve. (3) IN: CUTTER 30mm EX:CUTI’ER 30 mm ISIOLD SEAT WIDTH > I4) IN, EX: CUTTER 30 mm HONDA VF'I OOOF Iii SEAT WIDTH: 1,0 mm (0.04 in) IZiSERVICE LIMIT: 1.3 mm (0.05 in) I5) IN: CUTTER 33 mm EX:CUTTER 29 mm 1.0 mm (7) OLD SEAT WIDTH 10.04 in) X, /‘ \ \ 10-14 HONDA VF'I OOOF CYLINDER HEAD ASSEMBLY NOTE Install new valve slam sealr when assarn Lubricats each valve stem with molybdenum disulfide grease and insert the valve into the valve guide. To avoid damage to the sum seal, mm the valve slowly when inserting. Install the valve springs and retainers. The spring‘s tightly wound COIIS should face toward the head. Install the valve cottersl CAUTION. To prevent a [on of tzrlxl'zm, (10 no! Com- prm the valve spring mime [hall Mommy tu mm]! the valve keeper; Tap the valve stems gently with a soft hammer t9 firmly seat the coners. NOTE Suppon the cylinder head abave (he wurk bench surface to prevent possible valve damagel CYLINDER HEAD/VALVE l1) VALVE STEM SEAL l3I RETAINER (ZIVALVE COTI'ERS CYLINDER HEAD/VALVE Instali the o ring and spring onto the rocker arm shatt‘ Apply LOCTITEE" to the rocker arm bolt threads. Apply engine oil to the rocker arm shaft and insKaII the rocker arm, Install and tighten the rocker arm shaft bolt. TORQUE: 45—50 N‘m (4.5—5.0 ku-m, 33—36 ft-lh) CYLINDER HEAD INSTALLATION Ciean the cylinder head surIace of any gasket material. Install the rear cylinder cam chain guide With the washer and cIip‘ Instali the front cylinder cam chain guide. Install the from cylinder cam chain slipper base, NOTE Be careélr not [D drop the washer, clip or bolts to the crankcase, 10-16 II) ROCKER ARM II) HEAR CYLINDER CAM CHAIN GUIDE I3) FRONT CYLINDER CAM CHAIN GUIDE HONDA VF'I 00°F 12) ROCKER ARM SHAFT BOLT I4) O-RING (BISPRING 12) FRONT CYLINDER CAM CHAIN SLIPPER BASE HONDA V" 00°F CYLINDER HEAD/VALVE (II GASKET Install khe dowel pins and new head gaskeu. (2I DOWEL PINS I‘IJ TENSIONER BASE With the cam chain tensioner raised in the dIrECUDn of the arrow, Inserl a pin or piece of wire through the hole in me (ensxoner base and tensioner. I2! TENSIONER [II TENSIONER SLIPPER I?) CLIP (3) PIN Place the cylinder head on the cylinder. Pass xhe cam chain through the cam chain (ensioner and install the lansioner slipper as shown. NOTE Check that the lower end of the slipper fits In the sIIpper base correctly. (4; TENSIONEFI EASE 10-17 HONDA VF'I OOOF CYLINDER HEAD/VALVE ' Loosely tighten the cylinder head bolts. NOTE Tighten the cylinder head bolts to the speci- fied torque after all cylinder head bolts are installed. Install the rear exhaust pipes onto the rear cylinder head with new exhaust pipe joint gaskets. Install the rear exhaust pipe protector using the four screws. 10-18 HONDA VF'I OOOF CYLINDER HEAD/VALVE Install the exterior oil pipe with washers onto the cvlinder and cylinder head. l H) OIL PIPE Install ihe water pipes and hoses and tighten the hose clamps securely, (HWATER PIPES (ZJOILPIPE CIMSHAFT INSTALLATION m INDEX MARK CAUTION Follow [his procedur? finm beginning (a and. even if you 11"? only servicing one IylindPr head, Check the camshaft mark is {hat yau install each camshafz in its correct Iriclllian. The mark: on zhe camshaft mean. EX RR, ER: Rear cylinder exhaust IN RR, IR: Rear cylinder intake EX FR, EF: me z'ylina'er exhauxr IN FR, IF: From cylinder intake The ramshafr :pmrker: are interchange- able. 10-19 CYLINDER HEAD/VALVE Lubricate the cylinder head cam bearing surlaces with molybdenum disullide grease. 0 Rear Cylinder Camshafts Turn the crankshaft counterclockwise unti the T1-3 mark on the flywheel rotor aligns with the rear crankcase mating surfaces. CAUTION When turning the crankshaft, make sure the cum chains don'r [am at the cam chain ten- st'rmers or at the crankshaft. install the intake and exhaust Camshafts and sprockets thraugh the rear cylinder cam chain as shown. Turn the Camshafts so the camshaft marks face up. NOTE If the front cylinder Camshafts were not removed, check that the front camshaft marks face up If not, turn the crankshaft counter clockwise 360 degrees (one turn), If a valve clearance adjuster keeps the camshaft from seating fully in the cylinder head, back the adjuster out all the way‘ HONDA VF'I OOOF H) CAMSHAFT MAR KS 10-20 HONDA VF'I OOOF CAUTION If you farce a valve open while insralling the camshan holders, you may damage the helm or the camxhizf! bearing surfizcesl Place the mmshaft holders in the same locations noted during removal. The groove in the bottom of the holder must align with the camshaft locating ridge. install the camshaft holder bolts, but do not tighten them yet. NOTE The camshaft holder belts in each éomer of the Cvllnder head are longer than the others, If the cylinders were not removed, lock the cam chain tensioner for minimum tension: push the lock plats down while pulling or prying the \ension arm up; hold the arm pin up while you insert a pin or wlre through the lock holes. CYLINDER HEAD/VALVE [1) CAMSHAFT HOLDER (4) FULL UP “WWIRE CYLINDER HEAD/VALVE Check that the camshaft marks are still facing up, then align the sprocket index lines with the top of the rear cylinder head. Place the cam chain on the sprockets. Slide the sprockets onto the camshaft flanges, and install the sprocket bolts in the exposed holes. Check that the sprocket index lines align at T1-3. Unlock the cam chain tensioner, o Vallre Timing Inspection Check the front~tarrear cylinder camshaft timing as iollows. 0 When the T1-3 mark aligns with the rear c'rank- case mating surface, the index lines on all cam sprockets should align with the too of the cylinder heads. 0 All camshaft marks will either face up or dnwn. Turn the crankshaft as required to install the re- maining sprocket bolts at all four camshafts. Tlghtem the camshaft sprocket bolts to the specified torque. YOROUE: 13-20 N-m (1.3—2.0 kg-m,13—14ft~lb) l1l INDEX LINES HONDA VF'I OOOF 10-22 HONDA V" 00°F CYLINDER HEAD/VALVE (1)TENSIONER BASE BOLTS ‘1 I > Tighten the tensioner base bolts securely. Turn the crankshaft counterclockwise until there is maximum cam chain free play] then install the oil pipes under the cam chain. Install the cam chain guide on the oil pipe base plate: Tighten the cylinder head bolts in a criss-crass pattern In 2-3 steps, TORQUE: 9mm: 43~47N-m (4.374.7kg-m. 31 4341t-lb) 3mm: 21—25N-m (2.1 —2.5kg»m, 15— 18ft-lbl 6mm: 10—14N-m(1,0#1.4kg»m. 7<101blbl Lubricate the Cam lobes with oil. HONDA VF'I OOOF CYLINDER HEAD/VALVE Adjust the valve clearance (page 3-8)l Install the new cylinder head cover gasket. NOTE I Clean the gasket before app sealant. Apply sealant to the cvlinder head cover gasket lnstall the cyllnder head Covers and tighten the cover bolts. TORQUE: 8—12 N‘m (0.8—1.2 kg-In, 6—9 h-lb) Install the remaining parts in the reverse order ol removal. (“HEAR CYLINDER HEAD COVER (“FRONT CYLINDER HEAD COVER 10-24 ‘521303: 11 CRANKCASE 11- é HONDA. CRANKCASE 7 V“ 00°F 8 mm 21—25 N‘m (2.1—2‘5 kg-m, 15—1Eft-Ib) <9 5 10—14 NAm 9 mm 38—42 N-m (3.8—442 kg—m, 27—30 ft»lbl 11-0 HONDA VF'I 00°F CHANKCASE SERVICE INFORMATION 114 CRANKCASE DISASSEMBLY 11-2 CRANKCASE ASSEMBLY 11—3 SERVICE lllFflllMATlflll GENERAL I To service the pistons, crankshaft, connecting rods and transmission, the crankcase halves must be separated t The following parts must be removed before disassembling the crankcase. Oil pan Refer to section 2 Oil pump Refer to section 2 Water pump Refer to section 6 - Clutch/starter clutch Reler to section 7 Gearshift linkage Refer to section 8 - Alternator Refer to section 9 ‘ Cylinder heads Ruler tn section 10 ' Starter motor Refer to section 20 Nguual switch Refer to section 21 TORQUE VALUES 9 mm bolt: 38—42'N-m (18—41 kg-m, 27—301t-Ib) 8mm bolt: 21—25 N-m (2.172.?) kg-m, 1543mm 6 mm bolt: 10—14 N-m l1,0«1.4 kg .— M4, M5: 0.10 mm (0.004 ' ) C1: 0.10 mm (0.004 in) CZ, C3: 0.11 mm (0.004 in) Measure the ID. of (he gear bushings. SERVICE LIMIT: M4 gear bushing: 28.04 mm (0.986 in) c1 gear bushing: 22.06 mm (0.869 in) Measure the OD. of the mainshaft and countershaft. SERVICE LIMIT: Mainshafl (at M4 bushing): 17.92 mm (0.931 in) Counurshafl (at C1 bushing): 21.96 mm (0.865 in) CaleuIate the clearance between the bushing and shafr. SERVICE LIMIT: M4 bushing-xo-shah: 0.06 mm (0.002 in) C1 bushingm-shaft: 0.10 mm (0.004 in) (1) ATTACHMENT, 52 x 55 mm 07746—001040!) COUNTERSHAFT BEARING REPLACEMENT Drive the :ountershafr bearing out of the lower crankcase, Drive a new caunlershaf! bearing into the crankcase using the special tools, (2] DRIVER 07949—3710000 13-4 HONDA VF'I OOOF SHIFT FIIRK Mil] SHIFT DRUM 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. GEAR SHIFT DRUM AND SHIFT FORK INSPECTION Inspect the shift drum end for scoring, scratches, or evidence of insuffiment 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 CD. at right and left shift fork surfaces. Check for scratches, scoring or evidence of insufr ficient lubrication SERVICE LIMIT213t90 mm (0.547 inI Measure the right and left shift fork |.D. SERVICE LIMITS: LD. (right and left forkI: 14.04 mm (0.553 in) Measure the shift fork claw thickness, SERVICE LIMIT: 6‘1 mm (024 inI INSTALLATION Install the shift drum, Install the shift fork shaft so that the oil hole end is toward the right. Install the shift forks onto the shah. Ill SHIFT FORKS I3) SHIFT FORK SHAFT (1] LEFT SHIFT FORK TRANSMISSION I2l LOCK WASHER AND BOLT (4i SHIFT DRUM l2) OIL HOLE (5) BEARING STOPPEH PLATE (3i SHIFT FORK SHAFT 13-5 HONDA. VF'I OOOF TRANSMISSION (1) LOCK WASHER (2) BOLT Install a new lock washer and the bolt to the center . ' shift fork and tlghten the bolt. TORQUE: 16—20 N-m (1.6—2.0 kg-m,12—14 ft-lb) Bend up the lock washer’s tabs, Apply a locklng agent to the screw threads and install the bearing stopper plates. (31 BEAING s'TOPPER PLATES (H DRlVEH TRANSMISSIIJN ASSEMBLY 0774641030100 MAINSHAFT Install the mainshaft bearing with the special tools. (2] A'I'I'ACHMENT, 25 mm ID. 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, (l) MAlNSHAFT/Ml HST) M4 (251T) (19/22T) M5 (27Tl 13-6 HONDA VF'I OOOF TRANSMISSION COUNTERSHAFT Before installing the countershaft in the crankcase, insxall (he C5 gear and snap ring. @@ CS (33T) C1 (411') C4 (31T) CZ (SGT) C5 (281') (1) C3 GEAR Install the C3 gear and spline collar. Install she stupper washer while aligning the tab of the stopper Washer with the groove in lhe spline collar, Assemble the CZ, C4 and C1 gears, washers and collars. (2) SPLINE COLLAR (3i STOPPER WASHER CAUTION Align the oil holes in [heisplirxcd kinking: wilh [he ail hole: in the wmumhnfl. 13-7 HONDA VFI OOOF TRANSMISSION (1) COUNTERSHAFT BEARING HOLDER InslaH the coumershaft bearing holder bolts and tighten them. TORQUE: 21—25 N-m (2.1~2.5 kg-m, 15—18 ft-lbI Check she! the oil orifice is clear‘ (2) OIL ORIFICE (II MAINSHAFT Install the mainshafll than reassemble the upper and " Iower crankcase (see Section 11). we. ‘9 B? - ‘ z 13-8 $213239 14 FAIHING 14-0 HONDA FAIRING VF'I OOOF 14-0 HONDA FAIRING VF'IOOOF senvncz INFORMATION 1471 LOWER com 14_2 FAIRING 14—2 FAIRING BRACKET 14—3 SERVICE INFflRMATlflN GENERAL 0 The fairing bracket can be removed without removing the upper radiator. 14-1 FAIRING LflWER BOWL REMOVAL/INSTALLATION Remove the (our lower cowl attaching screws and the lower cowl. Install the lower cowl in the reverse order of re» moval. FAIRINE REMOVAL/INSTALLATION Remove the (WD fairing mount bolts and fairing. (“SCREWS viii/5; l2) LOWER COWL (ll FAIRING 12) MOUNT BOLT HONDA VF'I 00°F 14-2 HONDA VF‘I 00°F FAIRING Install the fairing aligning Its grooves with the rub- ber mounts on the fairing bracket and fuel tank, Tighten the two fairing mount bolts. (TJGROOVES FAIRING BRACKET (1lCOOLANT FILLER NECK l2lOVERFLOW TUBE REMOVAL Remove the fairing (page 144), Remove the headlight [page 1442]. Drain an amount of coolant for filler neck into a 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 HON DA VF'I OOOF Remove the horn by removing the bolt. Remove the two radiator grille mount hairs and grille. Remove the Instruments (page 21714) Disconnect aH wire couplers and connectors at the fairing bracket Remove the fairing bracket mount bo‘ts and bracket from the lrame. (1) HORN (2D BOLT (3) INSTRUMENTS (5) RADIATOR GRILLE (4) BOLT (1} WIRE COUPLERS/CONNECTORS (H FAIRING BRACKET [2) MOUNT BOLTS 14-4 HONDA VF'I OOOF FAIRING INSTALLATION Install the fairing bracket in the reverse order of removalt NOTE After installation, fill the filler neck with coolant. 14-5 15 FRONT WHEEL/SUSPENSION 15-0 HONDA VF] 00°F FRONT WHEEL/SUSPENSION 20—30 N«m (LO—3.0 kg-m, 14—22 mm !’ f %/ 30—40 N-m (go—4.0 kg-m, 22—29 ft-Jb E? / 90—120 N-m ) "_ % (so—12.0 kg-m, 20—30 N-m (2.0—3.0 kg-m, 14—22 ft~|b) > ‘ 65—87 ftrlb) 45—55 Nrm (4.5—5.5 kg-m, 33—40 mm 30740 N-m (30—49 kg-m, 22—29 M-lb) 30—40 N-m (3.0—4.0 kg-m, 22—29 ft~|b) Q3 55—65 N-m / (5.5—6.5 kg-m, 40—47 h~|b) a 18—25 N-m / (1 .8—25 kgAm, 13—18ft-lb) 10—15 N-m (Lo—1,5 kg-m, 7—9 mm 15-0 HONDA FRONT WHEEL/SUSPENSION SERVICE INFORMATION 15—1 FRONT WHEEL 15—7 TROUBLESHOOTING 15—2 FRONT FORKS 15—15 HANDLEBARS SERVICE IIIFIIIIMIITIIIII GENERAL 15—3 STEERING STEM o A lack or other support is required to support the front of the motorcycla when you are working on the front wheel or fork SPECIFICATIONS STANDARD SERVICE LIMIT Axle shaft runout # 0.2 mm (001 in] From wheel rim runout Radiai — 2.0 mm (008 in) Axiai — 2.0 mm (0.08 in] Fork spring free length 413.8 mm (16.29 in) 405.5 mm (153 in] Fork tube runout - [12 mm (0.01 in) Front Iork fluid capacity Right 380 cc [12.9 US oz, 13.4 Imp) Left 400 cc (13.5 US oz, 14.1 Imp) Front fork air pressure 0—40 kPa (0—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 baits Handlebar pinch bolts Front brake caliper bracket mount bolts Antidive piston pin bolt Front brake disc Front fork cap Front fork socket bolt AntiAdive case socket bolts 90-120 N‘m (SO—12.0 kg-m, 65—87 h-lb) 23—27 N-m (23—27 kg~m, 17—20 ft~lb) 20—30 N-m (Zn—3.0 kg»m, 14—22 ft-ib) 18—25 N-mI1‘8—2.5 kg-m,13-18 h-ib) 55—65 N-m (5.5-6.5 kg-m, 40—47 h-lb) 20—30 N-m (2,0—10 kg-m, 14—22 It-lb) 45—55 N-m (4.5—5‘5 kg-m, 32—40 ft-Ib) 30—40 Nrm (lo—4.0 kg-m, 22—29 It-lb) 30—40 N-m (lo—4.0 kgvm, 22—29 ft-lb) 10—15 N-m (10-1.5 kgrm, 7—9 ft-lb) 35—40 N«m (3.5—4.0 kgm, 25—29 ft-lbi 15—30 N«m(1,5—3.0 kg-m, 11—22 ft-lb) 15—25 N-m (1.5—2.5 kg-m, 11—18It-lb) 6—9 N«m (0.6—0.9 kg-m, 4—7 ft-lb) 15-1 HONDA VF'I OOOF TOOLS Special Hex, wrnech, 6 mm Snap ring pliers Fork seal driver Fork seal driver attachment Steering stem socket Bearing race remover Ball race removar Steering stern driver 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 shalt Bearing remover head, 15 mm TROUBLESHDDTING Hard steering 1. Steering bearing adiustrnent nut too tight 2. Flulty steering stern bearings 3. Damaged steering stem bearings 4. Insufficient tire pressure Steers to ona sidl or does not track straight 1. Sent forks 2. Sent front axle 3. Wheel installed incorrectly Front whul wobbling 1. Bent rim 2. Worn front wheel bearings 3. Faulty lire 4t 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 miss 1. Worn slider or guide bushlngs 2. Insufficient fluid in forks 3. Loose from fork fasteners 4. Lack of grease in speadameter gearbox 0791773230000 0791473230001 079477KA50000 07947- KFOOlOO 07916—371010!) 07946—371050!) 07953—4250002 079467M800000 07749 0010000 0774643010300 07746 70040300 07716 —0020400 07716—0020500 07746 — 0010400 07746 0050100 07746 70050400 FRONT WHEEL/SUSPENSION 15-2 HONDA VF'I OOOF FRONT WHEEL/SUSPENSION HANDLEBARS (1) FRONT BRAKE MASTER CYLINDER REMOVAL Disconnect the front brake swnch wires, Remove the from brake master cylinder. (1| RIGHT HANDLEBAR SWITCH Remove the right hand‘ebar switch. (1) CLUTCH MASTER CYLINDER Disconnect the clutch switch wires, Remove the clutch master cylmder. 15-3 Remove the len handlebar switch, Disconnect the choke cable from the choke lever. Remove xhe Ith and righl handlebar retainer rlngs. Lousen the left and right handlebar pinch bolts. Remove the handlebars from the fork tubes. Remove me throttle grip from the right handlebarv FRONT WHEEL/SUSPENSION (1) LEFT HANDLEBAR SWITCH ll) CHOKE LEVER {YD CHOKE CABLE [H STOPPER RING (2) HANDLEBAR PlNCHBOLT 1 5-4 HONDA VF'I 00°F FRONT WHEEL/SUSPENSION INSTALLATION Apply grease to the throttle grip sliding surface and slide the throttle grip over the handIebar. III RETAINER RING Install the handlebars onto the fork tubes, aligning the pin on the bottem of the handIebar with the cutout in the top bridge. Tighten the handlebar pinch boltsv TORQUE: 30—40 N~m (3.0—4.0 kg-m, 22—29 h-Ih) Install the handlebar retainer ringsr IZI PINCH BOLT (I) HOLE Align the right handlebar swuch [coating 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. 12) LOCATING PIN 15-5 HONDA VF'I OOOF Place the front brake master cylinder 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. 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 SWlICl’lV Tighten the upper screw first, then tighten the lower screw. 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. lll FRONT BRAKE MASTER CYLINDER l3) PUNCH MARK l1) “UP” MARK l3) lNDEX MARK FRONT WHEEL/SUSPENSION ‘4) INDEX MARK l2) LOCATING PlN lZl “UP” MARK (5) HOLDER (Zl CLUTCH MASTER CYLINDER (4i PUNCH MARK 15 6 HONDA VF'I OOOF FRONT WHEEL/SUSPENSION FRONT WHEEL REMOVAL Remove the right from brake caliper from the fork leg. Remove the rlght axle holder‘ NOTE lf you squeeze the lronr brake lever after [he caliper is removed, the callper piston will move out and make reassembly difficult, (1) RIGHT FRONT CALIPER l1} LEFT FRONT CALIPER Remove the speedometer cable set screw and dlS' connect the speedometer cable. Remove the left from caliper from the fork leg and ami-dive piston case Remove the lefi axle holder [2) AXLE HOLDER 1H AXLE NUT DISASSEMBLY Remove the from axle nut and axle. 15-7 HONDA VF'I OOOF Remove the spacer from the right side. Remove (he speedometer gear box from the Ieft side. Remove the left and right brake disc mounting boIts and discs. Remove the dust seaI from both sides. Remove the speedometer ratamer from the left SldE. WHEEL BEARING INSPECTION Check wheel bearing play by placing the wheel in a truing stand and spinning the wheeI by hand, Replace the bearings with new ones if they are noisy or have excessive pIay. I1I SPACER FRONT WHEEL/SUSPENSION IZI SPEEDOMETER GEAR BOX IIIBRAKE DISC 15-8 ‘ FRONT WHEEL/SUSPENSION HONDA VF'I OOOF WHEEL INSPECTION Check the rim runout by placing the wheel In a truing stand, Spin (he wheel slowly and read the runoux 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 repaired and must be replaced with a new one if the service limits are exceeded. AXLE INSPECTION Se! Ihe axle If! v blocks and measure the runout, SERVICE LIMIT: 0,2 mm (001 in) WHEEL BEARING REMOVAL If Ihe bearing need replacement remove the bear ings and distance coilar NOTE Never reinsIaII old bearings: once the bearings are removed, Ihev must be replaced with new ones. Iii BEARING REMOVER SHAFT 07746—0050100 12) BEARING REMOVER HEAD 07746—0050400 15-9 HONDA V" 00°F FRONT WHEEL/SUSPENSION ASSEMBLY Do not gér grensr on the brakr disc or Slopp- ing pawer will be minced. NOTE The cast wheel has no rim band. The from wheel uses a tubeless fire. For tubelsss (ire repair, refer to the Honda Tubeless Tire Manual. 11] DRIVE R 0774970010000 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 Doslllon ‘ 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 our. n v D (2) ATTACHMENT, 42 x 47 mm 07746—0010300 (3) PILOT, 15 mm 07746—0040300 15-10 HONDA VF'I OOOF FRONT WHEEL/SUSPENSION [ll SPEEDOMETER GEAR RETAINER Install the speedometer gear retainer in the left sIde ‘ a! the wheel hub, aligning Its tangs with the slots In the hub Install the left dust seal. (2) ALIGN (l)”L"MARK (ZJBRAKE DISC Place new gaskets on the disc mounting flange, then ‘ Install the left disc with its "L" mark facing out, Tlghten the dlsc mounting bolts. TORQUE: 35—40 NAm (3.5—4.0 kg-m, 25—29 ft-lb) (I) "R" MARK l2l SPACER Install the right dust seal. Place new gaskets on the disc mounting flange, then Install the right dlsc with its “Fl” mark faclng out, Tighten the mounting bolt to the same torque as left SIdE‘ Install the spacer. \ (3| DUST SEAL 15-11 HONDA V“ 00°F FRONT WHEEL/SUSPENSION lilDRIVE GEAR Fl” the speedometer gearbox with grease and install the plain washer and drive gear, l Install the speedometer gearbox in the wheel hub, aligning the tangs with the slots, l2) TANGS (3| SLOTS (1] AXLE NUT Install the front axle and axle nut. Tighten the axle nut. TORQUE: 55—65 N-m (5.5—6.5 kg-m, 40—70 h-Ib) NOTE rThere 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. ? HONDA VFI OOOF FRONT WHEEL/SUSPENSION (1) TIRE BALANCE MARK WHEEL BALANCE ‘ \ ' CAUTION 7 7 Wheel balance directly affects the stability, handling and overall tafer ofthe motorcycle. Always check balance when the tire has been removedfrom the rim. NOTE For optimum balance, the tire balance mark la paint dot on the side wall) must be located next to the valve stem. Remount the tire it necessary. Remove the dust seal and speedometer gearbox from the wheel. I2) 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 Iheavrestl 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 conr slstentlv in the same position. To balance the wheel, Install wheel weights on the highest side of the rlm, 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 I‘IITANG (ZILUG INSTALLATION Positlon 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. InstaIl the axle holders with the arrow pointing (onward. ISIARROW MAR 15-13 HONDA VF'I OOOF Install the right from caliper and tighten the bracket mount bolts. TORQUE: 30—40 N-m (3.0—4.0 kg-m, 22—29 ff-Ib) Tighten the right axle holder nuts to the specified torque, starting with the forward nut. TORQUE: 13-25 N-m (1.8—2.5 kq-m,13—18 h-lh) Install the left front caliper. Tighten the anti-dive piston pin bolt. TORQUE: 10—15 Nam (1.0—1.5 kg-m, 7—9 ft-lh) Tighten the caliper bracket mount bolt. TORQUE: 30—40 N-m (3.0—4.0 kn-m, 22—29 fl-lb) Connect the speedometer cable and secure it with the screw. Measure the clearance between each surface of the left brake dist: and the left caliper holder with a 07 mm (0.023 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 until the gauge can be inserted, After installing the wheel, apply the brake several times, then recheck both discs for caliper holder to dlsc clearance. Failure to proud}; adequate disc :0 caliller holder clearance may damage the brake dist and impair brake efficiency. FRONT WHEEL/SUSPENSION (ll CALIPER BRACKET MOUNT BOLTS ' - l2) ANTI-DIVE PIVOT BOLT (ll CALIPER HOLDER [2| BRAKE DISC 15-14 FRONT WHEEL/SUSPENSION FRIJNT FIJRKS REMOVAL Remove the following parts: — fairing. ~ headlight. ~ instruments. — handlebars. — frontwheel. — front fender and fork brace. Loosen the fork upper and lower pinch bolts. Pull each furk tune 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 fark stop rings Pull each fork tube out of the for bottom bridge. HONDA VF 1 00°F l1) FROK BRACE (2i FRONT FENDER (l l UPPER PINCH BOLTS (I) FORK STOP RING 15-15 HONDA VF'I OOOF FRONT WHEEL/SUSPENSION If replacement of the ioim is necessary, remove the two screws which attach the fork air joint to the top bridge. DISASSEMBLY He‘d rhe fork tube in a vise, with soft jaws or shop towel and remove the fark tube can CAUTION Do not dame; the sliding surface 7 Remove the fork spring, space and washer. Drain {he fork fluid by pumping the fork up and down several times. ('H FORK CAP ." H) SPRING (2}SPACER I (3} WASHER FRONT WHEEL/SUSPENSION Hold the fork slider m a vrse wlth soft iaws or a shop towel. Remove the socket bolt with a hex wrench. NOTE Temporarily instaH the springiarnd fork can if deicultv is encountered in removing the socket bolt. The piston and rebound spring can be removed (mm the right fork, Remove the dust sear, grease seal and washer. Remove the snap ring. HONDA VF1 OOOF (1) HEX WRENCH 6 mm 0791773230000 (“WASHER (ZJGREASE SEAL (3]DUST SEAL [1) SNAP RING PLIERS 0791445230001 (2) SNAP RING 15-17 HONDA VF'I OOOF Pull the fork tube out until resistance from the slider bushing ls felt. Then move it in and out, tapping the bushing lightly until rhe fork lube separates from the slider. The slider bushing will be forced our by the lurk tube bushing. Remove the oil lock piece from inside the slider. Remove the oil seal, back-up ring and slider bushing from the fork tube. NOTE Do not remove the fork tube bushings unless rt is necessary to replace it with a new one. On the lefr fork, remove the circlip, oil lock valve] spring, and spring seat from the piston. Remove the pisxon and rebound spring from me fork tube. (“FOR {HOIL SEAL K TUBE FRONT WHEEL/SUSPENSION (2) FORK SLIDER (2) BACK-UP RING l3) SLIDER BUSHING (4) FORK TUBE BUSHINGS (USPHING SEAT (3) SPRING (4)0lL LOCK VALVE (2) PISTON (5) CIRCLIP 15-18 FRONT WHEEL/SUSPENSION INSPECTION FORK SPRING FREE LENGTH Measure the fork spring free length, SERVICE LIMIT: 405.5 mm [1549 in) FORK TUBE/FORK SLIDER/PISTON Check the fork tuba, fork slider and pismn for score marks, scraiches, or excessive or abnormal wear. Replace any components which are worn or damaged. Check the fork piston ring for wear ar damage, Check the rebound spring for fatigue or damage. FORK TUBE Set the fork tube in V blocks and check its runout. SERVICE LIMIT: 0.20 mm (0.008 in) HONDA V F 1 00°F (3] PISTON RING MIFORK TUBE (2) PISTON \ /§ (1) REBOUND SPRING 33 (BISLIDER 15-19 HONDA VF TOOOF BUSHING/BACKUP RING Visually Inspect the sIIder and fork tube bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon IS worn so that the cop~ per surface appears on more than 3/4 oi the entlre surface. Check the back-up ring; replace it if them Is any distortion at the poms shown. ANTI-DIVE CASE Remove the four socket bolts and remove the arm'- dive case. Remove the piston and spring Remove the boots, DISIOI’I pin boIt coIIar and smp rubber. Check the spring and pistion Iur wear or damage. FRONT WHEEL/SUSPENSION (1) BUSHING (RI BACK-UP RING segé (4ICHECK POINTS (ZICOPPER SURFACES IIISPRING 3, “H IIICASE IZI (3) PISTON PISTON PIN BOLT COLLAR I4I0 RINGS (SI BOOT 15-20 FRONT WHEEL/SUSPENSION HONDA VF1 OOOF Remove setting screw, adjuster and orifice. Remove the check valve setting screw, valve spring and check ball. 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 fi- Apply a Thread Lock Agent to the threads ‘ of the screws and socket bolts before as sembly. Apply ATF m the piston and piston 0- ring, ‘ Apply silicone grease to the pivot bolt collar. Check the operation of the collar and piston. [1 l ADJUSTER (i) ORIFlCE \\ I .?~ \3: /"\ l5) SETTING SCREW (4) ADJUSTER 12) CHECK BALL (ZlSETTlNG SCREW (3) CHECK VALVE SETTING SCREW l3lSPFl|NG Vs; \ (EiSETl'lNG SCREW 15-21 HONDA VF'I 00°F FRONT WHEEL/SUSPENSION ASSEMBLY Before assembly, wash all parts with a high flash point nr non~flammabla solvent and wipe them off completely. (9) DUST SEAL p (UFOHKCA HO) u % OIL SEAL g gm [m BACK-UP RING (2i SPACER ‘ unsuoen BUSHING i (14) SLIDER ‘ 5 % Q (3 @73sz % 06 Q Q / WW CI HEIANTl-DIVE CASE (3iFISTON g TUBE mom LOCK EUSHINGS VALVE (8) REBOUND SPRING 113IO|L LOCK PIECE (1) SPRING SEAT (2]CIRCLIP Insth the rebound spring and piston into the fork ,, tubet On the left fork] instali the spring seat, valve spring, oil iock vaive and circlip on the piston‘ // (3)P|STON (4)5PRING (5)0lL LOCK VALVE 15-22 HONDA VFI 00°F FRONT WHEEL/SUSPENSION (ll (2] l3) OIL LOCK LEFT RIGHT PIECE Place the oil lock piece on the end of the piston. "BE 7 , , ,7 ‘ On the right fork, install the oil lock piece, 7 aligning the flats of the oil lock piece and piston and (4lOIL LOCK PIECE (5) FLATS (“DRAIN BOLT Insert the fork tube into the slider. NOTE [5 On the right fol, align the cutout OTUEO lock piece with the drain bolt in the slider. {2)CUTOUT Place the fork slider in a vise with soft jaws or a shop IOWEI. Apply a locking agent to the socket bolt and thread it into the piston. Tighten with a 6 mm hex wrench. NOTE Tempororily install the fork spring and fork cap bolt to tighten the socket bolt. TORQUE: 15—25 N-m (1.5—2.5 kn-m, 11—13 ft—lh} 15-23 HONDA VF'I OOOF 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 driven Install the snap ring with its radiused edge facing down and install the washer, oil felt and dust cover, Pour the specified amount of ATF into the fork tube. CAPAClTV: Right fork: 380 cc (12.9 US oz, 13.4 imp) Left fork: 400 no (135 US 01, 14.1 imp) Compress the front fork and measure the oil level from the top of the tube, SPECIFIED LEVEL: Right fork: 230 mm (9.0 in) Left fork: 230 mm (90 In] (1) FORK SEAL DRIVER 07947 7 KASOOOO \ l2l ATTACHMENT 07947—KF0010 [llSNAP RING PLIERS 07914—3230001 FRONT WHEEL/SUSPENSION (Z) DUST SEAL (3lFELT SEAL (All WASHER (bi SNAP RlNG l6) OIL SEAL l7lBACK»UP RING 2.30 mm (90 in) FRONT WHEEL/SUSPENSION Inskall the fork spnng, spring seal and spacer m Xhe fork tubev NOTE 7BR”.- xhe sprrifisilralrgmiun; ma small can end 9395‘ face wward theibonom, lns‘all and torque the fork mbe capr NOTE 0n me righl fovkialiigin the caxéix} on me damr ping adjuster rod with (he fla‘ side in the ‘ piston. 77,! TORQUE: 15730 NAm (1.6—3.0 kg-m, 11722 “VIN INSTALLATION Make sure the air joint O-rings are in good condiiion and apply grease to them. HONDA. VF'I OOOF m (2) Top BOTTOM (1) FORK TUBE CAP “JO-RINGS [2)AIR JOINT 15-25 HONDA VF'I OOOF mom WHEEL/SUSPENSION [HTOP BRIDGE [ZlSCBEWS Install the alt joint onto the fork top bridge and tighten the two screws, Install the fovks and temporarily tighten the botmm pinch bolts, Install the fork stop rlngs ln the qmovas ln the fork tube. Push the tork tubes up until the stop rings contact the air joints. l1) FORK STOP RING Tighten the bottom plnch boltsv TORQUE: 45—55 N-m [4.5—5.5 kg-m, 33—40 H-lbl “J FRONT WHEEL/SUSPENSION HONDA VFI OOOF Tighten the top pinch bollst TORQUE: 20—30 N-m (2.0—3.0 kg-m, 14-22 ft-lh) Loosely install the fork bracet Install the removed parts in the reverse order of removal, 4 from fender. 7 handlebars, — from wheel. 7 fairingl Wllh the from brake applled, pump the forks up and down several tunes. Tighten the front furk brace mounting haltsl TORQUE: 24—30 N-m (2.4—3.0 kg-m. 17 ~— 22 h-Ib) Fill the fork tubes With alr‘ RECOMMENDER PRESSURE: 0—40 kPa (0—0.4 kg/r:m2 , 0—6 psi) CAUTION Use nnly a handopcmled air pump 1:) fill the fork tubes. 00 m)! use compressed air. Maximum pressure is 300 kHz (3 kg/cm‘, 43 psi). Do m1! exceed (his or fork mbv component damage many occur. With the from brake applied, pump the forks up and down several times. Place the motorcycle on its center stand. Check the air pressure and adjust it necessary. ll) TOP PINCH BOLTS l1 lFRONT FORK ERACE (ll FRONT FENDER 15-27 HONDA VF‘I OOOF STEERING STEM REMOVAL Remuve the following components. — fairmq. — iuse box, 7 handiebars. — frontwneet. 7 brake hose 3an joinl. Loosen and remove the steering stem nut. Remove the forks. Loosen the top bndge pinch bolt and remove the top bridge with the fork an joint. Straighten the lock washer tabs and remove the lock nut and lock washer. FRONT WHEEL/SUSPENSION {7’ EXTENSION 07716—0020500 OR EQUIVALENT U.S.A. (IILOCK WASHER 12)LOCK NUT 15-28 HONDA VF1 OOOF FRONT WHEEL/SUSPENSION (H STEERING STEM SOCKET 07916—371010!) 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 me grease retainer. Remove thu bearing inner race and dust seal from the steering stem. (1| DUST SEAL 12) BEARING INNER RACE Remove the upper bearing race With the special (00L (1) BALL RACE HEMOVER 07953i4250002 15-29 HONDA. V“ 00°F FRONT WHEEL/SUSPENSION (I) BALL RACE REMOVER 07953 4250002 Remove the lower bearing race with the special tool. NOTE If the motorcycle has been involved in an T accident, examine the area around the steering head for cracks. J (7) BEARING RACE REMOVER 07946—3710500 m LOCK NUTfiflg—g i2) LOCK WASHER (3| BEARING ADJUSTMENT _, NUT mm 141 UPPER BEARING INNER @K— DUST SEAL RACE NS i5! UPPER BEARING OUTER W m, RACE \‘Q UPPER BEARING I6] GREASE RETAINER “g [7) LOWER BEARING OUTER RACE \® I8) LOWER BEARING INNER (12) RACE \@ \ LOWER BEARING 19) DUST SEAL ——>® III DRIVER (2i ATTACHMENT, 52x55mm D7749~0010000 0774670010400 Drive the upper bearing outer race into the steering head. Drive the iower bearing outer race into the steering head. t I3I ATTACHMENT, 42 X 47 mm III DRIVER 07749—0010000 07746—001030!) 15-30 FRONT WHEEL/SUSPENSION Install a dust seal onto the steering stem and press the lower bearing inner race over the stem with the special tool. INSTALLATION Pack the bearing cavities with bearing ease. Install the lower hearing and grease retainer onto the steering stem, [hen insert the steering stern into the steering head. Install the upper bearing and inner race. Install and tighten the adjusting nut to the specified torque, TORQUE: 23—27 N-m (2.3—2.7 kg-m, 14-22 hslh) HON DA VF'I 00°F (1) STEERING STEM DRIVER D7946—M800000 (1) UPPER BEARING 12) LOVIIER BEARING II) STEERING STEM SOCKET 07916—3710100 15-31 7 HONDA VF'I OOOF g Turn the steering stem locklorlock 475 times (D seat the bearings, then tighten the nut to the same torque. Install a new beanng adjustment nut lock washer allgnlng the tabs wlth the grouves In the nut. Bend two opposite tabs down into the grooves NOTE 700 NOT lnstall a used bearlng adlustment L nut lock washer. Hand nghten the luck nut Hold the adjustment nut and turther trghten the look nut only enough to allgn lts grooves With the luck washer (abs. NOTE It the lock nut grooves cannot be easily allgned with the lock washer tabs, remove the nut, turn it over and reinstall it. Bend twu lock washer tabs up into the lack nut grooves, Install the top bridge with the fork alr joint, lnstall the front lorks lpage 1525). Install and tlghten the steerlng stem nut TORQUE: 90—120 N-m (511—12.!) kg-m, 65—87 h-lb) FRONT WHEEL/SUSPENSION (It LOCK NUT (Zl LOCK WASHER l1) EXTENSION 0771670020500 (2] LOCK NUT WRENCH] 30 x 32 mm 07716—0020400 15-32 FRONT WHEEL/SUSPENSION STEERING HEAD BEARING PRELOAD mm” the from wheel (93991543). Place a stand under {he engine and rawse the from mm a" m. ground. Pusmon the steering stem [0 (he straight ahead posm'on. Hook 4 SDHHQ scale m xhe fork tune and measure the steermq head bearlng preload. NOTE FMakc mrc [hat (hem is no cable and wxre 1 halness mm lerence. \ g 7 W 4 The preload shou‘d be wlthln 104,6 kg 12114.53 lb) (or V'lghl and left mm; H the veamngs do nm (aH wixhin the range, lower the Mom wheel and adjun the bearing adiuslrnenl mu. After maka sum the bearmg pveload is acceptab‘e, mataH me removed part5 m the reverse ovder of remova‘. (1) SPRING SCALE (commercially availabie) 15-33 g5 $3333? 16 REAR WHEEL/SUSPENSION 16-0 HONDA REAR WHEEL/SUSPENSION ' VF'I OOOF 40—50 N-m (4.0—5‘0 kg-m, 29—36 h~lb) 40—50 N-m (MEI—5,0 kg-m, 29—36 ft-lb) 85-105 N-m - (8.57105 kg»m, 61 —76 h-lb) N 30—40 N‘m (an—4,0 kg-m, 40750 N-m . ; 22—29 Mb) (40—50 kg-m, 29—36 h-Ib) 80—100 N-m 15.0—10.0 kg-rn, 58—72 fi-lb) 18—25 N-m (1.0—2.5 kg‘m, 13—18 fl-lb) 20 30 Nm (2.07110 kg-m, 14 > 22 "413) 85—105 Nrm 18,5~10‘5 kg-m, 61~76 H-lb) 16-0 HONDA VF'I 00°F REAR WHEEL/SUSPENSION REAR WHEEL SWINGARM SERVICE INFORMATION TROUBLESHOOTING SHOCK ABSORBER 16—1 16—2 16—3 16—9 16—15 SERVICE INFURMATIIIN GENERAL n The rear wheeI uses a Tubeless lire. For tubeless Iire repairs, refer m the TUEELESS TIRE MANUAL SPECIFICATIONS 7 STANDARD SERVICE LIMIT Axle runcor — 0.2 mm [001 in) Rear wheel rim runout Radial 7 2.0 mm (0.06 in] Axial fl — 2.0 mrqlgrga in) Shock absorber airfissure TORQUE VALUES Shock arm-to»frame bolts Shock Ilnk-to-shuck arm boll Rear shock absorber mount bolts Swingarm pinch bolr Swingarm pivor bolrs Rear brake torque rod 8 mm 10 mm Final driven sprocket Rear brake dlsc Rear axle nut TOO LS Special Needle bearing remover Oil seal driver anachment OII seal driver attachment rrng Oil seal dnver Common Anachmenr, 32 x 35 mm Aitachmenr, 37 x 40 mm Artachment, 42 x 47 mm Attachmenr, 52 x 55 mm Attachment, 62 x 68 mm Pilot, 17 mm Pilot, 20 mm Pilot, 25 mm Driver Bearing remover shah Bearing remover head, 20 mm 07300 kPaTOrEifl (grunt, o 543 psl) 40—60 N-m (4.0—5.0 kg»m, 29736 beI 40—50 N-m (40—50 kg-m, 29736 fr-lbl 40-50 N-m MAJ—5,0 kg-m, 29—36 fr-Ibl 20v30 Nrm (2.0—3.0 kg-m, 14—22 beI 85—105 Nrm (8.5—105 kg-m. 61—76fl-Ib) 13—25 N-mI1.B—2.5 kg-m,13718fr-lbl 30740 N-m [3.0—4.0 kg-m, 22729 h-lb) 80—100 N~m (8 0—100 kg~m, 58—72 it-lh) 35—40 N-m (3.5—4.0 kg-m, 25—29 fr-lb) 35—105 N~m18‘5#10.5 kg-m, 61776 fl-lbl 07931—MA70000 07965 MBOO‘IOO 079657ME70100 079657MC7O100 07746—001010!) 07746—0010200 07746—0010300 07746—0010400 07746v0010500 0774670040400 07746—0040500 07746—0040600 07749~0010000 07746—0050100 07746—0050600 REAR WHEEL/SUSPENSION TRUUBLESHUUTING Oscillation . Bent rim . Loose wheel bearings . Faulty tire . Loose axle . Tire pressure incurrem . Swmgarm bearmgs warn , Worn (ires Nmmbuwa Soft suspension 1. Weak spring 2. lnsufficrent fluid m shock absorber 3. Shock absorber air pressure incorrect Hard suspension 1. Incorrect "Uld weight m shock absorber 2. Bent shock absorber 3. Shock absorber air prBssure incorrect Sum-mien min 1. Shock case binding 2. Loose fasteners HONDA VF'I OOOF 16-2 HONDA VF‘I OOOF REAR WHEEL/SUSPENSION REAR WHEEL R EMOVA L Place the motatcche on Its center stand. Loosen the drive chain ad[usting bolts lock nuts and the adiusting boIts. Remove the axle nut and axle. Push the wheel forward and remove the drive them from the drlvefl sprocket and remove the rear wheeI‘ NOTE If you depress the brake pedal after the rear wheel Is removed the caliper piston wiII move out and make reassembly difficult DISASSEMBLY Remove the rear brake dISC. Remove the dust seal. Remove the tmal driven sprocket and driven flange together. NOTE Do not separate the driven sprocket and flange, unless replacement or the driven sprocket or flange ls necessarv. Remove the dust seal Irom the final driven Ilange, I) LOCK NUT l I 0 IE) DRIVE CHAIN ADJUSTING BOLT (13] AXLE NUT III REAR BRAKE DISC IZI DUST SEAL III FINAL DRIVEN SPROCKET V I2) DUST SEAL [3) FINAL DRIVEN FLANGE 16-3 REAR WHEEL/SUSPENSION 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 the wheel by hand. Replace the bearings with new ones if they are noisy or have excessive play. REAR WHEEL RIM RUNOUT Check the rim fur 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 (0.03 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 HON DA VF 'l 000 F W @VLIFLAY HONDA VF'I OOOF FINAL DRIVEN SPROCKET Check the condition of the final driven sprocket teeth. Replace the sprocket if worn or distorted NOTE II the finaI driven sprocket requires replace ment, inspect the drive chain and drive ‘ sprocket. DAMPER RUBBERS Replace the damper rubbers If they are damaged or deteriorated. 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, REAR WHEEL/SUSPENSION Ii) GOOD (ZI REPLACE (1i DAMPER RUBBER III BEARING REMOVER SHAFT 0774670050100 (2I BEARING REMOVER HEAD, 20 mm 0774670050600 16-5 HONDA VF'I OOOF HEAR WHEEL/SUSPENSION 11) AXLE SLEEVE Remove the rear axie sleeve, Remove the snap ring. Drive the drwen flange bearing out. . I" 12) DRIVEN FLANGE BEARING [2| ATTACHMENT, 52 x 55 mm (3) ATTACHMENT, 42 x 47 mm 0774670010400 07746—0010300 PILOT,20 mm PILOT,20 mm 0774670040500 07746—0040500 - r Pack EH bearing Cavities with grease, Press distance coHar into place from (he left side. Drive (he right hearing In first, then [he left bearing. CAUTION ’5 Brim [he begrirlgs in :quah'TIyTWIt/z thieixealerfl end fiwing am, making sure they are fully { ' seared. _ a [H DRIVER 07749—0010000 16-6 HONDA (1) DRIVER 07749—0010000 Drive me driven flange bearing in. ' DRIVE R 0774970010000 ATTACHMENT] 62 x 68 mm 07746—0010500 Pl LOT, 25 mm 07746—0040600 ENJng Drive the having: in squarely with the n:an L'ml facing ouL "mkng sure (Iwy are fix/[y L scan-d. Install the snap ring and rear ax‘e sleeve. VF'I OOOF REAR WHEEL/SUSPENSION (2) ATTACHMENT, 32 x 68 mm 07746—0040500 PILOT, 25 mm 07746—001050!) ASSEMBLY NOTE The rear wheel uses a (ubeless tire, For tube- Iess fire repairs, refer to the Tubeless Tire LManual. Du nut gel {rem an [hfiafe disc or xtop- _ ping pa wer will he redm‘ed. 35—40 N-m (S‘s—4.0 kg-m, 25—29 mm (HFINAL DRIVEN FLANGE 80—100 N-m 13) DISC (4]FINAL omven ,fii % SPROCKET [8.0—100 kg-m, 58772 ft-Ib) 16-7 REAR WHEEL/SUSPENSION HONDA VF'I 00°F Install the rear axle sleeve, fmal driven flange and driven sprocket, If lhe driven sprocket was removed from the flange, tighten the driven sprouke‘ nu‘s m the specified torque. TORQUE: 80—100 N-m (SD—10.0 kg—m, 53—72 ft-lb) Install the dust seal. Install the brake mic and (ighten (he bolts. TORQUE: 35—00 N-m (3.5—4.0 kg-m, 25—29 fl-lb) Install the dusl seal, Install the left and right side spacers [1) DRIVEN FLANGE 12) DRIVEN SPROCKET 13) DUST SEAL (1) REAR BRAKE DISC 12) DUST SEAL l‘ll LEFT SlDE SPACER (2) RIGHT SIDE SPACER 16-8 Ii()nfll)1& VFIOOOF INSTALLATION Install the rear wheel in the reverse order of re- moval, NOTE ,7 , 7 W ' When lnstalling the wheel, carefully flt the brake dlSE between the brake pads. After installing the wheel, apply the brake several times. Then check that the wheel rotates freely Recheck wheel installation l It the brake drags or m the wheel does not L VDIBIE lreelv. J Tighten the rear axle nut. TORQUE: 85—105 N-m(8.5~10‘5 k9»m, 61—76 ft-lh) Adlusl the drlve chain slack (page 3-13)‘ SHIJCK ABSIJRBER REMOVAL Place the motorcycle on its center stand Remove the seat and lelt frame swde cover. Remove the breathev separator and the electric panel. Remove the battevv, Remave the rear shock absorber dampmg lorce knob from the heme by loosening the lock nut. REAR WH EEL/SUSPENSION (H LOCK NUT lzl BATTERY [3) DAMPING FORCE KNOB 16-9 REAR WHEEL/SUSPENSION Remove the shock absorber lower mounting bolx. Remover the shock absorber upper mounting bolt, rilt rhe shock absorber rearward and remove it from the frame by pulling it up. REAR SHOCK ABSORBER OIL SEAL REPLACEMENT Remove [he rear shock absorber (page 158). Remove the boot band and boot. To remuve the stopper ring, press down on ‘he backup plate and oil seal. Remove the stopper ring and back~up plate. Release air pressure and remove the air valve from the hose. (Zl LOWER MOUNTING BOLT ('ll OIL SEAL DRIVER 079657MC70100 (2] STOP RING BACKVUP (BIRING l4) OIL SEAL HONDA VF'I OOOF (1) UPPER MOUNTING BOLT (5) STOP RING I’ll AIR VALVE 16-10 HONDA VF'l OOOF Place about 300 1.2mJ (10.1 oz) of damper oil (ATF or equivalent) in a clean container. Place the shock absorber in a hydraulic press wirh an OIL SEAR DFllVEFl ATTACHMENT positioned as shown. Place rhe air hose in the oil and press the shock absorber several times unlil the damper is filled wirh the Oil. NOTE Do not over-press the shock. This shock absurber's store is 42.5 mm [1.67 in). Place the shock absorber up right in an oil drain pan. Let the shock stand for 5 minutes in allow air m escape. Reinstall the arr valve in the air hose. Place the shock absorber in the hydraulic press using the all seal driver attachment. Wrap a shop rowel around the shock absorber. Press the oil seal out by compressing the shock absorber. REAR WHEEL/SUSPENSION (1] DAMPER OIL (ATF OR EQUIVALENT) 1!. l2) OlL SEAL DRIVER ATTACHMENT 07965 MBOOlDO Ls, l1) OIL SEAL DRIVER ATTACHMENT 079657ME00100 (1) SHOP TOWEL l2) OIL SEAL DRIVER ATTACHMENT (4) 079657M300100 16-11 REAR WHEEL/SUSPENSION Leave the shock absorber for another 5 minules to let any remaining ATF drain out. NOTE Do not tilt she shock absorber or ATF w ll , flow out of the damper cas Turn the shock absorber upside down as soon as all the ATF has drained from the outer case. Fill the damper case win. the specified amount of ATE SPECIFIED AMOUNT: 120 or: (4.06 us on, 3.38 Imp. oz.) Install the gurde bushing into the damper case. Wrap a place of tape around xhe groove at the end of the shock absorber, Dip she oil seal in damper oil and install it on the damper. CAUTION Be careful nu! Io damage the or! sea! during msralla um. HONDA VF'I 00°F -51 (1)0lLSEAL [2] TAPE 16-12 HONDA VF 'l 000 F REAR WHEEL/SUSPENSION (1) ATTACHMENT 079657M300100 Press the oil seal into the shock absorber with a j! hydraulic press until the oil seal driver and oil yeal driver ring stops at the edge of the outer case. (2| OIL SEAL DRIVER 07965~MC70|DO (3i DRIVER ADAPTOR 07965—M E70001 (4i OIL SEAL (2) OIL SEAL DRIVER 079657MC70100 install the back-up ring. Install the stop ring, being certain that it Is seated in the ring groove in the outer case. NOTE Be sure stop ring is seated in the ring groove all the way around. Install the ham and but)! cIIp. ,4 ri U [I ? (TI UPPER MOUNTING BOLT INSTALLATION Apply paste grease (containing more than 45% (II molybdenum) to the upper mounting bushings, NOTE Use pdsle grease (comalnlng more than 45% of moiybdenumi as Iollows: ' MOLYKOTE Grn PASTE manufactured by Dow Corning, u SVA, Locol Paste mahlilaclured by Suinlco l Lubricant. Japan ‘ ' Other lubricants oi equivalent quality Install the shock absorber in the frame and tighten the upper and lower mounting boltsv TORQUE: 40—50 N-m (4.0—5.0 kg-m, 29—36 It~|bI (1) STOP RING /\ (2) BACK‘UP RING IZI LOWER MOUNTING BOLT 16-13 REAR WHEEL/SUSPENSION HONDA VF 1 00°F lfls‘al‘ the banerv. lnstalI the damping rorce knob onto the knob bracket on the frame, Install Ihe EIectric paneI and crankcase breather separator‘ NOTE Home me was, theTQnd tubes properIy (pages r79 mm ‘I‘IL Install the left frame sIde cover and seat. Adm the a” pressure (page 3-18). SHOCK ABSORBER LINKAGE REMOVAL Remove the left and rigm mufflers. Remove the shock link by removing the shock absorber lower mounting bolt, shock link-(o-shock arm bolt, swingarm pinch bolt, and shock link shaft. Remove the shock arms from the frame. (II BATTERY (2) DAMPING FORCE KNOB I‘IISWINGAHM PINCH BOLT (4D SHOCK LINK (2) SHOCK LINK (3ISHOCK ABSORBER LOWER MOUNTING BOLT SHAFT 15) LlNK-TO-ARM BOLT (e) SHOCK ARM 16-14 HONDA VF'I 00°F LINKAGE PIVOT INSPECTION Check the llnkage needle bearmgs and collars (or wear or damage, Inspect the dust seals for damage Replace parts as necessary. SHOCK LIN KAGE INSTALLATION Apply molybdenum dlsulfide glease to the needle bearlngs and dust seals. Install the shock arms and shock link and tighten each bolt in the order listed. TORQUE: SHOCK ARM-TD-FRAME: 40—50 N-m (4.0—5.0 kg-m, 29—36 H-Ihl SHOCK LINK-TO-SHOCK ABSORBER 40—50 Nsm “LO—5.0 kg-m, 29—36 ft-Ib) SHOCK LINK-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. SWINE ARM REMOVAL Remove the rear wheel (page 16-3]. Remove the right muffler. Remove the drive chain cover Remove the shock link pinch bolt and shock link shaft. REAR WHEEL/SUSPENSION Ill SWINGARM PINCH BOLT IZI SHOCK LINKVTOVSHOCK ABSORBER'BOLT (3) SHOCK LlNKrVTO: ARM BOLT I4l SHOCK ARM-T0 FRAME BOLT HONDA VF'I OOOF REAR WHEEL/SUSPENSION (1) LEFT PIVOT BOLT (2IRIGHT PIVOT BOLT Remove the left and right swing arm pivot bolts. ' Remove the luck pin from the rear brake torque rod bolt and remove the torque rod bolt. Remove the swing am from the frame, I1) LOCK PIN Remove the drive chain slider from the swingarm. (1) DRIVE CHAIN SLIDER 16-16 HONDA VF'I 00°F REAR WHEEL/SUSPENSION l1] DUST SEAL PIVOT BEARING REPLACEMENT Remove the pivot collar fram the swingarm‘s right pivut. Remove the dust seal. Remove the snap ting and drive out the right pivot bearingsl (El PlVOT COLLAR (3) SNAP RING [1) NEEDLE BEARING REMOVER 07931~MA70000 Remove the dust seal from the swingarm‘s left Pivot. Remove the left pivot needle bearing with the special tool. (“DRIVER (2)WOODEN 07749—0010000 BLOCK Drive a new needle bearing into the swingarm left pivot. CAUTION support the Tn prevent :wingarm damag (3) ATTACHMENT, 32 x 35 mm 07746—0010100 PILOT, 20 mm 07746—0040500 16-17 HONDA VF'I OOOF REAR WHEEL/SUSPENSION II) DRIVER 0774970010000 Drive new ball bearings into the swingarm right Pivnt, l (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 HONDA VF'I OOOF Make sure that the rear brake torque rod's flanged washer ‘5 installed in (he swingarm pivoL Conneci me rear brake torque rod to the swingarm and tighten the pivm bolt. TORQUE: 13—25 N-m (1.8—2.5 kg-m,13—13leb) Secure the bolt with the lock pin. \nstall me \eft and right pivot bolts. Tighten the rigm pivot bolt TOROUE: 35—105 N-m 13.5—10.5 kg-m, 61—76 fl~|b) nghlen the MK pivot bolt. TORQUE: 85—105 N-m (8.5—10‘5 kg»ml 51—76 ft-lb) REAR WHEEL/SUSPENSION (1) LOCK PW 12) BOLT HONDA. VFI 00°F REAR WHEEL/SUSPENSION (ll SHOCK LINK PINCH BOLT l2l SHOCK LINKSHAF‘TV . Connect the swingarm and shock link and install the shock link shaft and shock link pinch bolt. Tighten the shock link pinch bolt. TORQUE: 20—30 N-m (211—31: kg-m, 14—22 ft-Ihl install the drive chain cover onto the swmg arm. Install the right muffler Install the rear wheel (page 16-8)V 16-20 HONDA 17 VF 1 00°F HYDRAULIC BRAKE 17-0 HONDA HYDRAULIC BRAKES VF'I OOOF (c) Q @ av % 30740 N-m y 0 a 30—40 N-m (3.D~4,D kg»m, @% (3.04.0 kgm, 22—29 mm m 22—29 mm) 2% j” ‘3) 25—30 N‘m (2.5—10 kgrm, 13—22 ft-Ib) (2.5—3.5 kg-m, 13—25 fi-Ib) (2.54.0 kgrm, ‘ 1 18—22ft-Ibl 20—25 N-m (204,5 kg-rn, 14—1 8 n-Ib) (2.0725 kgrm, 14418 ft-Jb) HONDA VF'I OOOF HVDRAULIC BRAKES SERVICE INFORMATION TROUBLESHOOTING BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE PAD/DISC FRONT MASTER CYLINDER BRAKE CALIPERS REAR MASTER CYLINDER 17—1 17—2 17—3 17—5 17—8 17—10 17—14 SERVIBE IIIFIJRMATIIIII 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 nut 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. Alwavs check brake operation before riding the motorcycle. SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Front disc thickness 4.5—5.2 mm (0.17770205 in) 4.0 mm (0.157 in) Front disc runout 0.30 mm (0,012 in) Front master cylinder I,D. 15870-15913 mm (05248—015265 in) 15.92!) mm (0.6270 inl Front master piston 0.D. 15327715854 mrn (06231—06242 in) 15.815 mm (06226 in) Front caliper piston 0.0. 31948—31998 mm (1257842598 in) 31.940 mm (1.2575 in) From caliper cylinder I.D. '7 31030—32080 mm (12610426301111 32.090 mm (1.2634 in) Rear master cylinder I,D. 14000—14043 mm (05512—05529 in) 14.055 mm (0.5533 in) Rear master piston O.D. 13357—13384 mm (05495—05506 in) 13.945 mm (0.5490 in) Rear caliper cylinder I.D. 32.030732.on «35112610 1.2630 in) 32.090 mm (1.2634 in) Rear caliper piston O.D. 31348731398 mm (12578712558 in) 31.940 mm (1.2575 in] Rear disc thickness 6.5;71 mm (0256—0283 in) 6.0 mm (0.236 in) Rear disc runout — 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 30 740 N«m (3.0—4.0 kg~rn, 227291t-lbl 30 40 N-m13.0~4.0 kg-m, 227 29 ftrlb) 10*15 N-m (1.0 1.5 kg~ml 7711It-lbl 20725 NAm [2,072.5 kg-m, 14718 ftrlh) 25* 30 N-m [2.5—3.0 kg-m, 18—22 It~|bl 25735 N-m12.573.5 kg-m, 18 25 lt-Ib) 10715 N-m (1.0715 kgrm, 7 711It-IbI 17-1 HYDRAULIC BRAKES TOO L Special Snap ring pliers TRUUBLESHMTING Brake lever/pedal soil or spongy 1, Air bubbles in hydraulic sysXem 2. Low fluid level 3. Hydraulic system leaking Braka lever/pedal too hard 1‘ Sticklng pismnlsl 2. Clogged hydraulic sysiem 3 Pads glazed or worn excessively Brake drag 1. Hvdraulic sysiem sticking 2. Sticking piston(sl , 4‘ HONDA “é vnooor 07914—3230001 Brakn grab 1. Pads contaminated 2. Disc or wheel misaligned Brakl chnnzr or squeal 1. Pads contaminated 2. Excessive disc runoul 3. Caliper installed incorrectly 4. Disc 01 wheel misaligned 17-2 HONDA VF'I OOOF HYDRAULIC BRAKES BRAKE FLUID REPLlcEMENi/ Slam SAFER LEVEL ‘4' Alli BLEEDING Check the fluid level Wllh the fluid reservoir parallel to the ground. CAUTION Install the cover an the reservoir whenever operating the brake lever or pedal, Failure tn do st) will allow brake fluid to squirt out of the reservoir during brake operation. Avoid spilling fluid on painted surfaces Place clean shop tuwels over the fuel tank whenever the system is being serviced. 3i LOWER‘LEVEL BRAKE FLUID DRAINING (ll (2i Connect a bleed hose to the bleed valve to avoid spilling fluid. A brake fluid contaminated brake disc ar pad reduces stopping pnwer. Discard pads and 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 0’ the bleed valve. BRAKE FLUID FILLING Fill the reservoir with DOT4 brake fluid from a sealed container. NOTE Check the fluid level nitern while bleed g the brakes to prevent air from being pump ed into the system. When usmg the Brake Eleederl follow the manulacturer’s instructions. CAUTION Use only DOT4 brake fluid from a Milled containen Du not mix brake fluid types amt never re- use the emitaminatud fluid which has been pumped out during brake bleeding, beams: this will impair the efficiency [1/ the brake system Connect the Brake Bleeder or equivalent to the bleeder valve. [3) RUBBER HOSE l4) ELEEDER VALVE 17-3 HYDRAULIC BRAKES Pump the brake bleeder and loosen the bleeder valve Add flutd 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 alr is entering the bleeder from around the hi bleeder valve threads, seal the threads with tellontape. Close the bleeder valve and operate the brake lever or pedal, If it feels spongy, bleed the system by per- forming the air bleeder procedure If a Brake Bleeder or equivalent not available, till the system as follows: Pump up the system pressure with the lever or DBdBI until there are no air bubbles in the fluid llowmg out of the reservoir hole and lever or pedal resistance is felt AIR BLEEDING Bleed the system as follows: ll Connect a bleeder tube to the bleeder valve. 2) Squeeze the brake lever or depress the brake pedal, open the bleed valve 1/2 turn and then close the valve. NOTE Do not release the brake lever or pedal until the bleed valve has been closed. 3) Release the brake 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 at the hose. Fill the fluid reservoir to the upper level mark. A brake fluid contaminated brake disc at pad reduces napping power. Discard contamin- ated pads and clean a canmrnr'nared disc with a high quality brake degreasing agent. 3' HONDA VF'I OOOF ill REAR (2i BRAKE BLEEDER l3) RUBBER HOSE l4l‘BLEEDER VALVE lll (Zl FRONT 17-4 HONDA VF'I OOOF HYDRAULIC BRAKES BRAKE PAD/DISC ' (llRIGHTCALIPER 12) LEFTCALIPER FRONT PAD REPLACEMENT / 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: Remove the caliper bracket mount bolt, antl~dive piston pm bolt and caliper mount bolt. Remove the caliper from the bracket. Remove the pad pin retainer and pull the pad pins out of the caliperl Remove the brake pads. lll PAD SPRING Position the pad spring In the caliper as shown. Push the caliper pistons in all the way. 17-5 HYDRAULIC BRAKES HON DA VF'I OOOF 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. Place the pad pin retainer over the pad pins Push {he retainer down to secure the pins. install the pad pin retainer bolt. Apply silicone grease to the inside of the pivot bolt boot and pivot bolt and install the caliper onto the bracket, 17-6 Ill CALIPER BRACKET (3) PIVOT BOLT i4! SILICONE [Yl PIVOT BOLT BOOT i5) CALIPER HONDA VF'I OOOF HYDRAULIC BRAKES l‘llRIGHT CALIPER (2) BRACKET MOUNT BOLTS Install the caliper bracket onto the fork leg so the » ‘ disc is positioned betwem the pads, being careful not to damage the pads. l3) CALIPER MOUNT BOLT A (1) LEFT CALIPER [2) BRACKET MOUNT BOLT 7 Rrghr calrper: Tighlen the callper bracket mount balls and caliper mount bolL Left caliper: Tighten the caliper bracket mau'lt bolt, antrdive piston pin bolt and caliper mount boll. TORQUE: Caliper bracket mount bah: 30—40 N'm (3.0—4.0 kg-m, 22—29 fl-lb) Amidive pistun pin boll: 10—15 N-m (1.0—15 kgrm, 7—9 ft-lh) Caliper mount bolt: 20—25 Nrm (2.0-25 kg-m, 14—18fI-lbl \ \ fixV , r) ‘1 g (3) ANTI~D|VE PISTON PIN BOLT REAR BRAKE PAD REPLACEMENT r Loosen the caliper mount bolt and remove lt from the callper bracken Pivot the caliper up out ol the way. Replace the rear brake pads using rhe same method as used for from brake pad replacement. ll) CALIPER MOUNT BOLT HYDRAULIC BRAKES HONDA VF'I OOOF DISC THICKNESS Measure the thickness of each disc. SERVICE LIMIT: FRONT: 4,0 mm (0.16 in) HEAR: 6.0 mm (0.24 in) BRAKE DISC WARPAGE Measure brake disc for warpage. SERVICE LIMIT: 030 mm (01312 in) FRONT MASTER CYLINDER DISASSEMBLY Drain brake fluid from [he hvdrauIIC system. Remove the brake lever and rear view mirror from the master cylinder Disconnect the brake hose. CAUTION 7 W 7 Ir Amid spilling brake fluid on painted xurfaces. Place a rag over the fuel tank whenever the brake syxrem is being serviced. NOTE rWheiemoving the fluid hose bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking OUR. Disconnect the front Brake switch wires, Remove the front brake master cylinder. 17-8 HONDA V F 1 00°F Remove the piston boot and the snap ring from the mastEr cvllnder body. Remove the secundary cup and piston. Then remove the primary cup and spring. Remove the brake light switch from the master cylinder body, if necessarv‘ Clean the lnside of the master cylinder and reservoir with brake fluid. INSPECTION Measure the master cylinder l.D, Check the master cvlinder for scores, scratches or nicks. SERVICE LIMIT: 15.925 mm (0.5270 in) HYDRAULIC BRAKES (A (1) SNAP RING PLlERS 07914 73230001 17-9 HYDRAULIC BRAKES Measure the master piston 00. SERVICE LIMIT: 15.815 mm (0.6226 in) Check the primary and secondary cups lor damage before assembly. ASSEMBLY CAUTION Keep the master cylinder piston, cylinder and spring a: a set: don’r subsrimle individual parts. 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 assemblyl CAUTION When installing the cups, :10 not allow the Iipx In turn inside nut and be certain the snap ring is firmly Sealed in [he groove. HONDA VF'I OOOF l7)BRAKE FLUID DOTA illPlSTON % LIGHT SWITCH 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 tighten the lower bolt. Install the fluid hose with the bolt and two sealing washers. Install the brake lever. Install the rear vi2w mirror, Connect the from brake switch wires. Fill the reservoir to the upper level and bleed the brake system according to page 17-4. ill ALIGN 17-10 HONDA VF'I OOOF HYDRAULIC BRAKES BRAKE CALIPERS m RIGHT CALIPER (2» LEFT CALlPEH FRONT BRAKE CALIPER REMOVAL Place a clean container under the caliper and dis- connect the brake hose from the callpEr. CAUTION A Lvid spilling brake fluid (In minim! xurflu-ex. 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, antidive piston pin bolt and caliper mount bolt and remove the caliper lrom the bracket, REAR BRAKE CALIPER REMOVAL Place a clean container under the caliper and dis» connect the brake hose from the calipert Ava x ng brake fluid on the painted wrfaces to prevent paint damage. Remove the caliper mount bolt, pivot up and re- move the caliper from the bracket. ll) BOOTS (Zl PAD SPRING DlSASSEMB LY / Remove the brake pads (page 175). Remove the pad spring. Remove the caliper pivot collar and boots. Remove the pistons from the caliper (2) PIVOT COLLAR 17-11 HYDRAULIC BRAKES it 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 5 m} nozzle me close to the Inlet. Examine the pistons and cylinders for scoring, scratches or other damage and replace it necessarv. Push the plstpn seals in and lift them out, then discard them. Clean the piston seal grooves with brake fluid. CAUTION Be mrefid no! to damage the piston 31 r sulfur PISTON INSPECTION Check the pistons fm scaring, 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 (1.2575 In) HONDA. VF'I OOOF 17-12 HONDA V" 00°F HYDRAULIC BRAKES CYLINDER INSPECTION Check the caliper cylinder for scoring, scratches or other damage. Measure the caliper cylinder bore. SERVICE LIMIT: FRONT: 32.090 mm [12634 in) REAR: 32‘090 mm (1.2634 in) ASSEMBLY II the collar boots are hardened or deteriorated, replace them with new ones. The prston seals must be replaced with new ones whenever they are removed. Coat the seals With brake fluid before assembly (ll COLLAR BOOTS l2l PISTON SEALS NOTE H , ' . . ".' ‘l r Install the piston seals With their small dia l meter ends facing in. Install the pistons with the dished ends toward the pads. Apply mldium grade of HiATemperature silicon grease to the collar and inside of the collar grease. Install the collar boots and collar making sure that the boots are seated in the collar and caliper grooves properly. Install the pad Spring. Install the pads lpage 175]. 13] COLLAR l4] PAD SPRING [5) PISTONS (I) BUSHING FRONT BRAKE CALIPEH INSTALLATION Check the left caliper bracket collar, O~rings and bushings Ior excessive wear or damage, and replace if necessary. Apply paste grease (page 16713) to the collar and install it into the bushing. m COLLAR l3) O-RINGS PASTE GREASE 17-13 HYDRAULIC BRAKES Install the anti-dive piston collar into the hole in the piston and secure it With the clip, Make sure that the retainer clip is in position on the caliper bracket. inspect the condition oi the caliper pivot boat. Apply silicone grease to the caliper pivot bolt. Assemble the caliper and bracket. Install the caliper assembly over the brake disc so that the disc is positioned between the pads. CAUYION Be careful not ta damage [he pads. Right caliper: Tighten the caliper bracket mount bolts and caliper mount bolt. Leh caliper: Tighten the caliper bracket mount boIL antidive piston pin bolt and caliper mount bolt. TORQUE: Caliper bracket mount bolt: 30—40 N-m (3.0—4.0 kg«m, 22—29 R—lb) Anti~divu piston pin bolt: 10—15 N-m (LO—1.5 kg-m, 7—9 fl-lb) Caliper mnunt bolt: 20—25 M!" (2.0—2.5 kym, 14—18 ft-Ibi ll) ANTI-DIVE PISTON lZi CLIP (3) COLLAR (l) CALIPER PIVOT BOOT — l?) RETAINER CLIP [3! RIGHT CALIFER HONDA VF'I OOOF 17-14 HONDA VF1 OOOF (ll 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 174), REAR BRAKE CALIPER INSTALLATION Make sure that the retainer clip is in position on the caliper brackets Inspect the condition of the caliper pivot bootv Apply silicone grease to the caliper pivot bolt l2l RETAINER CLIP [1! HOSE 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 pads, being careful not to damage the pads. Install and tighten the caliper mount bolt, TORQUE: 20—25 N-m (Zn—2.5 kg«m, 14—18 ft-Ib] Connect the brake hase to the caliper with the bolt and two sealing washers, TORQUE: 25—35 N-m (2.5—3.5 k9—m,18—25 ft-Ib) Fill the brake fluid reservoir and bleed the rear brake system (page 17-4). \ l3) SEALING WASHERS (4| CALIPER MOUNT BOLT HYDRAULIC BRAKES 17-15 HONDA VF'I OOOF Hi BRAKE l2l BRAKE SWITCH REAR MASTER CYLINDER HOSE SPRING REMOVAL. Drain the rear brake hydraulic system (page 173). Remove the brake hose bolt and disconnect the brake hose‘ HYDRAULIC BRAKES Loosen the rear master cylinder mount boltst Remove the right tootpeg brackett Unhook the rear brake switch spring from the rear brake actuating arm. 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 tram the master cylinder push rod. Remove the rear master cylinder from the footpeg bracket, it. - (2i ACTUATING ARM [3) COTTER PIN (l) SNAP RING DISASSEMBLY 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 cutiet to remove the master piston and primary cup, Clean all parts with brake fluid, ‘ (2i SNAP RING PLIERS 07914—3236001 17-16 HONDA VF'I OOOF CYLINDER LD. 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 OD. SERVICE LIMIT: 13.945 mm (0.5490 in) Check the primary cup and piston cup for damage. ASSEMBLY CAUTION Keep the master cylinder piston, cylinder and spring as a set; do not substitute indiviv dual 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, d0 not allow the lips to mm inside out and be certain the snap ring is sealed fimly in the groove, Install the primary cup and piston. Install the push rod and snap ring. Install the rubber cnver. HYDRAULIC BRAKES HYDRAULIC BRAKES INSTALLATION install the master cylinder to the right foutpeg 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 halt. TORQUE: 10—15 N>m(1.0—1t5 kg-m.7—11ft-Ihl Connect the master cylinder hose to the master cylinder with a new O-ring and screw. Hack 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 iiuid bolt and two sealing washers. TORQUE‘.25—-35 N~m (2.5—3.5 kgm, 18—25 lt-lh) Fill and bleed the rear brake system (page 17-4). HONDA VF'I OOOF *Q'ihi I 9' (2| PUNCH MARKS 13) CUTTER PIN (i) BRAKE HOSE (ll BRAKE SWITCH SPRING 17-18 ; HONDA é vr1ooor 18 BATTERY/CHARGING SYSTEM 18-0 BATTERY/CHARGING SYSTEM l3IALTERNATOR (5} BATTERY/CHARGING SYSTEM (amen/WHITE T7 112mm x -: > (13’ 5 FUSE 30A _— I: 3— _ < O —. n: 1‘ — E 5- 114) .. ‘ a IGNITION _ IIIWOLTAGE SWITCH k SENSOR (15) . BLACK 17IALTEHNAT0R | c I —_—- HODREGULATOR/RECTIFIER (9| GREEN 18-0 HONDA VF'I OOOF BATTERY/C HARGING SYSTEM SERVICE INFORMATION TROUBLESHOOTING BATTE RV CHARGING SYSTEM 18—1 18—2 18—3 18—4 SERVICE lIIFllRMATIflII 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 far charging. If the battery must be charged an the motorcycle, disconnect the battery cables 00 not smoke or allow flames near a charging battery. The gas produced by a barrery will explode I‘fflames or sparks l are brought neurt All charging system components can be tested on the motorcycle. Alternatur removal is in Section 9. SPECIFICATIONS Battery Capacity 12V16AH Specific gravity 1,280/20°C (68°F) Charging rate 1‘6 amperes maximum Alternator Capacity 1,000 rpm 54000 rpm 10,2A min. (No load) 25,0A min. (No load) Voltage regulator Transnsmrized non-adjustable regulator 18-1 BATTERV/CHARGING SYSTEM TllllllllLESHflllTlNE No power — key turned on: 1. Dead battery — Low fluid level — Low specific gravity 7 charging system failure 2. Disconnected battery cable 3. Main luse burned out 4 Faulty ignition switch Low power — key turned on: 1. Weak battery - Low fluid level 7 Low specific gravity ~ Charging system lailure 2. Loose battery connection Low power — Ingll’ll running: 1. Battery undercharged — Low fluid level — One or more dead cells 2. Charging system failure 6 HONDA VF'I OOOF 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 18-2 HONDA VF'I OOOF BATTERY REMOVAL Remove the battery holder bolt, then swmg the holder out of the way. Dlsconnect the negative cable at the battery, then disconnect the positive cable. Disconnect the battery breather hose from the batterv‘ Remove the battery. TESTING SPECIFIC GRAVITY Test each cell with a hydrometer. SPECIFIC GRAVITY: 1270—1290 (ZODC, 68°F) 1.2707lt290 Fully charged Below 1.260 Undercharged NOTES ‘ The battery must be recharged if the spe- clfic gravity is below 1,230. - The specific gravity varies with the tempe- rature as shown in the accompanying table. ' Replace the battery if sulfatian is evident or if the space below the cell plates is filled with sediment. The battery contain: sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: Find: with water and get prompt medical mention. IIlPOSITIVE CABLE BATTERY/CHARGING SYSTEM [2) GROUND CABLE l3] BATTERY HOLDER , 3‘ EAYYERV VEMPERAVURF vs spzcmc GHAvmr svscmc smwv 1 30a m ls 20 25- 30' as 40' 50' 59' ea 77' ea 95 wow ELECTROLYTE TEMPERATURE samnc gmvlly (Bangui By a 007 luv um um: 18-3 BATTERY/CHARGING SYSTEM 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 l+l terminal. Connect the charger negative (—l cable to the battery negative l—) terminal, Charging current: 1.6 amperes max. Charge the battery until specific gravity is 1.270— 1290 a! 20°C (68°F). m.‘ ' Before charging a battery, remove the cap from each cell. - Keep flame: and sparks away from a charg- ing ballery. Tum power 0N/0FF at the charger, not at the battery [erminals to prevent sparks. ' Discontinue charging if the electrolyte Iempemmre exceeds 45 °C (1 13°F). CAUYION Quick-charging should only be done in an emergency; slow-charging is preferred, ' Rnute [he brealher tube as shown on the barrer caution label. After installing the battery, coat the terminals with clean grease, CHARGING SYSTEM CURRENT TEST NOTE B sure the battery is in good condition before performing this test. Warm up the engine. Remove the frame left and right side covers and 5951, coupler. Disconnect the headlight. Open the main luse cover and remove the mainfuse. Connect a voltmeter and ammeter as shown, Allow engine to idle Increase engine speed slowly. Charging amperage should be a minimum of 10.2 ampere: 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, 6 HONDA VF'I OOOF (H C A U T l 0 N 12) PIPING As SIIWN mow l 3) BITTERV [LBW l5) BAflERV HEATHER IUBE [6] "ISBN TM! BATI'ERV HEATHER TUBE SECURE . M Ill—670 lll MAlN FUSE TERMINALS 'J' 1 8-4 HONDA. V“ 00°F BATTERY/CHARGING SVSTEM l1) 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 be- tween the leads and ground. Replace the stator it there is no cnnlinuity between the leads, or ii there is continuity between the leads and ground. VOLTAGE REGULATOR/RECTIFIER TEST Remove the left Slde cover. Disconnect the regulator/rectifier couplets. Check for cuntinuitv between the leads with 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: CONTINUITY (3) RED/WHITE (9 probe 7 9 probe 3 l YELLOW GREEN 2 : o 0 || RED/WHITE YELLOW J 5 g m D REVERSE DIRECTION: N0 CONTINUITY E g E (9 probe— 9 probe g a“ E I GREEN YELLOW g E E n YELLOW RED/WHITE é ' ‘ - (“GREEN 1 8-5 HONDA V F 1 000 F BATTERY/CHARGING SYSTEM VOLTAGE REGULATOR PERFORMANCE TEST Connect a voltmeter across the battery, Check regulator performance with the engine running. The regu|ator must divert current to ground when battery voltage reaches 14.0 ~ 15.0 V_ 18-6 VF'IOOOF IGNITION SYSTEM 19-0 HONDA IGNITION SYSTEM VF'I 00°F (1] |GNIT|ON SWITCH (2) ENGINE STOP SW|TCH (“SPARK UNITS i r, ' -‘,‘ '_.' .’ ' (SISPARK PLUGS K (6)PULSEGENERATORS . (7) BATTERY (9D WHITE COUPLER HOHGNITION COIL (HISPARK PLUG (8| 1.3 CYLINDER SPARK UNIT 112IENG|NE/\O—J STOP SWITCH i 115 PULSE GENERATORS H7, \ T RED COUPLER T “6’24 CYLINDER SPARK UNIT 19-0 HONDA VF'I OOOF IGNITION SYSTEM senwce INFORMATION 19—1 TROUBLESHOOTING 19—2 IGNITION con. 19—3 TRANSISTOHIZED IGNITION SYSTEM 19—4 IGNITION TIMING 19—5 SERVICE IIIFflRMIITIlIN GENERAL 0 A TRANSISTORIZED IGNITION SYSTEM is used and no adjustments Cln be madl. SPECIFICATIONS < >: U \x ND NGK Spark plug Standard x24EFR-u9 DFR7EAv9 For mended high speed dviving X27EPR-U9 DPRSEAVB Spark plug gap 03—0.!) mm (0031—0035 in) Ignition (Imlng A! Ten: 10°BTDC Full advance 37" ETDC/3,800 Ipm PUISE Q'neramr “If 939 0.3—0.9 mm (0012—0035 in) 4 TOOL Special Timing inspection cover 079987 MB40000 19-1 IGNITION SYSTEM TRflUBLESHflUTIIIE The ignition system has two subsystems; one for the No. ‘I and No.3 cylinders and one Ior the No‘ 2 and No. 4 cylinders. Determine which subsystem is faulty] then proceed to the detailed tests belowr Engine cranks but will not start 7 Engine stop switch OFF — No spark at plugs — Faulty transistorized spark unit - Faulty pulse generator No spark at plug 7 Engine stop switch OFF 7 Poorly connected, broken or shorted wrres Between ignition switch and engine stop switch Between spark unit and engine stop switch Between spark unit and ignition coil Between ignition coil and plug Between spark unit and pulse generator — Faulty ignition coil — Faulty igmtion switch » Faulty spark unit 7 Faulty pulse generator Engine stam but runs poorly — Ignition primary circuit Faulty ignition coil Loose or bare wire Intermittent short circuit ~ Secondary circuit Faulty plug Faulty high [EnSan wire Timing advancl incorrect — Faulty pulse genlrator — Faulty spark unit HONDA VF'I 00°F 19-2 HONDA VF'I OOOF IGNITION SYSTEM (IIIGNITIONCOILS 1 Remove the seat and fuel tank. IIIIGNITION COIL TERMINALS CONTINUITY TEST Disconnect the coils primary leads. Measure the pnmavy cml resIsIance. RESISTANCE: 2.8 9 Measure the secondary EDII resIstance wm-I the spark plug caps In place RESISTANCE: 21—28 k Kl 19-3 IGNITION SYSTEM Remnve the high tension wire and measure the secondary coil resistance. RESISTANCE 13.6—155 kSZ TRANSISTDRIZED IGNITIIJN SYSTEM PULSE GENERATOR TEST Remove the right side cover. Disconnect the pulse generator coupler and measure the call resistance. RESISTANCE: Approximltely 480 {Z Between white/yellow and yellaw leads (1,3 cyr lindersl Between white/blue and blue leads (2,4 cy~ linders] PULSE GENERATOR REPLACEMENT Remove the clutch cover (page 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 (0312—01335 in) Install the clutch cover Ipage 7-22). Recheck the ignition timing (page 1975). HONDA VF 'I OOOF II IPULSE GENERATOR COUPLER (“1'3 CYLINDER PULSE l2l2~4 CYLINDER PULSE GENERATQR GENERATOR (3IFEELEH GAUGE 1 9-4 HONDA. V F 1 00°F SPARK UNIT II the pulse generators, ignition coils, and wiring are good, and the ignition (Imlng is not in specification: replace the spark UNIS With new ones and recheck the Ignition timing, Remove the rear cowl by removing the ram bolts. Replace the spark units with new one. Install the rear cowl in the reverse order oi removal. IGNITIIIN TIMING Warm upthe engine and remove the alternator cover. Align the F mark on the flywheel with the rear crankcase mating surface Use a felt pen to mark a dark line and "1-3F” In line with the F mark an the end surface of the flywheel. IGNITION SYSTEM IIIREARCOWL (“SPARK UNIT IZISPARK UNIT IIIFULL ADVANCE MARK 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. ATIDLE SPEED: The dark line (15F) should align with the index milk on the timing cover. 1,300—1,750 rpm: The advnnce starts. 3,100—3,500 rpszhe advance ends and the index mark should be between the full advance marks, Connect the timing light to the high tension wire of the No. 2 or No. 4 cylinder and check the igni~ tion tirmng for No.2 and No. 4 cylinders. NOTE The ignition system is transistorized and cannot be adjusted. It the ignition timing is incorrect, check the spark units and pulse generators. Replace pans as required. After timing inspection, check the engine oil level and add if necessary, HONDA V F 1 00°F HITiMING INSPECTION COVER 079987MB40000 l2IAT IDLE SPEED (3| up MARK Ml INDEX MARK IEIAT 3100—3500 rpm (6) FULL ADVANCE MARKS 19-6 HONDA VF'IOOOF ELECTRIC STARTER 20-0 HONDA VF'I OOOF ELECTRIC STARTER m CLUTCH SWITCH 6 (a) STARTER (2] RELAY SWITCH STARTE R BUTTON (4) STARTER MOTOR (5) NEUTRAL ' SWWCH . (6) BATTERY IIII STARTER I7) STARTER MOTOR RELAv SWITCH c“: ‘1’” GREEN/RED IaIFUSE . E (15) DIODE I 30A (9| 0 STARTER =E3 I; BUTTON u) 118) (12)RELAV COIL 2’ CLUTCH IGNITION SWITCH E SWITCH (13) 3 m 2 e @ (17) NEUTRAL INDICATOR § (19, GREEN GREEN - - HO) BATTERY T T 20-0 HONDA VF'I OOOF ELECTRIC STARTER SERVICE INFORMATION 20—1 TROUBLESHOOTING 20—1 STARTER MOTOR 20—2 STARTER RELAV SWITCH 20—5 CLUTCH DIODE 20—5 SERVICE INFORMAIIIIII GENERAL 0 The starter motor can be removed mm the engine in the frame. SPECIFICATIONS STANDARD SERVICE LIMIT Starter motor Brush spring tension 680—920 g (24.0w 580 g [20.4 oz) Brush iengtl‘l 12 0713.0 mm 1047 6,5 mm (0 26 In) IRIIUBLESIIIJIITINE Starter motor will nos turn: 1. Battery discharged. 2. Faulty ignition switch. 3. Faulty starter switch. 4. 5 6 7 Faulty neutral switch. . Faulty starter relay switch. . Loose or disconnected wire or cable. . Clutch diode open. Start" motor turns engine slowly I. 2. 3. Low specific gravity in battery, Excessive resistance in circuit. Binding in starter motor, Start!" motor turns. but engine does not turn: 1. Faulty starter clutch. 2. Faulty starter motor gears. 3. Faulty starter motor or idle gear. Starter motor and angIne turns, but angina doet "0‘ start 1. Faulty ignition system. 2. Engine problems. — Low compression. - Fouled spark plugs. 20- 1 HON DA V“ OOOF ELECTRIC STARTER (HSTARTER CABLE REMOVAL Will! [he ignition xwitch OFF, remove the ‘ negative cable a! Ihe baner before xerviz'ing (he xlarler molar. Remove me lower radiator (page 677). Dwsconnec! (he starter motor cabte at (he momr. Remove the starter momr mounting bells, and starter motor. 12’ STARTER MOTOR {3) BOLTS (4) CASE AND FIELD COIL (HORING (7D BRUSH HOLDER (B) BRUSH SPRING (QTO-RWG (6) CABLE TERMINAL AND BRUSHES (10) FRONT COVER 20-2 HONDA VF1 OOOF BRUSH INSPECTION Remove the starter motor case screws. Inspect the brushes and measure the brush length. Measure brush spring tension with a spring scale. SERVICE LIMITS: Brush length: Brush spring tension: 6.5 mm (0.26 in] 580 g (20.4 oz) COMMUTATOR INSPECTION Remove the starter motor case. NOTE Record the location and number of shims. Inspect the commutator bars for discoloration. Bars dISCOIOVEd In pairs indicate grounded armature calls. NOTE Do not use emery or sand paper on the com- mutator. Check for continuity between pairs of commutator bars. There should be continuity. Aiso, make a continuity check between individual commutator bars and the armature shaft. There should be no continuity. ELECTRIC STARTER IIIERUSH SPRING wRUSH LENGTH llICOMMUTATOR IIICONTINUITY BETWEEN COMMUTATOR BAR PAIRS: NORMAL I‘ll NO CONTINUITV BETWEEN COMMUTATOR BARS AND ARMATURE SHAFT: NORMAL 20-3 ELECTRIC STARTER FIELD COIL INSPECTION Check for continuity lrorn the cable terminal to the motor case‘ There should be no continuity. Then check for continuity from the cable terminal to the brush. There should be continuity. Replace the starter motor it the field coil does not have continuity or if it is shorted to the motor case. ASSEMBLY/INSTALLATION Assemble the starter motor. Align the case notch With the brush holder pin. Install the rear caver aligning its slot with the brush holder pm. Install the starter motor I" the reverse order of removal. HONDA VF'I 00°F I'IINO CONTINUITY BETWEEN CABLE TERMINAL AND MOTOR CASE: NORMAL K (ZICONTINUITY BETWEEN CABLE TERMINAL AND BRUSH WIRE IINSULATED): NORMAL (ZINOTCH (ZIPIN (1:5RUSH HOLDER HIPIN (ZISLOT If i4] REAR BRACKET (3IBRUSH HOLDER 20-4 HONDA. VF'I OOOF ELECTRIC STARTER STARTER RELAY SWITCH (HSTARTER RELAY SWITCH INSPECTION Depress the srarter switch button wnh me Ignmon ON. The coil is normal if the starter relay swnch clicks. Connec! an Ohmmeter (0 lhE star‘er relay swrtch termmals, Connect a 12 V banery re the swirch came Ierml nals. The swimh is normal if there is contlnuity, CLUTCH DIDDE REMOVAL Remove me hm ldnk, Remnve [he clurch mode from the wrre harness, 20-5 HONDA VF'I OOOF ELECTRIC STARTER (UNORMAL DIRECTION: CONTINUITY REVERSE DIRECTION NO CONTINUITY INSPECTION ‘ z ‘ . ‘3‘ ' Check (o: continuity with In ohmmexen ' m _ ‘ REVERSE DIRECTION 20-6 $131303? 21 SWITCHES SERVICE INFORMATION 21—1 THERMOSTATIC SWITCH 21—11 OIL PRESSURE SWITCH 21—2 TEMPERATURE SENSOR 21—11 BRAKE LIGHT SWITCH 21—2 BRAKE AND TAILLIGHT SENSOR Z‘I—12 NEUTRAL SWITCH 21—3 HEADLIGHT 21—12 CLUTCH SWITCH 21—5 INSTRUMENTS 21—14 HANDLEBAR SWITCHES 21—6 TEMPERATURE GAUGE 21—16 IGNITION SWITCH 21—7 TACHOMETER 21—16 FUEL PUMP 21—9 BULB 21—17 FUEL PUMP RELAY 21—9 FUSE HOLDER 21—19 FUEL LEVEL SENSOR 21—10 HORN 21—20 SERVICE IIIFIIIIIIATIIIII GENERAL I Some wires have different colored bands around them near the connector. These are connected to other wires which cor- respond with the band Color. 0 All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. o The following color codes used are indicated throughout this section and on the wiring diagram. Bu = Blue G = Green LG = Light Green R = Red HI = Black Gr = Grey 0 = Orange W = White Br = Brown LB = Light Blue P = Pink Y = Yellow 0 To isolate an electrical failure, check the continuity of the electrical path through the part, A continuity check can usually be made without removing the part from the motorcycle. Simply disconnect the Wires and connect a continuity tester or volt-ehmmeter to the terminals or connections 0 A continuity tester is useIul when checking to Iind out whether or not there IS an electrical cannection between the twa points. An dhmmeter IS needed to measure the resistance of a circuit, such as when there is a specific coil resistance anOIIF ed] or when checking for hlgh resistance caused by corroded connections 21-1 SWITCHES OIL PRESSURE SWITCH Dlsconnect the all pressure switch lead and remove the switch. Check for continuity while applying pressure to the Swutch. No continuity: Abova 20—40 kPa (0270.4 kg/cm‘, 2.5751 psi] Replace the switch if necessary Apply a liquid sealant to the switch threads before Installing the switch. Screw the switch into the crankcase but step two threads from the bottom Then tighten it to the specified torque. TORQUE: 10—14 N-m (1.0—1.4 kym,7—10it-lb) NOTE To prevent crankcase damage, do not ov ighten the switch BRAKE LIGHT SWITCH Check the rear brake light switch fat continuity with the rear brake applied. Check the front brake light switch for continuity with the front brake applied. Replace the switches if necessavv. HONDA VF'I OOOF 21-2 HONDA VF'I OOOF NEUTRAL SWITCH Remove the ieft side cover, Disconnect the neutral switch connectorl Check the swrtch for continuity between the switch connector terminal and ground. There should continuity with the transmission in neutral and no continuity with the transmission in any gear. Remove the slave cyimder and drive sprocket cover. [page 640) Loosen the water hose band and remove the water pump by removing the mount boits. Remove the drive sprocket mount bolt and drive sprocker, (page 575) Remove the oil bolL Remove the countershaft bearing cover by removing the mount bait. SWITCHES iiiNEUTRAL SWITCH CONNECTOR (2) WATER HOSE BAND HJOILBOLT HONDA VF'I OOOF SWITCHES Remove the neutral switch cover bolts and cover, ‘IZIBOLTS l1 ) SCREWS Remove the neutral switch attaching screws and the SWIICI‘I. INSTALLATION Install the neutral switch. Install the neutral switch cover with the mount bolts (2) NEUTRAL SWITCH III GASKET Install the new gasket and dowel pms. (ZIDOWEL PINS 21-4 HONDA VF 'I 000 F Install the countershafl bearing cover, Tighten the oil bolt, Install (he water pump and hose. Install the drive sprocket and llghten the drive sprocket mount bolt TORQUE: 50—54 N-m I5.0#5.4 kg-ml 35739 flrlb) Inslall \he clutch slave cylinder, drrve sprocket covel, and gearshllt pedal in the reverse ordav of removal. CLUTCH SWITCH Check the clutch swltch for Dominuity with the clutch lever released and applled. Replace ll It faulw. 'A II) COUNTERSHAFT BEARING COVER l‘IJDHIVE SFROCKET l2) WATER PUMP (IICLUTCH SWITCH IZIAFPLIED: CDNTINUITY RELEASED NO CONTINUITY SWITCHES SWITCHES HONDA VF'I OOOF HANDIEBAR SWITBHES The handlebar cluster swixches (lights, xurn signals, horn. etc.) must be replaced as assemblies. Remove me fairing, headlight, and headlight bracket. Continuity less for the components a! the handler bar cluster switches as foilow: Continuity should exist between the color coded wires in each chart. LIGHTING SWITCH coma BI/Bu I Bl/W BI/R BuIW —-o % I'II DIMMER SWITCH (2] PASSING SWITCH (3i TURN SIGNAL SWITCH (4) HORN SWITCH EAT. TL BAT, HL, DIMMER SWITCH COLOR Bu/W W Lu N Hi HL, Lo TURN SIGNAL SWITCH COLOR Gr LB HORN SWITCH COLOR W/G LG FREE PUSH O——O BAT, Ho PASSING SWITCH coma W/G Eu FREE 7T PUSH 7 o———-o 21-6 HONDA VF'I OOOF SWITCHES STARTER SWITCH III ENGINE SYDP SWITCH El to WI? wrth button depressed. No continuity With button released, COLOR BI V/R W FREE PUSH ro——o H IG ST 13> LIGHTING SWITCH ENGINE STOP SWITCH IZI STARTER SWITCH Bl to BI/W with the switch "RUN" positron. No continuity with "OFF" position COLOR Eil ‘BI/w OFF mm 70127 IG BAT; IGNITION SWITCH HHGNITION SWITCH Remove the fairing and headlight. Disconnect the Ignition swrtch coupler. Check continuity of terminals on the ignition switch coupler in each switch position. COLOR R R/EI BU/O Br/Wi Br WEI BAT, 1G FAN TL, TL, PA 21-7 SWITCHES REMOVAL Remove the vainngi Pull down the both from iorks and HIV ioinK from me (op budge. (page 15 15) Disconnect [he ignition switch coupler. Remove the Mo ignition swixch mount bulls and ignmon switch. DISASSEMBLY Pry open the retainer. HONDA VF'I OOOF HiTOP BRIDGE 91AM JOINT WIGNI TION SWITCH (1) RETAINER 21-8 HONDA VF'I OOOF Insert the key and turn it so it is part way between the "ON" and “OFF” detent positions. Push in the lugs, that are locked in the slots then pull the Contact base from the switch. Assemble and install the ignition switch in the reverse order of removal. FUEL PUMP Turn the ignltan switch off. Disconnect the fuel pump relay coupler. Short the white and black wire terminals at the fuel pump relay coupler with a jumper wire. Disconnect the fuel line at the carburetor and hold a graduated beaker under the tube. [In no! aIIaw 170171;: or sparks near gasoline. Turn the ignition swnch on and let fuel flow into the beaker for 5 seconds, then turn the ignition switch off. Multiply the amount in the beaker by 12 to determine the fuel pump flow capacity per minute. FUEL PUMP FLOW CAPACITV: 500 cc (30.4 US 01, 31.7 Imp oz) 1 10%/mlnute FUEL PUMP RELAY Remove the left lrame side cover, Turn the ignition Switch and engine stop switch ON and check for continuity between the white termi~ nal ol the fuel pumo relay coupler and ground. There should be no continuity. Press the starter button for a moment to turn the crankshaft but do not start the engine, Then, check that there is contlnuous battery voltage between the white wire terminal of the fuel pump relay coupler and the body ground. ll the relay fails elIhEI' check, replace it. SWITCHES (ilLUGS 21-9 SWITCHES HONDA VF‘I 00°F FIlEL lEVEl SENSIIR REMOVAL Remove the fuel tank and drain the fuel. Remove the fuel level sensor attaching nuts and fuel level sensor. INSPECTION Measure the resistance of the fuel level sensor in the full and empty float positions. RESISTANCE: FULL 3.5—9.5 Q EMPTY 90—100 fl Turn the ignition switch 0N. Connect the fuel level sensor coupler to the wire harness. Move the llnat to full and empty and check the fuel gauge needle in both positions, If the fuel gauge does not indicate the proper level, replace it with a new one. ll] FUEL\LEVEL SENSOR [ilFULL l2) FUEL GAUGE lSlEMPTY 21-10 HONDA VF'I OOOF é? THERMUSTATIC SWITCH The cooling fan motor is actuated by the thermo static switch located in lower the radiator, If the fan motor does not start, disconnect the black and green leads from the thermostatic switch and short them together with a jumper wire as shown Turn the ignition switch on. The cooling fan motor should start running, If it does not start, check for battery voltage from the black lead (positive) to black/blue (negativel of the fan motor coupler. If there is no voltage, check for a blown or faulty fuse, loose terminals or connectors, or an open circuit. If it starts, inspect the tan thermostatic switch as follows: Suspend the switch in a pan of coolant (50»50 mixturel and check the temperatures at which the switch opens and closes. Make sure that there IS no switch continuity with room temperature and gradually raise the coolant temperature. The switch should be contlnuity (close) at 107 7113°C I225 235°FL NOTE - Keep temperature for 3 minutes betore I testing continuity, A sudden change of temperature will cause error or tempere ture reading between the thermometer and the switch. - Do not let the thermometer or switch touch the pan as it wlll give a tales reading. - Soak the switch in coolant up to its threads TEMPERATURE SENSIJII Disconnect the green/blue wire from the tempera- ture sensor. Drain the coolant and remove the temperature sensor from the thermostat caset SWITCHES (2) THERMOSTATIC SWITCH LEADS lllTHERMOSTATIC SWITCH I3) JUMPER WIRE III THERMOSTATIC SWITCH i1) TEMPERATURE SENSOR 21-11 HONDA VF'I OOOF SWITCHES Suspend the unit in oil over a burner and measure the resistance through the unit as the orl heats up m TEMPERATURE SENSOR ‘15 l .r’. we Ase°c 85“C mfc 120°C 143°F 185°F 230“; 248°F 104.09 43,951 20.39 16.12 Temperature { Resistance L Wear glaves and eye praIEer'nn. NOTE 7 if 7 Oil must be used as the heated liquid to check operation above 100°C (212°Flr (21THERMOMETER You’ll get false readings if either the thermometer or temprature sensor touches the pan. BRAKE AND TAILIJGHT SENSBR Remove the rear cowl. Turn the ignitlon swrtch on. Check the source voltage at the black/brown lead, If there is no voltage, check and repair the source clrcuit. If there is voltage, measure the voltage at the white/yellow [posltivel and green/yellow (negative) wrres. VOLTAGE: 5V If there is no voltage, replace the sensor unit. (llERAKE AND TAIL LIGHT SENSOR HEADLIGHT REMOVA L/INSTALLATION Remove the fairing. 21-12 HONDA VF 1 00°F SWITCHES (“HEADLIGHT Push (he headhght and turn it counterclockwise to remove the headiighl with the head‘ight bracket. Disconnect the headlight coupler and remove the rubber cover‘ {HRUBBER COVER Remove me headlight bulb by remaving the clip. {MCLIP 21-13 HONDA SWITCHES VF1 INSTALLATION NOTE Install the rubber‘cover with the mp mark (acing up. lnstaII in the reverse order of removal. INSTRUMENTS REMOVAL Disconnect the Instruments wxre couplers. HICOUPLERS 21-14 HONDA VF1 OOOF SWITCHES Remove the (nu! mount nuts and speedometer Cable from me Instruments. Remace the bums. Pull out the instruments DISASSEMBLV Remove the Hip memr knob. ITITRIP METER KNOB 21-15 SWITCHES Flemove the screws and remove the instruments. Assemble and install the instruments in the reverse order of disassemble/removal. TEMPERATURE GAUGE Disconnect the wire from the temperature sensor and short It to groundt Turn the ignition switch to ON, The temprarure gauge needle should move all the way to the H. CAUYION [)0 m1! leave the temperature sensor wire grounded fur longer [hart a few seconds or the tempera/we gauge will be (imaged, TllflHllMETEll If the tachometer does not indicate properly, check and repair the 1-3 cylinder ignition system If the problem still appears, check continuity be tween the yellow wire terminal of the wire harness instrument coupler and the yellow wire of the 18 cylinder ignition coil. Repair or replace wire‘har- ness, if necessarv. If there is continuity, replace the tachometer with a new one. HONDA VF'I OOOF ii i TEMPERATURE SENSOR [1 l TACHOMETER SPARK UNlT l3lPULSE GENERATOR 21-16 Ii()lII)IL VFIOOOF SWITCHES BULB Licence Plake Light Remove me two hcence plate holder mount nuts. (HNUTS ( 1 ) SC R EWS Remove the two screws and remove the lens. Remove khe bulb and mum! in the reverse order of removaL HONDA VF'I OOOF SWITCHES Turn Signal Light Remove the screw and pull out the turn signal light lens. lllSCREW Tum the bulb socket and replace the bulb. Install thetum signal light in the reverse order of removal. ll lEULB SOCKET Tall/Stop Light Remove the rear cowl. Turn the bulb socket caumerelockwxse. 21-18 HONDA VF'I OOOF SWITCHES Replace the bulb and Install the rear cowl in the reverse order of removal. FUSE HflLDER Remove the fainng. DISCOnnEcl the fuse holder couplers (6p red and 41: red). I 1 ) SCH EWS Remove the two screws from the fuse homer covet 21-19 HONDA VF'I 00°F SWITCHES Remove two screws then remove the fuse holder from the (op brldge. lnslall the fuse holder in the reverse order of re moval. (1 ) HORN CONNECTORS Connect the fully charged 12V battery tn the termi- nals to test the horn. 21-20 HONDA VF'I OOOF VF1000F WIRING DIAGRAM mm mm SCHEMA ELECTRI m". 4. n— u um... um XI 1 “"3?” mm. lawn: a m mm mm uun ma r... g .. .. '1...“ u .-.. am.- 1mm. a m. m u mum unmfl H—rhh—kl—V Inn-mm. to" 54m . a... mum. .m ‘mn mm-mm-m mm..m.n.u.... hr umum n..._.> M. mem vo- wwvmuw nun-um” mum "‘“'l" ‘ '-’ law - n11— “I'D m m...»m 7 su...;...,....n.. .....u......., l"le Eg'iu' mi mm. mm _. m. “w m m fnlInnV rim-l 'm L-I-‘r- ‘- II»- Iran um. A. 1Ynm-UI “ II - m n— you. [Nanak-mm m. m ('5 w- mm W. a - in..." , mm mm. mm. . m. glam m.“ L M Vanadium-mm n ‘5 w... m mm» mm. {mu- mum-u mmuw smuL-musn up. snuu sum. a“ s": Wm my an...» n mm... m n 1.. a bum. r...“- n. a. m.“ - nix-w (mm-1r 11 mm a m... In: n m, n um... mm :- m 51mm mu m: “991nm w mm mm r‘u. mm: mm m su saw nu: ma rum - ...u... an . _. mm mm. mm. e «an. my... mm. 1 m"... ... rm m m u n: n ‘5 Mn um u m: w u l u u m M In: urr rln’ nu ma O-vO "- 0--O QUE svuml mm swu- n...... h um... um- mm. o m. e m. W m mu mmm m mm w... my“... ms. nu wms DIAGRAM H... , Par-mm u. .n .. ...... . a ' J. l .‘7’ '. 5" > m.) rm mm m. v m .2 um um. m... 1.... u :- —m—: ‘83 _. mu no In. nan Vn‘lmhmn . .r n v . I . m m... gunman m... 1.... . w... . v . . l 1 ‘ A an mm. mm. . m m. o m.- ..m.. m. .. - n . mu 5 m u mflfim... . m H n mam. .. um... .92.... “ n "'1 h" . . .. .- Mxmum tumult-x . v ..........:.. . I- . m. nmi 5mm 0...... .. mm. « p... u I mm :— g a . u.“ A c D “V’ " m", mum. uni-um" In.th mum-u. mm W mumrn lni-Iamll run-w- huh-lint mm W! 0-0 mum-m :mm um. um mm mm! um. an H um um mum. um I — I 22-1 HON DA VF'I 00°F 65 23 TRIIUBLE SHIIIITINII ENGINE DOES NOT START OR IS HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEEDS POOR PERFORMANCE AT HIGH SPEED POOR HANDLING ENGINE DIIES IIllT START IIII IS HAITI] Tl] START NOT REACHING CAREURETOR—> (I) I2) I3) [4) (5) (6) 1. Check luzl Ilow la carbulswr REACHING CAHBURETOR WEAK OR NO SPARKg—FI‘II I2I I3I I4) 2. PerIuvm a 3-polm spalk lusr GOOD SPARK [5) (6) I7] IE) LOW COMPRESSION _—>|1) IN 3, Tasx :vlindu compressian COMPRESSION NORMAL (3T (4] I5] I6) I7) 1!, Slanbv ENGINE STARTS BUT STOPS—+(II I?) I3) [4) followmg nuvmaI procedure ENGINE DOES NOT FIRE ‘5) 5. Remove and Inspect spalk ulug WET PLUG —‘—‘>(|I I2) (3) (“I 23—1 23—2 23—3 23—3 23—3 POSSIBLE CAUSE FueI Iank Emmy Clogged lqu Irno or Iuel irlrer srrokrno IloaI valve Faully Iuel pump Fauer qul pump relay Pinched fuel Iank vem hose Faulw spark nlugs Fouled spark pIugs Faullv snark unlr Broken or shamed hlgh lenSlon wires Faulry suark unn Broken or shoned ignnrun call FluIIy Ignllion swncn Faulry puIse generator Low bauer cnarqe Improper levE clearance lruo smlllI Valve stuck open Worn cvlmder and msron rrnos Dammzd cvlmder head gasket Sel‘xed valve Impropu uom limlng Improper choke opararron Carburetor uncorrzcllv adiusled lnruke pipe Iaaklng Improper rgnmpn nmrng (Snark unn or pulse generator) Fuel nunlaminuzd Carbureror flooded Camureror choke axcumuely closed. Cylinder Iloodud Alr cleaner duly 23- 1 TROUBLESHOOTING ENGINE lABIIS PIIWEII I. Raise whul: 0" ground and spin by hand WHEELS DO NOT SPIN FREELv—blll WHEEL SPINS FREELV Check Kira Dvessuve PRESSURE NORMAL AEEI (e vividly fvom low to second ENGINE SEEED LOWERED WHEN CLUTCH IS RELEASED r Ace-Int- llghtly ENIGNE SPEED INCREASES , Check ignition liming CORRECT . Check VIN: clearance CORRECT . Tut cvlindur compression NORMAL Chock onrburntor Ia! clogging NOT CLOGGED Ramove spark plug NOT FOULED 0R DISCOLORED chock oll Iml Ind condilian CORRECT Ramovu cylinder head coyor and inipecl IubricIlion VALVE TRAIN LUBRICATED PROPERLY Chick Ior Imam! overheating NOT OVERHEATI NG Ac: cr run in high speed ENGINE DOES NOT KNOCK (Z) (3) (4) (SI PRESSURE LOW —I—. (II Iii ENGINE SPEED CHANGED —>(11 WHEN CLUTCH ls RELEASED (z) (3) ENGINE SPEED DOES NOT INCREASE —>(I) (2) (SI (4) [5) INCORRECT—Fin (2] INCORRECT——>(1) (2) TOO LOWE” I l2) l3) l4) CLOGGED ——‘~‘——>III FOULED 0R DISCOLORED——>lll (Z) INCORRECT —-——>(1I (2) (3) VALVE THAIN NOT LUBRICATED—bfl) PROPERLY _ I2) —>[II 12) OVERHEATING [3) 14) 15) i3] ENIGNE KNOCKS ———>lll [2i (3) I4) HONDA VF'I 00°F 6 POSSIBLE CAUSE araltc dragging Worn or damaged wheel bearings Wheel belrlng need: lubrication Drive chlin too tlgnt finer axlu not sxcassivsly tight Puncturod lirI Faulty tlrc valve Clutch nipping Worn clutch dim/plat- Warped clutch disc/ulna Carburuor oholtc closod Cloggod ail cleansr Restricted cool How Cloggod mum" Clogged fuel tank vent hale Faulty spark unlt Fauitv pulse qlnemml lmDropar wlw adiuslmlnl Worn valve seat Vllva ttvclt open Warn cylinder and piston rings Leaking hm gum Improper vulva liming Carburetor not sorvicad frequanllv enough Plugs not sorviccd lrcqucntly enough Spark plug with incorrect heat range on lwei too hlgh nil lcvsl too low Contaminated ml Clagged oll passaga Clugged all control nIiIice Coolant leveI low Fln motor nm working man motor relay Ianltyl Thermostat stvolt closed Emtnvn urban buIId-up In Combusnon chamber Use oi poor ovnlltv Iuel Clurch Sllaplng Worn piston and cylinder Wrong typo of tool Excesslva carbon buildup In cumhumon chamber ignition tlmlng too lav-"cod (Faulty snark unitl 23-2 HONDA VF'I 00°F TROUBLESHOOTING PDDR PERFDRMANCE AT LDW AND IDlE SPEEDS POSSIBLE CAUSE 1. Chuck ignkinn Timing and Valli! Clears“! INCORRECT——(1] Improper vain clunnco (2) Improper innilion timing COHRECY (Faulty spark unit) 2 Check urburuor pilal screw udiunmnm INCORRECT ——> See Fuel System Seetien CORRECT 3‘ Check ior leaking intake Dlpz LEAKlNG———>lll Dateriorued lrlwlltav O—rlnp (2) Loose urburaror N0 LEAK at Parl‘nrm splrk test WEAK Ola INTEHMITTENT SPARK —> (I) Faulty, carhan or wet lauled spark plug GOOD SPARK (2) Faulty splrk unil (3) Faulty ignition call PDDR PERFDDMANBE AT HIDH SPEED NOTE: Ignhiun to (he No.2 and NO. 4 cylinders is Cut-o" at 1130041300 rpm to prevent engine damage. I, Check ignition timlng and valve claurince INCORRECT —>m Improper vulva ale-vane: (1) Flulw splvk unit CORRECT (3) Faulty pulee generator 2. Dlscunnecl Aunl llna at curbuvelov FUEL F LOW RESTRICYED——>(Il Fuel tank amptv (2| Clogged fuel line FUEL FLOWS FHEELV i3) Clogged luel rank breather hole in Clogged luel um [5) Faulty luel pump 3. “move carbumlor: and check lor CLOGGEO—> Clean clogged in; NO CLOGGED JETS 4. Check valve tlrmng lNConEECT———>Cem sprocket not installed amplrly CORRECT 5. Check valve spring llnsinn WEA<————> Faully mung NOT WEAKENED ——’ Check tire and suspensions pressures 1, ll steering ls heavy in Sleering Hem Bdlufllr nut mu lighl l2) Damaged steering head bearlngs 2, ll either wheel is wapblinp (II Excessive wheel bearing play (2) Barn rlm (:ll Improperly installed wheel (41 Swing-rm pivol belrmg axeusively Warn [5) Ban: ham: :4. ll the motorcycle pullsto one ride _-—————>ll) Ban! lrame (2) From Ind rear wheels not nllgnod [3| Blnl from lolk (41 Bnnlswingarm 23-3 MEMIJ