J “ *' SHDPMANUAL
V65 MAGNA-VF’I 1 DOC

MOTOR CO , LTD. 1982
IN JAPAN

 

HONDA
V65MAGNA

 

 

  

'fii HUW T0 USE THIS MANUAL
Follow the Maintenance Schedule (Section 3) LUBRICATION
recommendations to ensure that the vehicle is
in peak operating condition and the emission MAINTENANCE :-
levels are within the standards set by the US ,
Environmental Protection Agency. Perform- ' FUEL SYSTEM l.
ing the first scheduled maintenance is very im» ‘
portant, It compensates for the initial wear ENGINE REMOVAL/INSTALLATION E.
that occurs during the break-in period. i

COOLING SYSTEM I!

Sections 1 through 3 apply to the whole

motorcycle, while sections 4 through 21 CLUTCH SYSTEM
describe parts of the motorcycle, grouped
according to location,

  
 

GENERAL INFORMATION

 
  

 

    
 
    

GEARSHIFT LINKAGE

Find the section you want on this page, then

ALTERNATOR E.
turn to the table of contents on page 1 of that
section CYLINDER HEAD/VALVE Il:'
Most sections start with an assembly or CRANKCASE II.
system illustration, service information and *
troubleshooting for the section. The sub- PlSTON/CRANKSHAFT In

sequent pages give detailed procedures.
TRANSMISSION

ENGINE

       
 

If you are not familiar with this motorcycle,
read the TECHNICAL FEATURES in section
23.

DRIVE TRAIN

  
  

 

 

. FRONT WHEEL/SUSPENSION
If you don’t know the source of the trouble,

go to section 24, TROUBLESHOOTING, REAR WHEEL/SUSPENSION Ila.
ALL INFORMATION, ILLUSTRATIONS, DI- HVDRAULIC BRAKES mfi 7", '
RECTIONS AND SPECIFICATIONS INCLUD- m
ED IN THIS PUBLICATION ARE BASED ON BATTERV/CHARGING SYSTEM

THE LATEST PRODUCT INFORMATION
AVAILABLE ‘AT THE TIME OF APPROVAL IGNITION SYSTEM
FOR PRINTING, HONDA MOTOR co.,

LTD. RESERVES THE RIGHT TO MAKE

CHASSIS

 

 

 

    
 

ELECTRIC STARTER

  

CHANGES AT ANY TIME WITHOUT NO- 7 , ,
TICE AND WITHOUT INCURRING ANY SWITCHES

ELECTRICAL

 

 

OBLIGATION WHATEVER.

N0 PART OF THIS PUBLICATION MAY BE WIRING DIAGRAM E

REPRODUCED WITHOUT WRITTEN PER- ,

MISSION. TECHNICAL FEATURES E.
HONDA MOTOR CO., LTD. TROUBLESHOOTING E.

SERVICE PUBLICATIONS OFFICE ‘

 

 

 

 

’ i

 

Date OI Issue: Dec, 1982 1
'© HONDA MOTOR 00., LTD.

2,,

4

 

     

 

 

 

     

   

  
 

03m We: a mum « .

 

 

We;

       
   

 

   

x mt»;
m1 _<H ~u,>‘rr1»v,.xu l‘

   

 

HONDA
V65MAGNA

 

1. GENERAL INFBRMATIBN

 

 

GENERAL SAFETY 1—1
SERVICE RULES 1_1
MODEL IDENTIFICATION 1—2
SPECIFICATIONS 1—3
TOROUE VALUES 1-5
TOOLS 1—7
CABLE & HARNESS ROUTING 1—9
EMISSION CONTROL SYSTEM 1—11
EMISSION CONTROL INFORMATION LABEL 1—11

 

 

GENERAL SAFETY

If the engine must be running to do some work, make sure
the area is well-ventilated, Never run the engine in a closed
area. The exhaust contains poisonous carbon monoxide
gas

Gasoline is extremely flammable and is explosive under
certain conditions, Do not smoke or allow flames or spark:
in your working area,

SERVICE RULES

\“twanNING

The battery electrolyte contains sulfuric acid. Protect your
eyes, skin and clothing. In case of contact, flush thoroughly
with water and calla doctor if electrolyte gets in your eyes

WWARNING

The battery generates hydrogen gas which can be highly
explosive. Do not smoke or allow flame: or sparks near the
battery, especially while charging it.

1. Use genuine HONDA or HONDA-recommended parts and lubricants or their eqUivalent, Parts that do not meet HONDA‘s

design specifications may damage the motorcycle,
, Use the special tools designed for this product.

(an

. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English

fastenerst The use of incorrect tools and fasteners may damage the motorcycle.

014:.

unless a particular sequence is specified.

\IGI

, Install new gaskets, Brings, cotter pins, lock plates, etc. when raassembling. ‘
. When tightening belts or nuts, begin with larger~diameter or inner bolts first, and tighten to the specified torquedlagonally,

. Clean parts in cleaning solventupon disassembly. Lubricate any sliding surfaces before reassembly.
. After reassembly, check all partsyfor proper installation and Operation.

 

Date Of Issue: Dec, 1982
© HONDA MOTOR COL, LTD.

1-1

 

 

 

1-! NBA
V65MAGNA

 

GENERAL INFORMATION

MODEL IDENTIFICATIUN

 

 

 

 

 

BEGINNING F NO. SC120*DM000029 The color label is attached to the frame behind the left side
E NO. SCIZE—ZOOOOSS cover,

  
  

“a t a , f \ x3 I , _ ‘
The frame serial number is stamped on the steering head The vehicle identification number (VIN) is on the steering
right side. head left side

 

 

 

 

  

The engine serial number is stampecl on top of the right The carburetor identification number is on the carburetor
crankcase. bodv left side

 

   

 

4 Date of Issue: Dec, 1982
1 ' 2 ©,HONDA MOTOR 00., LTD.

  

HONDA
V65MAGNA

 

GENERAL INFORMATION

 

SPECIFICATIIINS

 

 

 

 

 

 

 

 

Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train

Maximum horsepower
Maximum torque

Oil capacity

Coolant capacity
Lubrication system

1 Air filtration
‘ Cylinder compression
Intake valve Opens
Closes
Exhaust valve Opens
Closes
Valve clearance (Cold)

Engine weight
Idle speed

 

 

ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,280 mm (89.8 in)
Overallwidth B10mm (31.9in)
Overall height 1,210 mm (47.6 in)
Wheelbase 1,595 mm (62.8 in)
Seat height 800 mm (31.5in)
Foot peg height 350 mm (13.8 in)
Ground clearance 155 mm I 6.1 in)
Dry weight 245 kg (540 lb)
Curb weight 265 kg (584 lb)
FRAME Type Double cradle
Front suspension, travel Telescopic iork, 160 mm (6.3 in)
Rear suspension, travel Swingarm/Shock absorber, 112 mm (4.4 in)
Gross vehicle weight rating 435 kg (960 lb)
Vehicle capacity load 168 kg (370 lb)
Front tire size M110/90-18 Tubeless
Rear tire size M140/90-16 Tubeless
Up to 90 kg Front ,32 psi (225 kPa, 2.25 kg/cm‘)
Cold me (200 lbs) load Rear 32 psi (225 kPa, 2.25 kg/cm‘)
pressures Up to vehicle Front 32 psi (225 kPa, 2.25 kg/cmzi
capacity load Rear 40 psi (230 kPa. 2.8 kg/cmz)
Front brake, lining swept area Double disc, 904 cm1 (1401 sq in)
Rear brake, lining swept area Single disc, 516 cm2 (80 sq in)
Fuel capacity 17 liters (4.5 US gal, 37 Imp gal)
Fuel reserve capacity 3 liters (0.8 US gal, 0,7 Imp gal)
Caster angle 59°40
Trail 105 mm (4.1 in)
Front fork oil capacity R: 565 cc (19.1 01), L: 580 cc (19.6 oz)
ENGINE Type Water cooled 4sstroke, DOHC engine

 

4 cylinders 90°v
79.5 X 55.3 mm (3.13 x 2.18 in)
1,098 cm3 (67 cu in)
10.5 :1
Silent, multi-link chain drive and DOHC with rocker arms
111.5 BHP/9,500 rpm
97 kg-m (70.1 it~|b)/7,500 rpm
3.5 liters (3.7 US qt, 3.1 Imp qt) after disassembly
3.0 liters (3,2 US qt, 2.6 Imp qt) after draining
3.45 liters (3.65 US qt, 3.04 Imp qt)
Forced pressure and wet sump

Paper filter
13 t 2 kg/cm2 (134 a 23 psi)
8°(BTDC)
40°(ABDC) .
43°(BBDC) at 1 mm llft
7° (ATDC)

lN/EX: 0.12 mm (0.005 in)
96.7 kg (2132 lb)
1,000: 100 rpm

 

 

 

Date of issue: Dec, 1982
© HONDA MOTOR C0,, LTD.

1-3

GENERAL INFORMATION

HONDA
V65MAGNA

 

 

ITEM

SPECIFICATIONS

 

CARBUFIETION Carburetor type/Throttle bore
Identification number
Pilot screw initial setting

Float level

(IV/36 mm (1.42 in)
VD70A
See page 4-16
6.0 mm (0.24 in)

 

DRIVE TRAIN Clutch
Transmission
Primary reduction
Secondary reduction
Final reduction
Gear ratio l

Gear ratio II

Gear ratio Ill

Gear ratio IV

Gear ratio V

Over drive

Gear shift pattern
Final drive gear oil capacity

Wet, multi-plate
5-speed with over drive
1.707
1.058
3.182
2.294
1.619
1.292
1.074
0.897
0,750
Left foot operated return system, 1—N—2—3—4—5—OD
170 cc (5.7 oz) aiter diassemblv

130 cc (4.4 oz) aiter draining

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRICAL Ignition Full transistor ignition

Ignition timing “F" mark 10°BTDC at idle

Full advance 37° BTDC at 3,300 rpm

Starting system Starting motor

Alternator 300W/2,000 rpm

Battery capacity 12V—1BAH

Spark plug NGK ND
Standard DPR BEA-9 XZIJEPR-US
For cold climate
(Below 5°C, 41°F) DPR 7EA—9 X22EPR-U9
For extended
high speed riding DPR BEA-9 X27EPR»U9

Spark plug gap 0.8—0}? mm (0031—0035 in)

Firing order 1—2—3—4

Fuse/Main iuse 10A, 15A/30A

LIGHTS Headlight (high/low beam) 60/55W

Tail/stoplight 8/27W 3/32 CD SAE NO. 1157

Front turn signal 23W 32 cp SAE N0. 1034

Hear turn signal 23W 32 cp SAE NO. 1073

Instrument lights 3.4W 2 cp

Neutral indicator 3W

Turn signal indicator 3W

High beam indicator 3W

 

 

 

1-4

Date of Issue: Dec, 1982
© HONDA MOTOR C0., LTD.

HONDA
V65MAGNA

 

TflRflUE VALUES

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

 

O E NG | N E
Item O‘ty Thread Dia. (mm) Torque N-m (kg~m, ft~|b) Remarks
Cylinder head cover 8 6 8—12 (03—11, 5.8—9.0)
Cylinder head 16 6 10—14 (1.0—1.4,7—10)
8 ' 8 21—25 (2.1—2.5, 15—18)
16 10 48—52 (4.8—5.2, 34—38)
Alternator 1 12 80—100 (80—400, 58—72)
Clutch center 1 25 50—60 (5.0410, 36—43)
Crankcase 14 10 43—47 (43—47, 31—34)
3 8 21~25 (2.0-2.5, 15—18)
14 6 10—14 (LO—1,4, 7—10) A LOCTITE‘D
Rocker arm shaft 8 22 45—50 (AS—5.0, 3346) 2113)), the threads
Cam sprocket 8 7 18—20 (13—20, 13—14)
Starter clutch 1 8 26—30 (26—10, 19—22)
Shift fork center 1 7 16—20 (1.6—2t0, 12—14)
Camshaft chain guide A 1 12 20—25 (2.0—2.5, 14—18)
Oil filter 1 20 15——20 (15—20, 11—14)
Out put gear case 2 8 21—25 (21—25, 15—18) Socket bolts.
Valve adiustment nuts 16 7 21—25 (2,1—2.5, 15—18) Apply oil to the
Drain bolt 1 12 35740 (3.5—4.0, 25—29) $3253” 59“”"9
Connecting rod nuts 8 8 30—34 (3.0—34, 22—25)
Drum stopper pivot shaft 1 6 8—12 (Ora—12, 5.8—9.0)
Primary drive gear 1 12 80—100 (80—10"), 58—72) Apply sealant to the
Oil pressure switch 1 — 10—14 (1 ,0—1t4, 7—10) threads
I CHASSIS
Item Q'tv Thread Dial (mm) Torque N~m (kg-m, ft»|b) Remarks
Sub-frame bolts (Upper) 2 10 60—70 (6.0—70, 43—51)
(Lower) 2 10 35—45 (3.5—4.5, 25—33)
Shock absorber mount bolts/nuts
(Upper) 2 8 40—50 (4.0—5.0, 29—35)
(Lower) 2 10 30—40 (3.0—4.0, 22—29)
Handlebar upper holder 4 8 40—50 (4.0—5.0, 29—36)
Rear brake pedal 1 8 24—30 (2.4—3.0, 17—22)
Change arm 1 6 10—1 5 (1.0—1.5, 7—1 1)
Side stand 1 10 35—45 (35—45, 25733)
Engine hanger bolts 2 8 20—30 (2.0—3.0, 14722)
4 10 35—45 (3.5—4.5, 25—33)

 

 

 

 

 

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

1-5

 

HONDA

 

 

 

 

GENERAL lNFORMATlON V65MAGNA
Item Q'ty Thread Dia. (mm) Torque N-m (kg~m, ft-Ib) Remarks
Brake hose bolts 7 10 25—35 (2.5—3.5, 18—25)
Caliper air bleed bolt 3 7 447 (0.4—0.7, 2.9—5.1)
Brake master cylinder holder 4 6 10*14 (1.0—1.4, 7—10)
ClutCh master cylinder holder 2 6 10—14 (LO—1,4, 7~10)
Axle pinch bolt 1 8 20—30 (2.0-3.0, 14722)
Front lork stabilizer 4 8 18—28 (1.8—2.8,13720)
Brake master cylinder cap 2 4 2—35 (0.2—0.35, 1.4—2.5)
Clutch master cylinder cap 2 4 2—3.5 (OX—0.35, 1.4725)
Final gear oil liller Cap 1 30 10—14 (1.0—1.4,7elo)
Front caliper 4 10 30—45 (3.0—4.5, 22733)
Rear brake torque rod 2 8 18~25 (1.8~2.5, 13—18)
Swingarm left pivot bolt 1 30 90—120 (9.0410, 65—87)
Swingarm right pivot bolt 1 30 16—20 (1,672.0, 12—14)
Swingarm pivot lock nut 1 30 100—130 (10.0—13.0, 72—94)
Final gear case nut 3 10 45—70 (45—70, 33—51)
Steering stem nut 1 24 90—120 (53.0—12.0, 65—87)
Front fork top pinch bolts 2 7 9713 (0.9—1.3, 7—9)
Front fork bottom pinch bolts 2 10 45—55 (45—55, 33—40)
Steering stem pinCh bolt 1 8 18—30 (1.8~3.0, 13—22)
Front axle 1 12 55—85 (5576.5, 40—47)
Front axle pinch bolt 1 8 18%30 (1373.0, 13—22)
Rear axle 1 18 85—105 (85710.5, 61—76)
Gearshift pedal pivot 1 8 18—25 (1372.5, 13—1Bl
1

 

F uel reserve se nsor

 

 

 

27—35 (2.7—3.5, 20-25]

 

 

 

Torque specifications listed above are for important lasteners. Others should be tightened to standard torque values listed

below,

0 STANDARD TORQUE VALUES

 

Torque Values

Torque Values

 

8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut

 

 

18—25 (1.8—2.5, 13—18)
30—40 (3.0—4.0, 22—29)
50—60 l5.0—6.0, 36—43)

 

“9'“ N-m (kgm, Mb) "em N‘m (kg-m, it-Ib)
5 mm bolt and nut 4—6 (0.4—0.6, 3—4) 5 mm screw 3—5 (0.3—0.5, 2—4)
6 mm bolt and nut 8—12 (0.8—1.2, 6—9) 6 mm screw 7—11 l0.7~1.1, 5—8)

6 mm flange bolt and nut
8 mm flange bolt and nut

10 mm flange bolt and nut
6 mm SH flange bolt

 

10—14(1,0—1.4,7—10)

20—30 (2.0—3.0, 14—,22) l
30740 (SD—4.0, 22—29)
75710.5 (0.75#1.05r,.5.4—7.6l

 

 

 

1-6

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA.
V65MAGNA

 

TOULS

GENERAL INFORMATION

 

 

0 SPECIAL
'; These tools are designed and have not been used betore.
DESCRIPTION NUMBER ALTERNATIVE NUMEEH HEF, sECT.
'Lock nut wrench, 42/55 mm 079167M540000 1:1
‘Dvive shalt dis/assembly tool 07564—Ma40100 14
'Valve guide driver attachment 0754a—Ma40000 ’ _ 10
mm {a 3
Vacuum gauge attachment A 075104000100 :4
Vacuum gauge attachment B 075104000200 3
Oil pressure gauge 075064000000 Equivalent tools commercially 2
Oil pressure gauge attachment 0751041220100 available in USA. 2
Compression gauge attachment 07510—M500101 a
Carburetov ollot screw wrench 075054220201 3
Swingarm lock nut wrench 0750874690001 Lock nut wrench KS—HBA7037 16
Valve adjusting wrench 0750040500100 469 (”5* “M a
Fletalner wrench 07910~MEBDDOD _ _ 14
Snap ring pliers 079144230001 {Emmy ‘°°' °°""“""°'“"V 7, 15, 17
Steering stern socket 075154710100 15
Lock nut wrench 0791644220000 7
Lock nut wrench, 30/34 mm 079167MBDOODO _ _ 1:1
0 mm hex. wrench 079174230000 {Egg}? ‘°°' °°'“'“e'“""“V 15
5mm holder 075234090101 13
Final pinion holder 07924—ME90000 14
Shalt puller 07931—ME40000 Pinion puller set 07535—111500000 14
IPinioncguller and 07531—4530200
P'In'lon Dune! anachmant kit 07931—M300000
Bearing race insert attachment 079314630300 14
Bearing remover hendle 079304710100 13
Bearing remover weight 07936—3710200 }Beering remover set 075354710000 1:1
Bearing remover, 17 mm 07936—3710300 1:1
Bearing ouiler 0 driver attachment 07534—111500000 14
Bearing remover shalt 07536—8890100 is
Bearing remover head 07936 4390200 10
Driver 075454710000 11
Valve guide driver 079424290100 ‘ 10
Socket bit, 17 mm 07703—0020500 {fgfig’gfim ‘°°' ‘°""“"'°“’”Y 16
Ball race 0 bearing driver ettechrnent 075454330300 14
Ball race remover 079464710500 15
Ball race driver 079454710700 15
Steering stern driver 0794541000000 15
Fork seal driver 07947—KA50100 15
Fork teal driver attachment 079477KF00100 15
Ball race remover 07953—4250002 15
Drive shatt dis/assembly tool 10) 07934—M000300 14
Rear shock absorber compressor 07967—Kc10000 1e
attachment
Valve guide reamer 07904—2000000 10
Flywheel cover ONQBVMBDODOO :l
075464710200 11

Anschmenl

 

 

 

 

 

 

 

 

Date of Issue: Dec, 1982 1
© HONDA MOTOR CO., LTD.

1-7

GENERAL IN FORMATION

   

HONDA
V65MAGNA

es

 

 

0 COMMON
DESCRIPTION NUMBER ALTERNATIVE NUMBER HEESECT,

Float level gauge 074014010000 1
Adjusting wrmch (A) 07708—0030300 ’ . 3
Lock nurwreueh, 30 x 32 mm 077154020400 :l-E‘g‘l‘l'gmfl‘fif’s'flff’mmm'wy 15
Exrenslou bar 077154020500 I5
Univarsal holder 077254030000 Flywheel holder 077254040000 7, 9
Rotor puller 077334020001 fimor puller 079334290001 9
Amanhmanl, 32 x 35 mm 077454010100 14
Anachmem. 37 x 40 mm 07746—0010200 14, la
Aneolrmem, 42 x 47 mm 077464010300 7,13414,1e
Anachmem, 52 x 55 mm 077464010400 13,14,16
Atlachmem, 62 x68 mm 077464010500 13
Pilot, I7 mm 077464040400 13
Pilot, 20 mm 077464040500 ls
Film, 30 mm 077464040700 la, 14
Pilot, 35 mm 077454040000 7, 13
Driver 077494010000 Driver 079494110000
Driver 077424030100 V 13, I4
Amohmeng 25 mm 077424030200 30m" 07945—37'0200 l4
Anachmsnt, :10 mm 077464030300 13
Bearing remover snelr 07746—0060100 15, la
laeerlne remover hsed, 15mm 077464050400 15
Bearing remover head, 20 mm 077464050000 15
Valve spring compressov 077574010000 10
Rear shock absorber compressor 079594290001 14, 16

 

 

 

 

 

 

 

 

1-8

\0

Dam of Issue: Dec,1982
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA GENERAL INFORMATION

 

 

CABLE & HARNESS RfllJTING

Note the following when routing cables and wire O
harnesses.

A loose wire, harness or cable can be safety hazard.
After clamping, check each wire to be sure it is @
secure,
0 Po not squeeze wires against the weld or end of “1%"
Its clamp when a weid»on 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 not pulled that or A

have excessive slack.

0 Protect wires and harnesses with electrical tape

or tube if they are contact a sharp edge or
corner. Clean the attaching surface thoroughly

before applying tape.

0 Do not use wires or harnesses with a broken
insulator. Repair by wrapping them with a pro»
tective tape or replace them.

0

Route wire harnesses to avoid sharp edges or
corners.

I Also avoid the projected ends of bolts and
screws.

0 Keep wire harnesses away from the exhaust pipes
and other hot parts.

I Be sure grommets are seated in their grooves
properly,

0 After clamping, check each harness to be certain
that it is not interferring with any moving or
sliding parts.

a After routing, check that the wire harnesses are
not twisted or kinked.

0 Wire harnesses routed along the handlebars
should not be pulled taut, have excessive slack,
be pinched, or interfer with adjacent or sur-
rounding parls in all steering positions.

 

Date of lssUe: Dec, 1982 11 1 _ 9
© HONDA MOTOR 60., LTD.

HONDA.
GENERAL INFORMATION V65MA°NA

 

R.TUFLN SIGNAL WIRE SPEEDOMETER WIRE

    
       
 

TH ROTTLE CAB LES

FRONT BRAKE HOSE CLUTCH HOSE

 

1 1 o 12 Date of Issue: Dec, 1982' ‘
' © HONDA MOTOR (20., LTD.

, , 3 HONDA
*% V65MAGNA

GENERAL INFORMATION

 

 

BATTERY BREATHER TUBE

  

STARTER MOTOR
WIRE

ALTERNATOR WIRE

ALTERNATOR WIRE

BATTERY GROUND CABLE

CLAMPS

"‘ GENERATOR
WIRE

REAR BRAKE SWITCH

 

Date of Issue: Dec,1982
©‘HONDA MOTOR (30;, LTD‘

1-11

HON DA
V65MAGNA

 

GENERAL INFORMATION

 

THROTTLE CABLES MAIN HARNESS

COOLANT RESERVE TAN K

/
, OVERFLDWTUBE
\ / v A
N 5‘!» -\
X
CLUTCH PIPE Ii; \
c00L|NG FAN f /
MOTOHWIRE / w
/o \

\\\~ .
n\
i?“ w./®RADIATOFI OVERFLOW TUBE\

7 n:
I. "\
\ \ FUELHOSE

            
    

THE RMOSTATI C SWITCH

FUEL FILTER
FUEL PUMP

  

 

14 Dam of Issue: Dec, 1982
1 '1 2 ©HONDA MOTOR (30., LTDI

. HONDA.
V65MAGNA GENERAL INFORMATION

EMlSSlflN DflNTRUL SYSTEM

The V65 engine is equipped with a crankcase emission control system which routes crankcase emissions through the air
cleaner and into the combustion chamber. Condensed crankcase vapors are accumulated in a storage tank which must be
emptied periodically. See the Maintenance Schedule in Section 3.

AIR CLEANER <2: : FRESH AIR
‘— 2 BLOW-EV GAS

   
 
  
   
    

BHEATHEH
SEP
CARBUHETOH AHATOR

DRAIN TUBE

\DHAIN PLUG

 

EMISSIIJN BflNTRflL INFORMATlflN
LABEL

An Emission Control Information Label is located
on the frame as shown. It gives basic tune-up
specifications.

EMISSION CONTROL

 

 

INFORMATION LABEL

 

 

Date of Issue: Dec, 1982 I5
©HONDA MOTOR 60., LTD. 1 '1 3

LUBRICATION

4 HONDA.
‘% V65MAGNA

 

FRONT CYLINDER
EX. CAMSHAFT

um
“(ERA-m FRONTCYLINDER

» IN‘ CAMSHAFT

 

     
    
 

1
It y In: '=>(T0 REAR CYLINDER)
CRANKSHAFT' I ‘
l
V I'I I
I

 

 

 

OIL STRAINER

r/ ‘—O|L PIPE

 

 

 

SHIFT FORK SHAFT

 

MAINSHAFT

COUNTERSHAFT ,

 

2-0 16

Date of Issue: Dec, 1982 .
© HONDA MOTOR CO‘, LTD.

$333? 2. LUBRICATION

 

 

SERVICE INFORMATION 2—1 OIL PRESSURE CHECK 2—4
TROUBLESHOOTING 2—2 'OIL PUMP 2—5
ENGINE OIL LEVEL 2—3 FINAL DRIVE OIL 2—10
ENGINE OIL 81 FILTER CHANGE 2—3 CONTROL CABLE LUBRICATION Z—10
OIL STRAINER CLEANING 2—4 LUBRICATION POINTS 2—11

 

 

 

SERVICE INFflRMATIflN

GENERAL

To service the oil pump, it is necessary to remove the right side cover and water pump assembly. See section 6 for water pump
removal and installation.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

Engine oil
Oil capacitv 3.0 liter (3.2 US qt, 2.6 Imp qt) after draining
3.5 liter (3.7 US qt, 3.1 Imp qt) after disassembly
Oil recommendation OIL VISCOSITIES
Use HONDA ASTROKE OIL or equivalent.
API SERVICE CLASSIFICATION: SE or SF.
VISCOSITY:
SAE 10W—40
Other viscositias shown in the chart may be
used when the average temperature in your
riding area is within the indicatEd range.
.343 .20 4o 0 w 2o an m;
Oil pressure + 2 + . no 17 oF
(at oil pressure switch) 5.4 — 0,7 kg/cm (77 - 10 psl) at 5,000 rpm (80 / 6 I
Oil pump delivery 28.8 liter (30.5 US qt)/min, at 5,000 rpm

 

 

Oil pump service data

 

 

 

 

 

 

 

 

 

STANDARD SERVICE LIMIT
Rotor tip clEarance 0.15 mm (0.006 in) 0.20 mm (0.008 in)
Pump body clearance 0.15—0.22 mm (0006—0009 in) 0.35 mm (0.014 in)
Pump end clearance 0,02—0.07 mm (0.001—0.003 in) 0.10 mm (0.004 in)

Final drive gear

Oil capacity 170 cc (5.7 oz.) afterdisassembly

130 cc (4.4 oz.) after draining
Recommended oil vaoid gear oil Algove 5°C/41°F SAE #90

Below 5°c/41"r~ SAE #90

 

 

 

 

 

Date of Issue: Dec, 1932 17 2 1
© HONDA MOTOR C0,, LTD. '

LUBR-ICATION

     

HONDA
V65MAGNA

gag

 

TORQUE VALUES

Engine oil drain plug 35—40 Nvm (3.5—4.0 kg-m, 25—29 ft-Ib)

Engine oil filter 15—20 N~m (1.5—2.0 kgm, 11—14mm — Apply Loctite® to crankcase bolt threads,

Oil Pressure switch 10—14 N-m (Lo—1.4 kg-m, 7~1o lt-lb) e Apply 3-BOND® or its equivalent to the
bolt threads.

TOOLS

Special

Oil pressure gauge 07506—300000!)

Oil pressure gauge attachment 07510—422010!)

TRflUBLESHflflTING

Oil level mo low

1. External oil leaks

2. Worn piston rings

3. Worn valve guide or seal

on contamination

1, Oil or filter not changed olten enough
2. Head gasket faulty

3. Worn piston rings

Low oil pressure

1. Oil level low

2, Pressure relief valve Stuck open
3. Plugged oil pickup scrEen

4. Oil pump worn

5, External oil leaks

Hinh oil pressure

1. Pressure relief valve stuck open

2. Plugged oil filter, gallery, or metering orilice
3, Incorrect oil being used

No oil pressure

1. Oil level low

2. Oil pump drive chain broken
3. Oil pump laulty

4. Internal oil leakage

:|— or commercially available equivalent.

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HON DA.
V65MAGNA LUBRICATION

 

ENGINE [llL LEVEL

Put the motorcycle on its center stand on level
ground. Start the engine and let it idle for 273
minutes. Turn off the engine. Remove the dipstick
wipe it clean and insert it without screwing it in.
Remove the dipstick and check the oil level.

<—UPPER

‘—
If the level is below the lower level mark, remove LOWER

the filler cap and fill to the upper level mark.

Check the oil pressure with the warning indicator
switch after the engine starts. The indicator should
go off after one or two seconds.

If it does not, stop the engine and check the oil
pump function and/or oil circuit.

ENGINE OIL & FILTER CHANGE

NOTE:

Change engine oil with the engine warm and
the motorcycle on its center stand to assure
complete and rapid draining.

 

 

 

 

Stop the engine.

Remove the oil filler cap, cylinder head oil drain
plug, engine bottom oil drain plug and drain the oil.
Remove the oil filterwith a filter wrench and let the
remaining oil drain out. Discard the oil filter.

Make sure that the sealing washers on the drain.
plugs are in good condition and install the plugs.
After completely draining the oil replace the oil
filter with a new one. Check that the oil filter O-ring

 

is in good condition, and coat it with oil before OIL FILTER 15720 Ntm
installing it. Coat the oil filter seal with oil. Fill the (1.5—2.0 kg-m,11—14it»lb)
crankcase with 3.0 liters (3.2 us qt, 2.6 Imp qt) DRAIN WASHERS

of the recommended oil (page 2-1).

Start the engine and let it idle for 2-3 minutes,
then stop the engine.

Make sure that the oil level is at the upper level
mark.

Make sure that there are no oil leaks.

   

/.
,,

DRAIN PLUG 35—40 N~m CYLINDER HEAD OIL DRAIN PLUG

(3.54.0 kg»m, 25—29 ft-ib) 10—14 N-ml1.0~1.4 kg-m,7—10fltlb)

Date of Issue: Dec, 1982 19 2 3
© HONDA MOTOR 00., LTD. '

   

LUBRICATION

OIL STRAINER CLEANING

NOTE:

 

The oil strainer can be removed with the

 

 

engine mounted in the frame.

 

Remove the front exhaust pipes.
Drain the engine oil (page 2—3),

Remove the oil pan bolts and oil pan

Remove and clean the oil strainer.

Check the operation of the pressure relief valve.
Make sure the 0~rlng is in good condition when-
ever the relief valve is removedr

Install the oil strainer and oil pan.

Install the exhaust pipes.

Fill the crankcase with the recommended oil (page
24).

[Ill PRESSURE CHECK

Warm the engine up to normal operating temper-
ature (approximately 80°C/l76nFlt

Stop the engine and disconnect the oil pressure
switch wiret

Remove the oil pressure switch and connect an
oil pressure gauge to the pressure switch hole
(page 2-5).

Check the oil leVEI.

HONDA
V65MAGNA

 

 

OIL STRAINER

r "w

    

[OIL PRESSURE SWITCH

 

2-4

70 Date of Issue: Dec, 1982
© HONDA MOTOR C0,, LTD.

HONDA
V65MAGNA

 

LUBRICATION

 

Start the engine and check the oll pressure at 5,000
rpm.
OIL PRESSURE:
5.4 i 0.7 kg/cm2 (77 i 10 psi) at 5,000 rpm
(80°C/17GoF)

Stop the engine.
Apply 3-BOND® sealant or equivalent to the
pressure switch threads and install,

TORQUE: 10—1‘ N-m (1.0—1.4k9-m,7—106t-lhl

Connect the oil pressure switch wire.

Start the engine.

Operate the warning indicator switch.

Check that the oil pressure warning indicator goes
out after one or two seconds.

If the oil pressure warning indicator stays on, stop
the engine immediately and determine the cause.

[IIL PUMP

REMOVAL

NOTE:

The oil pump can be removed with the engine
mounted in the frame.

 

 

 

 

Drain the engine oil. Remove the exhaust system,
Remove the right side cover.

Remove the oil pump driven sprocket by removing
the bolt and washer.

Remove the water pump assembly (page 6-12).

Remove the oil strainer (page 24) and the oil
pass pipe.
Make sure the 0~rings are in good condition.

  

OIL PRESSURE GAUGE
07506—2000000 (Not available in USA.)

  

9..“ ‘
,1 s ,. .
OIL PRESSURE GAUGE
ATTACHMENT 07510—4220100

' . 7,..__/"
OIL PUMP DRIVEN SPROCKET

 

OIL PASS PIPE

O-RINGS

 

Date of Issue: Dec,~1982
© HONDA MOTOR 00., LTD.

 

LUBRICATION

Remove the oil pump by removing the mounting
bolts,

Straighten and remove the pin holding the oil
strainer stay.
Remove the oil strainer stay.

Make sure the O~rings are in good conditions,

DISASSEMBLY

Remove the oil pump body cover and remove the
dowel pint
Remove the drive pin from the rotor shaft.

   

STRAINER STAY

OIL PUMP BODY COVER

 

HONDA
V65MAGNA

OIL PUMP

 

DOWEL PIN

 

 

2-6

22

Date of Issue: Dec, 1982
© HONDA MOTOR CO” LTD

HONDA
V65MAGNA

 

Measure the rotor tip clearance,

STANDARD: 015 mm (0006 in)
SERVICE LIMIT: 0.20 mm (0.008 in)

Measure the pump body clearance.

STANDARD: 0.15—0.22 mm (0.006—0.009 in)
SERVICE LIMIT: 0.35 mm (0.014 in)

Remove the rotor shaft and measure the pump
and clearance,

STANDARD: 0.02—0.07 mm (0.001—0.003 In)
SERVICE LIMIT: 0.10 mm (0.004 in)

Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

23

LUBRICATION

 

 

2-7

HONDA
V65MAGNA

 

LUBRICATION

ASSEMBLY OIL PUMP BODY OUTER ROTOR

Install the outer rotor into the body and insert the
rotor shaft.
Insert the drive pin into the rotor shaft‘

 

ROTOR SHAFT DRIVE PIN

Align the slots in the inner rotor with the drive pin.

      

DRIVE PIN INNER ROTOR

DOWEL PIN
Install the dowel pin and oil pump body cover.

 

 

24 Date of Issue: Dec, 1982 ,
2 ' 8 © HONDA MOTOR co., LTD.

HONDA
V65MAGNA LUBRICATION

 

 

INSTALLATION

Install the dowel pins and O-ring and install the 0
oil pump.

Install the strainer stay with a new pin and install
the oil pipe.

NOTE:

Make sure the O-rings are installed on the
strainer stay and oil pipe.

 

 

 

 

Install the oil strainer and oil pan.

 

Place the oil pump driven sprocket into the drive
chain.

NOTE:

The "IN" mark on the driven sprocket should
face the crankcase.

 

 

 

 

 

Install the washer and tighten the bolt,
Install the dowel pins and a new gasket.
Install the right side cover.

Install the water pump assy (page 6-11).

Install the exhaust pipe.

Fill the engine with the recommended oil (page
2-1).

 

‘ _......_/
DRIVEN SPROCKET DRIVE CHAIN

 

Date of Issue: Dec, 1982 75 9
© HONDA MOTOR 00., LTD. 2 '

HONDA
V65MAGNA

 

LUBRICATION

FINAL DRIVE 0“. ‘ _ A V ‘ IQIL FILLER CAP

am”
it“

    

 

CHECK

Place the motorcycle on its center stand on level
ground.

Remove the oil filler cap,

Check that the oil level reaches the lower edge of
the oil filler cap hole.

Check for leaks, if the level is low Pour fresh oil
through the oil filler hole until it reaches the lower
edge.

CHANGE

Remove the oil filler cap and drain bolt to drain all
oil from the final gear case.

 

OIL DRAIN BOLT

Install the drain bolt securely.

Fill the gear case with the recommended oil up to
the correct level (above).

OIL CAPACITV: 130 m: (4.4 ml

RECOMMENDED OIL: HVPOID GEAR OIL API,
GL—5 3A5 #90 (Above 5°c/41°Fl
sAE #80 (Below 5°C/41°F)

 

CIJNTRflL CABLE LUBRICATIDN

Periodically, disconnect the throttle cables at their
upper ends. Thoroughly lubricate the cables and
their pivot points with a commercially available
cable lubricant or a light weight oil.

 

26 Date of issue: Dec, 1982
2 '1 O ©HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

LUBRICATIUN PIJINTS

a [or CABLE LUBRICANT a

THROTTLE GRIP SWING AFIM
PIVOT

TH HOTTLE AN D
CHO KE CAB LES

Afim

 
       

        

EIEVJEEFI'II/VIDDTSBRAKE BRAKE DRIVEN FLANGE
'fil PEDAL PIVOT SPINDLES AND
W i PINS

    
 
 
 
 

or CABLE LUBRICANT

’fii (LITHIUM BASED

SPEEDOMETER CABLE MULTIPURPOSE
FOOT PEG GREASE)

PIVO I

   
 
  
 
  
 

STEERING
HEAD
BEARINGS

  

FOOT PEG
PIVOT

  
  
  
 
 

 

FINAL DRIVE
GEAR AND SHAFT
fl (HYPOID GEAR
OIL API,GL#5
SPEEDOMETER PIVOT DmvgsH AFT SA man—#90)
DRIVE GEAR JOINT
FRONT FORK SH'FT (LITHIUM BASED
(ATE) PEDAL PIVOT MULTIPURPOSE
GREASE)
Data DI Issue: Dec, 1982 27 2 1 1

© HONDA MOTOR CO., LTD,

HONDA
V65MAGNA

 

 

MEMO

 

 

23 Date of Issue: Dec, 1982
© HONDA MOTOR co., LTD.

 

Tang? 3. MAINTENANCE

 

SERVICE INFORMATION 3—1 COOLING SYSTEM HOSES
MAINTENANCE SCHEDULES 3—3 8‘ CONNECTIONS 3-12
< ENGIND CYLINDER COMPRESSION 3—12
FUEL LINES 3—4 < CHASS|S>

FUEL FILTER 3—4 BATTERv 3—13
THROTTLE OPERATION 3—5 BRAKE FLUID 3—13
CARBURETDR CHOKE 3—6 BRAKE FAD WEAR 3—14
AIR CLEANER 3—6 BRAKE SYSTEM 3—14
cRANKCASE BREATHER 3—7 BRAKE LIGHT SWITCH 3—15
SPARK PLUGS 3—7 HEADLIGHT AIM 3—15
IGNITION SYSTEM 3—3 cLUTCH 3—15
VALVE CLEARANCE 3—8 SIDE STAND 3—16
CARBURETOR SYNCHRONIZATION 3—10 SUSPENSION 3—16
CARBURETOR IDLE SPEED 3—11 WHEELS 3—17
RADIATOR COOLANT 3—11 STEERING HEAD BEARINGS 3—18
RADIATOR CORE 3—12 mm, BOLTS, FASTENERS 3—18

 

 

 

SERVICE INFllRMATlflN

G E N E RA L

0 Engine oil See page 28
0 Engine oil filter See page 2-3
0 Final drive gear oil See page 2-10

SPECIFICATIONS

 

 

 

 

< Engine >
Spark plugs:
Standard For cold climate (below 5°C, 41°F) For extended high speed riding
NGK ND NGK ND NGK ND
DPRSEA-Q X24EPH-U9 DPR7EA-9 X22EPR-U9 DPRBEAS X27EPH-U9

 

 

 

 

 

 

 

Spark plug gap: D‘s—0,9 mm (0.031—0‘035 in)

 

Date of Issue: Dec, 1982 19 3 1
© HONDA MOTOH 00., LTD. '

 

HONDA

 

 

 

 

MAINTENANCE 65
Ignition timing
At idle: 10°BTDC
Advance starts: 10°BTDC at 1,500 rpm
Full advance: 37°BTDC at 3,800 rpm
Valve clearance
Cold (Below 35°C, 95°F): Intake/Exhaust:0t12 rnm (areas in)
ldle speed: 1,000 i 100 rpm
Carburetor synchronization: All carburetors within 60 mm (24 in) H9
Cylinder compression: 13 t 2 kg/cm2 (184 i 28 psi)
Throttle grip free play: 2—6 mm (1/a—1/4 in)
< CHASSIS >
Tire:
. . Front Rear
Tire size
MUD/9048 M140/90-16
U” ‘° 9° “9 (20° “’5’ 32 (225, 225) 32 (225, 2.25)

Cold tire pressure, psi (kPa, kg/cmzl

load

 

90 kg (200 lbs) load

 

 

 

 

 

 

to vehicle capacity load 32 (2251-75) 40 (zao, 2.30)
. Bridgestone L303 0508
Tire brand
Dunlop F 11 K627

 

 

Front fork air pressure: 0—6 psi (0—40 kPa, 0—0.4 kg/cml)

TOOLS

Special

Vacuum gauge set

Vacuum gauge attachment A
Vacuum gauge attachment B
Carburetor pilot screw wrench
Compression gauge attachment
Valve adjusting Wrendt
Flywheel cover

Adjusting wrench (A)

07404~0030000 or M937B—021—XXXXX (USA, only)

07501—3000100
07501—3000200
07908—4220201

07510—MB00101
07908—MB00100
O7998¥MB00000

0770843030300

 

30

Date of Issue: Dec, 1982 _ _
© HONDA MOTOR 00., LTD.

 

HONDA
V65MAGNA

MAINTENANCE

 

MAINTENANCE SCHEDULE.

Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maimenance period.

I: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WHICHEVER | ODOMETER READING (NOTE 3)
FREOUENCY COMES L ‘
FIRST # K§L§§\$§§§.§§L§§\g§
c.
{a §§§$ §~ ~ $3
ITEM EVERY ‘ " q" “ ‘ ’3" ‘9‘ (WReferm page
‘ FUEL LINES I I I 3-4
* FUEL FILTER R 3-4
* THROTTLE OPERATION I I I I 3-5
g * CARBURETOR-CHOKE I I I 3-6
III: AIR CLEANER NOTE 1 R R R 36
; CRANKCASE BREATHER NOTE 2 C C C c C C 3-7
E SPARK PLUGS R R R R R R 3-7
3 * VALVE CLEARANCE I I I I 3-8
fi ENGINE OIL YEAR R R R R 2-3
5 ENGINE OIL FILTER YEAR R R R R 2-3
a * CARBURETOR-SYNCHRONIZATION I I I I 3-10
g * CARBURETOR-IDLE SPEED I I I I I I I 3-11
"1 RADIATOR COOLANT I I *R 311
* RADIATOR CORE I I I 3-12
" COOLING SYSTEM HOSES & I I I I 342
CONNECTIONS
FINAL DRIVE OIL I I R 2-10
BATTERY MONTH I I I I I I I 3-13
g BRAKE FLUID W's/1:33; I I I “R I I ‘R 3-13
'3' BRAKE PAD WEAR I I I I I I 3-14
I”—‘ BRAKE SYSTEM I I I I 3-14
3 * BRAKE LIGHT SWITCH I I I I 3-15
2:1 ‘ HEADLIGHT AIM l I I I 315
E, CLUTCH FLUID wags JR I I I *R I I “R 3-15
6 CLUTCH SYSTEM I I I I 3-15
5 SIDE STAND I I I 3-16
5' * SUSPENSION I I I l 3-16
2 * NUTS, BOLTS, FASTENERS I I I I 3-18
” WHEELS I I I I 317
" STEERING HEAD BEARINGS I I I I 318

 

 

 

' SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND
SERVICE DATA AND IS MECHANICALLY QUALIFIED.

“* IN THE INTEREST OF SAFETY, WE RECOMMENDED THAT THESE ITEMS BE SERVICED ONLV BY AN AUTHOR-
IZED HONDA DEALER.

1. SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS.

2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE (U.S.A. ONLV).

3. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCV INTERVAL ESTABLISHED HERE.

NOTES:

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

31

3-3

HONDA
V65MAGNA

 

MAINTENANCE

FUEL LINES

Remove the left and right side covers, and seat.
Make sure the fuel tank is less than half-full.

Drain it, if it is more than half~fu|l.

Remove the tank mounting bolts, lift the fuel tank
up and hold it in place with the tank support rod.

 

M
. m};

‘ TANK MOUNTING BOL

 

SUPPORT ROD
Check the fuel lines and replace any parts which
show deterioration, damage or leakage.

Disengage the tank support rod by lifting the tank
slightly. Let the fuel tank down into place and'
install the mounting bolts. Be careful not to pinch
or kink the vent and fuel lines,

 

FUEL FILTER

Remove the seat.

Remove the fuel filter from the holder.

Unclip the fuel lines.

Disconnect the fuel lines from the filter.

Replace the fuel filter with a new one when indicat-
Ed by the maintenance schedule, (See page 3-3)
Install the fuel filter.

 
    
  

Gasoline is flammable and is explosive under
certain conditions, Do no! smoke or allow
flames or sparks in your working area.

 

After installing, check that there are not fuel leaks.

 

a» . \
FUELKFILTER FUELLINE

 

32 Date of Issue: Dec, 1982
3 ' 4 © HONDA MOTOR CO” LTD.

HONDA
V65MAGNA

 

MAINTENANCE

 

THROTTLE IJPERATIIJN

Check ior smooth throttle grip full opening and
automatic full closing in all steering positions.
Check the throttle cables and replace them ii they
are deteriorated, kinked or damaged.

Lubricate the throttle cables (page 2-11), if throttle
operation is not smooth.

Measure throttle grip free play at the throttle grip
flange.

FREE PLAY: 2—6 mm (1/3-1/4 in)

Adjustment can be made at either end of the
throttle cable. Minor adjustments are made with the
upper adjuster and major adjustments are made with
the lower adjuster after lifting the fuel tank up.
Adjust by loosening the lock nut and turning the
adjuster.

Tighten the lock nut and recheck throttle operation.

Lower fuel tank into place and check throttle free
play once more.

U PPE R ADJUSTE R

LOWE R ADJUSTE R

LOCKLNUT

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

 

LUBRICATION

CARBURETUR CHOKE

The V65 choke system uses a luel enrichening
circuit controlled by a bystarter valves The by-
starter valve opens the enrichening circuit via cable
when the choke lever on the handlebar is pushed up
Check lor smooth upper choke lever operations
Lubricate the choke cable, if the operation is not
smooth,

Push the choke lever on the handlebar all the way
up to fully open. Make sure the choke valve is
open by trying to move the choke lever on the
carburetor, after lifting the luel tank up.

There should be no free play.

Adjust if necessary, by loosening the choke cable,

clamp on the carburetor and moving the choke
cable casing so the choke lever is fully open.
Tighten the clamps

Pull the choke lever all the way to fully closed.
Make sure the choke valve is fully closed by check-
ing for free play in the cable between the lever on
the carburetor and cable casing.

Reinstall the removed parts in the reverse order of
disassembly.

AIR CLEANER

Make sure the fuel tank is less than half-lull, Drain
it, if It is more than half-full.

Remove the tank mounting bolts and lllt the luel
tank up and hold It in place with the tank support
rods

Remove the air cleaner cover screws.

 

HONDA.
V65MAGNA

 

CHOKE LEVER

 

V J ‘
AIR CLEANER COVER

 

3-6

Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

g HONDA
V65MAGNA MAINTENANCE

 

  
  

 

. AIR CLEANER ELEMENT
Remove the aIr cleaner element and discard it in -

accordance with the maintenance schedule.

Also, replace the element any time it is excessively
dirty or damaged.

Install a new element and install the cover.
Disengage the tank support red by liftingup slighty.
Let the fuel tank down into place and install the
fuel tank mounting bolts. Be careful not to pinch or
kink the vent and fuel lines.

CRANKCASE BREATHER

Remove the plug from the drain tube to empty any
deposits,

Install the drain plug.

NOTE:

    
   

Service more frequently when riding in rain
or at full throttle, or if the deposit level can
be seen in the transparent section of the drain
tube.

 

SPARK PLUGS

RECOMMENDED SPARK PLUGS

 

.v 33*. ‘
NGK ND DRAIN PLUG

 

 

St d d DPRBEA-Q 24EPR-U9 CENTER
3" 3r X ELECTRODE SIDE ELECTRODE

 

For cold climiate
(Below 5°C,41°FJ

For extended
high speed riding

DPR7EA-9 X22 EP R-U9

 

l 0.8—0.9 mm

DPR9EA-9 X27EPR-U9 T (0.031—0.035inl

 

 

 

 

 

Disconnect the spark plug caps.

Clean any dirt from around the spark plug bases.
Remove and discard the spark plugs.

Measure the new spark plug gaps using a wire-type
feeler gauge.

SPARK PLUG GAP: 03—0.!) mm (0031—0035 in)

Adjust by bending the side electrode carefully,

With the plug washer attached, thread each spark __
plug in by hand to prevent crossthreading. .
Tighten the spark plugs another 1/2 turn with a i
spark plug wrench to compress the plug washer.

Connect the spark plug caps.

 

Date of Issue: Dec, 1982 35 3 7
© HONDA moron co., LTD. '

 

MAINTENANCE

HONDA
V65MAGNA

 

 

IGNITION SYSTEM

NOTE:

 

The ignition system is transistorized and can-
not be adjusted. If the ignition timing is in-
correct, check the spark unit and pulse gene-
rator and replace any faulty parts (Section

 

19).

 

 

Remove the alternator and left crankcase covers,
Install a flywheel cover (079987M300000L
Wipe off the oil from the flywheel.

Connect the timing light to the high tension wire
of the Not I cylindert
Start the engine and let it idle,

IDLE SPEED: 1,000 i 100 rpm

The timing is correct if the “F“ mark on the f|v~
wheel aligns with the crankcase rear mating surfaces,

VALVE CLEARANCE

NOTE:

Inspect and adiust valve clearance while the
engine is cold. (Below 35°C, 95°F)

 

 

Remove the heat guard, radiator cap and drain boltt
Drain coolant from engine and frame (P399 673).

NOTE:

Drain the coolant into a clean container for
reuse. Scheduled coolant replacement is every
2 years or 24,000 miles (38,600 km),

 

 

 

 

Remove the right and left frame side covers and
remove the seat.

Lift up the fuel tank by removing the front mount-
ing bolts. Be sure the tank is less than half-full.

If not, drain the tank,

Remove the spark plug caps and the spark plugs.

 

 

 

REAR CRANKCASE
MATING SURFACES ,*

A; ,, 7
SIDE COVER

 

3-8

36 Date of Issue: Dec, 1982
HONDA MOTOR (20., LTD,

HONDA
V65MAGNA

 

Remove the ignition coils with their bracket and
remove the insulator cover.

Remove the radiator (See page 645).

Remove the front and rear cylinder head cover bolts
and both cylinder head covers.

Remove the alternator and left crankcase covers.

INSPECTION

Measure and adjust the intake and exhaust valve
clearances as described below.

Rotate the crankshaft clockwise to align the T1.3
mark with the crankcase mating surfaces.

Make sure the No. 1 piston is at TDC (Top Dead
Center) on the compression stroke.

Check the valve clearances for the No, 1 cylinder
using two feeler gauges for each pair of valves; one
for each valve that shares a common rocker arm.
VALVE CLEARANCE (IN, EX): L}. >
q._1,2,rnm.lo.oosinl . C, 0 9 W“

If adjustment is needed] loosen the lock nuts and
turn the adjusting screws until there is a slight drag
on both feeler gauges. Both feeler gauges should
remain inserted during adjustment.

Hold the adjusting screws and tighten the lock nuts.
TORQUE: 21—25 N-m (2.1—2.5 kg-m,15—18 tt-Ib)

CAUTION:

The Int-k mm will come loose ifrrot tightened
to the correct torque value.

 

 

 

 

Recheck the valve clearance.

Rotate the crankshaft 27o“ clockwise to align the
T2.4 mark with the crankcase mating surfaces and
check the valve clearances for the No. 2 cylinder.

Adjust using the procedures for the No. 1 cylinder.

Rotate the crankshaft 90° clockwise to align the
T143 mark with the crankcase mating surfaces and
check the valve clearances for the No. 3 cylinder.

Adjust using the procedures for the No. 1 cylinder.

Rotate the crankshaft 270° clockwise to align the
TZA mark with the crankcase mating surfaces and
check the valve clearances for the No. 4 cylinder.

Adjust using the same procedures as for the No. I
cylindert

IGNITIO COILS

LATOR COVE Fl

T1.3MARK
“on ‘ '

I.

 

MAINTENANCE

 

 

VALVE ADJUSTING WRENCH
07908—MB00101 ,

\

  

 

Date of Issue: Dec, 1932
© HONDA MOTOR C0,, LTD.

37

MAINTENANCE

Install the removed parts, except the radiator cap,
in the reverse order of disassemblyt

Be sure the cast mark inside the rear cylinder head
cover faces the front and the tabs of the front cylin-
der head cover face the rear.

Check the engine oil level.
Fill the radiator with clean Coolant to the specified
level.

NOTE:

After filling the radiator, start the engine and
rev it at least three times to remove any air
bubbles from the cooling system. Add more
coolant mixture as necessary,

 

 

 

 

Install the radiator cap.

CARBIIRETDR SYNCHRUNIZATIDN

NOTE

Synchronize the carburetors with the engine
at normal operating temperature, transmission
in neutral and motorcycle on the center stand.

 

 

 

 

Remove the plugs from the No. 1, 2, 3 and 4 cylin-
der head ports and install the vacuum gauge adapv
ters.

Connect the vacuum gauges.

ADJUSTMENT

NOTE

The No‘ 1 carburetor cannot be adjusted; It is
the base carburetor.

 

 

 

 

Start the engine and adjust the idle speed.
IDLE SPEED: 1,000 t 100 rpm

Install the vacuum gauge adapter and Connect the
vacuum gauge.

Check that all carburetors are within 60 mm (2.4 in)
H9.

HONDA.
V65MAGNA

 

CAST MA R K

 

NO, 1 CYLINDER
,HEAD PORT PLUG
p 3»: . -

 

VACUUM GAUGE 0740470020000
or M937B—0217XXXXX (USA only)
. i

 

ADAPTERS

 

3-10

33 Date of Issue: Dec, 1982

HONDA MOTOR 00., LTD.

 

IEI!:)I\IIfi)£!L
V65MAGNA MAINTENANCE

CARBURETOR ADJUSTING
ADJUSTI G SCREW WRENCH 07908 4220201
Synchronize to specification by turning the adlust- - _ _ _ v ' . .
lng screws with the Special tool. ‘ '

 

Recheck the idle speed and synchronization.
Remove the gauge adapters and install the plugs.

 

TOP SCREW
a.

BARBURETUR IDLE spam -_ . , ,

NOTE
0 Inspect and adjust idle speed after all other
engine adjustments are within specifications.
0The engine must be warm for accurate adjust-

ment. Ten minutes of stop~and-go riding is
sufficient.

 

Warm up the engine, shift to NEUTRAL, and place
the motorcycle on its center stand.

Turn the throttle stop screw as required to obtain DECREASE
the specified idle speed. SPEED

IDLE SPEED: 1,000i100 rpm "

RADIATflR CUULANT

Remove the frame right side cover.

Check the coolant level of the reserve tank with the
engine runing at normal operating temperature.

The level should be between the “FULL” and
”LOW" level lines.

If necessary, remove the reserve tank cap and fill to
the "FULL" level line with a 50/50 mixture of
distilled water and anti-freeze.

Reinstall the cap and frame side cover.

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

 

MAINTENANCE

RADIATOR CflRE

Check the air passages for clogging or damage.
Straighten bent fins and collapsed core tubes.
Remove insects, mud or any obstruction with com-
pressed air or low water pressure.

Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.

CUOLINE SYSTEM HflSES

Inspect the hoses for cracks or deterioration, and
replace if necessary.
Check the tightness oi all hose clamps.

CYLINDER CflMPRESSIflN

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
reached within 4~7 seconds.

 

 

 

 

COMPRESSION PRESSURE:
13 2 2 kg/cm2 (184 i 28 psi)

If compression is low, check for the following:

— Improper valve clearance

— Leakv valves

— Leaking cylinder head gasket

- Worn piston/ring/cvlinder

If compression is high, it indicates that carbon
deposits have accumulated on the combustion
chamber and/or the piston crown.

3-12

40

COMPRESSION G
07510vMB00101

 

HONDA
V65MAGNA

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA.
V65MAGNA

 

MAINTENANCE

 

(CHASSIS>
BATTERY

Remove the right frame side cover and inspect the
battery fluid levels

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 and pull out the
battery. Disconnect the negative cable at the battery
terminal, then disconnect the positive cable,
Remove the filler caps and add distilled water to
the upper level line. Reinstall the battery.

NOTE:

Add only distilled water. Tap water will
shorten the service life of the battery.

 

The battery electrolyte contains sulphuric
acid. Protect your eyes, skin, and clothing.
If electrolyte gets In your eyes, flush them
thoroughly with water and get prompt

 

 

medical attention.

 

BRAKE FLUID

Check the brake fluid reservoir level.

If the level nears the lower level mark, fill the re-
servoir with DOT-4 BRAKE FLUID to the upper
level mark.

Check the entire system for leaks, ifthe level is low.

CA UTION:

~ Do not remove the cover until the handle-
bar has bcen turned so that the reservoir is
level.

- Avoid operating the brake lever with the
cap removed. Brake fluid will squirt out if
the lever is pulled.

' Do not mix different types of fluid, as they
are not compatible.

 

 

 

 

Refer to section 17 for brake bleeding procedures.

HOLDER BOLT UPPER LEVEL LINE

 

LOWER LEVEL LINE

UPPER LEVEL MARK

~~ l f. V
LOWER LEVEL MARK

 

 

Date of Issue: Dee, 1982
© HONDA MOTOR C0,, LTD.

41

3-13

HONDA
V65MAGNA

 

MAINTENANCE

BRAKE PAD WEAR . , BRAKEPADS

Check the brake pads (or 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 ot the brake disc (page 175).

CAUTION:

Always rephce the brake pads in pairs to
assure even disc pressure.

 

 

 

 

BRAKEDISC ARROW

 

BRAKE DISC BRAKE PADS
, ,7 , m r ‘

‘/

     

BRAKE SYSTEM

Inspect the brake hoses and fittings for deterio-
ration, cracks and signs of leakage. Tighten any
loose fittings.

Replace hoses and fittings as required.

  

BRAKE PEDAL HEIGHT

Adjust brake pedal height so the pedal is 7 mm (1/4
in) below the top of the foot peg.
CAUTION:

Incorrect brake pedal heréhr can cause brake
drag,

 

 

 

 

To Adjust:

Loosen the stopper bolt lock nut and turn the
stopper bolt.

Retighten the lock nut.

NOTE:

After adlusting the brake pedal height, check
the rear brake light switch and brake pedal
Iree play and adjust if necessary.

 

STOPPE R BOLT

 

 

 

 

3 1 4 42 Date of Issue: Dee, 1982
- © HONDA MOTOR 00., LTD.

HONDA.
V65MAGNA MAINTENANCE

 

BRAKE UGHT SWITCH _ BRAKE LIGHTSWITCH

NOTE:

Perform brake light switch adiustment after
adiusting the brake pedal play and height.

 

 

 

 

Adlust the brake light switch so that the brake
light will come on when the brake engagement

begins.
Adiust by holding the switch body and turning
the adjusting nut. Do not turn the switch body.

NOTE:

The front brake light switch does not require
adjustment.

 

 

 

 

 

ADJUSTING NUT

CASE MOUNTING EOLT

HEADLIGHT AIM . , - , v

Adjust horizontally by loosening both headlight
bracket mounting bolts.

Adjust vertically by loosening both headlight case
mounting bolts.

 

local laws and regulations.

 
  
 

An improperly adjusted headlight may blind
oncoming drivers, or it may fail to light the
raadfara safe distance.

\
.ns I
BRACKET MOUNTING BOLT

 

   

UPPER LEVEL MARK

    

CLUTCH

Check the clutch lluid reservoir level.

If the level nears the lower level mark, fill the
reservoir with DOT-4 BRAKE FLUID to the upper
level mark.

Check the entire system for leaks, if the level is low.

CAUTION:

Do not mmove the cover until the hand-
lebar has been turned so that the reservoir
is level.

- Avoid operating the clutch lever with the
cap removed. Fluid will squirt out if the
lever is pulled.

- Do not mix different types of fluid, as ~ __ j ‘
they are not compatible. LOWER LEVEL MARK

 

 

 

 

 

Date of Issue: Dec, 1932 43
© HONDA MOTOR 00., LTD, 3 '1 5

MAINTENANCE

SIDE STANI

Check the rubber pad for deterioration or wear.
Replace if any wear extends to wear line as shown.
Check the side stand spring for damage and loss ol
tension, and the side stand assembly for freedom
of movement. Make sure the side stand is not
bent.

NOTE:
- when replacing, use a rubber pad with the
mark l’Over 260 lbs ONLV".
~ Spring tension is correct if the measure-
ments fall within 2—3 kg (4,443.6 lb],
when pulling the side stand lower end with
a spring scale.

 

 

 

 

SUSPENSION

 
  
 
 

Do not ride a vehicle with faulty suspension,
Loose, worn or damaged xuxpension parts
impair vehicle stability and control.

 

FRONT

Check the action of the front forks by compressing
them several times.

Check the entire fork assembly for leaks or damage.
Raplace damaged components which cannot be
repaired.

Tighten all nuts and bolts,

Check the front fork air pressure when the forks
are cold.
Place the vehicle on its Center stand.
Remove the air valve cap and measure the air
pressure.
AIR PRESSURE:

0—6 psi {0—40 kPa, 0—0.4 kg/cm2l

HONDA
V65MAGNA

 

 

 

 

GOOD NO GOOD

 

 

 

AIR VALVE CAP

 

3-16

44

Date of Issue: Dec, 1982
©HONDA MOTOR 00., LTD.

HONDA
V65MAGNA MAINTENANCE

 

 

ANTI-DIVE SYSTEM INSPECTION

Select a safe place away from traffic to
perfnrm this inspection.

 

Check the operation of the anti~dive system by
riding the motorcycle and firmly applying the
brakes.

 

 

 

 

Position Anti-dive damper force
| LIGHT ANTI~D|VE
|| MEDIUM
IN HARD
IV MAXIMUM ANTI-DIVE

 

 

Inspect and if necessary, repair the system (Refer
to section 15l,

REAR

Place the motorcycle on its center stand.

Move the rear wheel sideways with force to see if
the swingarm bearings are worn,

Replace the bearings if there is any looseness (page
1&1 5).

Check the shock absorbers for leaks or damage.
Tighten all rear suspension nuts and bolts.

WHEELS

NOTE:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tire pressure should be checked when tires
are COLD.
Check the tires for cuts, Embedded nails, or other
sharp obiects.
RECOMMENDED TIRES AND PRESSURES:
Front Rear
Tire size M110/90-1B "1140/9046
UP (0
so kg 32 32
9°“ (200 lbs) (225,225) (225,225)
me
load
Dres- i
sure 90 kg
psi [100 lbs]
, 32 40
(m, load m
kg/cm‘] vehicle (225,216) (230,28)
capscllv
load
. BRIDGE-
Tlre L303 6508
brand STONE
DUNLOP m K627
Date of Issue: Dec, 1982 45 3 1 7

© HONDA MOTOR CO., LTD.

MAINTENANCE

Check the front and rear wheels for trueness (See
tion 15 and 16).
Measure the tread depth at the center of the tires.
Replace the tires if the tread depth reaches the
following limit:

Minimum tread depth:
Front: 1.5 mm (1/16 in)
Rear: 2.0 mm (3/32 In)

STEERING HEAD BEARINGS

NOTE:

 

Check that the control cables do not inter-
fere with handlebar rotation,

 

 

 

Raise the front wheel off the ground and check
that the handlebar rotates freely.

If the handlebar moves unevenly, binds, or has
vertical movement, adjust the steering head hearing
by turning the steering head adjusting nut (page
1538).

NUTS,BflLTS,EASTENERS

Check that all chassis nuts and bolts are tightened
to their correct torque values (Section 1) at the
intervals shown in the Maintenance Schedule (page
33).

Check all ootter pins, safety clips, hose clamps
and cable stavs.

 

HONDA
V65MAGNA

 

 

3-18

46

Date of Issue: Dec, 1982
© HONDA MOTOR C0., LTD.

HONDA
V65MAGNA

 

 

M EMO

 

Date of Issue: Decl 1982 47
© HONDA MOTOR 00., LTD,

FUEL SYSTEM

/. , HONDA
“é V65MAGNA

 

 

 

4-0

43

Date of Issue: Dec,1932
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

4. FUEL SYSTEM

 

SERVICE INFORMATION
TROUBLESHOOTING
CARBURETOR REMOVAL
VACUUM CHAMBER

FLOAT CHAMBER

PILOT SCREW
CARBURETOR SEPARATION
CARBURETOR ASSEMBLV

 

4—1

4—3
4—4
4—6

4—10
4—1 2

CARBURETOR INSTALLATION
PILOT SCREW ADJUSTMENT
FUEL TANK

AUXILIARY FUEL TANK

AIR CLEANER

FUEL PUMP

HIGH ALTITUDE ADJUSTMENT
(USA only)

4—16
4—16
4—17
4—17
4—13
4—1 8
4—19

 

 

SERVICE INFflRMATIflN

GENERAL

 

 

Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventiluted area Do not smoke

or allow flames or spark: in the work area.

Fuel pump inspection is in section 21.

Do not interchange these parts.
TOOLS

Special
Valve guide driver, 7 mm

Common
Float gauge

SPECIFICATIONS

The front cylinders use down draft carburetors.
When disassembling fuel system pans, note the locations of the O»rings. Replace them with new ones on reassembly.
The float bowls have drain screws that can be loosened to drain residual gasoline.

07942a8230000 (USA. only)

07401—0010000

The No. 1 and No. 3 carburetors use differentiet needles (thinner) and shorter springs than the No, 2 and No. 4 carburetors.

 

 

 

 

 

 

Venturi (“a Primary 12.2 mm (0.43 in)
‘ Secondarv 33,2 mm (1.31 In)

Identification No. VD70A

Float level 6,0 mm (0.24 in)

Main jet Front #140,Rear #140

Idle speed 1,000 2 100 rpm

 

Throttle grip free play

2—6 mm (008—024 in)

 

Pilot screw initial opening

 

 

See page 4-16

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

49

4-1

FUEL SYSTEM

TROUBLESHIJllTINli

Engine cranks but won't start

1. No fuel in tank

2. No fuel to carburetor

3. Engine flooded with fuel

4. No spark at plug [ignition system faulty)
5. Air cleaner clogged

6. Intake air leak

7. Improper choke operation

3. Improper throttle operation

Hard starting or stalling after starting
1. Improper choke operation

2. Ignition malfunction

3. Carburetor faulty

4. Fuel contaminated

5. Intake air leak

6. Idle speed incorrect

Rough idle

1. Ignition system faulty

2. Idle speed incorrect

3. Incorrect carburetor synchronization
4. Carburetor faulty

6. Fuel contaminated

Misllr' 9 during acceleration
1. Ignition system faulty

Baekflring
l. Ignition system faulty
2. Carburetor faulty

Poor performance (driveabilityl and poor fuel economy
1. Fuel system clogged
2. Ignition system faulty

HONDA
V65MAGNA

 

Lean mixture
1, Clogged fuel jets
2. Vacuum piston stuck closed
3. Faulty float valve
4. Float level low
5, Fuel cap vent blocked
6. Fuel strainer screen clogged
7. Restricted fuel line
8. Air vent tube clogged
9. Intake air leak
10. Restricted or faulty fuel pump

Rich mixture

1. Clogged airiets

2. Faulty float valve

3. Float level too high

4. Choke stuck or clogged
5. Dirty air cleaner

 

60 Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

CARBURETBR REMflVAL AIR CHAMBER cox/En

Check that the fuel tank is at least one~half empty.
Otherwise, drain the fuel tank until it is one-half
empty before raising the tank.

Remove the seat and front fuel tank mounting
bolts. Lift the fuel tank up and put the support
arm down‘

Remove the air cleaner cover and element.

Remove the right and left air chamber covers.

Remove the bolt attaching the thermostat housing
to the air chamber and the ground cablet

Remove the six screws and the air chamber top
cover.

Disconnect the breather tubet

FUEL SYSTEM

 

 

Date of Issue: Dec,1982 51
© HONDA MOTOR CO., LTD.

4-3

HON DA
V65MAGNA

 

FUEL SVSTEM

Remove the carburetor choke clamp and disconnect
the choke and throttle cables.

 

Loosen the carburetor bands and remove the car-
buretor assembly from the left side.

NOTE:

It may be necessary to loosen the engine
mount bolts and move the engine on its
rubber mounts to provide clearance for car-

buretor removal.

 

 

 

 

VACUUM CHAMBER

R E MOVA L
Remove the four vacuum chamber cover screws and

cover.

CAUTION
Do not interchange vacuum chamber covers,
:pringx, piston: or jet needles between car-

buretors.

     
 

 

to ER

 

52 Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

4-4

HONDA
V65MAGNA

 

FUEL SYSTEM

 

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 that the No. 1 and Not 3 carburetors use
thinner jet needles and shorter springs than the
Not 2 and No. 4 carburetors.

Push the needle holder in and turn it 60 degrees
with an 8 mm socket, Then remove the needle
holder, spring and needie from the piston.

Inspect the needle (or excessive wear at the tip and
for bending, or other damage.

Check the diaphragm tor deterioration and tears.

OMPRESSION SPRIN
_ _ t )

 

NEEDLE HOLDER

 

 

DIAPHRAGM

. ((0%
i

NEEDLE HOLDER

NEEDLE

 

 

 

Dale of Issue: Dec, 1932
© HONDA MOTOR CO., LTD‘

5“ 4-5

FUEL SYSTEM

HONDA.
V65MAGNA

 

 

INSTALLATION

Installation is essentially the reverse of removal.
Install the chamber cover so that its cavity aligns
with the hole in the diaphragm.

Be sure the thinner iet needles and shorter springs
are installed in the No. 1 and No.3 carburetors.

FLUIIT CHAMBER

REMOVAL

Remove the four float chamber screws and the float
chamber.

FLOAT LEVEL

Measure the float level with the carburetor inclined
15°745° from vertical and the float tang just
contacting the float valve.

SPECIFICATION: 6.0 mm (0.24 in)

NOTE:

Measure the float level nearest the float valvet

Adjust the float level by carefully bending the float
tang,

 

 

 

   

FLOAT LEVEL GAUGE

07401—0010000 FLOAT LEVEL

 

 

 

4-6

54 Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

HONDA
V65MAGNA FUEL SYSTEM

 

 

F LOAT AND JETS FLOAT PIN

    
    

Remove the float pin, float and float valve.

Inspec‘ ‘he float valve for grooves and nicks.
Inspect ‘he operation of the (loa‘ valve.

V {:3
FLOAT VALVE

F LOAT VALVE
EAT

Remove the starter in, main 19‘ and slow in.
Remove the flea‘ valve seat and filter,

 

 

Date of Issue: Dec, 1982 55 4 _ 7
© HONDA MOTOR 00., LTD.

FUEL SYSTEM

Inspect the float valve seat and filter for grooves,
nicks or deposits.

ASSEMBLY

Assemble the float chamber components in the
reverse order of disassemblv.

PILOT SCREW

REMOVAL

NOTE:

The pilot screws are factory pre-set and
should not be removed unless the carbure-
tors are overhauled.

The pilot screw plugs are factory installed
to prevent pilot screw misadiustmentt Do
not remove the plugs unless the pilot
screws are being removed.

Cover all opening with tape to keep metal

    
 
 
 
 
 

 

 

particles out when the plugs are drilled.

   

Center punch the pilot screw plug to center the
drill point.

Drill through the plug with a 4 mm (5/32 in) drill
bit, being careful not to drill into the pilot screw,

CAUTION:

HONDA
VéSMAGNA

 

FILTER VALVE SEAT

 

 

 

Be careful not to drill inlo [he pilot screw.
All pilol screws muxl be replaced even if only
one requires it for proper pllol screw adjust-
ment (page 4-16).

 

 

 

 

 

 

 

 

4-8

56 Dale of Issue: Dec, 1982
© HONDA MOTOR CO” LTD.

HONDA
V65MAGNA FUEL SYSTEM

 

 

 

Force a selHapping 4 mm screw (H/C 069399,
P/N 93903—35410) into the drilled plug and
continuE turning the screwdriver until the plug
rotates with the screw.

Pull on the screw head with pliers to remove the
plug.

Use compressed air to clean the pilot screw area and
remove metal shavings.

 

 

 

 

Turn each pilot screw in and carefully count the

number of turns before it seats lightly.
Make a note of this to use as a reference when
reinstalling the pilot screws.

CAUTION

Damage [0 the pilot screw sear w' occur ’f
the p (screw ghrened ag nsr the sea

 

   

Remove the pilot screws and inspect them. Replace
them if they are worn or damaged.

 

Pl LOT SCR EW

lNSTALLATlON

Install the pilot screws and return them to their
original position as noted during removal.

Perform pilot screw adjustment if new pilot screws
are installed (page 4-16).

NOTE

- Do not install new plugs on new pilot
screw holes until after adjustment has been
made.

' If you replace the pilot screw in one car-
buretor, you must replace the pilot screws
in the other carburetors for proper pilot
screw adjustment.

 

 

 

 

 

Date of Issue: Dec, 1982 57 4 9
© HONDA MOTOR co” LTD, '

FUEL SYSTEM

EARBURETDR SEPARATION

Remove the screws attaching the air chamber to the
carburetors and separate the chamber and carbu-
retors.

Remove the nuts, and remove the choke levers and
rods.

.Remove the cotter pins and washers, and remove
the choke rod.

Carefully separate the No. 3 carburetor from the
assembly. Then separate the N04 4 carburetore

CAUTION

Separate the carburetors horizontally [0 pre»
vent damage to the 1mm pipes.

 

HONDA
V65MAGNA

 

SCREWS

 

  
  

 

CHOKE RODS AND LEVERS

CHOKE ROD

FUEL No.10ARBURETOR
JOINTPIPE AIR JOlNT PIPE No.ZCARBURETOR

 

No.4 CARBURETOR I SYNCHRONIZATION THRUST
NO. 3 CARBURETOR SPRINGS SPRINGS
58 Date of Issue: Dec,1982

© HONDA MOTOR 00., LTD.

HOND.A
V65MAGNA FUEL SYSTEM

 

Disconnect the thrott|e link from the No‘ 1 and 2
carburetors by removing the cotter pins.

 

THROTTLE LINK

FUELJOINT PIPE No.1CARBURETOR
Carefully separate the No. 1 and No. 2 carburetors.

 

No. 2 CAR BU RETOR

CHOKE ARM SPRING COLLAR

    

Remove the choke arm collar and remove the choke
arm and spring‘
Remove the choke valve nut, spring and valve‘

 

Date of Issue: Dec, 1982 59
© HONDA MOTOR 00., LTD, 4 '1 1

FUEL SYSTEM

Check the Choke valve and spring for nicks, grooves,
or other damage.

CARBURETDR ASSEMBLY

Install the choke valve, valve spring and nut and
tighten the nut.

Install the choke arm and spring while hooking the
arm to the groove in the choke valve, Install the
choke arm collar.

Coat the new O-rings with oil and install them on
the fuel joint pipe for No. 1 and No. 2 Carburetors.
Install the fuel joint pipe to the NO. 1 and No. 2
carburetors,

/  ,

HONDA.
V65MAGNA

 

 

 

CHOKE VALVE SPRING

ARM VALVE SPRING

    

NUT ” ’ COLLAR

FUEL JOINT PIPE

 

O-RINGS

 

4-12

60

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

Reconnect the throttle linkage between the No. 1
and No, 2 carburetors, using new cotter pins.

Coat new Orrings with oil and install them on the
fuel and air joint pipes.

Put the No. 3 and No. 4 carburetors together with
the joint pipes.

Loosen the synchronixation adiusting screws until
there is no tension.

Install the synchronization springs.

Install the thrust springs between the throttle valve
shafts.

 

FUEL SYSTEM

THROTTLE LINK

  

ETOR

 
 

COTTER PINS No. 1 CARBUHETOR

FUEL JOINT PIPE

 

AIR JOINT PIPES

No. 1 CARBURETOR THRUST SPRING No. ECARBURETOR
m b _

 

i

~ - h
No.38VNCHHONIZATION SPRING

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

GI

4-13

    
   

 

 

 

FUEL SYSTEM

HONDA
V65MAGNA

 

 

Make sure the fuel joint and air joint pipes are
securely installed.

Install the choke rods and levers, using the runs and
new cotter pinsl

Make sure (he air chamber funnelsl grommets and
dowel pins are in place.

    

’ ,\T

No.2 CARBURETOR THRUSTSPRING NoA CARBURETOR
V 'y «7 _ ‘ » 7-

 

 

k .‘ w \ _
N02 SYNCHRONIZATION No.4 SYNCHRONIZATION
SPRING SPRING

CHOKE RODS AND LEVEHS

 

CHbKE ROD

FUNNEL GROMMETS

 

DOWEL PlNS

 

4-14

62 Data of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA FUEL SYSTEM

 

 

Place the air chamber over the carburetors aligning
the dowel pins with the carburetor holes.

Attach the air chamber to the carburetors with the
eight screws.

Turn the throttle stop screw to align the No. 1
throttle valve with the edge of the by-pass hole.

Align each throttle valve with the bypass 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,

 

No.2 ADJUSTING SCREW No.4 ADJUSTING SCREW

 

Date of Issue: Dec, 1982 63
©HONDA MOTOR CO., LTD. 4 '1 5

HONDA
V65MAGNA

 

FUEL SYSTEM

BARBURETUR INSTALLATIUN

Installation is essentially the reverse of removal.

NOTE

Route the throttle and choke cables properly
(page 1—9 to 1—12).

 

 

 

 

Perform the following inspections and adiustments.

Throttle operation (page 35).
Carburetor choke (page (#6).
Carburetor idle speed (page 3-11).

- Carburetor synchronization (page 3-10).

PILOT SCVR EW

PlLilT SCREW ADJUSTMENT

IDLE DROP PROCEDURE iU.S,A. ONLY)

NOTE

    

, The pilot screws are factory pre-set and no
adjustment is necessary unless the pilot
screws are replaced (page 4-8).

' Use a tachometer with graduations of 50

rpm or smaller that will accurately indicate
a 50 rpm change.

1, Turn each pilot screw clod<wise until it seat:
lightly and back it out to the specification
given. This is an initial setting prior to the final
pilot screw adjustment.

INITIAL OPENING: 3 turns out

 

CAUTION:
Damage to the pilot screw seat will occur
If the pilot screw is tightened against the
seat.

   

 

 

2, Warm up the engine to operating temperature.
Stop and go driving for 10 minutes is sufficient.

1 Attach a tachometer according to its manufac-
turer’s instructions.

4. Adjust the idle speed with the throttle stop
screw.
IDLE SPEED: 1.000 i100 rpm

5. Turn each pilot screw 1/2 turn out from the

 

initial setting. . >
6. If the engine speed increases by 50 rpm or _, I. a :3

more, turn each pilot screw out by successive ’ ’ I '4

1/2 turns until engine speed drops by 50 rpm or THROTTLE STOP SCREW

less.

4-16

 

54 Date of Issue: Dec, 1982
© HONDA MOTOR C0., LTD.

HONDA
V65MAGNA

 

7. Adjust the idle speed with the throttle stop
screw.

8. Turn the No. 1 carburetor pilot screw in until
the engine speed drops 50 rpm.

9. Turn the No. 1 carburetor pilot screw 1 turn
out from the position obtained in step 8.

10. Adjust the idle speed with the throttle stop
screw.

11. Perform steps 8, 9 and 10 for the No. 2, 3 and
4 carburetor pilot screws,

12. Drive new pilot screw plugs into the pilot screw
bores with a 7 mm valve guide driver (P/N 07942
—8230000). When fully seated the plug surfaces
will be recessed 1 mm into the pilot screw bore.

FUEL TANK

 
    

00 not allnw flames or sparks near gasoline.
Wipe up spilled gasnline at once.

 

  

Check the vent hole of the filler cap for blockage.
Check that fuel is flowing out of the fuel valve
freely. If fuel flow is restricted, clean the fuel
strainer.

Make sure that there are no fuel leaks.

AUXILIARY FUEL TANK

Drain fuel from the main and auxiliary tank.
Remove the seat, main fuel tank and side covers.
Removethe regulator/rectifier.

Disconnect the battery negative cable, then positive
cable and remove the battery.

Remove the rear wheel lpage16~3).

Remove rear fenders A and B.

Detach the auxiliary fuel tank hose from the fuel
pump.

Disconnect the fuel level sensor wire terminals.
Remove the auxiliary fuel tank mounting bolt and
tank.

Install the auxiliary fuel tank in the reverse order of
removal.

FUEL SYSTEM

 

   

PILOT SCREW PLUG

 

 

 

 

 

 

AUXILIARY
FUEL TANK

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

“5 4-17

FUEL SYSTEM

AIR CLEANER

CASE/CHAMBER

Check the air cleaner case for deterioration.

CRANKCASE VENTILATION SYSTEM

Check that the breather tube is not restricted.

”c?

FUEL PUMP

Remove the seat and side covers.

Disconnect the fuel pump coupler.

Remove the fuel pump mounting bolts.

Disconnect the fuel lines lrom the pump and
remove the pump.

NOTE:

Before disconnecting the fuel lines, turn the
fuel valve off and clamp the luel lines to
prevent the fuel from flowing out.

 

 

 

 

HON DA
V65MAGNA

 

 

MOUNTING BOLT

 

 

4-18

56

Date of issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

FUEL SYSTEM

 

,/ HIGH ALTITUDE lllllllSTMENT (USA only)

When the vehicle is to be operated continuously
above 2,000 m (6,500 feet) the carburetor must be
readjusted as follows to improve driveability and
decrease exhaust emissions.

Warm up the engine to operating temperature. Stop
and go driving for 10 minutes is sufficient.

Remove each pilot screw plug (page 4-8).

Turn each pilot screw clockwise 1 turn,

Adiust the idle speed to 1,000 i 100 rpm with the
throttle stop screw.

Drive new pilot screw plugs into the pilot screw
bores (Page 4-17).

NOTE:

This adjustment must be made at high alti-
tude to ensure proper high altitude operatlon.

 

 

 

 

Attach a Vehicle Emission Control Information
Update label onto the frame as shown. Refer to
Service Bulletin #SL132 for information on obtain~
ing the label.

NOTE:

Do not attach the label to any part that can
be easily removed from the Vehicle

 

 

WARNING

Operation at an altitude lower than 1,500 m

(5,000 feet) with the carburetor adjusted for
high altitudes may cause the engine to idle
roughly and stall.
When the vehicle is to be operated conti-
nously below 1,500 m (5,000 feet), turn each
pilot screw counterclockwise 1 turn to its
original position after removing each pilot
screw plug and adjust the idle speed to 1,000
i 100 rpm. Drive new pilot screw plugs into
the pilot screw bores (page 4-1 7). Be sure to
do these adjustments at low altitude

 

 

 

 

 

 

VEHICLE EMISSION CONTROL
INFORMATION UPDATE LABEL

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

67 4-19

HONDA
V65MAGNA

 
  
  
   
 
 
  
 
 
  
  
 
 
  
 
       
  

ENGINE REMOVAL/INSTALLATION

 

35—45 Nrm
(ls—4,5 kg-m.
25—33 fl-lb)

35—45 N‘m
(3,5—4‘5 kg-m,
25—33 (Mb)

35—45 N-m a:
135—45 kg»m, \
25—33 mm

20—30 Nm 1,
(z‘o—a‘o kg-m, M “
1442 Mb)

85—105 N‘m
(85—105 kg-m,
61—76 ft-Ib)

45—70 Nrm
(AS—7.0 kg-m,
35—45 N-m 33—51 fl-Ib)
(3.5—4.5 kgm,

25—33 fl-lb)

60—70 N-m

(Bo—7.0 kg-m, .
43—51 fl-Ib) ’
Q

9 35—45 Nlm
(3.5—4.5 kg-m,
25—33 ft-lb)

 

     
   

\
18—28 N‘m (LB—2‘8 kg-rn,

 

(Ls—2.8 kg~m, 13—20 "M
13—20 fl-Ib)
3—14 N‘m
23313:?“ 3—12 N-rn (us—1.2 kg-m,
6—9 mu)
5 0 68 Date of Issue: Dec, 1982
- © HONDA MOTOR (20., LTD,

V65MAGNA

 

HONDA 5 ENGINE REMOVAL/
. INSTALLATION

 

SERVICE INFORMATION
ENGINE REMOVAL
ENGINE INSTALLATION

 

5—1
5—2

'5—5

 

 

SERVICE INFORMATIIJN

GENERAL

0 A floor lack or other adlustable support is required to support and maneuver the engine.
0 The Iollowing parts or components can be serviced with the engine installed in the Irame:

Clutch - Alternator
‘ Gearshift linkage - Starter motor
Cylinder heads - Carburetors

SPECIFICATIONS

Engine dry weight 96.7 kg (213.2 lb)
Oil capacity 3.5 liters (3‘7 US, at)

TORQUE VALUES

Engine hanger bolt

 

8 mm bolt 20—30 N-m (2.0—3.0 kg-m, 14—22 ft-Ib)
10 mm bolt 35—45 N~m (3.5—4.5 kg-m, 25—33 ft~lb)
Sub-frame bolts
Upper 60—70 N-m (6.0710 kg-m, 43—51 fI-lbl
Lower 35—45 N-m (35—45 kgrm, 25—33 ft-Ib)
Rear axIe nut 85—105 N-m (ES—10.5 kg-m, 61—76 be)
Rear axle pinch bolt 20—30 N-m (2.0—3!) kg-m, 14—22 it-Ibl
Final gear case nut 45—70 N:m (4.5—7.0 kg~m, 33—51 ft-Ib)
Date of Issue: Dec, 1982 69 5 _ 1

HONDA MOTOR 00., LTD.

 

ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL

Place the motorcycle on its center stand.

Remove the seat and raise the fuel tank.

Remove the left and right frame side covers.

Drain the engine oil (page 22) and the coolant
(page 6-3).

Remove the rear wheel (page 16-3).

Remove the radiator (page 66).

Remove the carburetor (page 43).

Remove the exhaust chamber mount bolt.

Remove the exhaust muffler mount bolts and ioint
nuts.

Loosen the exhaust pipe clamp bolts and remove
the exhaust mufflers,

Disconnect the wire couplers for the alternator, oil
pressure switch and pulse generator.

Remove the wire bands.

Disconnect the spark plug wires.

Remove the bolt attaching the ground cable to the
crankcase and disconnect the ground cable.

CLAMP CHAM’BER
BOLT MOUNT BOLT OIL PRESSURE SWITCH AND

 

HONDA
V65MAGNA

   

 
 

JOINT NUTS

PULSEGENERATOR WIRE COUPLER

(

ALTERNATOR
WIRE COUPLER

’9

GOUND CAB LE

1/“

 

 

BOLT

 

5-2

70

' Date of Issue: Dec, 1982
HONDA MOTOR 00., LTD.

HONDA
V65MAGNA ENGINE REMOVAL/INSTALLATION

 

Disconnect the starter motor cable.

STARTER MOTOR

 

    

CRANKCASE REAR COVER
Remove the crankcase rear cover. :

 

Remove the crankcase rear cover front brackets
Remove the clutch slave cylinder.
NOTE:
Do not operate the clutch lever after removing
the clutch slave cylinder. To do s0 will cause

difficulty in reinstalling the slave cylinder.

 

"e » i

.R; ‘
CRANKCASE HEAR COVER
FRONT BRACKET

Date of Issue: Dec, 1982
HONDA MOTOR (30., LTD.

 

ENGINE REMOVAL/INSTALLATION

Remove the gearshift arm from the shift spindle.

Loosen the water pump hose band.

Disconnect the gearshift indicator switch coupler
and remove the wire band.

Disconnect the crankcase breather tube.
Place a floor jack or other adiustable support under
the engine.

NOTE:

The jack height must be continuously adjust-
ed so that mounting bolts can be removed,
and so stress is relieved from other bolts until
they are removed.

 

 

 

 

Remove the engine mounting bolts.
Remove the left sub-frame bolts and the subvirame.
Remove the engine from the left side.

 

 

HONDA
V65MAGNA

 

WATER PUMP HOSE BAND
t . x!

GEARSHIFT ARM

GEARSHAFT INDICATOR
SWITCH WIRE COUPLER
“ , for ‘

WIRE BAND

BREATHER TUBE

    

LEFT soB-FnAME

 

5-4

72 Date of Issue: Dec, 1992
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

ENGINE INSTALLATIIN

Check the engine mount rubbers for damage or wear
and replace if necessary

Install the engine mount rubbers.

Engine installation is essentially the reverse of
removal,

Use a floor jack or other adjustable support to
carefully manuever the engine into place.

CAUTION:

Carefully align mounting points with the jack
to prevent damage to mounting bolt threads
and wire harness and cables

 

 

Tighten all fasteners to the torque values given on
page 5-2.

NOTE

' Route the wires and cables properly (Page
1-9).

' Fill the crankcase to the proper level with
the recommended oil (Page 2-1).

~ Fill the cooling system (Page 68).

. Perform the following inspection and ad-
justments:
Throttle operation (Page 3-5),
Clutch (Page 3715i

 

 

 

 

ENGINE REMOVAL/INSTALLATION

 

Date oi Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

73

5-5

 

HONDA
V65MAGNA

 

ENGINE REMOVAL/INSTALLATION

Install the exhaust system:

Install new exhaust pipe joint gaskets.

Assemble the left and right exhaust pipes.

Tighten the exhaust pipe band loosely and install
the exhaust pipes.

Hand tighten all bolts and nuts, then torque them
in the order given below:

1. Tighten the exhaust pipe joint nutst
TORQUE: 8—14 N-m
(0.8—1.4 kg-m, 6—10 fl-lbl

2. Tighten the exhaust chamber mounting bolt.

TORQUE: 8—12 N~m
(0.8—12 kg-m, 6—9 ft-lbi

3. Tighten the rear rnufller hanger setting bolts.

TORQUE: 18—29 Nvm
(1.8—2.8 kg-m, 13—20 fl-Ib)

4. Tighten the exhaust pipe joint band bolts.

TORQUE: 18—28 N‘m
(1.8—2.8 kg-m, 13—20 ft-lh)

  

 

74 Date of Issue: Dec, 1982
5 ' 6 © HONDA MOTOR 00., LTD‘

HONDA.
V65MAGNA

 

 

MEMO

 

Date of Issue: Dec, 1982 75
© HONDA MOTOR C0,, LTD‘

COOLING SYSTEM

, HONDA
(g V65MAGNA

 

 

 

6-0

76

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD,

HON DA
V65MAGNA

 

6. COOLING SYSTEM

 

SERVICE INFORMATION
TROUBLESHOOTING
SYSTEM TESTING
COOLANT REPLACEMENT

 

6—1 THERMOSTAT 6—4
6—1 RADIATOR/COOLING FAN 6—6
6—2 WATER PUMP 6—10
6—3

 

 

SERVICE INFflRMATIflN

GENERAL

 

 

Do not remove the radiator cap when the engine is hot The coolant is under pressure and severe scalding could result.

The engine must be cool before servicing the cooling system,

sion protection. Do not use alcohol-based antifreeze,

Avoid spilling coolant on painted surfaces.

SPECIFICATIONS

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 made with the engine in the frame

After servicing the system, check for leaks with a cooling system tester.
Refer to Section 21 for fan motor thermostatic switch and temperature sensor inspections.

 

Use only distilled water and ethylene glycol in the cooling system. A 50—50 mixture is recommended for maximum corro-

 

Radiator cap relief pressure

0.75—1.05 kg/crn2 (10.77149 psi)

 

Freezing point

55% Distilled water + 45% ethylene glycol: —32°c (—25°F)
50% Distilled water + 50% ethylene glycol: 47°C (—34°F)
45% Distilled water + 55% ethylene glycol: 445°C (48°F)

 

Coolant capacity:
Radiator and engine
Reserve tank
Total system

30 liters (32 US qt)
0,45 liters (0.5 US qt)
345 liters (3.7 US qt)

 

Thermostat

Begins to open: so“ to 84°C (176° to 133°F)‘
Valve lift: Minimum of 8 mm at 95°C (0.315 in. at 203°F)

 

Boiling point (with 50—50 mixture):

 

 

Unpressurized: 107.7°c (226°F)
Cap on, pressurized: 125.6“0 (258°F)

 

 

TOO LS
Special

Cooling system Tester Commercially available

TRUIIBLESHIJIJTING

Engine temperature too high

. Faulty temperature gauge or gauge sensor

. Thermostat stuck closed

. Faulty radiator cap

. Insufficient coolant

. Passages blocked in radiator, hoses, or water jacket
. Fan blades bent

t Faulty fan motor

«sombrero-

Engine temperature too low
1. Faulty temperature gauge or gauge sensor
2. Thermostat stuck open

Coolant leaks
1. Faulty pump mechanical seal
2. Deteriorated O-rings

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD

77

6-1

 

COOLING SYSTEM

SYSTEM TESTING

COOLANT

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

Pressure test the radiator cap, Replace the radiator
cap if it does not hold pressure,.or if relief pressure
is too high or too low. I! 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:
0.9 1 (L15 kg/em2 (12.8 t 2.1 Psi)

Pressurize the radiator, engine and hoses, and check
for leaks,

CAUTION:

Excessive pressure can damage the radiator.
Do not exceed 1.05 [cg/cm“ {14.9 Psi}

 

 

 

 

Repair or replace components if the system will not
hold specified pressure for at least six seconds.

 

HONDA.
V65MAGNA

 

ANTIFREEZE TESTER

1.4

RESERVE TANK

 

 

 

COOLING SYSTEM TESTER
COMMERCIALLY AVAILABLE

  

RADIATOR CAP

 

 

 

 

6-2

78 Date of Issue: Dec, 1932
© HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

COOLING SYSTEM

BUULANT REPLACEMENT RADIATOR CAP

CAUTION:

The engine must be cool before servicing the
cooling system, or severe scalding may result,

 

 

 

 

Remove the radiator cap,

Drain the coolant from the radiator by removing the
drain plug located at the lower left sub~lrame,

DRAIN PLUG

. WATER PUMP COVER
Drain the coolant from the engine by removing the '

drain bolts at the water pump cover and cylinder

heads.

Replace the drain plug and bolts.

Fill the system with a 50—50 mixture of distilled

water and ethylene glycol.

Bleed air from the radiator.

0 Start the engine and run until there are no air
bubbles in the coolant, and the level stabilizes.

0 Stop the engine and add coolant up to the proper
level if necessary.

0 Reinstall the radiator cap.

0 Check the level of coolant in the reserve tank and
fill to the correct level if the level is low.

. \ .
DRAIN BOLT DRAIN BOLTS

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

 

f, ; HONDA.
“% V65MAGNA

COOUNGSVSTEM

THERMOSTAT ,7 RIGHTAIFI CHAMBER COVRE

/

REMOVAL

Remove the coolant drain plug and drain the
coolant (page 6-3).

Remove the right air chamber cover attaching screw
and the cover.

SCREW

AIR CHAMBER BOLT
Disconnect the wire from the temperature sensor. I-
Remove the bolt that attaches the thermostat ,
housing to the air chamber.
Loosen the hose bands.
Remove the thermostat housing.

.at x- »

HOSE BANDS THERMOSTAT HOUSING

 

THERMOSTAT HOUSING COVER
Remove the thermostat housing cover.

 

 

Date of Issue: Dec, 1982

BU
© HONDA MOTOR CO., LTD,

6-4

HONDA
V65MAGNA

 

COOLING SYSTEM

 

Remove the thermostat from the housing.

INSPECTION

Inspect the thermostat visually for damage.

Suspend the thermostat in healed water to check its
operation.

Do not let the thermostat or thermometer touch
the pan or false readings will result.

Replace thermostat if valve stayes open at room
temperature, or if it responds at temperatures other
than those specified.

Technical Date
Start to open

 

80° to 84°C l176°—183°Fl

8 mm minimum (0.31 in)
when heated to 95°C (203°F)
for five minutes.

 

Valve lift

 

 

 

 

INSTALLATION

Insert the thermostat into the housing.

Install a new O-ring on the thermostat housing
cover.

Install the thermostat housing cover and tighten
the bolts.

TH E RMOSTAT

 

HOUSING

 

 

     
 

TH E RMOSTAT

THERMOMETER

 

 

THERMOSTAT O-RING

COVER

HOUSING

 

 

Date of Issue: Dec, 1982
©HONDA MOTOR 00., LTD,

81

6-5

COOLING SYSTEM

Connect the housing to the hoses and tightEn the
hose bands.

Secure the thermostat housing to the air chamber
with the bolt attaching the ground wire terminal
at the same time.

Connect the temperature sensor wire to the sensor.

Install the right air chamber cover.
Fill the cooling system (page 6-3)'

RADIATflR/CDULING FAN

REMOVAL

Remove the seat and raise the fuel tank after mak-
ing sure that the tank is less than half full.

Remove the drain plug and drain the coolant (page
6-3).

Loosen the radiator side cover attaching bolts and
nuts and remove theside covers and grille.

Remove the leit steering head cover attaching nut
and cover.
Disconnect the fan motor coupler,

HGNDfi.
V65MAGNA

TEMPERATURE SENSOR

 

AIRCHAMBER GROUNDWIRE WIRE
3 a. i a

 

A» , ’x

THERMOSTAT HOUSING

BOLT RADIATOR GRILLE

 

 

6-6

82

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

HONfiA
V65MAGNA COOLING SYSTEM

 

OVERFLO TUBE

Disconnect the overflow tube at the radiator Iiller
neck.

Disconnect the thermostatic switch wires from the
switch,

Loosen the lower radiator hose band.

TH E RMOSTATIC

RADIATOR HOSE SWITCH WIRES
PPER RADIAT R HOSE BAND

 

Loosen the upper radiator hose band. /

Remove the radiator mounting bolts

Remove the radiator while pulling the upper and
lower hoses 0".

'fl‘

RADIATOR MOUNTING BOLTS

 

FAN SHROUD
DISASSEMBLY

Remove the four nuts attaching the fan shroud to
the radiator and remove the shroud

RADIATOR

 

Date of Issue. Dec, 1952
© HONDA MOTOR 00., LTD,

HONDA,
V65MAGNA

 

COOLING SYSTEM

Remove the fan attaching nut and pull the Van off
the fan motor.

FAN MOTOR
Remove the screws attaching the fan motor to the
fan shroud,

 

FAN SHROUD SCREWS

RADIATOR
RADIATOR INSPECTION

Inspect the radiator soldered joints and seams ior
leaks.

Eiow dirt out from between core fins with com
pressed air, Ii insects, etc., are clogging the radiator,
wash them off with low pressure water.

 

 

3., Date or Issue: Dec, 1932
6 - 8 © HONDA MOTOR 00., LTD.

HONDA
V65MAGNA COOLING SYSTEM

 

ASSEMBLY COOLING FAN

Install the fan motor onto the fan shroud and
tighten the three screws.

Install the fan over the motor shaft.

Apply a locking agent to the fan motor shaft
threads, install and torque the plain washer, lock
washer and nut.

 

Install the fan shroud onto the radiator and tighten
the four nuts.

 

INSTALLATION

Install the upper and lower hoses onto the radiator.

Install the radiator onto the frame and tighten the
mounting bolts.

Connect the upper and lower hoses and tighten the
hose bands,

Connect the wires to the thermostatic switch.
Connect the overflow tube to the filler neck.

Install the radiator grille and side covers.

Connect the fan motor coupler and install the left
steering head cover.

Fill the cooling system (page 66].
Install the fuel tank and seat,

 

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

 

HQNDA
V65MAGNA

 

COOLING SYSTEM

WATER PUMP ‘ ‘ WATER PUMP

MECHANICAL SEAL INSPECTION

 

Remove the crankcase rear cover.

Inspect the telltale hole for signs of mechanical
seal coolant leakage.

Replace the water pump as an assembly if the
mechanical seal is leaking.

TELLTALE HOLE

 

DRA N BOLT
REMOVAL -

Remove the drain plug from the lower left frame
and drain the coolant.

Remove the drain bolt at the water pump and drain
the coolant from the cylinders.

Remove the gearshift arm and left footpeg bracket.

 

LEFT FOOTPEG '
BRACKET

Disconnect the water hose from the water pump
cover.
Remove the water pump cover bolts and covert

 

WATER HOSE DRAIN BOLT '

 

86 Date of Issue: Dec, 1982
6 '1 0 © HONDA MOTOR CO, LTD.

\x

 

7 HONDA
{a V65MAGNA

Loosen the water hose bands.
Remove the water pump from the crankcase.

INSPECTION

Check the water pump for mechanical seal leakage
and bearing deterioration.
Replace the water pump as an assembly if necessary.

INSTALLATION

Apply a coat of clean engine oil to a new Owing
and install it in the water pump groove.

Align the water pump shaft groove with the oil
pump shaft and insert the Water pump into the
crankcase

 

COOLING SYSTEM

”WATER PUMP

 

 

O~RING

 

WATER PUMP ASSEMBLY O~R|NG

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR (20., LTD.

 

HQNDfi
V65MAG NA

 

COOLING SYSTEM

HOSE BANDS
Connect the water hose to the water pipe and the - K t

water pump and tighten the hose bands,

WATER PIPE

Insert the dowel pins into the water pump, and
install a new O~ring in the groove 0! the water pump
COVeI’.

Install the water pump cover and torque the bolts.

O’RING kWAT’EFl PUMP COVER”

PUNCH MARKS
Install the left foot peg bracket. ' '
Align the punch marks on the gearshift arm and
the spindle, and install the gearshift arm.

Install the crankcase rear cover.

Tighten the drain plug at the lelt sub~frame.

Fill the system with a BCPSD mixture of distilled
water and ethylene glycol (page 6-3lt

LEFT FOOT PEG H
BRACKET

33 Date of Issue: Dec, 1982

6'1 2 © HONDA MOTOR (30., LTD.

 

 

HON DA
V65MAGNA

 

 

MEMO

 

Dam of Issue: Dec, 1982 39
© HONDA MOTOR (20., LTD.

HONDA.

CLUTCH VéSMAGNA

 

2—3.5 N‘m
g / (0.27035 kg-m, 1.5—2.5 ftAIb)

   
 

25735 Nvm
(2.5—3.5 kgrm,
18—25 H-lb)

 

 

   

4—7 N‘m
10.470] kg-m, 375 h-Ib)

 

25735 N«m
(2.5—3!) kg-m, 18—25 ft-lb)

 

90 Daxe of Issue: Dec, 1982
7 ' 0 © HONDA MOTOR 00., LTD.

$3333? 7. CLUTCH

 

 

 

I
SERVICE INFORMATION 7—2 CLUTCH COVER REMOVAL 7—11
TROUBLESHOOTING 7—3 STARTERCLUTCH DISASSEMBLV 7—11
CLUTCH FLUID nEPLACEMENT/ CLUTCH DISASSEMBLY 7—13
A'“ BLEED'NG 7.4 CLUTCH ASSEMBLY 7—18
CLUTCH MASTER CVL'NDER 7-5 STARTER CLUTCH ASSEMBLY 7—21
CLUTCH SLAVE CYL'NDER 7—8 CLUTCH COVER INSTALLATION 7—23

 

 

50—60 N‘m
(5.0—6.0 kg»m,
36—43 fl-lh)

 
 
 

\
S M

80—100 N-m
(SD—10.0 kg»ml

 

 

 

0/ 264.0 N‘m
(2.64.0 kg~m,
19722 nrlb)
5?

o
O
J
Dale of Issue: Dec, 1982 91 7 _ 1

© HONDA MOTOR (30., LTD‘

HONDA
V65MAGNA

 

CLUTCH

SERVICE INFURMATIIJN

GENERAL

I This section covers removal and installation of the clutch hydraulic system, clutch and starter clutch,

0 DOT~4 brake fluid is used for the hydraulic clutch and is reIerred to as clutch Iluid in the section. Do not use other types
oI fluid as they are not compatible,

I Clutch maintenance can be done with the engine in the Irame.

 

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD SERVICE LIMIT
Clutch master cylinder Cylinder ItD. 15370—15913 rnrn (03248—06265 in) 1593 mm (0.627 in)
Piston O.D. 15327—15354 mrn (06231—06242 in) 15.80 mm (0.622 inI
Clutch slave cylinder Cylinder LD. SHAW—38,162 mm (15000—15024 in) 38.18 mm (1.503 in)
Piston 0.D. 38036—381375 mm (1,4975—1.4990 Ini 38.02 mm (1.497 in)
Clutch Outer guide |.D. 29995—311012 mm (1.1809—1.1816 in) 30.08 mm (1.184 in)
Spring Iree height 4.6 mm (0.18 in) 3.6 mm (0.14 in)
Spring preload/length 115—135 kg/Z mrn (254—298 |b/0.08 in) —
Disc thickness 3,72—338 rnrn (0.147—0.153 in) 3,1 mm (0.12 in)
Plate warpage — 0,230 mm (0.012 in)
Starter clutch Driven gearO.D. 54.170—54200 mrn (21327—21339 in) 54.16 mm (2.132 in)
TORQUE VALUES
Clutch hose oil bolts 25—35 N‘m12.5—3.5 kg-m,18—25't-Ib)
Clutch fluid reservoir cover 2-3.5 N‘m (OJ—0,35 kg-m, 1.5—2.5 It-lb)
Starter clutch bolt 80—100 N-m (SD—10.0 kg-rn, 58—72 It-Ib)
Clutch center lock nut 50—60 N‘m (5.0—6.0 kg-m, 36—43 ft-lb)
Starter clutch cover 26730 N~rn (2.6~3.0 kg-rn, 19—22 ft~lb)
Master cylinder holder bolt 10714 N‘rn (1041.4 kg-ml 7—10ft-lb)
TOO LS
Special
Snap ring pliers 07914—3230001
Lock nut wrench 07916—4220000
Common
Universal holder 07725—0030000
Driver 07749—0010000
Attachment, 42 x 47 mm 07746—0010300
Pilot, 35 mm 07746—0040800

 

7 2 52 Date of Issue: Dec, 1982
" © HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

TRflUBLESHflflTING

clutch lever 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 slips

1. Hydraulic system sticking
2. Discs worn

3, Springs weak

clutch will not disengage

1. Air bubbles in hydraulic system
2. Low fluid level

3. Hydraulic system leaking

4. Hydraulic system sticking

5‘ Plates warped

CLUTCH

Motocvcle creeps with clutch disengaged
1‘ Air bubbles in hydraulic system

2. Low fluid level

3. Hydraulic system leaking

4. Hydraulic system sticking

5i Plates warped

Excessive lever pressure
1, Hydraulic system sticking
2. Lifter mechanism damaged

Clutch operation feels rough
1. Outer drum slots rough
2. Sticking pistonls)

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

93

7-3

HQNDA
VésMfiGNA

 

CLUTCH

CLUTCH FLUID REPL CEMENT/
AIR BLEEDING

Check the fluid level with the fluid reservoir parallel
to the ground.

CAUTION:

' Install the diaphragm on the reservoir when
operating the clutch lever. Failure to do so
will allow clutch fluid to squirt out of the

reservoir during clutch operation.

Avoid spilling fluid on painted surfaces.
Place a rag over the iuel tank whenever
the system is serviced.

   

LOWER LEVEL

BLEED VALVE
CLUTCH FLUID DRAINING ' ' '

Connect a bleed hose to the bleed valve,

Loosen the slave cylinder bleed vlave and pump the
Clutch lever.

Stop operating the lever when no fluid flows out of
the bleed valve.

CLUTCH FLUlD FILLING

NOTE:

Do not m d
may not be compa ible

 

Close the bleed valve, fill the reservoir, and install
thediaphragm,

To prevent piston overtravel and clutch iluid see-
page, keep a 20 mm (3/4 in) spacer between the
handlebar grip and lever when bleeding the clutch
system. 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
felt. Then bleed the system.

 

 

 

94 Date of Issue: Dec, 1932
7'4 ©HONDA MOTOR 00,, LTD.

IICDBII)1%
V65MAGNA

 

CLUTCH

 

MASTER CYLINDER I.Dl INSPECTION

Measure the master cylinder |.D,
Check the master cvlinder for scores, scratches
or nicks.

SERVICE LIMIT: 15.93 mm (0327 in)

MASTER PISTON O,D. INSPECTION

Measure the master piston O.D.
SERVICE LIMIT: 1530 mm (0.622 in)

Check the primary and secondary cups for damage
before assemblv.

ASSEMBLY

CAUTION:

Handle the master piston, spring, primmy
cup and secondary cup as a mi

 

 

 

 

Coat all parts with clean DOT-4 brake fluid before
assembly.
Install the spring, primary cup and piston.

CAUTION:

When installing Ihe cups, do not allow the/1p:
10 turn inxide out,

 

 

 

 

Install the circlip making sure it is seated firmly in
the groove,

Install the boot and push rode

Install the clutch switch, if it was removed.

 

MASTER
CYLINDER

 

RESERVOIR COVER

§ ’4 /DIAPHRAGM
Z HOLDER

  
  
  
     
 

CLUTCH LEVER
PIVOT BOLT

spa PRIMARY cup
PBTONAND
0 /SECONDARV CUP

ING
@112: (CIRCLIP
@fikaom

PUSH ROD

CLUTCH

SWITCH
PUSH ROD END PIECE

 

Date of Issue: Dec, 1932
HONDA MOTOR CO., LTD.

97 7-7

CLUTCH

Place the master cylinder on the handlebar and
install the holder and the two mounting bolts,
Aligh the end of the holder with the punch mark on
the handlebar.

Tighten the top bolt first them the bottom bolt.

TORQUE: 10—14 N~m (1.0—1.4 kg-m, 7—101t-lbl

Install the oil hose with the bolt and its two sealing
washers.

Install the push rod end piece into the clutch lever
hole and install the clutch lever.

Connect the clutch switch wires to the switch
terminals,

Fill the reservoir and bleed the clutch system
(page 74).

CLUTCH SLAVE CYLINDER

DISASSEMB LY

Remove the left crankcase rear cover.

Remove the left crankcase rear cover bracket.

Place a container under the slave cylinder, remove
the oil bolt and disconnect the clutch hose.

NOTE:

Avoid spilling clutch fluid on painted sur-
faces.

 

 

 

 

Remove the slave cylinder.

7-8

 

HONDA.
V65MAGNA

 

CLUTCH HOSE

PUNCH MARK

RANKCASE HEAR COVER

- "V, ’.
OIL BOLT CRANKCASE REAR
COVER BRACKET

 

Date of Issue: Dec, 1982
© HONDA MOTOR 60., LTD.

HONDfi
V65MAGNA CLUTCH

 

AIR BLEEDING

NOTE:

~ Check the fluid level often while bleeding
the clutch to prevent air from being
pumped into the system,

. Use only DOT 4 brake fluid from a sealed
containert

~ Do not mix brake fluid types and never
reuse the fluid whidh has been pumped out
during bleeding, or the efficiency of the
clutch system will be impalre

   

 

 

 

1) Squeeze the clutch lever, open the bleed valve
1/2 turn then close the valve,

NOTE:

Do not release the clutch lever until the
bleed valve has been closed again,

 

 

 

 

2) Release the clutch lever slowly and wait several
seconds after it reaches the end of its travel.

Repeat the above steps until bubbles cease to appear
in the fluid coming out of the bleed valve

 

Fill the fluid reservoir to a point somewhere bet-
ween the upper and the lower level.

 

LOWER LEVEL

 

Date of Issue: Dec, 1982 95 7 _ 5
© HONDA MOTOR co., LTD4

CLUTCH

CLUTCH MASTER CYLINDER

DISASSEMBLY

Drain clutch fluid from the hydraulic system,
Remove the left rear view mirror and clutch lever.
Disconnect the clutch switch wires and remove
the clutch hoset

CAUTION:

Avoid spilling clutch fluid on painted surfaces.
Place a rag over the fuel tank whenever the
clutch system is serviced.

 

 

NOTE:

When removing the oil bolt, cover the end of
the hose to prevent contamination and secure
the hose,

 

 

 

 

Remove the master cylinder.

Remove the push rod boot, and circlip from the
master cylinder body.

Remove the piston and secondary cup.
Remove the primary cup and spring.
Remove the clutch switch, if necessary.

HONDA.
V65MAGNA

 

OIL BOLT

 

 

SNAP RING PLI ERS
0791473230001

 

 

 

CLUTCH MASTER
CYLINDER

PRIMARY CUP

SP |
R NG SECONDARY CUP

PISTON

 

 

7-6

96

Date of Issue: Dec, 1982
© HONDA MOTOR C0,, LTD.

 

HON DA.
V65MAGNA

 

CLUTCH

 

Remove the piston from the cylinder.

If the 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 fluid inlet to remove
the piston. Use the air in short spurts.

Remove the spring from the slave cylinder,
Remove the oil and piston seals.
Clean the piston groove with clutch fluid.

Check the piston spring for weakness or damage.

PISTON 0.D. INSPECTION

Check the piston for scoring or scratches.
Measure the outside diameter of the piston with a
micrometer.

SERVICE LIMIT: 38.02 mm (1.497 in)

SPRING

 

OILSEAL

PISTON SEAL

 

 

 

Date of Issue: Dee, 1982 99
© HONDA MOTOR (20., LTD.

7-9

CLUTCH

CYLINDER |.D. INSPECTION

Check the slave cylinder for scoring or scratches.
Measure the inside diameter of the cylinder bored
SERVICE LIMIT: 38.18 mm (1.503 in)

ASSEMBLY

Assemble the slave cylinder in the reverse order of
disassemblyt The oil seals must be replaced with
new ones whenever they have been removed,

Lubricate the piston and piston seal with a medium
grade of Hi-Temperature 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 oil seal
end facing out.

Install the insulator and slave cvlinder.

Connect the clutch hose with the oil bolt and the
two sealing washerst

Install the crankcase rear cover bracket.

Install the left crankcase rear cover.

Fill the clutch fluid reservoir with DOT-4 brake
fluid, and bleed the clutch system (page 7-4),

7-10

 

HONDA
V65MAGNA

 

 

 

OIL SEAL

 

SILICONE
GREASE

PISTON SEAL

INSU LATOR

 

SLAVE CYLINDER BODY

 

 

100

r \ V -
CRANKCASE REAR COVER
BRACKET

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO, LTD.

HON DA
V65MAGNA CLUTCH

 

 

CLUTCH COVER REMDVAL

Drain the engine oil‘
Remove the brake pedal and right footpeg,
Remove the clutch cover, gasket and dowel pins‘

BRAKE PEDAL RIGHT FOOTPEG

STARTER IDLER GEAR
\ .

STARTER CLUTCH DISASSEMBLY

Remove the starter idler gear shaft and gear.

Remove the alternator cover. Hold the flywheel
with a universal holder.

 

 

3 o
‘ ‘ ” ‘ , «m.»
UNIVERSAL HOLDER OR FLYWHE L HOLDER
07725—0030000 0772570040000

Date of Issue: Dec, 1982 101 7 1 1

© HONDA MOTOR (30., LTD. -

CLUTCH

Remove the starter clutch bolt.
Remove the starter clutch assembly and spacer.

Shift the primary driven subgear with a screw-
driver to take preload o" the primary drive gear
and remove the primary drive gear.

Remove the starter driven gear and needle bearing
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 weart

 

HONDA
VOSMAGNA

 

ii
STAR‘I’E R CLUTCH BOLT

PRIMARY DRI EN SUBGE R PRIMARV DRIVE GEAR
, s, V:

 

 

STA RTE R CLUTCH
SPRING

   

 

 

 

7-12

MNTQ
PLUNGER
STARTER CLUTCH COVER ROLLER
102 Date of Issue: Dec, 1982

© HONDA MOTOR 00,, LTD.

HONDA,
V65MAGNA

 

STARTER DRIVEN GEAR INSPECTION

Inspect the driven gear for damage or excessive
wear.
Measure the driven gear O.D.

SERVICE LIMIT: 54.16 mm (2.132 in)

CLUTCH DI'SASSEMBLY

NOTE:

Do not operate the clutch lever after removing
the clutch. To do so will cause difficulty in
reassembling the clutch,

    
  

 
 

 

Remove the snap ring, lifter plate, lifter guide,
release bearing and lifter rod.

Install the rear brake pedal.

Shift the transmission into high gear and apply the
rear brake.

NOTE:

When the engine is not in the frame, shift the
transmission into gear and use the MAIN-
SHAFT HOLDER, P/N 07923»6890100, to
hold the final shaft.

 

 

 

 

Remove the lock nut and lock washer.

Remove the clutch spring set plate, clutch spring
and washer.

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD

LIFTER GUIDE ‘

CLUTCH SPRING

07916—4220000

CLUTCH

 

 

HQNDA
V65MAGNA

 

CLUTCH

DISCS AND PLATES CLUTCH PRESSURE PLATE
Remove the clutch pressure plate. ~ , . ' -_r ,y , . >

1

Remove the clutch plates and discs.

Remove clu‘ch cemer B and the one-way clu‘ch as
an assembly,

  

«is

,Jaw
ONE WAY CLUTCH

 

CLUTCH CENTER A WASHER
‘ , ‘ v

  

Remove clutch center A and washer.

 

 

104 Dam of Issue: Dec, 1982
7 '1 4 © HONDA MOTOR 00., LTD.

HQNBA
V65MAGNA

 

Remove the clutch outer and outer guide.

INSPECTION
CLUTCH OUTE R

Check the slots in the clutch outer for nicks, cuts or
indentations made by the friction discs.

Check the clutch outer needle bearing for damage
or excessive play.

If the needle bearing is difficult to remove from the
clulch housing, use the following tools:

Driver: 0774970010000
Attachment, 37 x 40 mm: 07746—0010200
Pilot, 35 mm: 07746—0040800

CLUTCH OUTER GUIDE

Measure the ID, of the clutch outer guide.
SERVICE LIMIT: 30.08 mm (1,184 in)

 

CLUTCH OUTER GUIDE

CLUTCH

  

NEEDLE BEARING

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR C0., LTD.

105

7-15

 

CLUTCH

CLUTCH SPRING

Measure the height of the clutch spring as shown.
SERVICE LIMIT: 3.6 mm (0.14 in)

Replace the spring if its height is less than the
service limit.

CLUTCH DISC

Replace the clutch discs if they show sings of scor-

ing or discoloration. Measure the thickness of each
disc.

SERVICE LIMIT: 3.1 mm (0t12in)

Replace any discs that are thinner than the service
limit.

CLUTCH PLATE

Check the plate warpage on a surface plate, using
a healer gauge.

SERVICE LIMIT: 0.30 mm 10.012 in)

 

HONDA
V65MAGNA

 

 

 

 

7-16

105

Date of Issue: Dec, 1982
@ HONDA MOTOR (30., LTD,

HONDA
V65MAGNA

 

ONE WAY CLUTCH INSPECTION

Inspect the one way clutch for smooth operation.

Check the rollers tor excessive wear.

Measure the ID. oI clutch center B.
SERVICE LIMIT: 74.50 mm (2.933 MI

Measure the CD. of the one way clutch innef.
SERVICE LIMIT: 57.7 mm (2.27 in)

CLUTCH

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

107

HONDA
V65MAGNA

 

CLUTCH

CLUTCH ASSEMBLY

Install the clutch outer guide over the mainshaft.
Install the needle bearing into the clutch outer.

PINS‘

   

OIL PUMP DRIVE SPROCKET
W 5‘. ,.

   

Align the holes in the clutch outer with the pins
on the oil pumpdrive sprocket and install the clutch
outer over the guide

Install clutch center A and the washer.

FLANGED CAGE

Install the onean clutch into clutch center B with
its flanged cage facing in.

 

ONE-WAY CLUTCH CLUTCH CENTER B

108 Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

7-18

HONDA,
V65MAGNA

 

Install the clutch inner into the one»wav clutch by
turning it clockwise.

Install the one-way clutch/clutch center B assembly
over the mainshaft.

NOTE:

Make sure the one way clutch assembly is
installed correctly by turning the clutch
center B. The clutch center should turn
counterclockwise freely and should not turn

 

 

clockwise.

 

 

Coat the discs and plates with clean engine oil.
Install the clutch discs and plates as shown.

CAUTION:
Do not pull clutch center 8 out 41er talling
the discs and phtex or a plate wrth fall bet—
clutch centers A and Be
This will prevent the clutch from disengaging

 

CLUTCH

CLUTCH INNER

 

CLUTCH CENTER E (Turns counterclockwise)
. \

ONE-WAY CLUTC

 

 

 

. PLATE (7)
DISC (8)

 

 

Date of issue: Dec, 1982
HONDA MOTOR 00., LTD.

109

7-19

HONDA.
V65MAGNA

 

CLUTCH

CLUTCH PRESSURE PLATE
Install the clutch pressure plate. , ' 9 . . /

 

Install the clutch spring set plate, clutch spring, and

 

h . CLUTCH
was 9'” SPRING
NOTE:

Install the h spring with the dished face

towards th

 

 

 

Install the lock washer with its OUTSIDE mark
facing out,

 

Install the lock nut.

 

WASHER
CLUTCH SPRING

LOCK
WASHER SET PLATE

 

 

 

Place the transmission in 6th gear.
Apply the brake and tighten the lock nut.

NOTE:

When servicing the clutch with the engine out
of the frame, shift the transmission into gear
and hold the output shaft with the HOLDER
07923—6890101.

 

 

 

 

TORQUE: 50—60 N-m (5,0—6‘0 kg-m, 36—43 ftvlb)

 

\
LOCK NUT WRENCH
0791674220000

no Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

7-20

HONDA.
V65MAGNA

 

CLUTCH

 

Install the clutch lifter rodt

Install the clutch filter plate, lifter guide and hear-
ing.

Install the snap ringr

STARTER CLUTDH ASSEMBLY

Install the primary drive gear onto the crankshaft
while moving the primary driven subgear with a
screwdriver.

SCREWDRIVER

 

 

Data of Issue: Dec, 1982
© HONDA MOTOR CO” LTD.

 

CLUTCH

Install the thrust washer on the crankshaft.

Install the starter idler gear and shaft.

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 dowel pin and tighten the bolts.

TORQUE: 26—30 Nvm (2.6—3.0 kg-m,19—22 h-lb)

NOTE

Apply a locking agent to the bolt threads.

 

Install the starter driven gear by turning it counter-
clockwise.

TH RUST WASH E R
t ‘1’».

ROLLER PLUNGER

 

HONDA
V65MAGNA

IDLER GEAR SHAFT

 

 

DOWEL PIN CLUTCH COVER

STARTER DRIVEN GEAR

  

 

7-22

112

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

CLUTCH

    

PUNCH MARKS
Align the punch marks on the starter clutch and

crankshaft and install the starter clutch.

a"!

Hold the flywheel with a universal holder and
tighten the starter clutch bolt to the specified
torque.

TORQUE: 80—100 N‘m
(13.0—10.0 kg-m, 58—72 ft-lb)

Install the alternator covert

 

CLUTCH CflVER INSTALLATION

Install the dowel pins and a new gasket,

 

V
DOWEN PINS

Date of Issue: Dec, 1982

113
© HONDA MOTOR (20., LTDt

HONDA
V65MAGNA

 

CLUTCH

Install the clutch cover.
Install the right footpeg and rear brake pedal.
Fill the crankcase with oil (page 2-3).

 

 

114 Dale of Issue: Dec, 1982
7 ' 24 © HONDA MOTOR 00., LTD,

HONDA.
V65MAGNA

 

 

MEMO

 

Date of Issue: Dec, 1982
© HONDA MOTOH 00., LTD.

115

HONDA
GEARSHI FT LIN KAGE V65MAGNA

 

 

(«fig/g»

 

116 Date of Issue: Dec, 1982
8'0 .HONDA MOTOR 00., LTD.

 

$333? 8. GEARSHIFT LINKAGE

 

SERVICE INFORMATION 8—1
TROUBLESHOOTING 8—1
GEARSHIFT LINKAGE REMOVAL 8—2
GEARSHIFT LINKAGE INSTALLATION 8—4

 

 

 

SERVICE INFORMATION

GENERAL

0 The gearshiIt spindle and stopper arms can be serviced with the engine in the frame,
o If the shiIt forks, drum and transmission require servicing, remove the engine and separate the crankcase.

TRUUBIESHIJEITING

Hard lo shift
1. Air bubbles in the clutch hydraulic system.
2‘ Shift Iorks bent
3. ShIIt claw bent
4. Shift drum cam grooves damaged

Transmission Jumps out of gear
It Gear dogs worn
2. Shift shaft bent
3 shift drum stopper broken
4. Shift Iorks bent

 

Date 0! Issue: Dec, 1982 117
© HONDA MOTOR C0,, LTD,

 

HONDA.
V65MAGNA

 

GEARSHIFT LINKAGE

GEARSHIFT LINKAGE REMOVAL

Drain the engine oil.
Remove the leh crankcase rear cover.

Remove the lelt footpeg and gearshift pedal.
Remove the clutch cover and clutch assembly
(section 7).

Remove rhe oil pump driven sprod<et bolt,
Remove rhe oil pump drive chain, drive and driven
sprockets.

Remove the oil pump drive sprocke‘ washer,

     

. V ax . ,
OIL PUMP DRIVEN SPROCKET BOLT

 

8 2 MB Date of Issue: Dec, 1982
' © HONDA MOTOR 00,, LTD.

HONDA
V65MAGNA

 

GEARSHIFT LINKAGE

 

Remove ‘he drum stopper arm nut, arm and springs

Pull the gearshift spindle assembly out of ‘he crank~
cases

Remove ‘he neu‘ral stopper arm bolt, arm and
springs

    

 

DRUM STOPPER ARM
"A 273"): y » \

GEARSHIFT SPINDLE

NEUTRAL STOPPER ARM

 

 

Date of Issue: Dec, 1982
©HONDA MOTOR (20., LTD.

119

HONDA
V65MAGNA

GEARSHIFT LINKAGE

 

Remove the shift drum cam plate bolt and cam

SHIFT DRUM CAM PLATE
plate.

     

GEARSHIFT LINKAGE INSTALLATION

Install the dowel pin in the hole of the shift drumv
Insert the five pins in the holes of the cam plate.
Align the cam plate hole with (he dowel pin on the
shift drum and install the cam plate.

Tighten the bolt securely.

Install the washer, neutral stopper arm, spring and
arm bolt.

Tighten the arm bolt securely.

 

SPRING ARM BOLT

120 Date of Issue: Dec,1982
8 - 4 © HONDA MOTOR 00., LID.

HONDA
V65MAGNA

 

Assemble the gearshift spindle and return spring and
install as shown.

Install the washer, drum stopper arm, collar, spring,
washer and nut over the arm bolt.

Tighten the nut securely,

Rotate the gearshift spindle and check the linkage
for smooth operation.

install the oil pump drive sprocket washer on the
shalt.

Install the oil pump drive and driven sprockets
with drive chain and tighten the driven sprocket
bolt securely.

NOTE:

The driven sprocket has an "IN” mark that
must face the crankcase.

 

 

 

 

Install the clutch assembly and cover (section 7L

GEARSHI FT LINKAGE

 

Date ol Issue: Dec, 1982
© HONDA MOTOR CO., LTD

 

GEARSHIFT LINKAGE

Align the punch marks on the gearshift pedal and
gearshift spindle and install the gearshift pedal
assembly and left footpeg.

Install the left crankcase rear cover and fill the
crankcase with oil (page 7‘3)-

GEARSH T PEDAL
, ‘

 

 

HON DA
V65MAGNA

PUNCH MARKS
;

 

8-6

172

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HQNDA
V65MAGNA

 

 

MEMO

 

Date of Issue: Dec, 1982
© HONDA MOTOR 60., LTD.

HON DA
ALTERNATOR V65MAGNA

 

    

807100 N-m
(8,0—10‘0 kg-m, 58—72 ft-lb)

 

9 o 124 Date of Issue: Dec, 1982
- © HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

9. ALTERNATOR

 

 

SERVICE INFORMATION
FLYWHEEL REMOVAL
STATOR REMOVAL
STATOR INSTALLATION
FLYWHEEL INSTALLATION

 

 

 

SERVIBE INFIJRMATIIIN
GENERAL

U This section covers removal and installation of the alternator,
0 Refer to section 18 for inspecting and troubleshooting.

TORQUE VALUE

Alternator rotor/Flywheel bolt 80—100 N~m (8.0—100 kg-m, 58—72 It-Ib)

TOOLS

Common

Universal holder 07725—0030000
Rotor puller 07733—0020001 or 07933—3290001 (USA. only)

 

Date of Issue: Dec, 1982 125
© HONDA MOTOR (20., LTD.

9-1

HONDA
V65MAGNA

 

ALTERNATOR

FLYWHEEL REMOVAL

Place a cantainer under the alternator cover to each
engine oil.

ALTERNATOR COVER

    

Remove the alternator covert

UNVERSAL HOLDER
07725—003000!)
Hold the flywheel with a universal holder and re-
move the flywheel bolt.

 

ROTOR PULLER

079333—3290001 (U.
Remove the flywheel with the rotor puller.
Remove the woodrufl key from the crankshaft.

_ V .
UNIVERSAL HOLDER
0772570030000

 

126 Date of Issue: Dec, 1982
9 ' 2 © HONDA MOTOR 00., LTD.

HONDA.
V65MAGNA

 

ALTERNATOR

 

STATDR REMUVAL

Remove the seat and frame left side cover.
Disconnect the alternator coupler and remove the
wire bands.

Remove the lelt crankcase rear cover.

Remove the stator by removing the bolts and wire
clamp.

STATDR INSTALLATIIJN

Install the stator and wire clamp.

Install the left crankcase rear cover.

Route the alternator leads according to the diagram
in Section 1 and connect the alternator wire coupler
to the wire harness.

Secure the alternator leads with the wire bands.
Install the seat and lrame left side covert

ALTERNATOR COUPLER

 

ALTERNATOR COUPLER

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO” LTD

127

ALTERNATOR

 

HONDA
V65MAGNA

 

FLYWHEEL INSTALLATION

Install the woodruff key into the crankshaft.

Install the flywheel by aligning its keyway with the
key in the crankshaft.

Hold the flywheel with a universal holder and
torque the flywheel bolt,

TORQUE: 80—100 NAm
(BB—10.0 kg-m, 58—72 ft-lb)

Install the alternator cover.
Check engine oil level and add oil if necessary (page
23).

UNIVERSAL HOLDER

07725—0030000
4 ‘_

 

 

128

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD,

, 3 HONDA
6% V65MAGNA

 

MEMO

 

Date 01 Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

129

CYLINDER HEAD/VALVE V65MAGNA

 

 

8—1 2 Nvm
(0.8—1.2 kg~m, 6—9 Mb)

     
   
   
  
 

10—14 Nrm
(1.0—1.4 kg~m, 7—10ft-Ib)

(2.1~2.5 kg-m,15—1Bfl-lb)

48~52 N-m
(4.8—5.2 kg-m, 35~38 (Mb)

 

20~25 N~m
(IO—2,5 kg-m, 7~10 be)

18~20 N-m
(1.8720 kg-m,13—14lt-Ib)

48—52 Nrm
(4.8—5‘2 kg-m, 35—38 ft-lb)

 

130 Dale of Issue: Dec, 1982
0 © HONDA MOTOR 00., LTD,

10

firm?“ 10. CYLINDER 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 CYLINDER HEAD INSTALLATION 10—16
CYLINDER HEAD DISASSEMBLY 10—9 CAMSHAFT INSTALLATION 10—19

 

 

SERVICE INFIJRMATIUN

GENERAL

0 The Cylinder head can be removed with the engine in the frame.
0 If the cam sprockets of eilher front or rear cylinder are removed, (he valve timing of bolh cylinders must be checked during

reinstallation.
0 Camshaft lubricaling oil is fed through an oil line. Be sure the hole in the oil line is not Clogged.

o During assembly, apply molybdenum disulfide to lhe camshaft holder survaces to provide initial lubrication.
o The cylinder numbering is given below: m

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F RONT <9 G
‘—
SPECIFICATIONS LEFT
STANDARD SERVICE LIMIT
Compression pressure 13 x 2 kg/Cm2 (134 t 28 psi) —
Camshaft Cam helghl IN 35335735495 mm (13911—13974 in) 35.3 mm (1.39 in)
Ex 35335735495 mrn (13911—13974 in) 35.3 mm (1.39 in)
Hunout — 0.10 mm (0.004 in)
End clearance 005-025 mm (0002—0010 in) 0.30 mm (0,012 in)
Oil clearance Center 0030—0091 mm (0.0012—0.0036 in) 0.095 mm (0.0037 inl
Both ends 0030—0091 mm (00012—00036 in) 0.095 mm (0.0037 in)
Rocker arm Rocker arm I.D, 12000—12013 mm (04724—04731 inl 12.05 mm (0.474 in)
Shaft O.D. 11366—11034 mrn (0471144718 in) 11.93 mm (0.470 in)
Valve Valve srem CD. IN 5475—5490 mm (02156—02161 in) 5.47 mm (0.215 in)
Ex 5455—5470 mm (02148702154 in) 5.45 mm (0.214 in)
Valve guide I.D. 5500—5515 mm (02165—02171 in) 5.55 mm (0.219 in)
Stem~torguide clearance IN 0.010—0.040 mm (00004—00016 in) 0.03 mm (0.003 in)
EX 0030—0060 mm (00012—00024 in) 0.10 mm (0.004 in)
Valve stem runout 7 0.05 mm (0.002 in)
Valve Ienglh IN 07.05 mm (3.437 in) 86.55 mm (3,407 in)
EX 86.35 mm (3.419 in) 86.35 mm (3.400 in)
Valve seat widlh 1.2 mm (0.047 in) 1.5 mm (0.06 in)
Date of Issue: Dec, 1982 131 1 0_ 1

HONDA MOTOR 00., LTD.

HONDA

 

 

 

 

 

 

 

 

CYLINDER HEAD/VALVE V65MAGNA
Valve spring Free length Inner 40.85 mm (1.608 in) 39.45 mm (1.553 in)
Outer 44.5 mm (1.752 in) 43.1 mm (1.70 in)
Preload/Iength Inner 6.67—7.03 its/34.2 mm (14.70—17.26 6.37 kg/34.2 mm
lie/1.35mi (14.04 Ib/1.35 in)
Outer 13~7—16.1 k9/37.7 mm (30.20—35.49 3.0 kg/37‘7 mm
Ila/1.48 in) (6,6 Ila/1.48 in)
Cylinder head Warpage — 0.05 mm (0.002 in)

 

 

 

 

 

 

TORQUE VALUES

Cvlinder head cover
Camshaft holder (6 mm)
Cam chaln guide A
Cvlinder head (10 mm)
Cylinder head (8 mm)
Rocker arm shaft

Cam sprocket

TOO LS

Special

Valve guide reamer, 5.5 mm
Valve guide driver

Valve guide driver attachment

Common
Valve spring compressor

TRUUBLESHUEITINE

8712 Nm (0.8—1.2 kg»m, 679 ft~|b)

10714 N-m (1,071.4 kg-m, 7—10ft-lb)

20725 N‘m (2.0—2.5 kg-m,14—1Bft-lb)

48752 N~m (4.8—5.2 kg-m, 35—38 ft-lbl

21—25 N-m (2.1—2.5 kg-m,15—1Eft-Ib)

45—50 N-m (4.5—5.0 kg-m, 33—36ft-lbl Apply LOCTITE® to the threads
18—20 Ntm (1.8—2.0 kg-m, 13—14ft~|b)

0798472000000
0794273290100
079437M B40000

07757—0010000

Engine top~end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing

noises with a sounding rod or stethoscope.

Low compression
1. Valves
— Incorrect valve adjustment
7 Burned or bent valves
7 Incorrect valve timing
— Broken valve spring

2. Cylinder head
— Leaking or damaged head gasket
7 Warped or cracked cylinder head

3. Cylinder and piston (Refer to Section12J

Compression too high
1. Excessive carbon build-up on piston or
combustion chamber

Excessive noise

. Incorrectvalve adjustment

. Sticking valve or broken valve spring

. Damaged or worn camshaft

. Loose or worn cam chain

. Worn or damaged cam chain tensioner
. Worn cam sprocket teeth

. Worn rocker arm and/or shaft

“amoun—

 

10-2

Date of Issue: Dec, 1982

‘32 © HONDA MOTOR 00., LTD.

HONDA
V65MAGNA CYLINDER HEAD/VALVE

 

CAMSHAFT REMIJVAL QlLDRAIN BOLT ‘ ‘ FRONTCYFINDER

Drain the coolant (page 6-3) and engine oil from
the front cylinder head by removing the bolts and
washers.

Remove the radiator (page 645).

Remove the cylinder head cover lrom the front
cylinder head.

Remove the cylinder head cover and cover base
lrorn the rear cylinder head.

   

FRONT CYLINDER REAR HEAD COVER
CYLINDER BASE
CAM CHAIN GUIDE
Remove the oil pipe and cam chain guide mounting '
bolts and remove the cam chain guide.
Remove the alternator cover and rotate the crank-
shalt clockwise until the cam chain has free play.

Remove the oil pipe while pulling up on the middle
of the chain

Remove the exhaust pipes (section 5).

Remove the carburetor (section 4),

Remove the engine mounting bolt on rear cylinder
head.

OlL PIPE

 

Date oi Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

 

CYLINDER HEAD/VALVE

Turn the crankshaft clockwise until the T1.3 mark
aligns with the rear crankcase mating surfaces

Place rags or shop towels over the rear cylinder head
to prevent parts lrom being dropped into the crank
case.

Remove the intake and exhaust cam sprocket bolts.

Turn the crankshaft clockwise one turn (360°) and
remove the other cam sprocket bolts,

Slide the cam sprockets with the cam chain 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 be reinstalled in their
original locationst

 

INTAKE CAM SPROCKET

HONDA
V65MAGNA

 

‘ :“m
1}: ’e
MATING SURFACE

EXHAUST CAM SPROCKET

 

CAMSHAFT HOLDERS CAM CHAIN

 

CAMSHAFT HOLDERS

 

10-4

134

Date of Issue: Dec, 1982
© HONDA MOTOR C0., LTD.

HONDA
V65MAGNA

 

CYLINDER HEAD/VALVE

 

INTAKE CAMSHAFT DOWEL PINS
Remove the camshaft holder dowel pins and the

intake and exhaust camshafts.

Remove the cam sprockets from the camshafts.

EXHAUST CAMSHAFT

CAMSHAFT HOLDER
CAMSHAFT/CAM HOLDER We» _
|NSPECT|ON

Inspect the camshaft and holder journal sUrfaces
for scoring scratches, or evidence of insufficient
lubrication.

 

CAMSHAFT RUNOUT

Check camshaft runout with a dial indicatora
Support both ends of the camshaft with Vblocks.

SERVICE LIMIT: 0‘10 mm (0.004 in)

 

 

Date of Issue: Dec, 1982 135
© HONDA MOTOR CO., LTD. 1 0 ' 5

CYLINDER HEAD/VALVE

CAM INSPECTION

Uslng a micrometer, measure each cam lobe.
SERVICE LIMITS: IN, EX: 35.3 mm (1.39 in)

Check for wear or damage.

Wlne any oil from the journals
Lay a strip of plastigauge lengthwise on top of each
camshaft journal.

PLASTI GAUGE

Install the camshaft holders and tighten in a
crisscross pattern.

NOTE:

Do not rotate the camshaft when using
plastigauge,

 

 

 

 

TORQUE:
A: 6mm BOLT: 10—14 N~m
(1.0—1.4 kg-m, 7—10ft-lbl
B: 8 mm BOLT: 21 —25 N-m
(2.1—2‘5 kg-m, 15—18 ft-lb)
c: 10 mm BOLT: 48—52 N~m
(4.8—5.2 kg-m, 35—38 fI-lbl

 

‘% V65MAGNA

 

10-6 135

Date of Issue: Dec, 1982
© HONDA MOTOR Cot, LTD,

HONDA
V65MAGNA

 

Remove the camshaft holders and measure the
width of each plastigauge. The widest thickness
determines the oil clearance.

SERVICE LIMIT:

CENTER: 0.095 mm (0.0037 in)
BOTH ENDS: 0.095 mm (0.0037 in)

When the service limits are exceeded, replace
the camshaft and recheck the oil clearance

Replace the cylinder head and camshaft holders
if the clearance still exceeds service limits.

CYLINDER HEAD REMflVAL

Loosen the water hose clamp.
Remove the water pipes and hose.
Remove the water pipe O»rings.

Remove the oil pipe and sealing washers,

Remove the from and rear cam chain tensioner
base mounting bolts.

Pull the cam chain tensioner base up.

CYLINDER HEAD/VALVE

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

137

CYLINDER HEAD/VALVE

HONDA
V65MAGNA

 

 

Remove the slipper clip, washer and pin and remove
the tensioner slipper base‘

Remove the cylinder head bolts

Remove the cylinder heads using a screw driver
at the my points.

    

PRY POINT

Remove the front and rear cylinder head gaskets
and dowel pinsl

TENSIONER SLIPPEH

WASHER

GASKET

 

TENSIONEH BASE

 

 

\
DOWEL PINS

 

10-8

133

Date of Issue: Dec, 1982
© HONDA MOTOR (20., LTD.

HONDA
V65MAGNA

 

Remove the rear cylinder cam chain guide bolts
and guide.

NOTE:

 

When removing the front cylinder cam chain
guide, the crankcase must be separated,

 

 

 

CAM CHAIN GUIDE AND CAM
CHAIN TENSIONER INSPECTION

Inspect the cam chain guide and tensioner for
damage or excessive wear.

Inspect the cam chain tensioner slipper (or damage
or excessive wear.

Inspect the spring for good tension, replace it
necessary.

CYLINDER HEAD DISASSEMBLY

Remove the rocker arm shaft and rocker arms.

Remove the rocker arm spring and Owing from
the shaft bolt.

Data of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

 

CYLINDER HEAD/VALVE

FRONT REAR
CAM CHAIN GU DE CAM CHAIN GU DE

 

TENSIONER GUIDE TENSIONER SLIPRER

 

TENSIONER SPRING

ROCKER ARM
ROCKER ARM SHAFT BOLT

ROCKER ARM SPRING O-RING
SHAFT EOLT

10-9

CYLINDER HEAD/VALVE

Remove the valve spring cotters, retainers, springs
and valves.

CAUTION:

To prevenl 10:: of tension, d0 not tom-
press the valve springs mare Ihan neces»
sary to remove the callers.

' Positian the hrge retainer on the cum-
prexsor attachment, so the compressor will
not touth the cylinder head.

 

 

NOTE:

Mark all disassembled parts to ensure correct
reassembly.

 

 

 

Remove the valve stem seals,

Remove carbon deposits from the combustion
chamber and clean 0" the head gasket surfaces.

NOTE:

- Avoid damaging the gasket surfaces.
~ Gaskets will come off easier if soaked in

solvent.

 

CYLINDER HEAD INSPECTION

Check the spark plug hole and valve areas for
cracks

Check the cylinder head for warpage with a
straight edge and feeler gauge,

SERVICE LIMIT: 0.05 mm (0.002inl

  

Q “‘3 .
VALVE SPRING COMPRESSOR

07757~0010000

 

HONDA
V65MAGNA

 

 

 

 

10—10

140

Date of Issue: Dec, 1982
© HONDA MOTOR (10., LTD.

HONDA
V65MAGNA

 

ROCKER ARM INSPECTION

Inspect the rocker arms for wear or damage to
the camshaft contact surface or for a clogged oil
hole.

Measure the ID, of each rocker arm.
SERVICE LIMIT: 12.05 mm (0.474 in)

ROCKER ARM SHAFT AND SPRING
INSPECTION

Measure each rocker arm shaft O.D.
SERVICE LIMIT: 11.93 mm (0.470 in)

Inspect the shaft for wear or damage and calculate
the shaft to rocker arm clearance.

SERVICE LIMIT: 0.12 mm (0.005 in)

Inspect the rocker arm shaft spring for wear or
damage.

Measure the free length of the inner and outer valve
springs.
SERVICE LIMIT:
INNER (IN, EXI: 39.45 mm (1.553 in)
OUTER (IN, EX): 113.1 mm (1.70 inI

CYLINDER HEAD/VALVE

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR C0., LTD.

141

10-11

CYLINDER HEAD/VALVE

VALVE STEM-TO-GUIDE
CLEARANCE

Inspect each' valve for bending, burning, scratches
or abnormal stem wear.

Check valve movement in the guide and measure
and record each valve stem O.Dt

SERVICE LIMITS: IN: 5.47 mm (0.215 in)
EX: 5.45 mm (0214 in)

NOTE:

Ream the guides to remove any carbon b ’
up before check 9 clearances

Measure and record each valve guide |.D. using a
ball gauge or inside micrometer.

SERVICE LIMIT: 5.55 mm (0,219in)

Subtract each valve stem CD. from the corres-
ponding guide ID. to obtain the stem to guide
clearance.

SERVICE LIMIT: IN: 0.08 mm (0.003 In)
EX: 0,10 mm (0.004 In)

NOTE:

If the stem-to-guide clearance exceeds the
service limits, determine if a new guide with
standard dimensions would bring the clear-
ance within tolerancel If so, replace any
guides as necessary and ream to fit.

 

 

It the stem-to-guide clearance exceeds the service
limits with new guides, replace the valves also.

NOTE:

Reface the valve seats whenever the valve
guides are replaced (page 10-13).

 

 

 

 

HONDA
V65MAGNA

 

 

VALVE GUIDE REAMER

 

 

 

10-12

‘42 Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA.
V65MAGNA CYLINDER HEAD/VALVE

 

 

VALVE GUIDE DRIVER
07942—3290100

VALVE EIJIDE REPLACEMENT

Heat the cylinder head to 100°C (212°F) with a
hot plate or oven.

  
  

CAUTION:

. Do not use a torch to hear the cylinder;
it may cause warping,
To avoid bums, wear heavy gloves when
handling the heated cylinder head.

 

 

 

 

Support the cylinder head and drive out the old
guides from the combustion chamber side of the
cylinder head.

VALVE GUIDE DRIVER
D7942~3290100

 

Drive new guides in from the rocker arm side of
the cylinder head.

NOTE:

Cylinder head heat should still be at loo°c
(212°F) tor installation or the new guides,

 

 

 

 

   

V\ l ‘ ,‘ .

VALVE GUIDE DRIVER ATTACHMENT

07943—MB40000 VALVE GUIDE REAMER
07984—2000000

Let the cylinder head cool to room temperature

and ream the new Valve guides.

NOTE:

Use cutting oil on the reamer during this
operation.

Rotate the reamer in the same direction
when inserting and removing it.

  
  
 

 

 

Reface the valve seat (page 10-14) and clean the
cylinder head thoroughly to remove any metal
particles,

 

Date of Issue: Dec, 1932 .
©HONDA MOTOR co., LTD. 43 1 0-1 3

CYLINDER HEAD/VALVE

VALVE SEAT INSPECTIDN/
REFACINII

Clean all intake and exhaust valves thoroughly to
remove carbon deposits,

Apply a light coating of valve lapping compound
to each valve face. Lap each valve and seat using
a rubber hose or other hand-lapping tool.

NOTE:

Take care not to allow the compound to enter
between the valve stem and guide, Alter |ap<
ping, wash out the compound completely
and apply a coat ol engine oil to the valve
face and seat

 
   
 

 

 

  

Remove the valve and inspect the lace.

CAUTION:

The valve: mrmor be ground. If the valve
face is rough, worn unevenly, 0r con/acts [he
seal improperly, the value must be replaced.

 

 

 

 

Inspect the valve seat.

If the seat is toowide, too narrow, or has low spots,
the seat must be ground,

NOTE:

Follow the refaoev manufacturer's operating
instructions.

 

 

 

 

After cutting the seat, apply lapping compound
to the valve face, and lap the valve using light
pressure,

After lapping, wash any residual compound 0" the
cylinder head and valve. ’

 

IN: CUTTER (30 mm?) |N,EX: CUTTER (30mm43l

EX: CUTTER (25 mm¢l

   

OLD SEAT WIDTH

OLD SEATWIDTH

50°

9 HONDA
«é V65MAGNA

 

   
  
 

SEAT WIDTH:
0.99—1 .27 mm
(0039—0050 in)

SERVICE LIMIT:
1.5 mm (0.06 in)

IN: CUTTER (29 mmqfil
EX: CUTTER l24.5 mmqfi)

    

039—1 .27 mm
(003970050 in)

 

10-14

144

Date ol Issue: Dec, 1982
© HON DA MOTOR CO., LTD.

HONDA.
V65MAGNA

 

CYLINDER HEAD/VALVE

CYLINDER HEAD ASSEMBLY yALyE STEM SEAL RETAINER

NOTE:

Install new valve stem seals when assembl
Use valve guide driver 0774 010100.

 

   

 

 

 

Lubricate each valve stem with molybdenum
disulfide grease and insert the valve into the valve
guide. To avoid damage to the stem seal, turn the
valve slowly when inserting.

1s

Install the valve springs and retainers, The springs
tightly wound coils should face toward the head.

VALVE COTTE RS

Install the valve cutters.

CAUTION:

' To prevent loss of tension, do not com-
press the Valve spring more than necessary
to install the valve keepers.

Position the large retainer on the compres»
sor attachment, so the compressor will not
touch the cylinder head.

 

 

 

 

Tap the valve stems gently with a soft hammer to
firmly seat the cutters.

NOTE:

Support the cylinder head above the work
bench surtaee to prevent possible valve
damage.

 

 

 

 

 

 

Date of Issue: Dec, 1982 145
©HONDA MOTOR CO., LTD. 1 0'1 5

CYLINDER HEAD/VALVE

Install the O-ring and spring onto the rocker arm
shaft.

Apply LOCKTITE® to the rocker arm bolt threadst
Apply engine oil to the rocker arm shaft and install

the rocker arm.
Install and tighten the rocker arm shaft bolt,

TORQUE: 45—50 N-m
(4.5—5.0 kq-m, 33—36 ft-lbI

CYLINDER HEAD INSTALLATION

Clean the cylinder head surface of any gasket
material

Install the dowel pins and new head gasketst

Install the rear cylinder earn chain guidet

 

ROCKER ARM
53 ' ‘“

HONDA
V65MAGNA

ROCKER ARM
SHAFT BOLT

 

  
  

 

SPRING O-RING

 

 

DOWE LPINS

 

10-16

146

Date of Issue: Dec, 1932
© HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

CYLINDER HEAD/VALVE

 

Install the cylinder head and temporarily install the
cylinder head bolts.

 

 

With the cam chain tensioner raised in the direction
of the arrow, insert a pin or piece of wire through
the hole in the tensioner base and tensioner.

Pass the cam chain through the cam chain tensioner
and install the tensioner slipper as shown

NOTE:

Check that the lower end of the slippEr fits
in the slipper base correctly.

 

 

 

 

 

CYLINDER HEAD BOLTS

’ '\

  
  

TENSIONER BASE HOLE

 

TENSlONER

TENSIONER BASE

TENSIONER SLIPPER CLIP

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

”7 10-17

HONDA
V65MAGNA

 

CYLINDER HEAD/VALVE

 

Install the exterior oil pipe with washers onto the
cylinder and cvlinder head.

 

OIL PIPE

WATER HOSE
Install the water pipes and hose and tighten the hose

bands securely.

 

' OIL PIPE

 

143 Date of Issue: Dec, 1982
1 0'1 8 ©HONDA MOTOR COt, LTD.

HONDA
V65MAGNA

 

CYLINDER HEAD/VALVE

 

CAMSHAFT INSTALLATION

NOTE:

Follow this procedure from beginning to
end, even if you are only servicing one
cylinder head,

. Check the camshaft marks so that you
install each camshaft in its correct location.
The marks on the camshaft mean:

EX RR (ER): Rear cylinder exhaust
IN RR (IR): Rear cylinder intake
EX FR (EF): Front cylinder exhaust
IN FR (IF): Front cylinder intake

' The camshaft sprockets are interchange-

able.

 

 

 

 

Rear Cylinder Head

Lubricate the cylinder head cam bearing surfaces
with molybdenum disuIIide grease.

Turn die crankshaft clockwise until the T1-3 mark
on the flywheel rotor aligns with the rear crankcase
mating surfaces.

CAUTION:

  
  

 
  

When turning the crankshaft, make sure the
cam chain: don’t [am at the cam chain ten-
:r‘onerx or at the crankshaft.

 

 

MAR KS

 

T1-3 MARK
0

‘9”; e

REAR CRANKCASE MATING SURFACE

 

Date of Issue: Dec] 1982
© HONDA MOTOR 00., LTD.

149

10-19

CYLINDER HEAD/VALVE

Install the intake and exhaust camshaft and spro-
ckets through the rear cylinder cam chain as shown.
Turn the camshafts so the camshalt marks face up.

NOTE:

 

If the lront cylinder Camshafts were not re-
moved, check that the front camshaft marks
face up. If not, turn the crankshaftclockwise
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.

CAUTION:

 

If you force a valve open while installing the
camshaft holders, you may damage the
holder: or the camshaft bearing surfaces.

 

 

 

Place the camshaft 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.

HONDA
V65MAGNA

 

INTAKE CAMSHAFT

EXHAUST CAMSHAFT»

CAMSHAFT H0 LDERS

 

 

10-20

150

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

   

«e

CYLINDER HEAD/VALVE

 

If the cylinders were not removed, lock the cam
chain tensioner for minimum tension: push the lock
plate down while pulling or prving the tension arm
up; hold the am up while you insert a pin or wire
through the lock holes,

Check that the camshaft marks are still facing up.
then align the sprocket index lines with the top oi
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 hoIES.
Check that the sprocket index lines align at T1-3.
Unlock the cam chain tensioner.

 

 

 

LOCK PLATE

 

 

CAMSHAFT MARKS

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR (20., LTD.

151

10-21

CYLINDER HEAD/VALVE

Front Cylinder Head

NOTE‘
Install the rear cylinder head camshafts before
you install the front camshafts.

Lubricate the cylinder head cam bearing surfaces
with molybdenum disulfide grease.

 

Rotate the crankshaft counterclockwise 90 degrees
(1/4 turn), until the T24 mark aligns with the rear
crankcase amting surfaces,

CAUTION:

 

,
When turning the crankshaft, make sure the
cam chain doesn‘t [am at the cam chain
lensioner or at [he crankshaft,

Install the intake and exhaust camshafts and spro-
ckets through the front cylinder cam chain as
shown.

Turn the camshafts so the camshaft marks face up.

Rotate each front camshaft counterclockwise 45
degrees (1/8 turn) to seat the cam fully in the
cylinder head.

If a valve adjuster keeps the camshaft from seating
fully in the cylinder head, back out the adiuster all
the way,

Install the front cylinder camshaft holders and
bolts, as described for the rear cylinder head.

Do not tighten at this time.

Lock the cam chain tensioner for minimum tension,

HONDA.
V65MAGNA

 

 

 

REAR CRANKCASE MATING SURFACE

MARKS

_ INTAKE CAMSHAFT ,

’ ' l t
EXHAUST CAMSHAFT

 

 

10-22

152

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA.
V65MAGNA

 

Align the index dots on the front cylinder cam
sprockets with the top of the cylinder head (viewed
from the left side of the engine).

Place the cam chain on the sprockets

Slide the sprockets onto the camshaft flanges, and
install the sprocket bolts in the exposed holes
(rotate the crankshaft clockwise a little if neoes~
sary).

Check that the sprocket index dots align at T2-4.

Unlock the cam chain tensioner‘

Front/Rear Cylinders

Check the front-to-rear cylinder camshaft timing
as follows,

NOTE:

When the T18 mark aligns with the rear
crankcase mating surface, the index lines
on all cam sprockets should align with the
top of the cylinder heads.

All camshaft marks will either face up or
down,

 

 

 

 

Turn the crankshaft as required to install the
remaining sprocket bolts at all four Camshafts

Tighten the camshaft sprocket bolts to the specified
torque,

TORQUE: 18—20 Nam l1.8—2.0 kg-m,13—14ft~lbi

Tighten the tensioner base bolts securely.

  

CYLINDER HEAD/VALVE

INDEX DOTS

 

 

 

iENSIONER BASE

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

10-23

HONDA
V65MAGNA

 

CYLINDER HEAD/VALVE

CAM CHAIN GUIDE
Turn the crankshaft until there is maximum cam :. _ 1
chain free play. then install the oil pipes under the
cam chain.

    

 

install the cam chain wide on the oil pipe base
plate.

Tighten the cylinder head 10 mm bolts in a criss-
cross pattern in 2—3 steps.

TORQUE: 48—52 New" (4.8—5.2 kg-m, 35—33 ft-lb)

Tighten the cylinder head 8 mm bolts in a crisscross
pattern in 2—3 steps.

TORQUE: 21—25 N'm (2.1—2.5 kg-m, 15—18 ft-Ibl

Tighten the cam shaft holder 6 mm bolts. I.
TORQUE:10—14 N-ml1t0—1t4 kg-m, 7—10 fl-Ih) OIL PIPE

 

Lubricate the cam lobes with oil.

 

ARROW CASTING
Adjust the valve clearance (page 3-9).

Inspect the cylinder head cover gasket for damage
or deterioration.

NOTE:
Clean the gasket before applying sealant.

Apply sealant of the head cover gasket,

Install the front cylinder head cover and gasket.
Install the rear cylinder head cover base, cover and
gaskets, Be sure that the arrow casting on the rear
head cover faces the front of the engine.

 

 

 

 

install the remaining parts ‘In the reverse order of
removal.

 

HEAD COVER BASE FlEAFl HEADCOVER

 

154 Date of Issue: Dec, 1982
1 0- 24 ©HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

 

MEMO

 

Date of Issue: Dec, 1982 155
© HONDA MOTOR CO., LTD.

HONDA
CRANKCASE % V65MAGNA

 

B mm
21#25 N-m
(2,1—25 kg-m,15—1Bfl-lb)

6 mm
10—14 N~m

 
 

10—14 N‘m
(1,071.4 kg-m, 7#10 be)

10 mm
43—47 N-m
(4.3—4.7 kg-m, 31—34 fl-Ib)

 

1 1 _ o 156 Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

amen? l l. CRANKCASE

 

 

 

SERVICE INFORMATION 11—1
CRANKCASE DISASSEMBLY 11—2
CRANKCASE ASSEMBLY 11—3 ‘

 

 

SERVICE lNFflRMATIflN

GENERAL

0 To service the piston, crankshaft, connecting rod and transmission, the crankcase halves must be separated.
0 It a new crankcase is installed perform countershaft shim selection procedures (Page 1347),
l The following parts must be removed before disassembling the crankcase.

 

Oil pan Refer to section 2

Oil pump Refer to section 2

Water Dumv Refer to section 6 l
~ Clutch/starter clutch Refer to section 7 I
' Gear shift linkage Refer to section 8
~ Alternator Refer to section 9
. Cylinder heads Refer to section 10
- Starter motor Refer to section 21

TORQUE VALUES

 

10 mm bolt: 43747 N-m (4.3—4.7 kg-m, 31—34 ft~|b) l-

8mm bolt: 21—25N-m (2‘1#2.5 kg-m, 15718ft~|bl ‘

6 mm bolt: 10—14 N~m(1.0—1,4 kg-m, 7710 ft-lb) l
l

TOO LS

Special I

Driver 07949—371000!)

Attachment 07946—371020!)

Date of Issue: Dec, 1982 157 1 1 1

© HONDA MOTOR C0,, LTD.

(IRAN KCASE

33 HONDA.
“é V65MAGNA

 

BRANKBASE DISASSEMBLY

Remove the upper crankcase bolts. Refer to service
Information General (page 114) for removal of
necessary parts before disassembling crankcase.

Remove the mainshaft bearing holder by removing
the screw and bolts.

Remove the output gear case mounting bolts and
output gearcaset

Measure the thickness of the output gear ease
gasket and note it,

NOTE:

Whenever removing the output gear case,
perform output gear case gasket selection,
if not measured right away

Index the bearing holder to the case for

ease of reinstallation.

  
  

 

 

Remove the gearshift indicator switch.

 

SIDE G AR CASE

 

11-2

153

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD

HONDA
V65MAGNA CRANKCASE

 

 

Turn the engine over and remove the lower crank~
case bolts.

NOTE:

Remove the bolts in two or more steps and
in a crisscross pattern to prevent damage to
‘ the crankcase.

 

 

 

 

Separate the crankcase.

Remove the following parts:

0 Piston and connecting rods (Section 12),
Crankshaft (Section 12).

Shilt fork and shilt drum (Section 13).
Transmission (Section 13).

 

 

Drive the countershaft bearing out 0! the case.

 

 

COUNTERSHAFT BEARING

 

BRANKBASE ASSEMBLY

Drive the countershalt bearing into the crankcase.

ATTACHM ENT
07946—3710200

  
     

DR IV ER
07949—3710000

 

 

 

 

Date of Issue: Dec, 1982 159 1 1 3
© HONDA MOTOR 00., LTD. -

CRANKCASE

Install the following parts:

Shift fork and shift drum (Section 13).
0 Transmission (Section 13),

c Crankshaft (Section 12).

o Piston and connecting rods (Section 12).

Apply molybdenum disulfide grease to the shift
Fork grooves of the M2, CB and C6 gears.

C6 GEAR

   

HONDA
V65MAGNA

 

05 GEAR»

 

11-4

150

Date of Issue: Dec,1982
© HONDA MOTOR COt, LTD.

HONDA
V65MAGNA

 

CRANKCASE

 

Clean the crankcase mating surfaces.
Apply liquid sealant to the mating surface of the
lower and upper crankcase

CAUTION:

Do not apply sealant to the area near the _,
main bearings. A

 

 

DO NOT COAT THIS

 

 

 

 

Install the dowel pin.

Assemble the crankcase halves, aligning the shift
fork claws with the gears.

Tighten the bolts to the specified torque values in
the sequence shown.

TORQUE VALVES:
10 mm huh: 43-47 Nrm
(4.3—4.7 kn-m, 31 —34 ft-lh)
8 mm bolt: 21—25 Nvm
(2.1—2.5 kg-m, 15—1Bft-lh)
6 mm bolt: 10—14 N-m
(LO—1.4 kg-m, 7—10ft-Ih)

Tighten the belts in a crisscross pattern and in 2—3
steps

 
       

   

 

  

t it
I. ’1 N
r ,
'x/ r/ . If
mnmw»

  

 

 

 

Date of Issue: Dec, 1982 161
© HONDA MOTOR 00., LTD.

11-5

ORAN KCASE

HONDA
V65MAGNA

 

 

Tighten the upper crankcase bolts to the specified
torque in a crisscross pattern and in 2—3 steps.
TORQUE: 8 mm: 21—25 N-m
(2.1—25 kg-m, 15—18 ft-lb)
6 mm: 10—14 N-m
(1.0—1.4 kg-m, 7—10 ft-lbl

Install the gearshilt indicator switch‘

Install the mainshaft bearing holder and tighten the
screw and bolts,

Install a new output gear case gasket with one of
the same thickness as removed.

NOTE:

   
 
    

Early production engines had gaskets that
were not marked.

The gasket is crushed 0.05 mm when the
output gear case is installed,

 

install the output gear case with a new gasket.
Install the bolts and then tighten to the specifiecl
torque.

TORQUES:
8 mm socket bolts:
21—25 N~m (2‘1—2‘5 kg-m,14—18 ft~lb)

 

    
 

6 mm BOLT

MAINSHAFT BEARING HOLDER
«I: >

6 mm FLANGE BOLTS 8 mm SOCKET BOLTS

 

 

11-6

162

Date of Issue: Dec, 1982
HONDA MOTOR 00., LTD,

V65MAGNA

 

 

MEMO

 

Date of Issue: Dec, 1982 183
© HONDA MOTOR C0., LTD.

:; HONDA
V65MAGNA

 

CRAN KSHAFT/PISTON

 

 

(3.0—3‘4 kg-m, 22—25 hrlb)

{— FRONT

 

1 2 0 164 Date of Issue: Dec, 1982
' HONDA MOTOR 00., LTD‘

 

12. BRANKSHAFT/PISTUN

 

 

 

HONDA

V65MAGNA
SERVICE INFORMATION 12—1
TROUBLESHOOTING 12—2
CONNECTING ROD REMOVAL 12—3
PISTON REMOVAL 12—4
CRANKSHAFT REMOVAL 12—7

BEARING INSPECTION
BEARING SELECTION

CRAN KSHA FT INSTALLATION

PISTON AND ROD INSTALLATION 12—12

12—8
12—10 I
12—12

 

 

SERVICE .INFIJRMATIUN

GENERAL

0 All bearing inserts are select fit and are identified by color code. Select replacement bearings from the code tables. After
installing new bearings, recheck them with plastigauge to verify clearance,
0 Apply molybdenum disulfide grease to the main journals and crankpins during assembly.

0 Before removing the piston and connecting rod assemblies, clean the top of the cylinder of any carbon deposits.
' For servicing the piston, connecting rod and crankshaft, the crankcase assembly must be separated (Section 11).

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM STANDARD SERVICE LIMIT

Crankshaft Connecting rod big end side clearance 0.10—0.30 mrn (0.004—0.012 in) 0.4 mm (0.016 in)
Runout — 0.03 mm (0.001 in)
Crankpin oil clearance 0028—0052 mm (0.0011—0.0020 in) 0.07 mm (0.003 in)
Main lournal oil clearance 0028—0052 mm (0.0011—0.0020 in) 0.07 mm (0.003 in)

Cylinder I.D. 79500—79515 mm (11299—31305 in) 79.60 mm (3.133 in) I
Warpage — 0.05 mm (0.002 in)

Piston Ring-to‘groove Top 0015—0045 mm (00006—00018 in) 0.10 mm (0.004 in) I
“93'3"“ Second 0015—0045 mm (00006—00018 in) 0.10 mm (0.004 in) E
Ring end gap Top 0.20—0.35 mrn (0.008—0.014inl 0.50 mm (0.02 in)

Second 0.20—0.35 mm (0008—0014 in) 0.50 mm (0.02 in)
Oil (Side rail) 0.20—0.70 mm (0008—0028 in) 0.9 mm (0.035 in)

Piston 0D. 79.460—79.490 rnm (3.1283—3.12951nl 79.35 mm (3.124 in)
Piston-to-cylinder clearance 0.01—0.055 mm (0004—0002 in) 0.10 mm (0.004 in)
Piston pin bore 20002—20008 mm (07875—07877 in) 20.06 mm (0.780 in)
Piston pin OD. 19994—20000 rnm (0.7872—0.7874 in) 19.90 mm (0.787 in)
Piston»to~piston pin clearance 0.002—0.014 mm (00001—00006 in) 0.04 mm (0.002 in)
Connecting rod small end |.D. 20016—20034 rnrn (07880—07807 in) 20.08 mm (0.791 in)
Piston pin~toconnecting rod clearance 0.016—0040 mrn (0.0006~ 0.0016 in) 0.060 mm (0.0024 in)

Cam chain Length at 13 kg (29 lb) tension 36135—36240 mm (14250—14269 in) 364.9 mm (14.37 in)

TO R 0U E:

Crankpin: 30—34 N~m (3.0—3.4 kg-m, 22—25 ft-Ib)

TOO L
Special

Piston Fling Compressor

Commercially available

compressor (Automotive style)

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

165

12-1

CRANKSHAFT/PISTON

 

HON DA
V65MAGNA

 

TRUUBLESHBUTINE

Excessive noise

1‘ Crankshaft
0 Worn main bearing
0 Worn rod bearing

2. Piston and Connecting Rod
0 Worn piston or cylinder
0 Worn piston pin or pin hole
I Worn rod small and

Low compression or uneven compression
1. Worn cylinder or piston ring

Excessive smoke

‘l. Worn cylinder, piston or piston rings
2. Improperly installed piston rings

3‘ Damaged piston or cylinder

Overheating

1. Excessive carbon build-up on piston head
2. Blocked or restricted flow of coolant

3. Sticking thermostat

Knocking or abnormal noise
1, Warn pistons and cvlinders

2, Excessive carbon build-up on piston head.

 

12-2

166

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

 

HONDA.
V65MAGNA

 

CRANKSHAFT/PISTON

 

CIJNNECTING ROI] REMOVAL

Separate the crankcase assembly (Section 11).

Check the connecting rod side clearance.
SERVICE LIMIT: 0.40 mm (0316 in)

Remove the connecting rod bearing caps and note
their locations.

Push the connecting rods and pistons out through
the top of the cylinder bores.

CAUTION:

0n enginex with high mileage, inspect the
cylinder: for a ridge just above the highest
point of ring travel. Any ridge may be re-
moved with an autumalive type ridge reamer
before removing the pixlan: to allow the
pixtons and ring: to pan through the cylinder.

 

 

 

 

 

 

 

 

 

CYLINDER
WEAR RIDGE

 

 

_ __A

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

“57

12-3

 

CRANKSHAFT/PISTON

Mark the rods, pistons, bearings and caps as you
remove them to indicate the correct cylinder and
position on the crankpins.

PISTON REMflVIIL

Remove the piston pin clips, Push the piston pin
out and remove the piston.

Mark the piston pins to indicate their correct
piston position.

PISTON/PISTON RING INSPECTION

Measure the piston ring-to~groove clearance.

SERVICE LIMIT: 0.10 mm (0.004 in)
(TOP/SECOND)

Remove the piston rings and mark them to-indioate
the correct cylinder and piston position.

Clean the piston orowu, removing all carbon de-
posits.

Inspect the piston for cracks or other damage and
the ring grooves for excessive wear and carbon
build~up.

 

HONDA
V65MAGNA

 

 

PISTON PIN CLIP

 

12-4

Date of Issue: Dec, 1982
©HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

Using a piston, push the ring into the cylinder
squarely and measure the and gap.

SERVICE LIMITS:

TOP: 0.5 mm (0.02 in)
SECOND: 0.5 mm (0.02 in)
OIL ISide rail): 0.9 mm (0.035 in)

Measure the piston 0.D.

NOTE:

Take measurements 10 mm (0.4 in) from the
bottom, and 90° to the piston pin hole.

 

 

 

 

SERVICE LIMIT: 79.35 mm (3.124 in)

Inspect the cylinder bores for wear or damage.
Measure the cylinder ID. at three levels in X and Y
axis.

SERVICE LIMIT: 79.60 mm (3.134 in)

Calculate the piston-to-Cylinder clearance.
SERVICE LIMIT: 0.10 mm {0,004 in)

Oversize pistons are available in the following sizes:
0.25, 0.50, 0.75 and 1.00 mm.

  

CFlAN KSHAFT/PISTON

 

 

 

 

 

MIDDLE

   

 

eorroM

 

 

 

 

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR C0., LTD.

169

12-5

CRAN KSHA FT/PISTON

 

HON DA
V65MAGNA

 

Measure each piston pin hole |,D.
SERVICE LIMIT: 20‘06 mm (0780 in)

Measure each piston pin 0,D.
SERVICE LIMIT: 19.98 mm (0.787 in)

Calculate the piston pin to piston clearance.
SERVICE LIMIT: 0.04 mm (0.002 in)

Measure the connecting rod small end ID. If the
reading exceeds the service limit, replace the rod

SERVICE LIMIT: 20.08 mm (0.791 in)

 

 

 

12-6

Date of issue: Dec, 1982
© HONDA MOTOR 00., LTDt

HONDA.
V65MAGNA

 

GRANKSHAFT REMOVAL

Remove the crankshaft.
Remove the cam chain,

CRANKSHAFT INSPECTION

Set the crankshaft on a stand or Vee blocks.

Set a dial indicator on the center main bearing
journal, Rotate the crankshaft two revolutions and
read the runout.

SERVICE LIMIT: 0.03 mm 10.001 in)

CAM CHAIN LENGTH MEASUREMENT

Place the cam chain on the camshaft sprockets
with the punch marks positioned as indicated.
Secure one camshaft sprocket and apply 13 kg
(29 lbs) of tension to the other.

Then measure the distance between the punch
marks as shown.

SERVICE LIMIT: 364.9 mm (14.37 in)

NOTE:

The punch marks should be parallel to each
other.

 

 

 

 

Replace the cam chain if it is longer than the service
limit,

CRAN KSHAFT/PISTON

CAM CHAIN

(REAR CYLINDER!“ CRANKSHAFT

CAM CHAIN ‘

(FRONT CYLINDER)

 

 

 

  

13 kg
(29ml

PUNCH MARKS

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

I71 12-7

CRANKSHAFT/PISTON

BEARING INSPECTION

CONNECTING RODS

Inspect the bearing inserts for damage or separation. V

Clean all oil from the bearing inserts and crankpins.
Put a piece of plastigauge on each crankpin avoiding
the oil hole.

CAUTION:

The bearing tabs should face toward the
exhaust ports. Remember the front and rear
cylinder exhaust pom fizce opposite direc-
lions.

 

 

 

 

Install the bearing caps and rods on the correct
crankpins, and tighten them evenly.

TORQUE: 30—34 N-m (So—3.4 kg-m, 2225 ft-lbI

NOTE:

Do not rotate the crankshaft during inspec~
tion.

 

 

 

 

Remove the caps and measure the compressed
plastigauge on each crankpln.
OIL CLEARANCE SERVICE LIMIT:

0.07 mm (0.003 in)

 

PLASTIGAUGE

HONDA
V65MAGNA

 

 

 

 

12-8

Date of Issue: Dec, 1982
© HONDA MOTOR COt, LTD.

HONDA
% V65MAGNA

 

CRAN KSHAFT/PISTON

 

MAIN BEARINGS

Inspect the bearing inserts {or damage or separation.
Clean all oil from the bearing inserts and journals.
Put a piece of plasligauge on each journal, avoiding
the oil holes,

Install the main bearings on the correct journals
on the lower crankcase and tighten them evenly
in 2—3 steps in the sequence shown.

TORQU E VA LUES:

6 mm bolt: 10-14 N-ln
(1.0—1.4 kg-m, 7—10 ft-lb)
8 mm bolt: 21—25 N-m
(2.1—2.5 ku-m,15—18 k-lb)
10 mm bolt: 4347 Nan
(4.3—4.7 kg~m, 31—34 ft-lh)

NOTE:

Do not rotate the crankshaft d
tron.

 

Remove the lower crankcase and measure the com
pressed plastigauge on each journal.
OIL CLEARANCE SERVICE LIMIT:

0.07 mm (0.003 in)

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD

173

12-9

CRAN KSHAFT/PISTON

BEARING SELECTIGN

If rod bearing clearance is bevond tolerance, select
replacement bearings as follows:

CONNECTING ROD BEARING
INSERTS

Determine and record the corresponding rod ID.
Code number.

NOTE:

The number 1 or 2 on each connecting rod is
the code for each connecting rod I.D.

 

 

 

 

Determine and record the corresponding crankpin
O.D. code number (or measure the crankpin O.D.),

NOTE:
The letters A or B on each crank Weight is the
code for each crankpin O.D.

 

 

 

 

Cross reference the crankpin and rod codes to deter
mine the replacement bearing color.

 

CRANKPIN 0,D. CODE N0.

 

 

 

 

 

 

 

 

A a
39.992— 39334»
40.000 mm 39.992 mm
'68 gr 3333ng C(Yellaw) EIGreenI
ggdg
Z - _
85 8 2 jg-g‘gm B(Green) A(Bmwn)

 

 

 

 

BEARING INSERT THICKNESS:

A (Brownl: 1.494—1‘498 mm (00588—03590 in)
B (Green): 1,490—1.494 mm (0.0587—0‘0588 in)
C IVelIow): 1.486—1.490 mm (00585—03587 in)

HONDA
V65MAGNA

 

|.D, CODE

 

O.D, CODE

 

COLOR CODE

 

12-10

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

MAIN BEARING
Determine and record crankcase |.D. code numbers.

NOTE:

 

The letters (I or II) on the upper rear crank-
case shown are the codes for the main journal
ID. from left Io right.

 

 

 

Determine and record the corresponding main
journal O.D. code numbers (or measure the main
journal O.D.l.

NOTE:

 

A number 1 or 2 on each crank weight is

 

 

the code (or the adjacent main journal O.D.

 

Cross reference the case and iournal codes to deter
mine the replacement bearing.

MAIN JOURNAL O.D.
CODE NOI

 

 

 

 

1 2
39.992— 39,934—
40,000 mm 39.992 mm
~ - 43.000—
3 g I 41003 mm 0 (Yellow) 9 (Green)
w
43.0037
38 II 43.016 mm B(Green) A(Emwn)

 

 

 

 

 

 

MAIN BEARING INSERT THICKNESS:

A (Brown): 1.498—1.502 mm (0.0590—0.0591 in)
H (Green): 1.494—1.498 mm (0.0588—0‘0590 in)
0 (Yellow): 1.490—1t494 mm (00587—00588 in)

CRAN KSHAFT/PISTON

COLOR CODE

 

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD

175

12-11

CRANKSHAFT/PISTON

CRANKSHAFT INSTALLATION

Install the main bearings into the upper crankcase.
Applv molybdenum disuliide grease to the upper
and lower main bearings,

Install the crankshaft with the cam chain.

PISTlJN AND RBI] INSTALLATION

Clean the piston domes, ring lands, and skirts,

Carefully install the piston rings onto the piston

Stagger the ring end gaps as shown.

NOTE:

HONDA
V65MAGNA

 

 

 

 

Be careful not to damage the piston and
piston rings during assemblyt
All rings should be installed with the
markings facing up,

~ Alter installing the rings they should rotate
freely, without sticking.

 

 

 

 

 

 

SIDE RAIL

jSPACER
m mmsuoag’ SIDE RAIL
70mm on MW GAP

i

V

 

 

 

12-12

176

Date of Issue: Dec,1932
© HONDA MOTOR CO, LTD.

HONDA
V65MAGNA

 

Coat the rod small end with molybdenum disulfide
grease,

Assemble the pistons and connecting rods with the
pistons and piston clips as follows,

Front cylinder connecting rod and piston assembly.

Note that the front cylinder connecting rods are
marked MB4-F.

Install the pistons on the front connecting rods so ’

that the intake ”IN" mark is facing opposite the oil
hole in the rod.

Rear cylinder connecting rod and piston asseniblv.

Note that the rear cylinder connecting rods are
marked MB4-R.
Install the pistons on the rear rods so that the intake
”IN" mark is facing the same direction as the oil
hole in the rod.

NOTE:

- Do not Interchange the pistons, piston
pins or connecting rods.

- Make sure that the piston pin clips are
properly seated,

 

 

 

 

Align the hole in the connecting rod bearing insert
with the hole in the connecting rod and install the
insert.

CRANKSHAFT/PISTON

FRONT CYLINDER ”MBA-F” MARK

 

“IN” MARK OIL HOLE

REAR CYLINDER ”M3443" MARK

 

OlL HOLE ”IN" MARK

 

OIL HOLES

 

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

177 12'13

CRAN KSHAFT/PISTON

HONDA
V65MAGNA

  

 

Install the connecting red cap bearing insert.
Apply molygdenum disulfide grease to the connect
ing rod bearings.

Coat the cylinders, piston rings/grooves and pistons
with 0“.

Install the rod and piston assemblies into the
cylinders from the top of the crankcase. Be sure
each assembly is returned to its original position as
noted during removal,

NOTE:

The plston Intake N" marks should be
facmg each other as shown

 

 

Compress the piston rings with a ring compressor
and insert the piston and rod into the cylinder,

NOTE:

- Be careful not to damage the pistons or
rings during assembly.

' To prevent damage to the crankpin jour-
nals, slib short sections of rubber hose over
the rod bolts before Installation.

 

 

 

 

 

 
  

CONNECTING ROD BEARING

"IN" MARKS

PISTON RING COMPRESSOR
(Commercially available)

 

12-14

178

Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

HONDA
V65MAGNA

 

Install and torque the connecting rod caps.
TORQUE: 30—34 N~m (CLO—SA kg-m, 22—25 fl-Ib)

NOTE:

   
 

their correct location as marked during

removal,
' Tighten the nuts in two ur more slaps.
After tightening the bolts check that the

Lidmove freely without binding.

Assemble the crankcase (See page 11-3).

‘ Be sure the bearing caps are installed in

 

 

CRAN KSHAFT/PISTON

 

Date of Issue: Dec,1982
© HONDA MOTOR C0,, LTD.

I79

12-15

? HONDA

TRANSMISSION % V65MAGNA

 

90—110N4m

@
(9‘O~11.0 kg-m,

5—80f— ' -: ' v ®®
6 ‘ “’1 70780 N-m %‘ %@
(7,075.0 kg-m, 51 —58 Mb) ®\b
Q, \a \e g,@ \
r". ‘ ~

       
 

30734 Nrm
(SD—3.4 kg~m, 22—25 (Mb)

 

1 3 _ o 130 Date of Issue: Dec, 1982
© HONDA MOTOR CO‘, LTD‘

1mm 13. TRANSMISSION

 

 

SERVICE INFORMATION 13-1 COUNTERSHAFT INSPECTION 13—17
TROUBLESHOOTING 13—2 SHIFT FORK AND SHIFT DRUM 13—18
TRANSMISSION DISASSEMBLV 13—3 TRANSMISSION ASSEMBLY 13—21
OUTPUT DRIVEN GEAR COUNTERSHAFT 13—22
REMOVAL 13—9

GEAR TOOTH CONTACT

PATTERN CHECK 13—14

 

 

SERVICE INFORMATION

GENERAL

The gearshaft linkage can be serviced with the engine in the frame (Section 8),

For internal transmission repairs, the crankcase must be separated (Section 11).

Replace the countershatt and output driven gear as a set.

When using the lock nut wrench, use a deilecting beam type torque wrench 14~20 inches long. The lock nut wrench in-
creases the torque wrench‘s leverage, so the torque wrench reading will be less than the torque actually applied to the lock
nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench when used
with the lock nut wrench, The torque wrench scale reading is given with the actual torque specification.

 

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

l STANDARD SERVICE LIMIT
Transmission Backlash low 0039—0179 mrn (00035—00070 in) 0.24 mm (0.009 In) .
2nd, 3rd, 4th, 5th, 6th 0060—0136 mm (00027—00054 in) 0.18 mm (0.007 in)
Gear |.D. M5, M6, 02,03, 04 31000—31016 rnrn (12205—12211 In) 31.13 mm (1.228 In) I
gag bu‘hir‘g M5, M0, c2, c3, 04 30950—30975 mrn (12185—12195 In) 3093 mm (1.218 In) I
FE" ””5“"‘9 M5, ca 27995—28010 mrn (11022—11030 in) 28.05 mm (1.104 In) I
Mainshaft 0.0. at MS 27977—27990 mm (1.1015—1.1020 in) 27.92 mm (1.099 In)
g°smmhm at 04 27977—27990 mm (1.1015—1.1020 In) 27.92 mm (1.099 In)
Gear-to-bushing M5, M6,02,C31 04 . . 1‘
or shaft gear~to-bushing 0.025—0.066 mm (00010—00026 In) 0.10 mm (0.004 In) I
clearance ' -
3:554 b“""“9“° 0005—0039 mm (00002—00015 In) 0.05 mm (0.002 In)
Shift fork CIafih'Ifiess 6.43—6.50 mrn (0253—0256 in) 6.1 mm (0.24 In)
|.D. LLett and right 14000—14018 mm (05511—05519 in) 14.05 mm (0.553 In)
Fork shaft 0.0. 13906—13904 mm (0549—0550 In) 13.90 mm (0.547 In)
Date of Issue: Dec, 1902 18' 1 3- 1

© HONDA MOTOR 00., LTD.

TRANSMISSION

TORQUE VALUES:

Output gear case hearing holder

Output gear case 8 mm socket bolt

Output gear bearing lock nut (outer)
(inner)

TOOLS:

Special
Lock nut wrench, 30/64 mm
Lock nut wrench, 42/56 mm
Shaft holder

Bearing remover, 17 mm
Remover handle

Remover weight

Common

Driver

Pilot, 30 mm

Pilot, 35 mm
Attachment, 62 x 68 mm
Attachment, 52 x 55 mm
Attachment, 42 x 47 mm
Pilot, 17 mm

Driver

Attachment, 30 mm

TROUBLESHOOTING

Hard to shift

1. Clutch slave cylinder sticking

2. Shift fork bent

3t Shift shaft bent

4. Shift claw bent

5. Shift drum cam groovesdamaged

HONDA
V65MAGNA

 

30—34 N-m (3.0~3.4 kg-m, 22—25 ft-lb)
21—25 N~m (2.1—2.5 kg-m,14—18 ft-Ib)
90—1 10 Nm (9,041.0 kg-m, 65—80 ft-lb)
70—80 N-m (7‘0—B.0 kg~m, 51—58 ft-Ib)

07916~M500000

07916—MB40000

07923—6890101

07936~3710300

07936—3710100} 0" Bearing remover set 07936—3710000
07936—3710200

07749—0010000 or Driver 0794976110000
07746—0040700
07746—0040800
07746—0010500
07746—0010400
07746—0010300
07746—0040400
07742»0030100
07746—0030300

Transmission jumps out of gear
1. Gear dogs worn

2. Shift shaft bent

3. Shift drum stopper broken
4. Shift forks bent

 

13-2

I82 Date of Issue: Dec,1982
© HONDA MOTOR CO, LTD.

HONDA
V65MAGNA TRANSMISSION

 

For servicing of the gearshift linkage, see Section 8.

TRANSMISSIIJN DISASSEMBLY

Separate the crankcase (Section 11L
Remove the dowel pin from the crankcase.

Inspect the backlash of each gear,
SERVICE LIMIT:
Low: 0.24 mm loaooe in)
2nd, 3rd. 4th, 51h, 61h: 0.18 mm (0.007 in)
Remove the mainshaft and countershaft.

Remove the output gear case.

 

MAINSHAFT
Index the countershaft bearing holder to the output t
gear case, for ease of reassembly.

NOTE:

When removing the countershaft, pull the
countershaft with remaining gears out of
crankcase after removing the CI, C5, CZ, CB
gears, spline washersl plain washers and bush»
ings in the crankcase

 

 

 

 

 

CZ GEAR

 

Date of Issue: Dec, 1982
© HONDA MOTOR COt, LTD.

 

TRANSMISSION

TRANSMISSION INSPECTION

Check gear dogs, dog holes and (eelh for excessive
or abnormal wear, or evidence of insufficient
lubricarion,

Measure (he ID. of each gear.

SERVICE LIMITS:
M5, M6, C2, ca, CA gear: 31.18 mm (1.228 inl

Measure the ID. and OD. of the gear bushings.

SERVICE LIMITS:

M5, M6, CZ, C3, 04 gear bushing O.D.:
30.93 mm (1.218 in)

M5, (:4 gear hushlng |.D.:
28.05 mm (1.104 in)

Measure the CD. of the mainshaft and counter-
shafL

SERVICE LIMITS:
A (at M5 bushing): 27.92 mm (1.099 in)
B (at 04 bushing): 27.92 mm (1.099 in)

Calculate the clearance between the gear and gear
shaft or bushing.

SERVICE LIMITS:

M5, M6, CZ, CS, C4 gauMo-bushing:
0.10 mm (0.004 in)

M5, c4 gear bushing-to-shaft:
0.05 mm (0.002 in)

HONDA
V65MAGNA

 

 

 

 

 

 

I.D.

0.D.

 

 

 

 

13-4

154 Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

DRIVE GEAR REMOVAL

Remove the dowel pin and O-rings.

Place the output gear case in a vise with soft iaWs,
being careful not to distort the case

Place the shaft holder tool on the output driven gear
shaft, wedging it against the vise to lock the shaft.

Unstake the inner bearing race lock nut with a drill
or grinder. Be careful that metal particles do not
enter the bearing and that the threads on the shaft
are not damaged.

SHAFT HOLDER

TRANSMISSION

DOWEL PlN
‘ ‘ 'Q

  
  

O~R|NGS

OUTPUT G EAR CASE

\
DRIVE GEAR SHAFT

07923#6890101

 

Remove the inner bearing race lock nut.
Discard the nuts,

 

SHAFT HOLDER
0792376890101

 

LOCK NUT WRENCH, 42/56 mm
07916—MB4OODD

 

COUNTE RSHAFT

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

185

13-5

TRANSMISSION

Remove the countershaft bearing holder bolts and
holder from the case,

Remove the output drive gear and shim.

Place the countershaft/holder in a press.

Press the countershaft out of the bearing holder.

COUNTERSHAFT BEARING
REPLACEMENT

NOTE:

The oountershaft must be removed before
replacing bearings

 

 

Place the bearing holder in a vise with soft laws
or shop towel.

NOTE:

Do not damage the bearing holder, especially
the crankcase mating surface.

 

 

 

 

Unstake the outer race lock nut with a punch

Remove the bearing outer race lock nut with a
special tool. Discard the lock nun

HON DA.
V65MAGNA

 

 

 

 

 

 

 

LOCK NUT WRENCH. 42/56 mrn
07916—ME40000

  

BEARING HOLDEFI

 

 

13-6

136 Date of Issue: Dec, 1982
HONDA MOTOR CO., LTD.

 

HON DA
V65MAGNA

 

Place the bearing holder in a press and remove the
bearing.

Press in a new bearing.

Place the bearing holder in a vise with soft jaws
and install and tighten a new outer race lock nut
to the specified torque value.

TORQUE: 90—110 N-rn
I9.0—11‘0 kg-m, 65—80 ft-lhI

Torque wrench scale reading:
80L100 N-m (SD—10.0 kg-m, 53—73 ft-lhI

Stake the new lock nut.

COUNTEHSHAFT INSTALLATION

NOTE:

The countershatt and driven gear must be
replaced as a set if they or the gear case or

 

the bearing require replacement.

Place the countershaft and countershatt bearing
holder into a press. Press the countershaft into the
bearing.

NOTE:

Place the threaded end of the pilot into the
countershaft.

 

 

 

 

Place the adjustment shim over the bearing holder,

NOTE:

If the countershaft/driven gear, bearing or
gear case are replaced, a new adjustment shim
must be selected (page 13-15, Backlash
Inspection),

 

 

 

TRANSMISSION

 

ATTACHMENT, 62 x 68 mm

07746—0010500

D R IVE R
0774970010000

 

 

\
a

 

 

%

 

 

 

 

 

 

BEARING HOLDER

07746—0040800

 

 

    
  

BEARING HOLDER

LOCK NUT WRENCH,
42/56 rnm
07916—MB40000

 

 

 

   
  

PILOT, 35 mm
07746—0040300

BEARING HOLDER

 

 

 

Date of Issue: Dec, 1932
© HONDA MOTOR CO” LTD,

137

13-7

TRANSMISSION

Place the countershalt/bearing holder and correct
adiusting shim into the output gear case,

Install the bolts and sealing washers with the cover
bracket.

Tighten the bolts in a crisscross pattern until the
drive gear bearing holder seats against the use
Then tighten to the specified torque.

TORQUE: 30—34 Nrm l3.0—3,4 kg-m, 22—25 ft-lbl

Place the case into a vise with soft laws.

Install and tighten a new countershalt nut to the
specified torque.

TORQUE: 70—80 N-m (7.0—8.0 kg-m, 51—58 ft-lhl

Torque wrench scale reading:
64—73 N-m (6.4—7.3 kg-m, 46—53 tt-lh)

Stake the lock nut,

 

HONDA
V65MAGNA

 

 

SHAFT HO LDE R
07923—6890101

 

 

 

 

42/56 mm
- 07916—MB40000
O ‘0
'l 0 0A0 0
”0 v
\ A

 

 

LOCK N UT WR ENCH,

 

 

©/

 

 

V7-

COUNTER SHAFT

 

 

 

 

 

 

 

 

 

13-8

188

Date of Issue: Dec, 1982
© HONDA MOTOR 60., LTD.

HONDA
V65MAGNA

 

TRANSMISSION

 

[lUTPlIT DRIVEN GEAR REMOVAL

Remove the output driven gear oil seal from the
output gear C858.

Place the output gear case into a vise, clamping it at
the shift shaft spindle boss.

Unstake and loosen the output driven gear bearing
inner race lock nut using a special lock nut wrench
and shaft holder.

Remove the driven gear bearing holder mounting
bolts and remove the gear and holder from the case.

l

LOCK NUT WRENCH, 30/64 mm
07916—MBOOOOO

SHAFT HOLDER ’

OIL SEAL

0792376890101 LOCK NUT

BEARING OUTER RACE
HOLDER

 

DRIVEN GEAR

  

BEARING HOLDER

BEARING INNER RACE

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

189

TRANSMISSION

HONDA
V65MAGNA

 

 

Remove the shim and O~ring from the bearing
holder.

OUTPUT DRIVEN GEAR BEARING
REPLACEMENT

Place the output driven gear bearing holder into a
vise with soft jaws. Unstake and remove the output
driven gear bearing outer race lock nut from the
holder.

Press the output driven gear from the holdert

Place the bearing holder in a press and press the
bearing out.
NOTE:

Be careful not to damage the bearing holder
gear case mating surface.

 

 

 

 

BEARING HOLDER

  

 

LOCK NUT WRENCH,
30/64 mm
07916—MBOOOOO

    

 

 

 

 

D Rl V ER
07749—0010000

 

J8

PILOTl 30 mm
07746—004070!)

 

 

 

 

ATTACHMENT, 52 X 55 mm
07746—0010400

 

 

 

13-10

190 Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD‘

HONDA
V65MAGNA TRANSMISSION

 

 

Press in a new bearing and make sure it rotates

freely. DRIVER
07749—0010000
4 (L

\—

 

 

 

 

ATTACHMENT52 x 55 mm PILOT, 30 mm
07746—001040!) 07746—004070!)

 

 

Place the bearing holder into a vise with soft jaws, LOCK NUT WRENCH
Install and tighten a new bearing outer race lock 30/54 mm
nut to the specified torque value. 07916—M300000

TORQUE: 90—110 N>m
(en—11.0 kg-m, 65—80 Mb)

Torque wrench scale reading:
80—110 N-m (Eb—10.0 kg-m, 58—72 ft-Ib)

    

BEARING HOLDER

 

 

 

OUTPUT DRIVEN GEAR
INSTALLATION

NOTE:

  
 

  

When the gear set, driven gear bearing and/
or gear case has been replaced, use a shim
030 mm (0.012 in) thick for initial re-
ference,

   

 

  

Place the output driven gear bearing holder into a

press.
Then press in the output driven gear.

Install the o-ring and correct shim. See page 13-14
for shim selection procedure.

 

 

Date of Issue: Dec, 1982 191
.HONDA MOTOR 00., LTD. 1 3 '1 1

HONDA
V65MAGNA

 

TRANSMISSION

 

Attach the bearing holder onto the gear case with
The iour hex bolts. Tighten the belts in a crisscross
panern in two or more steps.

TORQUE: 30—34 N-m13.0—3.4 kg-m, 22—25 ft-lbl

 

 

   
   
  

Install a new bearing inner race lock nut and tighten
it to the specified torque. BEARING INNER RACE

LOCK NUT
TORQUE: 70 —80 N-m (7.0—8.0 kg-m, 51—58 h-Ib) \

Torque wrench scale reading:
64—73 Ntm (5.4—7.3 kQ-m, 46~53 ft-lb)

HOLDE R
0792345890101

LOCK NUT WRENCH,
30/64 mm
07916'Ml300000

 

 

 

Stake both new lock nuts and install a new oil seal.

 

OIL SEAL

 

1 3 1 192 Date of Issue: Dec, 1982
- 2 © HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

TRANSMISSION

OUTPUT DRIVEN GEAR CASE
BEARING REPLACEMENT

Heat the output gear case around the bearing to
Bo°c(17e°F).

CAUTION:

Always wear gloves when handlingjheated
gear case.

 

 

 

 

 

3—15
BEARING

BEARING REMOVER, 17 mm
07936—3710300

 

Remove the bearing with the bearing remover.

Ea.

‘ ,
HANDLE WEIGHT
07936—3710100 07936—3710200

DR IVE R 07749—0010000

 

Drive a new bearing imo the omput gear case.

 

 

a; \

ATTACHMENT, 42 x 47 mm PILOT, 17 mm

0774670010300 07746—0040400
Date of Issue: Dec, 1982 193

©HONDA MOTOR CO., LTD, 1 3'1 3

TRANSMISSION

HONDA
V65MAGNA

 

 

GEAR TUUTH CUNTACT PATTERN
CHECK

Remove the drive and driven gears (pages 135,
13-8).
Apply Prussian Blue to the driven gear teeth.

Install the drive and driven gears with the standard
shims.

Rotate the drive gear several times in the normal
direction of rotation.

Check the gear tooth contact pattern after removing
the drive gear,

Contact is normal If Prussian Blue in transfered
to the approximate center of each tooth and slightly
to the side,

If the pattern is not correct, remove and replace the
driven gear adjustment shim,

Replace the shim with a thinner one if the contact
pattern is too high.

 

 

DRIVEN

G EAR/SHAFT

HEEL ’ TOE * HEEL
\
FACE+ ‘
DRIVE COAST
FLANKT SIDE SIDE

    

 

COU NTE RSHAFT

 

 

 

T00 HIGH:

   

FACE

l

FACE
DRIVE SIDE COAST SIDE

 

 

 

13-14

194

Date of Issue: Dec, 1982
© HONDA MOTOR C0., LTD.

HONDA
V65MAGNA

 

TRANSMISSION

 

 

Fleplace the driven gear adjustment shim with a
thicker one if the contact is too low. DR 'VEN
GEAR/SHAFT
The pattern will shift about 1.5—2.0 mm (0.007
0.08 in) when the thickenss at the shim is changed
by 0.10 mm (0.004 in).
OUTPUT DRIVEN GEAR ADJUSTMENT SHIM:
0.40 mm (0.016 in)
0.45 mm (0.018 in)
0.50 mm (0.020 in)
0.55 mm (0.022 in) ,
0.50 mm (0.024 in) T00 LOW' COUNTERSHAFT
I €.j I
FLANK Dan/E COAST FLANK
SIDE . SIDE

 

    

 

 

BACKLASH INSPECTION

Place the output gear case in a vise with soft iaws or
a shop towel.

Set a horizontal type dial indicator on the counter-
shait as shown.

Hold the driven gear with the shaft holder and
rotate the countershaft by hand until gear slack is
taken up,

Turn the countershaft back and forth to read
backlash.

STANDARD: 0.08—0.23 mm

(0003—0009 in)
SERVICE LIMIT: 0.40 mm (0.015 in)

Remove the dial indicator. Turn the countershaft
120° and measure backlash. Repeat this procedure
once more

Compare the difference of the three measurements.

DIFFERENCE 0F MEASUREMENT
SERVICE LIMIT: 0.10 mm (0,004 in)

 

 

Date of Issue: Dec, 1982 195
© HONDA MOTOR 00., LTD.

13-15

TRANSMISSION

If the difference in measurements exceeds the
limit, it indicates that the bearing is not installed
squarely. inspect the bearings and reinstall if neces-
sary.

If backlash is excessive, replace the countershaft
gear adjustment shim with a thlnner one.

If the backlash is too small, replace the counter-
shaft shlm with a thicker one.

Backlash is changed by about 0.06—0.07 rnrn
(0002—0003 in) when thickness of the shim is
changed by 0.10 mm (0.004 in).

COUNTERSHAFT/OUTPUT DRIVE GEAR
ADJUSTMENT SHIMS:

0.40 mm (0.016 In)

0.45 mm 10.013 in)

0.50 mm (0.020 in)

0.55 mm 10.022 in)

0.60 mm (0.024 in)

HONDA
V65MAGNA

 

 

 

 

 

 

13-16

196

Date of Issue: Dee. 1982
© HONDA MOTOR 00., LTD.

 

HONDA
V65MAGNA

 

BflUNTERSHAFT INSPECTIIJN

NOTE:

TRANSMISSION

 

 

Countershaft spacer selection should be per-

formed whenever you replace any or the

iollowing parts:

~ Crankcase (Section 11)

. Countershaft bearing (Section 11)
Countershaft

 

 

 

Select the correct output gear case gasket. (page
1345).

Install the output gear case assembly and new gasket
onto the lower case.

Assemble the transmission with the original spacer.

Measure the clearance between the bearing and
spacer with a feeler gauge.

CLEARANCE: 0.3—0.4 mm (01112—0016 inl

If the clearance exceeds the limit, select a spacer to
obtain the correct clearance:

SPACER/THICKNESS:
0.35 mm (0.03301)
0.90 mm (0.035 In)
0.95 mm 10.037 in)
1.00 mm 10.039 inl
1.05 mm 10.041 inl

FEELER GAUGE

    

 

 

COUNTERSHAFT BEAR'NG

  

 

 

 

 

SPAZE R

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

13-17

HONDA.
V65MAGNA

FORK GUIDE
SHAFT

 

TRANSMISSION

SHIFT FORK AND SHIFT DRUM

REMOVAL

Bend the lock washer tab down and remove the
center fork mounting bolt.
Remove the shin Iork shaft and shiIt forks.

CENTER FORK

   

  

RIGHT QRK

   
 

Remove the bearing stopper plates.
Remove the shift drum.

n. "Ls” 0
BEARING STOPPER PLATES

GEAR SHIFT DRUM AND SHIFT
FOFIK INSPECTION

Inspect the shift drum end for scoring, scratches,
or evidence of insufficient lubrication.
Check the shift drum grooves for damage.

 

 

198 Date of Issue: Dec, 1982
1 3'1 8 ©HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

Inspect the shift drum hole and shift fork shaft hole
for scoring or scratches.

Measure the shift fork shaft O‘Dr at right and left
shift fork surfaces.
Check for scratches, scoring or evidence of insuf-
ficient lubrication.

SERVICE LIMIT: 13.90 mm (0547 in)

Measure the right and left shift fork |.D.
Measure the shift fork claw thicknesst

SERVICE LIMITS:

I.D. (right and left fork): 14.04 mm (0.553 in)
CLAW THICKNESS: 6.1 mm “3.24 in)

 

TRANSMISSION

 

 

 

Dale of Issue: Dec, 1982 199
© HONDA MOTOR CO., LTD.

13-19

HONDA
V65MAGNA

 

TRANSMISSION

INSTALLATION

Install the shiftdrum.

Apply a locking agent to the screw threads and
install the bearing stopper plates.

T‘fikeflw -

a r» v ‘
BEARING STO PER PLATES

 

SHIFT FORKSHAFT H SHIFT FORKS

     

Install the shift forks and shaft

CAUTION:

Install the shift fork Shaft :0 that the plugged
end it toward [he left side.

 

 

 

 

Install the lock washer and tighten the center fork
bolt.

TORQUE: 16—20 N-m (1 .6—Z.D kg-m, 12—14 ft-lbl

Bend the lock washer tabs up‘

PLUGGED END LOCKWASHER

 

200 Date of Issue: Dec, 1982
1 3' 20 ©HONDAMOTOR 00., LTD.

HONDA.

 

 

V65MAGNA TRANSMISSION
DRIVER
TRANSMISSION ASSEMBLY 07746—0030100
MAINSHAFT

Install the mainshaft bearing with the special tools
as shown.

 

ATTACHMENTI 30 mm ID.
07746—0030300

Check the gears (or lreedom of movement or rota»
tion on the shalt.

Check that the snap rings are seated in the groovest

 

 

Date of Issue: Dec, 1982 201
©HONDA MOTOR CO., LTD. 1 3'21

HONDA
V65MAGNA

 

TRANSMISSION

CUUNTERSHAFT

 

Before placing the countershaft in the crankcase,
install the C4 and CG gears, washers and collar.

   

    

 

SPLINED COLLER 03 GEAR

Install the stopper washer while aligning the tab of
the stopper washer with groove in the splined
collar.

Install the C3 gear and splined collar. W
“

Assemble the 02, c5 and C1 gears, washers and {$5723
collars.

 

202 Data of Issue; Dec, 1982
1 3 ' 2 2 HONDA MOTOR CO, LTD.

HONDA
V65MAGNA TRANSMISSION

 

 

install the lower crankcase (Refer to Section 11).
NOTE:

Check the oil orifice for clogging, before
installing the lower crankcase.

%—

 

    

. # I‘ ‘
OIL ORIFICE

 

 

Date of Issue: Dec, 1982 203
©HONDA MOTOR 00., LTD. 1 3'23

HONDA
V65MAGNA

 

DRIVE TRAIN

 

8 mm: 23728 N.m

(2.3—2.8 kq-m, 17-20 h-lb)
10 mm: 35—45 N‘m

(3.5—4.5 kq-m, 25733 be)

    
   

100—120N~m
(10—12 kg-m,
72—87frlb)

9’0 06®\100420Nm

(10—1 2 kg-m,
® 72—87 lt-lb)

             

 

..
@r
a, ,
'@ v - w
\w
w. a
,- \g‘ pk @
‘ J @.‘45—70N~m
@ (4,5—7‘0 kq-m, 33—51 ft-lb)
D fl :0 , 932
1 4-0 2"" ©i§%?qn‘£“r3.0T°c§n'co., LTD,

1:333? 14. DRIVE TRAIN

 

 

SERVICE INFORMATION 14—1 ‘
TROUBLESHOOTING 14—2 I
FINAL DRIVE REMOVAL 14—3
DRIVE SHAFT 14-3
FINAL DRIVE GEAR 14—6
FINAL DRIVE INSTALLATION 14—18 ‘

 

 

 

SERVICE INFURMATIUN i

GENERAL ‘

e The final drive gear assembly must be removed together with the drive shaft, 1
0 Replace all oil seals and 0~rings whenever (he final drive gear assembly is disassembled. i
0 Check tooth comact panern and gear backlash when the bearing, gear set and/or gear case have been replaced.

 

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD SERVICE LIMIT
Final gear oil Capacity 170 CC (57 015) after disassemblv —
Recommended oil Hypoid-gear oil API, GL—5
Above 5“c/41°F SAE #90 —
Below 5°c/41°F SAE #80
Gear backlash 0.08—0.18 mm (D.003*0.007 in) 0.30 mm (0.012 in)
Gear assembly preload 0270.3 Nvm (2a3 kg-cm, 1.7—2.6 in~|bI — I
Damper case oil capacity 80 cc (2.7 oz) — I
Damper cam spring free length 65 mm (2.6 In) 63 mm (25 in) i
TORQUE VALUES I
Pinion bearing retainer 100—120 N-rn (10-12 kg~m, 72—87 fi-Ib)
Pinion nut 100—120 N-rn (10~12 kglm, 72—87 fl-Ib)
Gear case cover bolt 10 mm 35—45 N~m (3.5g45 kg-m, 25*33 Nib)
3 mm 23—28 N-rn (2.3—2.8 kg-m, 17—20 fi-Ib)
Final gear case attaching nu! 45770 N-m (4,5—7ID kg-m, 33*51fi-lb)
Dale of Issue: Dec, 1982 205 1 4 _1 i

HONDA MOTOR CO” LTD,

DRIVE TFlAIN

TOOLS

Special

Drive shaft dis/assembly tool
Drive shaft dis/assembly tool C
Retainer wrench

Final pinion holder

Shaft puller

Bearing race insert attachment
Bearing puller & driver attachment
Ball race & bearing driver attachment

Common

Driver

Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Attachment, 32 x 35 mm
Attachment, 37 x 40 mm
Pilot, 30 mm

Driver C

Attachment, 25 mm ID.
Shock absorber compressor

TRUUBLESHIJUTING

Excessive noise

HONDA
V65MAGNA

 

07964—MB40100

07964—M300300

07910—M E80000

D79247ME90000

07931—M E40000 or Pinion puller set D79357MBDOOOD

or Pinion puller 07931—4630200 and

Pinion puller attachment kit
D79317MBOOODO

07931~4630300

07934-MBODOOD

07945—333030!)

07749—0010000
0774670010300
0774641010400
07746—0010100
07746~001D200
0774670040700
07746»0030100
07746—0030200
07959—3290001

] or Driver 07945—3710200

1. Worn or scored ring gear shaft and driven flange

2. Scored driven flange and wheel hub

3, Worn or scored drive pinion and splines

4, Worn pinion and ring gears

5. Excessive backlash between pinion and ring gear

6. Oil level too low

Oil leak

1. Clogged breather
2. Oil level too high
3. Seals damaged

 

14-2

206 Date of Issue: Dec, 1932
© HONDA MOTOR 00.. LTD.

HONDA.
V65MAGNA

 

FINAL DRIVE REMOVAL

Place the motorcycle on its center stand Drain the
final gear oil (Page 240) and remove the rear wheel
(page 16-3).

Remove the left shock absorber (page IS-QL

Place an oil drain pan under the gear case and swing
arm mating suriaces to catch any damper cam oil
that may leak out during removal oi the gear caset

Remove the iinal gear case attaching nuts and
remove the gear case irom the swing arm.

DRIVE SHAFT

REMOVAL

If the drivershaft came out oi the swing arm attachA
ed to the iinal gear case with it was removed, do the
following:

Insert the axle through the gear case and secure the
case in a vise with soit laws or shop rags bv clamp-
ing the axle. Place the shock mount between the
jaws for stabilityt

Place an oil drain pan under the damper case to
catch the damper oil that will spill out.

Separate the damper unit irom the gear case by
gently revolving the damper in a circular motion
while tugging slightly.

After removing the damper unit from the gear case,
remove and discard the outer stop ring that lies in
the groove on the splined end of the damper. This
ring serves as an aid in mass production, and should
not be installed when the final drive is reassembled,

DISASSEMBLY

Drain the gear oil from the damper caset

Remove the large spring Clip irom the damper cam
to avoid damaging it.

Compress the drive shaft with the rear shock ab-
sorber compressor and attachment tools.

Date of Issue: Dec, 1952
©HONDA MOTOR 00., LTD.

FINAL DRIVE CASE
ATTACHING NUTS

DRIVE TRAIN

 

 

Pull while
revolving,

OUTER STOP RING:
Discard itt

 

 

DIS/ASSEMBLY TOOL
07964—MI340100

 

 

    

 

 

R EAR SHOCK
ABSO RE E R
COMPR ESSOR
07959—3290001

 

 

 

207

DIS/ASSEMBLY TOOL C
07964—M B00300

14-3 ‘

DRIVE TRAIN

HONDA
V65MAGNA

 

 

Remove the spring stop ring and drive shaft from
the compressor.

Remove the spring stop, damper cam and damper
lifter Irom the drive shaft.

Check the damper lifter and cam for wear or
damage.

CAUTION:

D card the stop
upon reuxxembly.

   

Remove the oil seal and oil seal guide from the
damper case.
NOTE:

Replace the oil seal with a new one if it is
removed.

 

 

 

 

 

SPRING STOP RING

 

DAMPER LIFTER

DAMPER CAM

   
  

 

0(-

SPRING STOP STOP RING

DAMPER CASE

OIL SEAL

OIL SEAL GUIDE

 

14-4

203 Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA DRIVE TRAIN

 

 

DAMPER CAM SPRING
Remove the damper cam spring,

Measure the damper cam spring free length.
SERVICE LIMIT: 63 mm (2.5 in)

 

FREE LENGTH

DAMPER CASE
Remove the damper case and O-ring from the drive
shaft.

Inspect the O-ring and replace it if necessary.

Replace the damper case on the drive shaft.

 

0»R|NG DRIVE SHAFT

 

ASSEMBLY DRNER
0774943010000

 
  

Install the damper cam spring into thedamper case.
Drive the oil seal guide and oil seal in with the driver
and attachment.

Assemble the remaining parts in the reverse order
of disassemhly.

NOTE:

Replace the O-ring, oil seal and stop ring with
new ones when reassembling the drive shaft.

 

 

 

 

ATTACHMENT, 37 x 40 mm DIS/ASSEMBLY TOOL
07746—0010200 07964—MB40100

 

 

 

 

Date of Issue: Dec, 1982 209
© HONDA MOTOR 00., LTD, 1 4 '5

DRIVE TRAIN

FINAL DRIVE GEAR

RING GEAR REMOVAL

Remove the distance collar.

Remove the dust guard plate bolts. Remove the dust
guard plate by turning it clockwise.

Remove the eight case cover bolts and cover. It the
ring gear stays in the cover, do the following:

Place the cover in a press with the ring gear down,
Make sure the cover is well supported.

Press the ring gear out of the cover with driver
07749—0010000 and attachment 07746—0010100.

Remove the ring gear from the final drive case,

Remove the Oering guide by tapping it "am the
opposite side.

DISTANCE COLLAR .

DUST GUARD PLATE

CASE COVE R

 

HONDA
V65MAGNA

 

 

 

14-6

210

Date of Issue: Dec, 1982
HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

DRIVE TRAIN

 

RING GEAR BEARING REMOVAL

Remove the ring gear bearing and gear adjusting
spacer.

CASE COVER OIL SEAL REPLACEMENT

Remove the oil seal from the case cover and press
in a new oil seal.

PINION GEAR REMOVAL

Install the pinion joint holder onto the pinion joint
and remove the pinion shaft nut.
Remove the tool and pinion joint.

ATTACHMENT, 32 x 35 mm 07746—0010100
PILOT, 30 mm 07746—0040700

 

  

RING GEAR BEARING

 

BEARING PULLER
(COMMERCIALLY

/AVAILABLE)

 

 

OIL SEAL

 

 

 

 

PINION HOLDER
07924—ME90000

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO‘, LTD.

211

14-7

HONDA
V65MAGNA

 

DRIVE TRAIN

 

LOCK TAB
Remove the retainer lock tab. *

 

RETAINER WRENCH
07910—ME8 000

   
   

Remove the pinion retainer with the lock nut
wrench.

“I“ I ‘ a _. ; '
PINION HOLDER 07924—ME90000 PINION PULLER ATTACHMENT KIT
WITH SHAFT PULLER OH O7931~MBOOOOO WITH PINION

07931—ME40000 PULLAR 07931—4630200

OR PIN ION PULLER
07935—MB00000

Pull a" the pinion assembly wixh the pinion puller.

 

 

1 4 8 212 Date of Issue: Dec, 1982
- © HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

PINION BEARING REMOVAL

Remove the O-ring from the pinion shaft,

Pull the outer and inner bearing races off the shaft
with the bearing puller.

Pull the remaining inner race off with the same tool.

Remove the pinion adjustment spacer.

PINION RETAINER OIL SEAL
REPLACEMENT

Remove the O-ring and oil seal from the pinion
retainer,

Drive a new oil seal into the retainer,

Coat a new O-ring with oil and install it onto the
retainer.

To install new oil seal, use driver 0794543330300

Date of Issue: Dec, 1982
HONDA MOTOR (30., LTDV

O-RING

DRIVE TRAIN

 

PINION BEARING

BEARING PULLER
(COMMERCIALLY AVAILABLE)

 

OIL SEAL

PINION RETAINER

213

OARING

DRIVER

 

ATTACH M ENT
0794573330300

14-9

DRIVE TRAIN

HONDA
V65MAGNA

 

 

CASE BEARING AND OIL SEAL
REPLACEMENT

Heat the gear case 80°C (176°F). Tap the gear case
with a plastic hammer and remove the ring gear and
pinion bearings.

I'm——

Always wear gluves when handling the gear
case after it has been heated.

 

 

NOTE:
Use bearing remover, 35mm,07936—3710400

 

 

 

 

to remove ring gear case hearing.

 

Remove the ring gear shaft oil seal.

Drive a new oil seal into the case, using the special
(ools shown.

Drive new pinion and ring gear bearings into the
case.

RING GEAR BEARING

PINION BEARING

  
  
     

D R IVE R
07749-0010000

 

ATTACHMENT '
DRIVER 07945—3330300

07749—0010000

  

V /

-(
‘3'”..H :0
ATTACHMENT, 32 x 35 mm
0774670010100

0: ‘ mud, { 0‘»
ATTACHMENT, 52 x 55 mm
07746—0010400

 

14-10

214 Dale of Issue: Dec, 1982
HONDA MOTOR CO, LTD.

HONDA
V65MAGNA

 

BREATHER HOLE CLEANING

Remove the breather hole cap and blow rhrough rhe
breather hole with compressed air.

PINION GEAR ASSEMBLY

Install ihe original pinion gear spacer.

NOTE:
When rhe gear set, pinion bearing and/or gear
case has been replaced, use a 20 mm thick
spacer.

   
  

 

Press the bearing onto the pinion gear shah with the
special Iools shown.

Inssall a new O-ring over the pinion shafl.

Dale of Issue: Dec, 1982
© HONDA MOTOR COT, LTD,

 

DRIVE TRAIN

CASE COVE R

 

PINION BEARING PINION SPACER

 

DRIVER OR DRIVER
07746—0030100 07945—3710200
f

ATTACHMENT, 25 mm ID.
07746—0030200

215

 

14-11

DRIVE TRAIN

 

HONDA
V65MAGNA

 

Place the pinion assembly into the gear housing.
Drive the pinion assembly into the gear case until
pinion retainer threads can engage with the case
threads.

Apply gear oil to the O-ring and threads on the
pinion retainer. Install the O-ring guide tool.

Screw in the pinion retainer to press the pinion
bearing in place, then tighten it to the specified
torque.

TORQUE:
100—120 N~m (10—12 kg-m, 72—87 ft-lb)

RING GEAR ASSEMBLY
Install the original spacer onto the ring gear.

NOTE:

if the gear set, pinion bearing, ring gear bear»
ing and/or gear case is replaced, install a 2.0
mm thick spacer.

 

 

 

 

Place a new ring gear bearing on the ring gear shaft.
Place the old bearing on top of it. Then, drive the
new bearing onto the shalt with the old bearing and
attachment. Then remove the old bearing,

ATTACHM ENT
0793174630300

RING GEAR SPACER

 

RETAINER WRENCH
D7910—ME80000

 

  

 

 

ATTACHM ENT
D7934—M300000

   

 

 

 

14—12

216

Date oi Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

lnstall a new O»ring on the O-ring guide,
Apply grease to the O-ring and drive the O-ring
guide onto the ring gear shaftt

Install the ring gear into the gear case cover.
Measure the clearance between the ring gear and
the ring gear stop pin with a leeler gauge.

CLEARANCE: 0.30—0.60 mm (0.01Z—D.OZ4 in)

H the clearance exceeds the service limit, remove
the ring gear. Heat the gear case cover to approx-
materly 80°C (176°F) and remove the stop pin by
tapping the cover.

   

Alwayx wear gloves when handling the gear
case after it has been heated

 

   

|nsta|| a stop pin shim to obtain the correct clear»
ance,

SHIM THICKNESS: A 0.10 mm (0.004 in)
B 0.15 mm (0.006 in)

Install the shim and drive the stop pin Into the case
cover,

O-RING GUIDE O-RING vfi

 

\m
GEAR CASE COVER STOP P

STOP PIN

 

DRIVE TRAIN

3t; .
ATTACHMENT, 42 x 47 mm

07746A001030

07749—0010000

DRIVER

 
   

O

 

 

 

 

IN FEELER
GAUGE
RING GEAR
03070.60 mm

STOP PIN

(0.012—0.024 in)

 

 

 

 

 

SHIM

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00‘, LTD.

217

14-13

DRIVE TRAIN

Clean all sealing material ON the mating surface of
the gear case and cover.

NOTE:

 

' Keep dust and dirt out oi the gear case.
Be careiul not to damage the mating
surfaces.

 

 

 

Apply liquid sealant to the mating suriace oi the
gear case cover.

GEAR TOOTH CONTACT PATTERN
CHECK

Apply a thin coat of Prussian Blue to the pinion
gear teeth for a gear tooth contact pattern check.
Place the wave washer and ring gear into the gear
case.

Apply gear oil to the lip of the oil seal on the gear
case cover and install the gear case cover.

Tighten the cover bolts in 2—3 steps until the cover
evenly touchs the gear case, then tighten the 8 mm
bolts to the specified torque in a crisscross pattern
in two or more steps.

TORQUE: 23—28 N~m (2.3—2.8 kg»m, 17—20 ft-lb)

Then tighten the 10 mm bolts.
TORQUE: 40—50 Nm (4.5—5.0 kg-m, 33—36 ft-Ib)

 

HONDA.
V65MAGNA

 

PRUSSIAN BLUE

8 mm 30th

WAVE WASH E R

 

  

 

14-14

218

Date oi Issue: Dec, 1982
HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

 

Remove the oil filler cap from the final gear case.

Rotate the ring gear several times in the normal
direction of rotation. Check the gear tooth contact
pattern through the oil filler hole. The pattern is
indicated by the Prussian Blue applied to the
pinion before assembly.

Contact is normal it the Prussian Blue is transfered
to the approximate center of each tooth and slightly
to the flank side.

If the patterns are not correct, remove and replace
the pinion spacer. Replace the pinion spacer with a
thicker one if the contacts are too high, toward the
face.

Replace the pinion spacer with a thinner one if the
contacts are too low, to the flank side. The patterns
will shift about 1.5—2.0 mm (0.06—0.08 in) when
the thickness of the spacer is changed by 0.10 mm
(0.004 in).

PINION SPACER:
A 1.82 mm (0.072 in)
1.88 mm (0.074 in)
1.94 mm (0.076 in)
2.00 mm (0.079 in) Standard
2.06 mm (0.081 in)
2.12 mm (0.084 in)
2.18 mm (0.086 in)

ca-nrrruom

 

 

 

 

 

 

 

DRIVE TRAIN
NORMAL
, TOE \
HEEL’ \HEEL
FACE FACE
FLANK FLANK

DRIVE SIDE COAST SIDE

 

 

T00 HIGH

 

 

 

 

 

 

 

FACE FACE

iii? ffiil

DHIVE SIDE COAST SIDE

 

 

 

PINION SPACER TOO LOW

 

FLANKl I?» § l FLANK

DRIVE SIDE COAST SIDE

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

” 1445

DRIVE TRAIN

BACKLASH INSPECTION

Remove the oil filler cap.

Set the final gear assembly into a jig or stand to
hold it steady. Set a horizontal type dial indicator
on the ring gear, through the oil filler hole.

Hold the pinion gear spline by hand. Rotate the ring
gear by hand until gear slack is taken up. Turn the
ring gear back and forth to read backlash.

STANDARD: 0.08—0.18 mm (0003—0007 in)
SERVICE LIMIT: 0.30 mm (0.02 inl

Remove the dial indicator. Turn the ring gear 120°
and measure backlash. Repeat this procedure once
more.

Compare the difference of the three measurements.

DIFFERENCE 0F MEASUREMENT
SERVICE LIMIT: 0.10 mm (0.004 in)

If the difference in measurements exceeds the limit.
it indicates that the bearing is not installed squarely.
Inspect the bearings and reinstall if necessary.

If backlash is too small, replace the ring gear spacer
with a thinner one.

Backlash is changed by about 0.06#0.07 mm
(030243303 in) when thickness of the spacer is
changed by 0.10 mm (0.004 in).

RING GEAR SPACER:

A 1.82 mm (0.072 inl

B 1.88 mm (0.074 In)
C 1.94 mm (0.076 in)
D 2.00 mm (0.079 in) Standard
E 2.06 mm (0.031 inl
F 2.12 mm (0.084 in)
G 2.18 mm (0.0861nl
H 2.24 mm (0.088 inl
| 2.30 mm (0.091 in)

 

HONDA
V65MAGNA

 

 

 

 

 

 

 

 

 

 

RING GEAR SPACER

 

 

 

 

14-16

220

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

DRIVE TRAIN

 

PINION JOINT INSTALLATION

Install the appropriate pinion retainer lock tab.

NOTE:

There are two types of lock tabs as shown.

Apply gear oil to the oil seal lip contact surface
of the pinion joint and install the pinion joint.

Install the pinion joint holder tool and tighten the
pinion nut.

TORQUE: 100—120 N~m (10—12 kgvm,
72—87 ft-IbI

Remove the pinion joint holder tool.

Make sure that the gear assembly rotates smoothly
without binding by turning the pinion joint,

 

 

 

LOCK TABS

 

 

 

PIN ION HOLDER
07924—ME90000

 

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

111

DRIVE TRAIN

Install the dust guard plate and torque the bolt.
Install the distance collart

FINAL DRIVE INSTALLATIIJN

Fill the damper case with the recommended type
and amount of lubricant.
RECOMMENDED OIL: HYPOID GEAR OIL APl,
GL—5

Above 5°c/41°F: SAE #90

Below 5°C/41DF: SAE #80

OIL CAPACITV: 80 cc (27 oz)

Keeping the damper case vertical, place the damper
spring onto the damper cam and install the final
drive gear case over the damper cam.

NOTE:

 

Be careful not to damage the damper case

oil seal during assembly.
Do not let the gear case separate from the

 

 

damper case or the oil will spill out.

 

HONDA
V65MAGNA

 

_ DISTANCE COLLAR
9w ‘ _, ,

  
  

 

 

FINAL GEAR CASE DAMPER SPRING

 

14-18

Date of Issue: Dec, 1982

222
© HONDA MOTOR CO,, LTD

HONDA
V65MAGNA

 

DRIVE TRAIN

 

Make sure the universal joint is in line with the
driveshatt. Then insert the drivershaft into the
swing arm aligning its splines with the outer shaft
splines. Keep the gear case and damper case together
or damper oil will leak out.

Secure the gear ease to the swing arm with the three
attaching nuts. To ease axle installation, do not
tighten the gear case nuts until aiter the axle is
Installed.

install the rear wheel (page 16-8).

Tighten the axle nut.

TORQUE:
85—105 N-m (13.5—10.5 kg-m, 61—76 tt-Ih)

Tighten the three final gear case attaching nuts.
TORQUE: 45—70 N-m (4.5—7.0 kg-m, 33—51 ft-Ib)

Tighten the axle pinch bolt.
TORQUE: 20—30 Nam (LO—3.0 kg-m, 14—22 ft-lh)

Install the shock absorber (page 16-13].

Make sure that the drain bolt is tightened.
Remove the oil filler cap and pour in the specified
amount of recommended oil.

RECOMMENDED OIL: Hypoid Gear Oil
Above 5°cl41°1=): SAE # so
Below 5°C (41°F): SAE #30

OIL CAPACITY:
170 cc (5.1 mi Dry
130 cc (4.4 oz) Refill after draining

FINAL GEAR CASE
ATTACHING NUTS
me 1‘

OIL DRAIN BOLT

    

 

Date of Issue; Dec, 1982
© HONDA MOTOR (20., LTD.

223

14-19

 

FRONT WHEEL/SUSPENSION

HONDA
V65MAGNA

 

40750 N-m
(4.075.!) kg-m, 29—36 ft-lb)

       
      
         
 
 

90—120 N-m

_ 65—87 ft-lb)

55—65N-m
(5,5—6.5kg-m, ‘ N . (2.5—3.0kg~m,18~22ft~lb)
4o-4an-Ib) x A . f :7 9‘13““

- (us—1,3 kg-m, 7—9 mt.)

 
 

(4.5—5.5 kg-m,
33—40 ft-lb)

   
 
   
 

30—45 NAm a
(cm—4.5 kg-m, * "\
22—33 1t-Ib) 1848'm
(1 .8~2.8 kg-m,
13—30 N-m 13—20 ft-Ib)
(1.34m kg-m,

13~22 't-lb)

30—45 N-m
(3.0—4.5 kg~m,
22—33 't-Ib)

 

 

© HONDA MOTOR (30., LTD.

1 5 0 224 Date of Issue: Dec, 1982

 

113m? 15. FRONT WHEEL/SUSPENSION

 

 

SERVICE INFORMATION 15—1 IGNITION SWITCH 15—9
TROUBLESHOOTING 15—2 HANDLEBARS 15—10
FUSE/COUPLER BOX 15—3 FRONT WHEEL 15—15
HEADLIGHT 15—4 FRONT FORKS 15—22
INSTRUMENTS 15—5 STEERING STEM 15—35

 

 

 

SERVICE INFORMATION

GENERAL

0 A jack or other support is required to support the moxorcycle.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD SERVICE LIMIT
Axle shah runout — 0,2 rnrn (0.01 in)
Front wheel rim runout Radial 0.3 mm (0.01 in) max. 2.0 mm (0.03 in)
Axial 0.3 mm (0.01 in) max. 2.0 mm (0.08 in)
Wheel bearing plav — 0.03 mm (0.001 in)
Fork spring free length 414.7 mm (16.33 in) 404mm (15.9 in)
Fork tube runouL 7 — 0.2 mm (0.01 in)
Front fork (luid capacity Right 505 cc119.1 ozI, L2“ 580 oc119.0 ozI —
Front (ork air pressure 040 kPa (070.4 kg/om’, 0—0 psi) —
TORQUE VALUES
Handlebar upper holder 40—50 N-m (4.04.0 kg-m, 29530 (Mb)
Handlebar pinch bolt 25—30 N-m (2.5—3.0 kg-m, 18—22 ft-lb)
Caliper mounting bolt 30—45 Nvm (3.0—4.0 kg-m, 22—33 fl-lb)
Front axle 55—05 N-m (5.5—0.5 kg-m, 40—47 fl-Ib)
Axle pinch bolt 18—30 N«rn (1.84.0 kg-m, 135220113)
Frontforksocketbolt 15— 25Nm(1. 5— —2.-5kgm 11— iaft lb)
Fork tubecap 15 30Nm(1. 5»3.-,0kgm 11— 22ftlb)
Steering bearing adjustment nut 14 16 N m (1. 4 1 6 kg m 10 12 ft- -|b) (See pages 15 30 and 39)
Steering stern nut 90— 120 N m (9 0— 12 0 kg rn, 0547 ft- lb)
Brake disc 25—30 N-m (2.5—3.0 kg»m, 18—22 beI
Front fork top pinch bolt 9713 Nrm (0.9—1.3 kg-m, 7—9 fl~|b)
Front fork bottom pinch bolt 45755 N~m (4.5—5.5 kg-rn, 33—40 fl-lb)
Front fork stabilizer bolts 1048 Nm (1.8—2.8 kg-m, 13—201t-lb)
Front brake master cylinder holder bolt 10—14 N-m (1.0—1.4 kg-m, 7—10f(»|b)
Clutch master cylinder holder bolt 10714 N-m (1.0—1.4 kg-m, 7—10ft-Ib)
Date of Issue: Dec, 1982 225
©HONDA MOTOR co., LTD. 1 5'1

FRONT WHEEL/SUSPENSION

TOOLS

Special

Hex. wrench, 6 mm

Snap ring pliers

Fork seal driver

Fork seal driver attachment
Steering stern socket

Ball race driver

Ball race remover

Ball race remover

Steering stern driver

Common

Driver

Attachment, 42 x 47 mm
Pilot, 15 mm

Lock nut wrench, 30 x 32 mm
Extension bar

Bearing remover shaft

Bearing remover head, 15 mm

TRDUBLESHIJIJTING

Hard steering

1. Steering bearing adjustment nut too tight

2. Faulty steering stern bearings
3. Damaged steering stern bearings
4. Insufficient tire pressure

Steers to one side or does not track straight
1. Unevenly adjusted right and left shock absorbers

2. Bent front forks
3. Bent front axle
4. Wheel installed incorrectly

Front wheel wobbling

1. Bent rim

2. Worn front wheel bearings

3. Faulty tire

4. Axle nut tightened improperly

Soft suspension

1. Weak fork springs

2. Insufficient fluid in front forks
3. Front fork air pressure incorrect

Hard suspension

1. Incorrect fluid weight in front forks

2. Front fork air pressure incorrect
3. Bent fork tubes

4. Clogged lluid passage

5. Clogged antidive orifice

Front suspension noise

1. Worn slider or guide bushings
2. Insufficient fluid in forks

3. Loose front fork fasteners

4. Lack of grease in speedometer gearbox

HONDA
V65MAGNA

 

07917—3230000 or commercially available
0791473230000 or commercially available
07947—KA50100

07947—KF00100

07916—3710100

07946—371070!)

07946~3710500

07953—425000?

07946—MBOOOOO

0774943010000 or Driver 0794945110000
07746—001030!)

07746—0040300

07716—0020400 or commercially available
07716—0020500 or commercially available
07746~0050100 or commercially available
07746»0050400 or commercially available

 

15-2

226 Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

 

FUSE/COUPLER BIJX
REMOVAL/INSTALLATION

Remove the fuse holder cover.

Disconnect the horn wires from the horn terminals.

Remove the bolt attaching the horn bracket
The bracket and horns will come off as an assembly.

Remove the coupler box cover.

Disconnect all wire couplers and connectors in the
coupler box‘ Note their position for ease of re-
installation.

 

 

 

 

 

 

 

 

 

 

 

 

 

Date of Issue: Dec] 1982
© HONDA MOTOR 00., LTD,

227

15-3

FRONT WHEEL/SUSPENSION

Remove the two coupler box attaching bolls and
the coupler box,

HEADLIGHT

REMOVAL

Remove the headlight mounting bolt.
Disconnect the wire coupler and remove the head-
lightt

CASE REMOVAL/INSTALLATION

Remove the headlight case mounting bolts and the
headlight case,

Install the headlight case in the reverse order of
removalr

 

HONDA
V65MAGNA

 

 

 

15-4

228

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD,

HONDA
V65MAGNA FRONT WHEEL/SUSPENSION

 

BRACKET REMOVAL/INSTALLATION

Remove the coupler box cover (page 15-3),

Disconnect the front turn signal wire connectorst
Remove the headlight bracket mounting bolts and
bracket/turn signal assemblies.

Install the headlight bracket in the reverse order
ofremovalt

 

LOWE R COVE R

INSTRUMENTS

INDICATOR LlGHT BULB
REPLACEMENT

Remove the headlight and case (page 15-4).
Remove the instrument lower cover attaching
screws, and lower covert

SCREWS

 

 

Date of issue: Dec, 1982
©HONDA MOTOR 00., LTD.

 

FRONT WHEEL/SUSPENSION

Remove the indicator panel attaching wrews and
panel,

Replace any inoperative bulbs,

After Installing a new bulb, check for continuity
If the new bulb does not light, inspect the wiring for
an open or short circuit, or loose connectionst

INSTRUMENT REMOVAL

Reche the coupler box cover (page 153).
Remove the headlight and case (page 154).

Disconnect the speedometer cable from the instru-

ments
Disconnect the instrument wire couplerst

Remove the instrument mounting nuts, and instru‘

ment,

15-6

 

 

HONDA
V65MAGNA

 

INDICATOR PANEL

  

 

‘ i
SPEEDOMETER CABLE

230 Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

 

DISASSEMBLY

Remove the instrument lower cover.

CAUTION:

 

Do nat leave the instruments upxide dawn or
dumping fluid will leak onto the inside 0f the
lens.

 

 

 

Remove the meKer setting nuts, and meters.

Remove the meter lower cover screws and lower
covers.

    

SC R EWS

 

LOWER COVE R

SETTING NUTS

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD‘

231

HONDA.

FRONT WHEEL/SUSPENSION V65MAGNA

 

 

BULBS
Replace anv inoperative bulbs.
If a replacement bulb does nol light, check the
wiring for a short or open circuit, or check for ‘
loose connections.

 

ASSEMBLY/INSTALLATION

Lubricate the speedometer cable before reconnect
ing it.

Assemble and install the instruments in the reverse
order of disassembly and removalt

 

 

 

232 Date of Issue: Dec, 1982
1 5 ' 8 © HONDA MOTOR CO‘, LTD.

HONDA.
V65MAGNA

 

IGNITION SWITCH

REMOVAL/INSTALLATION

Remove the headlight and headlight case.

Remove the coupler box cover (page 15-3).

Remove the instruments (page 156).

Disconnect the ignition switch wire coupler.
Remove the ignition switch mounting bolts, and
ignition switch.

Install the ignition switch in the reverse order of
removal,

DISASSEMBLY/ASSEMBLY

Open the wire clamp,

Insert the ignition key and turn it to between the
ON and OFF detent positions.

WIRE CLAMP

Push the lugs into the slots and pull the contact
base from the switch.

Assemble the ignition switch in the reverse order of
disassembly.

FRONT WHEEL/SUSPENSION

IGNITION SWITCH

LUGS

 

 

Date of Issue: Dec, 1982 233
© HONDA MOTOR C0,, LTD,

15

9

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

HANDLEBARS CL_UTCH MASTER CYLINDER

ii

 

R E MOVA L

Disconnect the clutch switch wires.

Remove the clutch master cylinder,
Hams

mm :2 , i

 

Disconnect the choke cable from the choke lever.

CHOKE CABLE

 

LEFT HANDLEBAR SWITCH
Remove the left handlebar switch.

 

 

234 Date of Issue: Dec, 1982
1 5 '1 O ©HONDA MOTOR CO., LTD.

HQNDA
V65MAGNA

 

Remove (he right handlebar swimh and disconnect
the from brake switch wires.

Remove the brake master cylinder.

Remove the handlebar set screw,

Loosen the handlebar pinch bolt and remove the
handlebar.

Am;
HANDLEBAR SET SCREW

 

H

FRONT WHEEL/SUSPENSION

 

HANDLEBAR PlNCH BOLT

 

Date of Issue: Dec, 1982
HONDA MOTOR CO., LTD,

235

  

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

UPPER HOLDERS
Remove the bolt caps and the handlebar cover. '
Remove the handlebar upper holder bolts.

Remove the handlebar upper holders and the center
handlebar.

INSTALLATION

Place the center handlebar onto the lower holder,
aligning its punch mark with the upper surface o!
the lower holder.

Place the upper holder onto the lower holder with
its punch mark facing forwardt

Tighten the forward bolts first, then tighten the
rear bolts.

TORQUE: #0—50 Nam (4.0—5.0 kg-m, 29—36 lt-lb)

Install the bolt caps and handlebar covert

AHNDLEBAR COVER

PUNCH MARK PINCH BOLT
Install the right and left handlebars into the center
handlebar,
Install the handlebar set screws,

Applv grease to the handlebar pinch bolts.
Tighten the pinch bolts alter aligning the punch
marks with the slits on the center handlebar.

TORQUE: 25—30 Nam (2.5—3.0 kgvm, 18—22 ft-lb)

 

SET SCREW

 

235 Date of Issue: Dec, 1932
1 5-1 2 ©HONDA MOTOR co., LTD.

HONDA.
V65MAGNA

 

Apply grease to the throttle grip sliding surface and
install the throttle grip over the handlebar.

Install the front brake master cylinder with ”UP"
mark facing up.

Align the end of the holder with the handlebar
punch mark.

Tighten the upper bolt first, then the lower boltt

TORQUE: 10—14 N-m (1.0—1.4 kg-m, 7—10ft-lb)

Connect the brake light switch wires.

Install the right and left switches by aligning the
locating pin with the hole in the handlebar.

Tighten the forward screwisl first, then tighten the
rear screwt

m

FRONT WHEEL/SUSPENSION

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

 

HONDA.
V65MAGNA

 

FRONT WHEEL/SUSPENSION

CHOKE LEVER
Connect the choke cable to the choke lever. » ax

CHOKE CABLE

 

PUNCH MARK

Install the clutch master cylinder.
Align the end of the holder with the punch mark

on the handlebart
Tighten the upper bolt first, then tighten the lower

bolt.
TORQUE: 10—14 N-m (1.0—1.4 kw", 7—101t—lb)

Connect the clutch screw wires.

 

 

Date of Issue: Dec, 1982

233
© HONDA MOTOR C0., LTD.

15-14

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

 

FRONT WHEEL
REMOVAL

Remove the speedometer cable set screw and the
speedometer cablel

Remove the right and left side caliper assemblies by
removing the bolts.

NOTE:

Do not operate the front brake lever after
removing the calipers To do so will cause
difficulty in fitting the brake disc between
the brake pads.

 

 

 

 

   
 

 

SFEEDOMETER I
CABLE
AXLE PINCH BOLT

 

Loosen the axle pinch bolt.
Loosen and remove the front axle.

Remove the front wheel,

DISASSEMBLY

Remove the brake disc mounting bolts, and discs,

 

 

Date of Issue: Dec, 1982 239 _
©HONDA MOTOR C0., LTD, 1 5 1 5

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

 

SIDE COLLAR
Remove the side collar and right seal. .

 

SPEEDOMETER GEAR
RETAINER
Remove the left seal and speedometer gear retainer. N‘

 

WHEEL BEARING REMOVER HEAD 15 mm
07746—0050400

COMMERCIALLY AVAILABLE IN USA.
Remove the wheel bearings and the distance collar , . ‘
from the hub,

NOTE:

 

If the bearings are removed, they should be
replaced with new ones‘

 

 

 

 

- L
BEARING REMOVER
SHAFT 0774670050100

240 Date of Issue: Dec, 1982
1 5'1 6 ©HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

 

WHEEL BEARING INSPECTION

Check wheel bearing play by placing the wheel in
a swing stand and spinning the wheel by hand.
Replace the bearings with new ones iI they are noisv
or have excessive plav.

SERVICE LIMIT: 0.03 mm (0.001 in)

WHEEL INSPECTION

Check the rim runom by placing the wheel in a
swing stand. Turn the wheel slowly and read the
runout using a dial indicator.

SERVICE LIMITS:

RADIAL HUNOUT: 2.0 mm (0.03 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

Set the axle in V blocks and measure the runout.
SERVICE LIMIT: 02 mm (001 InI

 

 

PLAY

 

 

 

 

 

 

 

 

 

Date oI Issue: Dec, 1982
© HONDA MOTOR C0,, LTD

241

15-17

FRONT WHEEL/SUSPENSION

ASSEMBLY

   

ping power will be reduced.

 

Do not get greaxe on the brake diu- ar trop-

  

HON DA
V65MAGNA

   

 

 

NOTE:

The case wheel needs no rim band.

The front wheel uses a tubeless tirer For
tubeless tire repair, refer to the HONDA
TUBELESS TIRE MANUAL

 

 

 

 

Pack all bearing cavities with grease
Drive in the right bearing first and press the distance
collar into place.

NOTE:

Be certain the distance collar is in position
belore installing the left bearing.

 

 

Drive in the left bearing squarely,

NOTE:

Make sure that the bearings are fully seated
and that the sealed sides are lacing out.

 

 

 

 

ATTACHMENT, 42 x 47 mm 07746—0010300

D R IVE R
07749—0010000

    

ATTACHMENT, 15 mm 00746—0040300

 

15-18

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTDt

HON DA
V65MAGNA

 

Install the speedometer gear retainer in the wheel
hub, aligning the tangs with the slots

Install the left seals

Install the right seals Apply grease to the inner seal
lip and insert the side collar.

Attach new gaskets to each brake disc.

RETAINER

FRONT WHEEL/SUSPENSION

 

 

 

 

 

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD

243

15-19

FRONT WHEEL/SUSPENSlON

Install the brake disc with the ”R" mark on the
right and the disc with the “L" mark on the left'

TORQUE: 25—30 N~rn (25—3.!) kg-m, 18—22 tt-lb)

Install the speedometer gearbox in the wheel hub,
aligning the tang: with the slats.

Clean the brake discs with a high quality degreasing
agent.

INSTALLATION

Fit the calipers over the discs, taking care not to
damage the brake pads, Install the caliper mounting
belts,

TORQUE: 30—45 N-m (3.0—4.5 km“, 22—33 ft-lbl

Align the speedometer gearbox with the tang on the
left fork leg as shown.
Tighten the axle to the specified torque.

TORQUE: 55—65 Nam (5.5—6.5 kg-m,40—47 ft-lb)

Measure between the outside surface of the right
brake disc and the inside of the right caliper holder
with a 0.7 mm ([1028 in) teeler gauge.

It the gauge cannot be inserted, pull the right fork
out until the gauge can be inserted.

 

flfl

0.7 mm (0.028 In)

“Fl”: OR ”L" MARK

FEEL

HON DA
V65MAGNA

 

      

x ‘i‘x
ER GAUGE

 

15-20

244

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA FRONT WHEEL/SUSPENSION

 

 

AXLE PINCH BOLT

Tighten the axle pinch bolt to the specified torque.
TORQUE: 18—30 N'm (1.8-3.0 kn-m, 13-22 ft-Ih)

There should still be at least 07 mm (0.028 in)
clearance between the caliper holder and Elise

CAUTION:

After installing the wheel, apply the brakes
several times and recheck the clearance an
both sides, Failure to provide clearance will
damage the brake discs and affect braking
efficiency,

   
  

 

    

Install the speedometer cable.

LA- 7

 

t j _ ',
SPEE DOMETE Fl CABLE

 

Date of Issue: Dec, 1982 245
© HONDA MOTOR 00., LTD. 1 5 ' 21

FRONT WHEEL/SUSPENSION

FRONT FORKS

R E MOVA L

Remave the follawing parts:
— front wheel‘

— brake callpers,
— front fender.

Remove the fork bracer

Release fork air pressure.

Loosen the fork upper and lower pinch bolrsr

 

HONDA
V65MAGNA

 

FORK PINCH BOTS

 

15-22

246

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MA6NA

 

FRONT WHEEL/SUSPENSION

 

Pull each fork tube down and out of the fork top
bridge and air jointt Rotate the fork tube while
pulling.

Remove the fork stop ringsv

Pull each fork tube out of the bottom bridge.

If service of the air joints is necessary, remove the
following parts:

— coupler box (page 15-3).

— headlight and case (page 154).

— instruments (page 15-6).

Remove the two screws attaching the fork air joints
to the fork top bridge‘

Remove the air joints.

AIR JOINT

- ‘FORK STOP RING

 

SCH EWS

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR (30,, LTD.

 

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

 

Loosen the air jolnt pipe connectors and remove O»FIINGS

the joint pipe.
$°®0®
%

JOINT PIPE

AIR JONT

 

CONNEC/TOR

 

 

 

FORK TUBE CAP
DISASSEMBLY

Hold the fork tube in a visa, with soft laws or a shop
towel and remove the forkgube cap,

CAUTION:

Do not damage the sliding surface,

 

 

Remove the fork spring, spacer and washer.
Force out the fork fluid by pumping the fork up
and down several times

 

 

 

 

 

243 Date of Issue: Dec, 1982
1 5- 24 ©HONDA MOTOR CO., LTD

HONDA
V65MAGNA FRONT WHEEL/SUSPENSION

 

HEX WRENCH (6 mm) 07917—3230000

Hold the fork slider in a vise with soft jaws or a
shop towel.
Remove the socket bolt with a hex wrench.

NOTE:

Temporarily install the spring and fork tuba
cap if difficulty is encountered in removing
the bolt.

 

 

The piston and rebound spring can now be removed
from the right fork.

 

DUST SEAL PLASTIC WASHER
Remove the dust seal, sponge seal and plastic
washer‘

   

SPONGE SEAL
SNAP RING PLIERS 07914—3230001 1

SNAP RING OR COMMERCIALLY AVAILABLE IN U.S.A.

  

Remove the snap ring,

 

 

Date of Issue: Dec, 1932 249 ‘
© HONDA MOTOR 00., LTD, 1 5 - 2 5 l

FRONT WHEEL/SUSPENSION

Pull the Iork tube out until resistance Irom the
slider bushing is felt. Then move it in and out,
tapping the bushing lightly until the fork tube
separates from the slider. The slider bushing will be
forced out by the fork tube bushing.

Remove the oil lock piece from inside the slider.

Remove the oil seal, back-up ring and slider bushing
from the fork tube.
NOTE:

Do not remove the fork tube bushing unless
it is necessary to replace it with a new one.

 

 

 

 

From the left fork, remove the clrclip, oII lock
valve, spring, and spring seat from the piston.
Remove the piston and rebound spring from the
fork tube.

15-26

SLIDER BUSHING

FORK TUBE

 

 

HONDA
V65MAGNA

 

FORK SLIDER

BACK-UP RING OIL SEAL

FORK TUBE BUSHINGS

PISTON

250

SPRING SEAT

 

CIRCLIP

OIL LOCK SPRING
VALVE

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

INSPECTION

FORK SPRING FREE LENGTH

Measure the fork spring free length.
SERVICE LIMIT: 404 mm (153 in)

FORK TUBE/FORK SLIDER/PISTON

Check the Iork rubE, iork slider and piston for
score marks, scratches, or excessive or abnormal
wear. Replace any componems which are worn or
damaged‘

Check she fork piston ring for wear or damage.
Check she rebound spring for fatigue or damages

FRONT WHEEL/SUSPENSION

 

 

PISTON

@

PISTON RING
FORK TUBE

 

  

 

 

 

 

 

 

\ REBOUND
SPRING
FOR K TUBE
Set the fork rube in V blocks and read the runout,
SERVICE LIMIT: 0.20 mm (0.008 in)
Dam of Issue: Dec, 1982 151

© HONDA MOTOR 00., LTD.

15-27

HONDA

 

 

 

FRONT WHEEL/SUSPENSION V65MAGNA
BUSHING/BACKUP RING

Visuallv inspect the slider and fork tube bushings.

Replace the bushings if there is excessive scoring or BUSHING BACK-UP RING

scratching] or if the teflon is worn so that the
copper surface appears on more than 3/4 of the
entire surface,

Check the backup ring; replace it if there is any
distortion at the points shown.

ANTI-DIVE CASE

Remove the four socket bolts and remove the anti-
dive case.

Remove the piston and spring.
Remove the boots, pivot bolt collar and stop
rubber,

 

 

 

 

 

 

CHECK POINTS

COPPER
SU R FACES

 

 

SPRING

ANTI-DIVE CASE

 

   

0C)
9

BOOT STOP RUBBER

 

15-28

252

Date of Issue: Dec, 1982
©HONDA MOTOR 00., LTD‘

HONDA.
V65MAGNA FRONT WHEEL/SUSPENSION

 

Check the spring and piston lor wear or damage.

 

CHECK BALL

    

Remove the check valve setting screw, valve spring
and check ball,

 

 

VALVE SPRING l

 

Assemble the anti-dive case in the reverse order ol
disassembly.

NOTE:

Apply a Thread Lock Agent to the threads
of the screws and socket bolts before
assembly.

Apply ATF to the piston and pistonO-ring,
Applv silicone grease to the pivot bolt
collar.

Install the pivot bolt collar boot holder

as shown,

 

 

   

 

BOOT HOLDER

 

 

 

 

Date of Issue: Dec] 1982 253
©HONDA MOTOR 60., LTD. 1 5' 29

HONDA

FRONT WHEEL/SUSPENSION V65MAGNA

 

Check the operation of the collar and piston.
STANDARD PISTON STROKE: 2.5 mm (0.10 in)

 

ASSEMBLY

Before assembly, wash all parts with a high flash

point or non~flammable solvent and wipe ‘hem off
completely.

 
    
 

DUST

FORK PLASTIC SEAL SEAL CONNECTOR

TUBE WASHER

CAP SNAP SEONGE Q3. AIRJOINT

RING 3 AL

K S 1 % m AIR ALVE
FOR OIL E
TUBE “ K 3 AL

\BACK-UP RING
\SLIDER

. BUSHING 5 w Q0
i’
\FORK

STABILIZER
ANTI-DIVE CASE

SPACER
\
‘

  

REBOUND
SPRING ‘ PIECE BUSHING

\
“he
:9

DRAIN BOLT

 

15-30

Date of Issue: Dec, 1982
© HONDA MOTOR C0.l LTD.

HONDA
V65MAGNA

 

Insert the rebound spring and piston into the fork
tube.

On the left fork, install the spring seat, valve springl
oil lock valve and circlip on the piston.

Place the oil lock piece on the end of the piston
and insert the fork tube into the slider.

Place the fork slider in a visa with soft laws or a
shop towel.

Apply a locking agent to the socket bolt and thread
it into the piston. Tighten with a 6 mm hex wrench,

NOTE:

Temporarily install the fork spring and fork
tube cap to tighten the socket boltt

 

 

 

 

TOROUE: 15—25 N~m (1.5—2.5 kg-m,11—18It»lb)

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 too] on top.

Drive the bushing into place with the seal driver and
remove the old bushing or equivalent tool.

Coat a new oil seal with ATF and install it with
the seal markings facing up. Drive the seal in with
the seal driver.

Date of Issue: Dec, 1982
© HONDA MOTOR CO, LTD.

FRONT WHEEL/SUSPENSION

SPRING SEAT

PISTON

 

CIRCLIP OIL LOCKVVALVE
HEX WRENCH, 6 mm 07917—3230000

OR COMMERCIALLVY AVAILABLE [N U.S.A.
_ _ ‘ ‘ I "as ,

VALVE SPRING

 

FORK SEAL DRIVER
07947—KA50100

’ , .~_ I 1.
FORK SEAL DRIVER ATTACHMENT
07947—KF00100

265

 

15-31

 

FRONT WHEEL/SUSPENSION

Install the snap ring with Its radiused edge facing
down and install the plastic washer, the sponge seal
and the dust seal.

Pour the specified amount of ATF into the fork
tube.

CAPACITV:

Flight fork: 565 cc (19.1 oz)
LeIt fork: 580 cc (19.6 01)

Irlstall the fork spring, spring seat and spacer in the
fork tube.

NOTE:

Note the spring direction, the narrow pitches
should be at the top of the fork tube.

 

 

 

 

 

HONDA.
V65MAGNA

 

SNAP RING PLIERS
07914—3230001

 

PLASTIC
WASHER

SNAP RING
OIL SEAL

BACK-UP
RING

SLIDER
BUSHING

 

 

 

 

 

 

 

 

BOTTOM TOP
<— —>

(IIIIIIIIIIIIIWWWWWWII

 

15-32

256 Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

Install and torque the fork tube cap.
TORQUE: 15—30 N-m (LS—3.0 kg-m, 11—22 ft-Ib)

INSTALLATION

It the air joints are disassembled, install new O»rings
in the air ]oint groovet

Install the air joint pipe connectors, with new seals
and O»rings over both ends of the air Ioint pipe and
loosely tighten the connectors.

Install the front forks and temporarily tighten the
lower fork pinch bolts.

Install the air joint stop rings in the grooves in the
fork tubest

Install the fork air joints over the fork tubes and
tighten the connectors.

TORQUE: 4—7 Nvm (0.4—0.7 kg-m, 3—5 ft-lb)

FORK TUBE CAP

FRONT WHEEL/SUSPENSION

 

 

 

O-RINGS
0®>e®

%
AIR JOINT

CONNECTOR %/ CS)

JOINT PIPE

SEAL

$0M

if

O-RING

 

 

Al R JO'lN‘i‘S

 

STOPRINGS

 

Date of Issue: Dec, 1982
HONDA MOTOR COt, LTDt

H's-33

FRONT WHEEL/SUSPENSION

Loosen the lower fork pinch bolts and adiust the
fork tube level so that the air joints touch the
underside of the fork top bridge.

Tighten the airjoint mounting screws.

Tighten the upper and lower fork pinch boltst

Tonous:
Upper: 9—13 N-m (0.9—1.3 km, 7—9 ft-Ib)
Lower: 45—55 N-m (4.5—5.5 kg-m. 33—40 tt-lhl

Loosen install the front fork stabilizer.

Install the removed parts in the reverse order of
removal.

— front fender.

— front wheel,

— brake calipers.

— instruments.

— coupler box.

— headlight case and headlight.

With the front brake applied, pump the front forks
up and down several times,
Tighten the front fork stabilizer mounting bolts.

TORQUE: 18—28 N-m (1.8—2.8 kg-m, 14—21 lt-Ib)
install the bolt caps.

Fill the fork tubes with air to 0—40 kPa (0—0.4
kg/cm’, 0—6 psi). and check for leaks.

CAUTION:

Use only a hand operated air pump to fill

the fork Iubes. Do not use compressed air.

- Maximum pressure is 300 kPa (3 kg/cm’,
43 psi]. Do not exceed this or fork tube
component damage may occur,

     

 

With the front brake applied, pump the front
forks up and down several times. Place the motor-
cycle on its center stand. Check the air pressure
and adiust if necessary.

‘4?

 

 

HONDA
V65MAGNA

SCREWS
w.

 

15-34

258

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

STEERING STEM

REMOVAL

Remove the following components.

— coupler box (page 15-3).

— headlight and case (page 154) and brackets.
— instruments (page 15-6).

— ignition coil (page 159).

— handlebars (page 15-10)t

— front wheel (page 1545).

— brake three way loint.

Remove the angle sensor.

Loosen the steering stern pinch bolt.

Remove the steering stem nut, fork top bridge,
lront forks and fork air joints (page 1522).

Date cl Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

 

FRONT WHEEL/SUSPENSION

 

ANGL ENSOR
LOCK NUTWRENCH, so x 32 mm

  

COMMERCIALLY AVAILABLE IN U.S.A. EXTENSION BAH

'V STEM NUT STEM PINCH FORK TOP
BOLT BRIDGE

“9 15-35

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

 

Straighten the lock washer tabs and remove the LOCK WASHER

C NU
lock nut and lock washer. L0 K T

     

STEERING STEM SOCKET

0791 —3710100
Loosen the bearing adjustment nut and remove ' ‘
the steering stemt

 

Check the steering stem bearings for damage or
wear.

BEARING REPLACEMENT

NOTE:

Replace the bearing and bearing race as a set.

Remove the bearing from the steering stem.

 

BEARING

 

zen Date of Issue: Dec, 1982
1 5' 36 ©HONDA MOTOR co., LTD.

HONDA
V65MAGNA

 

Remove the upper bearing race with the special
tooit

Remove the lower bearing race with the special tool.

NOTE:

 

If the motorcycle has been involved in an
accident, examine the area around the steering
head for cracks.

 

 

 

Drive the upper bearing outer race into the head
pipe with the special tools,

Drive the lower bearing outer race into the head
pipe with the special tool.

Date of Issue: Dec, 1982
© HONDA MOTOR COt, LTDt

 

FRONT WHEEL/SUSPENSION

BALL RACE REMOVER
07953—4250002

 

BALL RACE REMOVER
01953—4250002

‘c

BALL RACE REMOVEH
0794673710500

A ACHMENT, 42 x 47 mm BALL RACE DRIVER
07746—0010300 0794673710700

15-37

 

HONDA.

FRONT WHEEL/SUSPENSION . -‘ V65MAGNA

., ‘ STEERING STEM DRIVER
07946 MEOOCICIO

 

Install a dust seal onto the steering stern and press i P ‘
the lower bearing inner race over the stem with
the special tool.

  

 

BEARING RETAINER
INSTALLATION ,

Pack the bearing cavities with bearing grease.

Insert the steering stem into the steering head
pipe and install the bearing retainer and upper
bearing inner racer

 

STEERING STEM SOCKET
07916—3710100
Install and tighten the bearing adjustment nut. \ _

TORQUE: 35—45 N-rn (3.5—4.5 kg-m, 25—33 ft-lb)

  

 

262 Date of Issue: Dec, 1982
1 5‘ 38 ©HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

FRONT WHEEL/SUSPENSION

Loosen the bearing adjustment nut until it can be
turned by hand.

Turn the steering stem lock-to-lock 5 times to seat
the bearings.

 

Tighten the adjusting nut to the specified torque.
TORQUE: 14—16 Nsm (1.4—1.6 kg-m,10—1th-lb)

Check to be sure that the bearings operate smooth-
Iv,

   

i

LOCK WASHER 1
Install a new bearing adjustment nut lock washer

aligning the tabs with the grooves in the nut Bend
two oposite tabs down into the grooves.

NOTE:

DO NOT install a used bearing adjustment
nut lock washer,

 

 

 

 

 

 

Date 04 Issue: Dec, 1982 263
HONDA MOTOR CO., LTD. 1 5 ' 3 9

FRONT WHEEL/SUSPENSION

Hand tighten the lock nut.

Hold the adjustment nut and further tighten the
lock nut only enough to align its grooves with the
lock washer tabs.

NOTE:

It the lock nut grooves cannot be easily
aligned with the lock washer tabs, remove the
nut, turn it over and reinstall it.

 
   

  

 

Bend two lock washer tabs up into the lock nut
grooves.

Install the front forks (page 1533)‘
Install the fork top bridge and tighten the stern nut.

TORQUE:
90—120 N‘m (9‘0—123 kg-m, 65—87 it—lb)

Tighten the steering stern pinch bolt.
TORQUE: 18—30 N-m (1.8—3.0 kg-m, 13—22 ft-lb)

Install the removed parts in the reverse order of
removalt

HONDA
V65MAGNA

 

LOCK WASHER LOCK NUT

   
  

LOCK NUTWRENCH, 30 x 32 mm
COMMERCIALLY AVAILABLE iN U.S.A.

 

EXTENSION BAR
COMMERCIALLY AVAILABLE IN USA.

STEERING STEM PINCH BOLT

 

 

15-40

Date of Issue: Dec, 1982

154
© HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

 

MEMO

 

Date of Issue: Dec, 1982 265
© HONDA MOTOR C0., LTD.

HON DA

  

 

  
 
 
 
 
  
 
   
   
  
  

REAR WHEEL/SUSPENSION V65MAGNA
40—50 N-m
(AD—5.0 kg‘m,
29—36 fl-lb}

100—130 N»m

(10.0—13.0 kg~m,
72794 fl-Ib)

30740 N-m
(3,044.0 kg-m,
22—29 fl-Ib)

 

20—30 N-m
(2.0—3.0 kg~m,
14—22 frlb)

15~20 N~m
(1.5—2.0 kg~m,
12—14 fl-lb)
85*105 N‘m
(85710.5 kg-m,
90—120 N«m 61—76 ft-Ib)
(SD—12.0 kg-m,
65—87 ft~|b)

45~70 N-m
(4.5—7.0 kg~m, 33»51 ft~lb)

 

1 6 _ o 266 Dam of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

 

Irma? 16. REAR WHEEL/SUSPENSION

 

 

 

 

SERVICE INFORMATION 16—1

TROUBLESHOOTING 16—2

REAR WHEEL 16—3

SHOCK ABSORBER 16—9

SWING ARM 16—14
SERVICE INFURMATIUN

GENERAL

0 The rear wheel uses a lubless tire. For tubeless tire repairs, refer to the TUBELESS TIRE MANUAL

I When using the lock nut wrench, use a deflecting beam type torque wrench 14-20 inches long. The lock nut wrench in
creases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the lock
nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench when used
with the lock nutwrench. The torque wrench scale reading is given with the actual torque speclfication.

SPECIFICATIONS

 

 

 

STANDARD SERVICE LIMIT
Axle runout — 0.2 mm (0.01 in)
Rear wheel rim runout Radial — 2.0 mm (0.08 in)

 

 

Axial

__ 2.0 mm (0.08 in)

 

Wheel bearing play

— 0.03 mm (0.001 in)

 

Shock absorber spring free length

 

 

248 mm (9.76 in) 244 mm (9.6 in)

 

 

 

TORQUE VALUES

Rear axle nut

Axle pinch bolt

Shock absorber mount bolt/nut Upper
Lower

Swing arm left pivot bolt

Swing arm right pivot bolt

Swing arm pivot lock nut

Rear brake torque rod

Final gear case attaching nut

TOOLS

Special Shock absorber compressor attachment
Swingarrn pivot lock nut wrench
Socket bit, 17 mm
Bearing remover shaft
Bearing remover head
Bearing remover weight

Common Driver
Attachment, 42 x 47 mm
Pilot, 20 mm
Attachment, 37 x 40 mm
Shock absorber compressor
Attachment, 52 x 55 mm
Bearing remover shaft
Bearing remover head

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

85405 N-m(8.5—10.5 kg-m, 61—76 ft-lb)
20—30 Nam (2.0—3.0 kg-m, 14—22 ft~|bl
40—50 N«m (4.0—5.0 kg-m, 29fi36 ft-Ib)
30—40 N~rn (3.0—4.0 kg-m, 22729 ft-lb)
90—120 N‘rn (53.0—12.0 kg»m, G5e87 ft-lb)
15—20 N-m (1.6—2.0 kg-m, 12fl14ft-lb)
100—130 N-m (10.0—13.0 kg-m, 724M ft-Ib)
18—25 N-m (1.8—2.5 kg-m,13—18 ft-lbl
45—70 N-m (4.5~7.0 kg-m, 33—51 ft-lb)

07967eK010000

07908—4690001 or KS—HBA—08-469 (U.S.A. ONLY)
07703—0020500 Commercially available in U.S.A.
0793678890100

07936—8890200

07936»3710200

07749—0010000
07746—0010300
07746—0040500
07746—0010200
07959—3290001
07746—0010400
07746—0050100
0774670050600

267 1 6

1

REAR WHEEL/SUSPENSION

 

HONDA
V65MAGNA

 

TRflUBLESHUflTING

Oscillation

. Worn tires

, Tire pressure incorrect

r Faulty tire

. Bem rim

, Loose axle

. Swingarm bearings worn
. Loose wheel bearings

“0301:13de

Soft suspension
1. Shock fluid leaking
2. Shock absorber worn inrernally

Hard suspension
7 Bent shock absorber

Suspension noise
1, Shock ease binding
2. Loosefasteners

 

16-2

258

Date 04 Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA

 

REAR WHEEL/SUSPENSION

 

REAR WHEEL

REMOVAL

Place the mo‘orcycle on i‘s cemer sand and remove
‘he axle nuL

Loosen the axle pinch bol‘ and remove the rear
axle‘

Move ‘he wheel to the right to separa‘e it from the
final drive gear case.
Remove the rear wheel.

AXLE NU

 

 

 

Da‘e of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

269

16-3

REAR WHEEL/SUSPENSION

 

HONDA.
V65MAGNA

 

DISASSEMBLY

Remove the rear disc bolts and the dies.

Remove the final driven flange mount bolts and lift
the driven flange out of the hub.

Remove the oil seal from the hub

Inspect the condition of the bearings (page 1&5)‘
Remove the bearings with the bearing remover shaft
(07746—0050100) and head (O7746—0050600),
Remove the distance collari

The bearing must be replaced with a new one if it
is removed.

 

 

16-4

270

Date of issue: Dec, 1982
© HONDA MOTOR 60., LTD,

HONDA
V65MAGNA

 

REAR WHEEL/SUSPENSION

 

INSPECTION
AXLE

Set the axle in V blocks and read the axle runout
with a dial indicator.

The actual axle runout is 1/2 oI total indicator
reading.

SERVICE LIMIT: 0.2 mm (0.01 in)

WHEEL BEARINGS

Place the wheel in a truing stand with a vertical dial
indicator positioned on the inside of the rim.

CareIully lift up on the bottom of the wheel to
read the bearing play.

Rotate the wheel by hand to determine the general
condition of the bearing.

Replace any bearings that are noisy or that have
excessive Dlay.

SERVICE LIMIT: 0.03 mm (0.001 in)

WHEEL RIM RUNOUT

Check the rim for runout by placing the wheel in
a truing stand. Turn the wheel slowly, and read the
runout using a dial indicator.

SERVICE LIMITS:

RADIAL RUNOUT: 2.0 mm (0.08 in)
AXIAL RUNOUT: 2.0 mm (0.08 in)

The wheel cannot be trued and must be replaced
if the above limits are exceeded.

 

 

 

 

PLAY

 

 

 

 

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

16-5

HONDA

 

 

 

REAR WHEEL/SUSPENSION V65MAGNA
ASSEMBLY
NOTE
E Use lithium~hased MULTIPURPOSE grease

with MoSZ-additive as iollows:

' MOLYKOTE BRZ-S manufactured by Dow
Corning, U,S.A.

MULTIPURPOSE M~2 manufactured by
Mitsubishi Oil, Japan

' STAVLUBE NLGI #2.

Other lubricants oi equivalent quality.

' The wheel uses a tubeless tire, For tubeless
tire repairs, vetev to TUBELESS TIRE
MANUAL.

 

 

 

LITHIUM BASED
MU LT| PU RPOSE
G REASE
(MoSZ—additive)

   

D R | VE R
0774970010000

Pack all bearing cavities with grease.

Press the distance collar into place from the left
side. Drive the right ball bearing in first, then the
left ball bearing

CAUTION

> Drive [he bearingx in squarely
- [mm]! the bearingx with the sealed end

facing out, making .vure they are fully
xealed,

  
 
 

 

 

 
 

ATTACHMENT, 52 x 55 mm ATTACHMENT, 42 x 47 rnrn
07746—0010400 07746—0010300
PILOT, 20 mm 07746—0040500 PILOT, 20 mm 07746A0040500

272 Date of Issue: Dec, 1982
1 6- 6 ©HONDA MOTOR CO., LTD.

    

HONDA
V65MAGNA

 

Install a new oil seal into the hub

Install the final driven flange onto the hub and
tighten the bolts.

Install the rear disc and tighten the bolts.

OILSEAL
war» *

REAR WHEEL/SUSPENSION

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

27::

REAR WHEEL/SUSPENSION

INSTALLATION

Apply MULTIPURPOSE NLGI No. 2 Grease
(MOSZ-additive) lo the final driven flange splines of
‘he rear wheel and ring gear‘

Engage ‘he rear wheel with the final drive ease,
making sure ‘he splines are correcllv aligned,

Insert the rear axle through the swing arm, washer,
caliper bracket, side collar, hub and final drive gear.
Tighten the axle nutr

TORQUE:
85—105 N-m (8.5—10‘6 kg-m, 61 ~76 ft-lhl

Tighten the axle pinch boll.
TORQUE: 20—30 N~m (2.0—10 kg-In, 14—22 ft-lb)

HON DA
V65MAGNA

 

 

AXLE NUT

  

&

 

AXLE PINCH BOLT

 

 

16-8

274

Date of Issue: Dee,1982
© HONDA MOTOR CO., LTD.

HONDA
V65MAGNA

 

REAR WHEEL/SUSPENSION

 

SHOCK ABSURBER

REMOVAL

Remove the left mufflerr

Remove the seat.
Remove the tool box

Remove the right and left shock absorber upper
mount bolts.

Remove the two bolts attaching the rear cowl and
rear grip.

Remove the rear cowl attaching screws and remove
the rear cowl and rear gripe

UPPER MOUNT
BOLT

REAR GRIP

 

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO“ LTD.

275

16-9

REAR WHEEL/SUSPENSION

Remove the shock absorber lower mount bolt or
nut and remove the shock absorber.

DISASSEMB LY

Lightly compress the damper upper adjuster and
remove the adjuster stopper ring.
Remove the upper adjuster cover‘

Release the shock from the compressor tool.
Remove the damper adiuster, springs and steel balls.

HONDA,
V65MAGNA

 

 

 

 

 

 

,1 ' a.»
ADJUSTER STOPPER RING

STEEL BALL§
2

    

SPRINGS

DAMPE R ADJUSTE R

 

16-10

276 Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA REAR WHEEL/SUSPENSION

 

 

 

Install the attachment onto the spring. ATTACHMENT SHOCK ABSORBER

07967»KC10000 COMPRESSOR

Set the shock in the compressor as shown and 0795973290001

compress the spring 30 mm by turning the com-
pressor handle.

 
 
  

Remove the upper retainer through its cutout and UPPER RETAINER

remove the compressor,

 

 

SPRING FREE LENGTH

Measure the rear shock absorber spring free length‘
SERVICE LIMIT: 244 mm (9.6 in)

WIN

  

 

 

 

 

Date of Issue: Dec, 1932 277
©HONDA MOTOR (20., LTD. 1 6 ' 1 1

HON DA
V65MAGNA

 

REAR WHEEL/SUSPENSION

ASSEMBLY

Place the spring and spring upper seat on the
damper.

NOTE:

Install the spring with the Lightly wound end
facing up

 

 

 

 

RUBBER BUSHING

  
 
   

STOPPER RING——‘>< 2 /

SPRING\

DAMPER

   

ADJUSTER

DAMPER ADJUSTER“> SPRINGS

STEEL BALLS

UPPER RETAINER—p _

 

UPPER SPRING SEAT—>‘

Set the shock absorber in the compressor with the
allachmem and compress the spring.

Install the upper retainer and remove (he com-
pressor and attachment.

 

ATTACH M ENT
D7967—KC10000

SHOCK ABSORBER
COMPR ESSO R
0795943290001

 

 

 

 

1 6 1 2 273 Date of Issue: Dec, 1982
- © HONDA MOTOR CO., LTD,

HONDA
V65MAGNA

 

Install the steel balls on their original position.
Install the springs and upper adjuster.

Install the upper adjuster cover, aligning the tabs of
the cover with cutouts in the adluster.

Lightly compress the damper upper adiuster and
install the stopper ring.

INSTALLATION

Install the shock absorber and tighten the lower
mount bolt or nut,

TORQUE: 30—40 N-m (3.0—4.0 kg-m, 22—29 ft—lb)

Install the rear cowl and rear grip,
Install the tool box.

Tighten the upper mount bolt.
TORQUE: 40—50 N-rn (4.0—5.0 kg-m, 29—36 h-Ib)

Install the seat.
Install the left muffler.

 

REAR WHEEL/SUSPENSION

CUTOUTS

  

 

 

 

 

 

 

REAR GRIP

  

_ _ I
REAR COWL

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

279

16-13

REAR WHEEL/SUSPENSION

SWINGARM
REMOVAL

Remove the rear wheel (page 16-3) and the final
drive gear case (page 14-3).

Remove the shock absorbers.

Remove the rear brake torque rod.

Remove the swingarm pivot caps and loosen the
right pivot bolt lock nut.

Remove the right pivot bolt, using an 17 mm socket
bit.

Remove the left pivot bolt and remove the swing
arm.

Remove the boot from the swingarm.

; HONDA.
V65MAGNA

  

CALIPER

TORQUE ROD
SWINGARM PIVOT LOCK NUT WRENCH 07908—4690001
OR KSeHBA—OSANSQ (U.S.A. ONLY)

 

LOCK NUT

LEFT PIVOT BOLT

  

V V ,

v - ‘ r, ~~ ' 3‘
RIGHT PIVOT BOLT SOCKET BIT, 17 mm D7703~0020500

COMMERCIALLY AVAILABLE IN U,S.At

 

16-14

230 Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

   

HONDA
V65MAGNA

 

PIVOT BEARING REPLACEMENT

Remove the dust seals and bearings from both
sides of the swingarm as follows:

Remove the swingarm bearings using the bearing
remover head, 07936—8890200, shaft. 07936—
8890100 and weight 07936—3710200, Install the
remover and expand it as much as possible behind
the bearing race, Strike the weight lightly several
times to move the race out enough so that the
remover can be expanded completely. Expand the
remover completely, Slide the weight again with
enough force to remove the race.

INSTALLATION

NOTE:

Replace the inner and outer bearing races as
a set. Replace the grease retainer plate when-
ever it is removed,

 

 

 

 

Install new grease retainer plates. Drive new outer
bearing races into the swingarm.

Apply grease to the pivot bearings dust seals and
pivot bolt tips.
Install the bearings and dust seals.

REAR WHEEL/SUSPENSION

 

 

BEARING REMOVER
HEAD
07936—8890200

     
    

1 SLIDING HAMMER WEIGHT
3 07936—3710200

BEARING REMOVER
SHAFT
07936—8890100

 

 

 

DRIVER ATTACHMENT,
07749—001000!) 37 x 40 mm 07746—0010200
WM“
Kt” , x. c

   

 

RIGHT PIVOT BOLT

     
  

BEARINGS

Qt.W

DUST SEALS LEFT PIVOT BOLT

   

 

Date of Issue: Dec, 1982
HON DA MOTOR 00., LTD.

131

16-15

HONDA

REAR WHEEL/SUSPENSION V65MAGNA

 

. ”UP" MARK
Install the sWIngarm boot with the "UP" mark up.

SOCKET BIT, 17 mm 07703—0020500

_ COMMERCIALLY AVAILABLE IN USA.
lntall the swmgarm and pivot bolts. ,

Tighten the left pivot bolt to the specified torque.
TORQUE: 90—120N-m
(9.0—12.0 kg-m, 65—87 [t-lb)

Tighten the right pivot bolt to 40 N-rn (4t0 kg-m,
29 (Mb), loosen it and retighten to the specified
torque.

TORQUE: 16—20 N-m (1.6—2.0 kg-m,12—14 ft-lb)

Move the swingarm up and down several times.
Retighten the right pivot bolt to the specified
torquel

 

 

1 6 _ 1 6 232 Date of Issue: Dec, 1982

© HONDA MOTOR (30., LTD,

HONDA
V65MAGNA

 

REAR WHEEL/SUSPENSION

 

Tighten the lock nut while holding the right pivot
bolt,

TORQUE: 100—130Nrm
(10.0—13.0 kg-m, 72—94 lt-lh)

Connect the rear brake torque rod to the swingzrm
and tighten the nut.

TORQUE: 18—25 N-m (1.5—2.5 kg-m, 13—15 lt-Ib)
Secure the nut with a new cotter pin.
Install the final gear (page 1449).

Install the shock absorbers (page 1643).
Install the rear wheel (page 16-8).

 

 

SWINGARM LOCK NUT WRENCH
—4690001 0R KS#HBA—087469 (U S A.)

h . ‘* .
SOCKET BIT, 17 mm COMMERCIALLY
AVAILABLE IN USA.

 

\.
REAR BRAKE TORQUE ROD

 

Date ol Issue: Dec, 1982
© HONDA MOTOR CO., LTD,

16-17

HONDA

 

 

  
  
  
  

HYDRAULIC BRAKES V65MAGNA
10—1 4 N -m

2—3‘5 Nlm _ _ _ >

“324335 kg-m, (1.0 14 kg m, 7 10 ft lb)

1.4—2.5 ft-lb)

25—35 N-m
9 fi". (25—3.?) kg-m,

Q 18—25 fi-Ib)
30—45 N-m
(Sn—4.5 kg-m,

22—33 ft-Ib)

(340—4‘5 kg-m, 22—33 frlb) ~

25—35 N-m %@
(2.5—3‘5 kg-m, 18725 ft-Ib)

 
 
 
  

2,9~5.1 frlb)

4*7 N-m
(0.4—0] kg-m,
B

 

284 Date of Issue: Dec, 1982
1 7 ' 0 © HONDA MOTOR 00., LTD.

 

 

 

 

HONDA
vasmem I7. HYDRAULIC BRAKE
SERVICE INFORMATION ”—1 FRONT MASTER CYLINDER 17—8
TROUBLESHOOTING 17—2 BRAKE CALIPERS 17—10
BRAKE FLUID REPLACEMENT/ REAR MASTER CYLINDER 1743
AIR BLEED'NG 17-3 BRAKE PEDAL SHAFT 17—16
BRAKE PAD/DISC 17—5

 

 

SERVICE INFURMATIIJN

GENERAL

The front and rear brakes can be removed without disconnecting the hydraulic system.

Once the hydraulic systems have been opened, or if the brakes feel spongy, the system must be bled.

Avoid spilling brake fluid on painted surfaces or instrument lenses, as severe damage can result.

0
o
0 Do not allow foreign material to enter the system when filling the reservoirs.
-
0

Always check brake operation before riding the motorcycle.

SPECIFICATIONS

 

STANDARD

SERVICE LIMIT

 

Front disc thickness

4.8—5.2 mm (019—010 in)

4.0 mm (016 in)

 

Front disc runout

030 mm (0.012 in)

 

Front master cylinder I.D.

15.870—15913 mm (06248—06265 in)

15.93 mm (0.627 in)

 

Frcnt master piston O.D.

15327—15854 mm (06231—06242 in)

15.8 mm (0.62 in)

 

Front caliper piston O.D.

31948—31998 mm (12578—12598 in)

31.940 mm (1.2575 in)

 

Front caliper cylinder l.D.

31030—32.an mrn (12610—12630 in)

32.09 mm (1.263 in)

 

Rear master cylinder |.D.

14000—14043 mm (05512—05529 in)

14.055 mm (0.5533 in)

 

Rear master piston O.D.

13.957a13.984 mm (05495—05506 in)

13.945 mm (0.5490 inl

 

Rear caliper cylinder |.D.

30230—30280 mm l1.1902—1.1921 in)

30.29mm(1t193inl

 

Rear caliper piston O.D.

30148—30198 mm (1.1869—1.1889 in)

30.140 mml1t1866 in)

 

Rear disc thickness

6.9—7.1 mm (0.272e0.280 in)

6.0 mm (0.24 in)

 

Rear disc runout

 

 

 

 

0.30 mm (0,012 in) l

 

TORQUE VALUES

Brake hose bolt

Front brake caliper
Rear brake pedal
Master cylinder holder
Rear brake torque rod

TOOL

Special
Snap ring pliers

25735 N-m (2t5~3.5 kg<m, 18—25 ft-lb)
30—45 N-m (3.0—4.5 kg-m, 22—33 ft-lb)
24730 Nrm (2.4——3.0 kg~m, 17—221t-Ib)
10414 N~m (1.071t4 kg-m. 7710 ft~|bl

18—25 N-m (1.8—2t5 kg-m, 13—18ftrlbl

07914—3230001

 

Date of Issue: Dec, 1982

HONDA MOTOR C0., LTD.

285

17-1

HYDRAULIC BRAKES

TROUBLESHOOTING

Brake lever/pedal soft or spongy

1, Air bubbles in hydraulic system
2. Low fluid level
3. Hydraulic system leaking

Brake lever/pedal too hard

1‘ Sticking pistonls)
2‘ Clogged hydraulic system
3. Pads glazed or worn excessively

Brakes drag

1. Hydraulic system sticking
2. Sticking pistonis)
3. Incorrect rear brake pedal adjustment

HONDA
V65MAGNA

 

Brakes grab

1. Pads contaminated
2. Disc or wheel misaligned

Brake chatter or squeal

1. Pads contaminated

2. Excessivedisc runout

3. Caliper installed incorrectly
4. Disc or wheel misaligned

 

17-2

236 Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD,

HONDA.
V65MAGNA

 

HYDRAULIC BRAKES

 

BRAKE FLUID REPLACEMENT/
AIR BLEEDING

Check the fluid level with the fluid reservoir paraIIEI
to the ground,

CAUTION:

. Install Ihedlaphragm on the reservoir when
operating the brake [ever (or pedal). Failure
to d0 :0 will allow brake fluid to xqm‘r! out
a f the reservoir during brake operation.

' Avoid spilling fluid on painted or phlxlic
xurfacex. Place a rag over the five! tank
whenever the system is serviced.

 

BRAKE FLUID DRAINING

Connect a bleed hose to the bleeder valve.

Loosen the caliper bleeder valve and pump the
brake lever for pedal).

Stop operating the lever (or pedal) when no iluid
flows out of the bleeder valve.

A contaminated brake disc or had reduces

slapping pawer. Discard contaminated pads
and clean a contaminated disc will: (I high
qualiry brake degreasing agent.

 

BRAKE FLUID FILLING

NOTE ,
Do not mix different types oi brake fluid
since they are not compatible.

Close the bleed valve, fill the reservoir with DotA4
brake fluid, and install the diaphragm,

To prevent piston overtravcl and brake fluid
seepage, keep a 20 mm (3/4 in) spacer between the
handlebar grip and lever when bleeding the front
brake system. 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 felt.

 

 

a , p.
LOWER LEVEL

UPPER LEVEL

 

LOWER LEVEL

 

 

Date oi Issue: Dec, 1982
© HONDA MOTOR 00., LTD

287

17-3

 

i
i

HONDA
V65MAGNA

 

HYDRAULIC BRAKES

AIR BLEEDING

NOTE

. Check the fluid level often while bleeding
the brakes to prevent air from being pump-
ed into the system.

. Use only DOT 4 brake fluid from a sealed
container.

' Do not mix brake fluid types and never re
use the contaminated fluid which has been
pumped out during brake bleeding, because
this will impair the efficiency of the brake
system.

 

 

 

 

1) 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 until the
bleed valve has been closed.

 

 

 

 

2) 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 coming out of the bleeder valve.

Fill the fluid reservoir to the upper level mark.

 
    
 
  

A contaminated brake disc or pad reduces
stopping power. Discard contaminated pads
and clean a contaminated disc with a high
quality brake degrensing agent.

 

 

 

1 7 4 288 Date of Issue: Dec, 1982
' © HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

BRAKE PAD/DISC

FRONT PAD REPLACEMENT

NOTE:

 

Always replace the brake pads in pairs to
assure even disc pressure,

 

 

 

Remove the pad pin retainer bolt and caliper bolt.

Remove the calipers.

Remove the pad pin retainer and pull the pad pins
out of the caliper.
Remove the brake pads.

Position the pad spring in the caliper as shown.
Push the caliper pistons in all the way.

PAD PIN RETAINER

HYDRAULIC BRAKE§
CALIPER PIVOT

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

HYDRAULIC BRAKES

 

HQN’DA
V65MAGNA

 

Install the new pads in the caliper.

lnstall 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
the retainer down to secure the pins.

Check to be sure that the retainer clip is in place
on the caliper bracket.

 

 

17-6

790

Date of Issue: Dec, 1982
HONDA MOTOR 00,, LTD.

HONDA
V65MAGNA

 

Install the calipers over the brake discs so that the
discs are positioned between the pads, making sure
not to damage the pads. Install the caliper pivot
bolts.

Install the caliper bolts.

Install the pad pin retainer bolts.

REAR PAD REPLACEMENT

Replace the rear brake pads using the same method
as used for front brake pad replacement.

DISC THICKNESS

Measure the disc thickness with a micrometer.

SERVICE LIMIT:
FRONT: 4.0 mm (0.16 in)
REAR: 6.0 mm (0.24 in)

BRAKE DISC WARPAGE

Measure the brake disc warpage on a surface plate
with a feeler gauges

SERVICE LIMIT: 03 mm (0.012 in)

 

CALIPER BOLT

PAD PIN RETAINER BOLT

HYDRAULIC BRAKES

 

 

 

Date of Issue: Dec, 1932
© HONDA MOTOR CO., LTD.

291

17—7

HYDRAULIC BRAKES

FRflNT MASTER CYLINDER

DISASSEMBLY

Drain brake fluid tram the hydraulic system.
Remove the brake lever and rear view mirror from
the master cylinder. Disconnect the brake hose.

CAUTION:

Avoid spilling brake fluid on painted or

plastic surfaces, Place a rag over Ihefuel tank
whenever the brake system is serviced.

 

NOTE
When removing the oil hose bolt, cover the
end of the hose to prevent contamination.
Secure the hose to prevent fluid from leaking
out.

 

 

 

 

Remove the master cylinder.

Remove the piston boot and the circlip from the
master cylinder body.

Remove the secondary cup and piston. Then remove
the primary cup and spring.

Remove the brake light switch from the master
cylinder body, it necessary.

Clean the inside ofthe master cylinder and reservoir
with brake fluid.

OIL HOSE BOLT

  

HONDA
V65MAGNA

 

 

9a
SNAP RING PLIERS
07914—3230001

 

 

PISTON

%/

/%

SECON DARY
CUP

PRIMARY CUP

E
E

%

 

 

 

17-8

292

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

 

HONDA.
V65MAGNA

 

HYDRAULIC BRAKES

 

INSPECTION

Measure the master cylinder l,D.
Check the master cylinder for scores, scratches or
nicks.

SERVICE LIMIT: 15.93 mm (0327 in)

Measure the master piston O.D.
SERVICE LIMIT: 15.8 mm (0.62 in)

Check the primary and secondary cups for damage
before assembly.

ASSEMBLY

CAUTION:

Replace the master cylinder piston, cylinder
and spring as a set.

 

 

 

 

Assemble the master cylinder. Coat all parts with
clean brake fluid before assembly, Install the spring
and primary cup together.

Dip the piston cup in brake fluid before assembly.

CAUTION:

When installing the cups, do not allow the lips
to turn inside am. Be certain the ciwlip is
seated firmly in the gruuve.

 

 

 

 

Install the piston and clip.
Install the boot.

 

 

 

 

PISTON

BRAKE FLUID

DOT-4

i

é

  

FRONT BRAKE

LIGHT SWITCH

 

 

 

Date of Issue: Dee, 1982
© HONDA MOTOR 00., LTD.

293

17-9

 

HYDRAULIC BRAKES

Place the master cylinder on the handlebar and
install the holder and the two mounting bolts.
Align the end of the holder with the punch mark
on the handlebar, and tighten the upper bolt first
then tighten the lower bolt‘

TORQUE: 10—14 N‘m (1.0—1.4 kg-m, 7—10 lt-Ib)

Install the oil hose with the bolt and its two sealing
washers.
Install the brake lever.

Fill the reservoir to the upper level and bleed the
brake system according to page 17-4.

BRAKE CALIPERS

REMOVAL

Place a Clean container under the caliper and dis-
connect the brake hose from the caliper.

CAUTION:

A void spilling brake fluid on painted xurfacex.

Remove the caliper bolt and pivot bolt,
Remove the caliper.

 

OIL HOSE BOLT

HON DA
V65MAGNA

 

CALIPER BOLT

BRAKE H SE VOT BOT

‘ ’
CALIPER BOLT

‘I

 

 

17-10

294

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HO DA
V65MAGNA

 

DISASSEMBLY

Remove the pad pln retainer.

Remove the pads and pad spring,

Remove the caliper pivot collar and boots.
Remove the pistons from the caliperr

If necessary, applv 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
expelled. Use the air in short spurts.

 

Do not bring the nozzle (00 close to the rule

Examine the pistons and cylinders for scoring,
scratches or other damageartd replace if necessary.

Push the piston seals in and liit them out and
discard them.
Clean the oil seal grooves with brake fluid.

CAUTION:

Be careful ml to damage the pimn :1
surface

 

 

 

PAD SPRING

PIVOT COLLAR

 

HYDRAULIC BRAKES

BOOTS

  

 

 

Date ol Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

795

17-11

HYDRAULIC BRAKES

PISTON INSPECTION

Check the pistons for scoring, scratches or other
faults. Measure the piston diameter with a micro-
meter.

SERVICE LIMIT:

FRONT: 31.940 mm (1.2575 In)
REAR: 30.140 mm (1.1866 in)

CYLINDER INSPECTION

Check the caliper cylinder for scoring, scratches or
other faults. Measure the caliper cylinder boret

SERVICE LIMIT:
FRONT: 32.09 mm (1.263 in)
REAR: 30.29 mm (1.193 in)

ASSEMBLY

If the piston boots are hardened or deteriorated,
replace them with new ones, Tth piston seals must
be replaced with new ones whenever they are
removed. Coat the seals with silicone grease or brake
fluid before assembly.

Install the pistons with the dished ends toward the
pads.

Install the collar boots and collar making sure that
the boots are seated in the collar and caliper grooves
properly.

Install the pad spring and pads,

HONDA
V65MAGNA

 

 

 

CO LLAR
BOOTS

 

PISTON OIL SEALS PAD SPRING COLLAR

 

17-12

296 Date of Issue: Dec, 1932
HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

INSTALLATION

Be sure that the retainer clip is in position on the
caliper bracket.

Inspect the condition 0! the caliper pivot bolt boot.
Apply silicone grease or brake fluid to the caliper

pivot bolt.
Install the caliper assembly over the brake disc so
that the disc is positioned between the pads.

CAUTION:

Be careful not to damage the pads.

Install the caliper pivot bolt and caliper bolt.
Connect the brake hose and tighten the brake hose
bolt.

TORQUE: 25—35 N~m 12.5—35 kg-m, 18—25 ft-lbi

Fill the brake fluid reservoir and bleed the brake
system (page 17-4).

REAR MASTER CYLINDER

REMOVAL

Remove the right foot peg bracket.

 

HYDRAULIC BRAKES

CALIPER PIVOT BOLT
. V t \

A
BRAKE HOSE CALIPER
BOLT BOLT
BRAKE HOSE BOLT
'7

v/f'

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO.V LTD.

297

HYDRAULIC BRAKES

Remove the cotter pin and pull out the joint pin
connecting the master cylinder push rod end and
rear brake pedal shalt

Place a clean drain pan under the master cylinder
and disconnect the brake hoses from the master
cylinder.

CAUTION:

A void spilling brake
surfaces to prevent p

 
  

id on painted or plastic
t damage

 

Remove the master cylinder attaching bolts and
remove the master cylinder.

DISASSEMBLY

Remove the rubber cover.

Remove the snap ring with snap ring pliers (07914—
3230001) and remove the push rod from the master
cylinder.

ATTACH I NG BOLTS

SNAP RING

 

 

HONDA.
V65MAGNA

 

 

 

17-14

293

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

 

 

 

HONDA
V65MAGNA

 

Remove the master piston, primary cup and spring‘

It may be necessary (0 apply a small amount at air
pressure to the fluid autlet ta remove the master
pistan and primary cup.

Clean all parts with brake fluid.

REAR MASTER CYLINDER I.D,
INSPECTION

Measure the inside diameter 0f the master cylinder
beret

SERVICE LIMIT: 14.005 mm (05533 in)

Check for scores, scratches or nicks.

REAR MASTER PISTON O.D.
INSPECTION

Measure the master piston O.D.
SERVICE LIMIT: 13.945 mm (0.549 in)

Check the primary cup and secondary cup Ior
damage belare assemblyt

MASTER CYLINDER BODV
’ film/m.

PRIMARY CUP AND SPRING

HYDRAULIC BRAKES

PISTON

PUSH ROD

 

 

 

Date of Issue: Dec, 1932
© HONDA MOTOR 00., LTD.

299

17-15

HYDRAULIC BRAKES

ASSEMB LY
CAUTION:

 

Replace [he master cylinder plslon, cylinder
and spring as a set.

 

 

 

Assemble the master cylinder.
Coat all parts with clean brake fluid.

Dip the piston cup in Dot 4 brake fluid before
assembly.

CAUTION:

When installing [he cups, do not allow the lips
to turn inside out Be certain the snap ring is
seated firml y in the groove.

 

 

 

 

Install the primary cup and piston.

Install the push rod and snap ring.
ASS E M B LY

Install the master cylinder and tighten the attaching
bolt.

Connect the push rod end and brake pedal shaft
with the joint pin. Secure the joint pin with a new
cotter pin.

Connect the brake hoses to the master cylinder and
tighten the brake hose bolt.

TORQUE: 25—35 N-m (2.5—3.5 kg<m, 18—25 It-lb)
Install the right foot peg bracket.

Fill the brake fluid reservoir and bleed the rear
brake system (page 1774).

BRAKE PEDAL SHAFT

REMOVAL

Unhook the brake light switch spring and remove
the rear brake pedal.

Remove the cotter pin and joint pin, and then
disconnect the pedal shaft from the master cylinder
push rod.

Unhook the brake return spring and remove the
rear brake pedal shaft.

17-16

MASTER CYLINDER BODY

PRIMARY CUP AND SPRING

300

HQNDA
V65MAGNA

 

MASTE R PISTON

 

PUSH ROD

OTTER PIN B AK LIG T
SWITCH SPRING

 

Date oi Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

HONDA
V65MAGNA

 

INSTALLATION

Applv grease to the brake pedal shaft and install it
in the frame,

Hook the brake return spring correctly.

Connect the pedal shaft to the master cylinder push
rod end and install the joint pin. Secure the joint
pin with a new cotter pin.

Install the brake pedal aligning the punch marks on
the shaft and pedal.

Tighten the brake pedal bolt.

TORQUE: 24—30 N-m (2.4—3.0 kg-m, 17—22 ft-lb)
Hook the brake light switch spring.

 

HYDRAULIC BRAKES

PUNCH MARKS

BRAKE LIGHT
SWITCH SPRING

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO.‘ LTD,

301

17-17

fig HONDA
V65MAGNA

BATTERY/CHARGING SYSTEM

’ ofifig flap—l IGNITIONSWITCH

t’vvé:

   
 
 

REGULATOR/RECTIFIER

 

 

 

 

 

 

 

 

 

 

 

 

 

ALTERNATOR
— RED/WHITE _T—
RED
f T >
_ m
_ HJ
FUSE 30A _— I:
g_ _ <
O _ m
_l _
.1 _
g _ —
MAIN
VOLTAGE SWITCH
I SENSOR
ALTERNATOR ' I 6 MIA“
GREEN REGULATOR/RECTIFIER
BATTERY/CHARGING SYSTEM ’5'
302 Date of Issue: Dec] 1982

1 8 '0 © HONDA MOTOR CO., LTD.

came 18. BATTERY/CHARGING SYSTEM

 

 

SERVICE INFORMATION 18—1
TROUBLESHOOTING 18—2
BATTERY 18—3
CHARGING SYSTEM 18—4

 

SERVICE lNFflRMATIUN

GENERAL

0 Battery fluid level should be checked regularly. Fill with distilled water when necessary.

0 Quick charge a battery, only in an emergency. Slochharging is preferred.

0 Remove the battery irom the motorcycle for charging. If the battery must be charged on the motorcycle, disconnect the
battery cables.

    

Do not minke, and keep flamex away from a charging battery. The gas produced by a battery will explode r'fflames
or sparkx are brought near.

  

0 All charging system components can be tested on the motorcycle
0 Alternator removal is in Section 9.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

F Capacity 12v 18AH
Battery Specific gravity 1180/2000 (63°F)
Charging rate 1.8 amperes maximum
, 1,000 rpm 5,000 rpm
Alternator Capacity
10.2A min. (No load) 25A min. (No load)
Voltage regulator Transistorized non~adiustab|e regulator
Date of Issue: Dec, 1982 303 1 8 1

© HONDA MOTOR (30., LTD.

BATTERY/CHARGING SYSTEM

TRUUBLESHUBTING

No power — key turned on:
1. Main fuse burned out
2. Dead battery
# Low fluid level
— Low specific gravity
— Charging system failure
3. Disconnected battery cable
4. Faulty ignition switch

Low power — key turned on:
1. Weak battery
~ Low fluid level
— Low specific gravity
— Charging system failure
2. Loose battery connection

Low power — engine running:
1. Battery undercharged
— Low fluid level
— One or more dead cells
2. Charging system failure

HON DA
V65MAGNA

 

Intermittent power:

1. Loose battery connection

2. Loose charging system connection

3, Loose starting system connection

4. Loose connection or short circuit in ignitlon
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

 

1 8-2

304

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

HONDA
V65MAGNA

 

BATTERY/CHARGING SYSTEM

 

BATTERY

REMOVAL

Remove the right side covert

Remove the battery holder bolt.

Pull the battery out, and disconnect the ground
cable at the battery terminal then disconnect the

positive cable.

Remove the battery.

TESTING SPECIFIC GRAVITY
Test each cell with a hydrometer.

SPECIFIC GRAVITY: 1.270—1‘290 (20°C, 63°F)

 

 

 

 

 

1270—1290 Fully charged
Below 1.260 Undercharged
NOTES

 

. The battery must be recharged if the spe-
cific gravity is below 1.230.

' The specific gravity varies with the tempe-
rature as shown in the accompanying table.

~ Replace the battery it sulfation is evident
or it the space below the Cell plates is filled
with sediment.

 

The battery ummt'ux sulfuric acid. Avoid
contact with skin, eyes, or clatltiug.
Antidote: Flush with water and get prampt

 

 

medical attention.

 

CHARGING

Remove the battery cell caps.

Fill the battery cells with distilled water to the
upper level line, it necessary.

Connect the charger positive (+) cable to the battery
positive (+) terminal.

Connect the charger negative (—) cable to the
battery negative (~) terminal.

Charging current: 1.8 amperes max.
Charge the battery until specific gravity is 1.270—
1290 at 20°C (68°F).

BATTERY HOLDER BOLT GROUND CABLE

 

‘ 3y BATTERY TEMPERATURE vs srzcmc snavnv
I 304

I so
t 29
I 23
27

123

SPECIFIC GRAVITY

125

 

6' 0* s- to' 15' 20‘ 25‘ 30' 35' AO'
r- :2- «r 50‘ 59‘ 65. 77‘ w 954 I04‘
ELECTRDLVTE rmrmnun:

 

 

 

um Specific gravttv change: by 0 m7 «at every 10°C.

  
  

 

 

 

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

305 18-3

 

BATTERY/CHARGING SVSTEM

mam—

Befare charging a battery, remove the cap
from each cell.

Keep flames and sparks away from (I charg-
ing battery.

- Tam power UN/UFF at the charger, not
at the battery terminals to prevent sparks.
D/sconti'mre charging If the electrolyte
temperature exceeds 45 °c (113°F).

 

CAUTION:

' Quick-charging should only be done in an
emergency; slow-charging is preferred.

~ Route the breather tube as shown on [he
batIery caution label.

 

 

 

 

After installing the battery. coat the terminals with
clean grease,

CHARGING SYSTEM

CURRENT TEST
NOTE

Be sure the battery Is In good condition
before perform ng th test

Warm up the engine.

 

Remove the frame right side cover.

Disconnect the black wire at the regulator/rectifier
coupler.

Disconnect the headlight.

Disconnect the battery positive cable at the battery
terminal and connect an ammeter between the
battery cable and terminal.

Allow engine to idle.

Increase engine speed slowly.

Charging amperage should be a minimum M102 at
1,000 rpm and should be a minimum of 25 amperes
at 5,000 rpm.

Check the stator (page 18-4) and then the regulator/
rectifier (page 18-5), if the charging specifications
are not met.

STATOR CONTINUITY TEST

Remove the right 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 if there is no continuity between
the leads, or if there is continuity between the leads
and ground.

 

HONDA
V65MAGNA

 

 

 

18-4

306

Date of Issue: Dec, 1982

© HONDA MOTOR 00,, LTD.

HONDA
V65MAGNA

 

VOLTAGE REGULATOR/RECTIFIER
TEST

Remove the right side cover.
Disconnect the regulator/rectifier couplers.

Check for continuity between the leads with an
ohrnrneter.

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: CONTINUITV

BATTERY/CHARGING SYSTEM

 

 

 

 

 

@ probe 9 Frobe
I YELLOW GREEN
ll RED/WHITE YELLOW

 

REVERSE DIRECTION: NO CONTINUITY

 

 

 

 

® probe 6 probe
I GREEN YELLOW
ll YELLOW RED/WHITE

 

 

 

 

VOLTAGE REGULATOR
PERFORMANCE TEST

Connect a voltmeter across the battery.

Check regulator performance with the engine
running The regulator rnust divert current to
ground when battery voltage reaches 14.0 ~
15.0 V,

 

 

 

 

 

 

 

RED/WHITE
0
Z
9
5 s
g x E
g D
_ w
a 3 gt,
3‘ f- s"
5 t a:
O
z x
GREEN
BLACK

 

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

307

18-5

HONDA
IGNITION SYSTEM é V65MAGNA

ENGINE STOP

SWITCH
I ' —| s
' P .

 

    
 
     

IGNITION SPARK UNITS

SWITCH

PULSE
GENERATORS BATTERY

T0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TACHOMETER ENGINE STOP 'GNITION
IGNITION COILS ‘ SWITCHON SWITCH
1—3
2-4 k 3]
_ _ >_
_ — u:
i E
1 2 3 4 rv : g
2—4 i
_ t T T 7 RS '7
SPARK PLUGS SPARK UNITS PULSE GENERATO
1 9 0 308 Date of Issue: Dec, 1982
- © HONDA MOTOR CO., LTD.

 

 

 

 

 

 

 

 

 

 

HONDA
V65MAGNA _
SERVICE INFORMATION 19—1
TROUBLESHOOTING 19—-2
IGNITION COIL 19—3
TRANSISTORIZED IGNITION SYSTEM 19-4
SERVICE INFORMATION
GEN E RAL
O A TRANSISTORIZED IGNITION SVSTEM is used and no adjustments can be made.
SPECIFICATIONS
ND NGK
Spark plug Standard x24EPR»U9 DPRBEA-Q
For cold climate Below 5°C (41°F) X22EPR»U9 DPR7EA-9
For extended high speed driving x27EPR-U9 DPR9EA-9

 

 

 

Spark plug gap

0.6—0.9 mm (0031—0335 In)

 

Ignition timing

At idle 10° BTDC

 

Full advance 37° BTDC/3,800 rpm

 

 

 

Pulse generator air gap

 

04—05 mm (001641.024 in) I

 

 

Date of Issue: Dec, 1982

309

© HONDA MOTOR 60., LTD.

19-1

 

IGNITION SYSTEM

TROUBLESHOOTING

The ignition system has two sub-systems; one lor
the No. 1 and No. 3 cylinders and one for the No.2
and No, 4 cylinders, Determine which subsystem is
faulty, then proceed to thedetailed tests below.

Engine cranks but will not start

— Engine stop switch OFF

— No spark at plugs

7 Faulty transistorized spark unit
— Faulty pulse generator

No spark at plug

— Engine stop swtich OFF

— Poorly connected, broken or shorted wires
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 ignition switch

Faulty spark unit

Faulty pulse generator

Engine starts but runs poorly
— ignition primary circuit
Faulty ignition coil
Loose or bare wire
intermittent short circuit
— Secondary circuit
Faulty plug
Faulty high tension wire

Timing advance incorrect
— Faulty pulse generator
— Faulty spark unit

6 HONDA
V65MAGNA

 

19-2

310

Date of Issue: Dec, 1982
© HONDA MOTOR C0,, LTD,

HONDA
V65MAGNA

 

IGNITION SYSTEM

 

IGNITION Cflll

REMOVAL

Remove the side covers and seat.

Make sure the fuel tank is less than half-lulli Drain
it, if it is more then half-full. Remove the xank
mounting bolts and lift the fuel tank up and hold ix
in place wixh ihe tank support rod.

Disconnect The ignition wire leads.

Remove the coils by removing the attaching bolls.

CONTINUITY TEST
Measure xhe primary coil resisxance.

RESISTANCE: 2.3 ohms

Measure the secondary coil resisxance wixh ‘he
spark plug caps in place.

RESISTANCE: 21—28 k ohms

    

IGNITION COILS

 

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD,

311

19-3

HONDA
V65MAGNA

 

 

Remove the spark plug cap resistor retainers and
resistors from the caps.
Measure the secondary coil resistance.

RESISTANCE: 13.6—15.5 kohms

TRANSISTDRIZED IGNITIEIN SYSTEM

PULSE GENERATOR TEST

Lift the fuel tank up and hold it in place with the
support rod. Be sure that the tank is less than half»
full.

Disconnect the pulse generator coupler and measure
the coil resistance.

RESISTANCE: Approximately 480 ohms

Between white/yellow and yellow leads (1, 3 cylin~
clers)
Between white/blue and blue leads (2, 4 cylinders)

PULSE GENERATOR REPLACEMENT

Remove the clutch cover (page 7-11).

Remove the pulse generator mounting bolts, and
pulse generators.

Install new pulse generators.

19-4

 

l~3 CVLINDER PULSE

GENERA OR

312

_ _ a [A < ‘
Z- CYLINDER PULSE

    

GENERATOR

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA
V65MAGNA

 

IGNITION SYSTEM

 

Check the air gap with a feeler gauget

STANDARD AIR GAP:
0.4—0.6 mm (01116—01124 in)

Install the clutch cover (page 7-23).
Recheck the ignition timing (page S-BL

SPARK UNIT

If the pulse generators, ignition coils and wiring
are good, and the ignition timing is not within
specification; replace the spark units with new ones
and recheck the ignition timing.

 

 

Date of Issue: Dec, 1982
HONDA MOTOR (30., LTD.

313

19-5

II()I\II)1\
K
ELECTRIC STARTER V65MAGNA

  
   
      
  
  
 
    

STARTE R
BUTTON

STARTER

CLUTCH RELAY SWITCH

SWITCH BATTERY

 
  

STARTER
STARTER MOTOR RELAY SWITCH

      
    

file» m,

«IE-f.) '
ta)

GREEN/RED

 

 

“‘5. I

5.,

 

 

 

         

 

 

STARTER '

BUTTON RELAY con.
IGNITION SWITCH
.

9 ED SHIFTINDICATOR
GREEN GREEN

 

CLUTCH
SWITCH

 

GEAR CHANGE

I
o
I:
E
w

 

 

 

 

BATTERY

 

2 O '0 314 Date of Issue: Dec, 1982

© HONDA MOTOR CO., LTD.

 

Ema? 20. ELECTRIC STARTER

 

 

 

 

 

 

 

 

SERVICE INFORMATION 2071
TROUBLESHOOTING 2071
STARTER MOTOR 2072
STARTER RELAY SWITCH 20—5
CLUTCH DIODE 2075
SERVICE INFORMATION
G E N E R A L
I The starter motor can be removed with the engine in the frame.
SPECIFICATIONS
STANDARD SERVICE LIMIT
Starter motor Brush spring tension 680—920 g (24.0—32.5 oz) 545 9 (19,2 oz)
Brush length 12.0—13.0 mm (0.47—0.51 in) 6.5 mm (026 in)

 

 

 

 

 

 

TRUUBLESIIIJUTING

Starter motor will not turn:

- Battery discharged

— Faulty ignition switch

7 Faulty starter switch

— Faultv gear change switch

— Faulty starter relav switch

— Loose or disconnected wire or cable
7 Clutch diode open

Starter motor turns engine slowlv
— Low specific gravity

7 Excessive resistance in circuit
7 Binding in starter motor

Starter motor turns, but engine does not turn:
7 Faultv starter clutch

7 Faultv starter motor gears

— Faultv starter motor or idler gear

Starter motor and engine turns, but engine does
not start

7 Faulty ignition sVstem

7 Engine problems

 

 

Date of Issue: Dec, 1982
HONDA MOTOR CO., LTD.

20-1

HON DA
V65MAGNA

 

ELECTRIC STARTER

STARTER MOTOR

REMOVAL

 
  
     

With the Ignition switch OFF, remove the
negative cable at the battery before servicing
the starter motor.

 

Disconnect the starter motor cable at the motor.
Remove the starter motor mounting bolts, and
the starter motor.

 

CASE AND FIELD COIL

  
  

ARMATURE

BRUSH HOLDER

BRUSH SPRING

REAR COVER SHIMS

   

CABLE TERMINAL AND BRUSHES

FRONT COVER

 

 

316 Date of Issue: Dec, 1982

© HONDA MOTOR CO., LTD.

HONDA
V65MAGNA ELECTRIC STARTER

 

BRUSH INSPECTION BRUSH SPRING

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: 6.5 mm (0.26 in)
Brush spring tension: 545 9 (19.2 oz) \

    
 
  

BRUSH
LENGTH

COMMUTATOH
COMMUTATOR INSPECTION

Remove the starter motor case.

NOTE:

Record the location and number of thrust
washers.

 

 

 

 

Inspect the commutator bars for discoloration.
Bars discolored in pairs indicate grounded armature
coils.

 

NOTE:

Do not use emery or sand paper on the com-
mutator.

 

 

 

 

COMMUTATOH BAR PAIRS
CONTINUITY: NORMAL

Check for continuity between pairs of commutator
bars.

Also, make a resistance check between individual
commutator bars and the armature shaft.

There should be no continuity.

COMMUTATOR BARS AND ARMATURE SHAFT
NO CONTINUITY: NORMAL

Date oi Issue: Dee, 1982 317 20_3

© HONDA MOTOR CO., LTD.

ELECTRIC STARTER

FIELD COIL INSPECTION

Check for continuity from the cable terminal to
the motor case and from the cable terminal to the
brush wire.

Replace the starter motor if the field coil is not
continuous or if it is shorted to the motor case.

ASSEMBLY/INSTALLATION

Align the case notch with the brush holder pin.

Install the rear cover aligning its slot with the brush
holder pin.

Install the starter motor in the reverse order of
removalt

HONDA
V65MAGNA

 

CABLE TERMINAL-MOTOR CASE

NO CONTINUITY: NORMAL

  

 

CABLE TERMINAL-BRUSH WIRE (BLACK)
CONTINUITY: NORMAL

BRUSH HOLDEfi VNOTCH PIN

PIN

   

BRUSH HOLDER

  
   

REAR eRACKET

 

20-4

318

Date of Issue: Dec, 1982
© HONDA MOTOR 00., LTD.

HONDA,
V65MAGNA ELECTRIC STARTER

 

 

STARTER RELAY SWITCH

INSPECTION

Depress the starter switch button with the ignition
ON. The coil is normal if the starter relay switch
clicks.

 

Connect the an ohmmeter to the starter reiav switch
terminals.

Connect a 12V battery to the switch cable (ermiv
nals. The switch is normal it there is continuity.

 

 

 

 

CLUTCH DIODE

REMOVAL

Lift the fuel tank up and hold it in place with the
support rods Be sure the tank is less than halHuIl.
Remove the clutch diode (mm the wi re harness.

IN ONE DIRECTION: CONTINUITY
IN THE REVERSE DIRECTION: NO CONTINUITY

 

INSPECTION

Check for continuity with an ohmmeter,

 

 

Date of Issue: Dec, 1982 319
© HONDA MOTOR CO., LTD. 20-5

HONDA
V65MAGNA

 

 

MEMO

 

320 Data of Issw: Dec, 1932
© HONDA MOTOR (30., LTD.

 

lame? 21. SWITCHES

 

 

SERVICE INFORMATION 21—1 FUEL PUMP 21—7
OIL PRESSURE SWITCH 21—2 THERMOSTATIC SWITCH 21—7
BRAKE LIGHT SWITCH 21-2 TEMPERATURE SENSOR 21—8
GEAR CHANGE SWITCH 21—3 TEMPERATURE GAUGE 21—9
HANDLEBAR SWITCHES 21—4 TACHOMETER 21—9
IGNITION SWITCH 21—5 BRAKE AND TAIL LIGHT SENSOR 21—10
CLUTCH SWITCH 21—6 WARNING LAMP CHECK UNIT 21—10
LOW FUEL WARNING LIGHT 21—6 TURN SIGNAL CANCEL SYSTEM 21—10

 

 

SERVICE INFORMATION

GENERAL

Some wires have different colored bands around them near the connector. These are connected to other wires which cor-
respond with the band color.

All plastic Plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnectingt

The following color codes used are indicated throughout this section and on the wiring diagram.

B = Blue G = Green LG = Light Green R = Red
Bk = Black Gr = Grey 0 W = White
Br = Brown LB = Light Blue P V = Vellow

 

To isolate an electrical failure, check the continuity of the electrical path through the part. A continuitv check can usually
be made without removing the part from the motorcycle Simply disconnect the wires and connect a continuity tester or
volt-ohmmeter to the terminals or connections.

A continuity tester is useful when checking to find out whether or not there is an electrical connection between the two
points. An ohmmeter is needed to measure the resistance of a circuit. such as when there is a specific coil resistance involv-
ed, or when checking for high resistance caused by corroded connections.

 

 

Date of Issue: Dec, 1982 321 21 1
© HONDA MOTOR CO., LTD. '

SWITCHES

[llL PRESSURE SWITCH

Drain the engine oil.
Disconnect the oil pressure switch lead and remove
the switch.

Check for continuity while applying pressure to the
switch.

Replace the switch il necessary.

Apply a liquid sealant to the switch threads before
installing the switch.

Screw the switch into the crankcase and leave two

threads from the bottom. Then tighten it to the
specified torque.

TORQUE: 10—14 N-m (1.0—1.4 kg-m, 7—109t-lb)

NOTE:

Do not overtighten the switch, or the crank
case may be damaged.

BRAKE LIGHT SWITCH

Check the rear brake light switch for continuity
with the rear brake applied.

 

 

 

 

Check the Trent brake light switch for continuity
with the from brake applied.

Replace the switches if necessary.

 

HONDA.
V65MAGNA

CONTINUITY: BELOW
0.3 i 0.1 kg/cm2 (4.3 2 1.4 psi)

x //,-// ‘I

 

FRONT BRAKE LIGHT SWITCH

 

 

Elm-2

322

Date of Issue: Dec, 1982
© HONDA MOTOR CO, LTD.

HONDA
V65MAGNA

 

GEAR CHANGE SWITCH

Lift the fuel tank up and hold it in place with the
support rod‘ Be sure the tank is less than half-full.

Disconnect the change switch couplert

Check for continuity between each terminal and
ground in each gear positiont

 

colorant-As v LglR ak/vfiw/e n/w any are cacflun

Pmltion

 

m
N

2nd
3rd
4m
5n.
on

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REMOVAL

Remove the gear change switch cover.

Remove the gear change switch attaching screws,
and the switch.

 

SWITCHES

 

Date of Issue: Dec, 1932
© HONDA MOTOR 00., LTD

323

HONDA
V65MAGNA

 

SWITCHES
HEADLIGHT

HANDLEBAII SWITCHES HI—Lo SWITCH

The handlebar cluster switches (lights, turn signals,
horn, etc.) must be replaced as assemblies.

Continuity tests for the components of the handle»
bar cluster switches follow:

Continuity should exist between the color coded
wires in each chart.

 

HORN BUTTON TUHN SIGNAL SWITCH V

HEADLIGHT Hl—LOW SWITCH Headlight Hi—LOW SWitch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HI: B/W to B HLZ HI Lo
MIDDLE (NI: B/WtthoB .
Lo: B/W to w H' C O
(N) o—+—o
Lo 0 0
Color code B/W B W
TURN SIGNAL SWITCH Turn Signal Switch
LEFT: Grto 0, Br/B to LB/W W L R P1 PR PL
OFF: Br/B to LB/W and OM
RIGHT: Gr to LB, Br/B to cm LEFT 0 O O 0
OFF < >74 >7——( >
RIGHT O O Q 0
Color code Gr 0 LB Br/B LB/W O/W
HORN BUTTON Horn Button
LG to G with button depressed Ho BAT 3
No continuity with button released
Color code LG ‘ W/G
324 Date of Issue: Dec, 1982

21 '4 © HONDA MOTOR 00,, LTD.

HONBA
V65MAGNA

 

STARTER BUTTON

Bk to V/R with button pushed in.
Bk/R to B/W with out.

Starter Button

 

IG ST HL1 HL2

 

FREE 07—0

 

PUSH O\—O

 

Color code Bk Y/R Bk/R B/W

 

 

 

 

 

 

 

ENGINE STOP SWITCH

RUN: Bk to Bk/W
OFF: No continuity

Engine Stop Switch

 

 

 

 

 

BAT2 no
0FF
RUN 07—0
OFF
Colmande Bk Bk/W

 

 

 

 

 

IGNITION SWITCH

Remove the fuel tank and disconnect the ignition
switch coupler,

Check continuity of terminals on the ignition switch
coupler in each switch position.

SWITCH POSITION

 

 

 

 

 

 

LOCK: No continuity
OFF: No continuity
0N: R to Bk, Br/W to Br — continuity
PARK: Br to Ft — continuity
m PA BAT1 I6 111 112
PosIllon
P o——o
0N (kw (fix)
I
OFF
LOCK
c°'°’ Br R Bk Br/W Br
code

 

 

 

 

 

 

 

 

 

 

SWITCHES

ENGINE STOP SWITCH

STARTE R BUTTON

IGNITION SWITCH

"I

 

Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

21-5

SWITCHES

CLIITBH SWITCH

Check continuity of the clutch lever (safety) switch
with the clutch released and applied.
Replace if necessary.

LIIW FUEL WARNING LIGHT

Place the motorcycle on its center stand.

Turn the ignition switch ON and check that the low
fuel warning light comes on for 1 to 4 seconds. If
the light does not go on, check for a bioWn fuse or
bulb, loose connection or open circuit in the wire
harness.

Check that the low fuel warning light comes on
within 60 seconds after the ignition switch has been
turned 0N with the amount of fuel in the fuel tank
below 3 liters (0.8 US gal),

NOTE:

The light will not go on Immediately after the
ignition switch is turned 0N.

If the light does not go on within 60 seconds,
replace the sensor.

Check that the low fuel warning light will not light
when the ignition switch is turned ON when the
amount of fuel in the fuel tank is more than 3 liters
(0.8 US gal).

If the warning light goes on. check for a short
circuit in the wire harness or couplert

Replace the fuel reserve sensor if no shorts are
found.

HONDA
V65MAGNA

 

CLUTCH SWITCH

CLUTCH APPLIED: CONTINUITY
CLUTCH RELEASES: N0 CONTINUITY

 

 

 

21-6

326

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

HONDA
V65MAGNA SWITCHES

 

 

FUEL PUMP . FUEL PUM? COUPLER

Du In)! allow flames or spa! s new gust) m

Fabricate the special test wire harness as shown and
connect it between the battery and the fuel pump
coupler.

 

 

DIODE (SHINDENGEN SlFl 200R EQUIVALENT)

Disconnect the fuel tube at the carburetor and hold
a graduated beaker under the tube.

Turn the ignition switch 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 CAPACITY:
614 cc (22 ollt10%/minute

THERMOSTATIC *SWITBH

The cooling lan motor is actuated by the thermo-
static switch located in the lelt tank of the radiator.

Run the engine until coolant temperature reaches
ss~92°c (1917197°F). The fan motor should
start running. The fan motor should stop when the
coolant temperature drops to 33—37%: [1827
133°F).

If the fan motor does not start, disconnect the black
and green leads lrom 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 starts, replace the tan
thermostatic switch and retest.

If it does not start, check for battery voltage from
the black lead (positive) to the black/blue lead
(negative) 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.

 

JUMPER WIRE

 

Date of Issue: Dec, 1982 327
©HONDA MOTOR C0,, LTD. 21 ' 7

HONDA
VéSMAGNA

 

SWITCH ES

TEMPERATURE SENSIJR

Disconnect the green/blue Wire from the tempera-
ture sensor.

TEMPERATURE SENSOR

    

With the engine cold, use an ohmmeter to measure
resistance between the temperature sensor terminal
and the engine.

Check the temperature of the coolant.

 

 

328 Date of Issue: Dec, 1982
21 ' 8 © HONDA MOTOR (30,, LTD.

HONDA
V65MAGNA SWITCHES

 

 

Run the engine and measure the change in resistance
of the sensor with the engine at operating temper»

 

 

ature.
Tem erature 60°C 85°C
" (140°F) (135%)
Resistance
04. 43,9
(Ohms) 1 0

 

 

 

 

 

Replace the sensor if it is out of specifications by
more than 10% at any temperature listed.

TEMPERATURE GAUGE

Disconnect the wire from the temperature sensor
and short it to ground.

Turn the ignition switch ON. The temperature
gauge segments should move all the way to the
right.

CAUTION:

Do not leave the temperature sensor wire
grounded for longer than a few seconds or the
temperature gauge will be damaged.

 

   

 

 

 

 

 

 

 

 

 

 

 

 

TACHOMETEH
If the tachometer does not indicate properly, check
and repair the No1 cylinder ignition system. SPARK UNIT
If the problem still appears, Check Continuity
between the yellow wire terminal of the wire
harness tachometer coupler and the yellow wire
terminal of the No. 1 cylinder ignition coil and
repair the circuit if necessary. (9
If there is continuity, replace the tachometer with
a new one.

PULSE GENERATOR

Date of Issue: Dec, 1982 329 2 1 9

© HONDA MOTOR (30., LTD.

SWITCHES

BRAKE AND TAIL LIGHT SENSflR

Turn the Ignition switch on.

Check the source voltage at the black/brown lead.
If there is no voltage, check and repair the source
circuit.

If there is voltage, measure the voltage at the
white/yellow (positive) and green/yellow (negative)
wires.

VOLTAGE: 5 V

If there is no voltage, replace the sensor unit,

WARNING LAMP CHEBK UNIT

The tail/stoplight warning lamp and low fuel
warning lamp should light for a few seconds and
go out when the ignition switch is turned on.

If the light do not operate properly, turn the
ignition switch on.

Check the source voltage at the black/brown lead If
there is no voltage, check and repair the source
circuitt

ll there is voltage, check the warning lamp bulb
and wiring between the unit and warning lampt

If the bulb and wiring are OK, check the ground
circuit.

If the ground circult is OK, replace the check unit.

TURN SIGNAL CANCEL SYSTEM

ANGLE SENSOR

Turn the handlebar right and left and check the
angle sensor for wear, damage or looseness,

HGNDA
V65MAGNA

 

BRAKE AND TAIL
LIGHT SENSOR

 

 

 

21-10

330

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

 

 

1mm 23. TECHNICAL FEATURES

 

 

ONE-WAY CLUTCH SYSTEM

 

OPTICAL-FIBER ANTITHEFT DEVICE

23—1
23—3

 

 

ONE-WAY CLUTCH SYSTEM

First time on a production motorcycle, this system has been proven on the race circuits 0! Europe in Hondas Gran Prix road

racers.

Rear wheel lock up caused by rapid downshifting and the resulting high engine compression braking force; is prevented by the

slippage of the one-way clutch.

ONE-WAY CLUTCH

CLUTCH
CENTER

0 Construction

 

 

ONE-WAY
CLUTCH OUTER

CLUTCH OUTER
COMP

The one-way clutch is installed with the clutch oenter inside the clutch outer. Half the clutch plates are controlled by the
onean clutch. The enemy clutch allows those plates to slip when backloading force during deceleration might normally

cause the rear wheel to lock-up,

Except for the one-way clutch, the primary driven gear/clutch assembly is a conventional design.

 

Date of Issue: Dec, 1982
© HONDA MOTOR CO., LTD

335

23-1

HONDA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TECHNICAL FEATURES V65MAGNA
0 Operation CLUTCH OUTER
During acceleration, cruising and deceleration,
power is transmitted through the clutch ‘In the
normal manner:
Clutch outer—"fiction disc» plate—>one»way clutch ONE-WAY
+ mainshaft. CLUTCH
OUTER
CLUTCH
CENTER ‘ ONE-WAY
' CLUTCH
' ONE-WAY
CLUTCH
—- ~ -— INNER
MAINSHAFT
When there is a backloading on the clutch caused by
the rear wheel nearing lockup, the one-way clutch
(A) will slip just enough to prevent the wheel from
looking: without losing the benefit of maximum
engine compression braking, ONE WAY
CLUTCH
INNER
CLUTCH/I
CENTER

 

 

 

 

 

 

 

 

 

 

 

 

CLUTCH
o POWER FLOW DIAGRAM OUTER
r _________
l
| FFlICT ON DISC l T FRICTION DISC l

 

   

MAIN SHAFT

l

|

i
CLUTCH PLATE

 
     
 
 

 

 
 
 
   

    

CLUTCH CENTE R

 

<— ORDlNARY POWER FLOW
-—-- BACK LOAD

336 Date o! Issue: Dec, 1982
23' 2 ©HONDA MOTOR CO., LTD.

 

HONDA
V65MAGNA

 

TECHNICAL FEATURES

OPTICAL FIBER ANTI-THEFT DEVICE

The divice consists of a built-in power source, buzzer, photo transistor light emitting diode (LED), and fiber scope locking
wire.

F unction

Braking the fiber scope causes the buzzer to sound due to interrupted transmission of light from the LED to the photo tran~

sister. A 9V dry battery is used to operate the system. The wire can be connected and disconnected with the ignition key and
is stored in a compartment at the rear of the seat

PHOTO TRANSISTOR

   

FIBER SCOPE

LIGHT EMITTING DIODE

 

Date of Issue: Dec, 1982 337
© HONDA MOTOR Cot, LTD. 2 3 ' 3

HONDA
V65MAGNA

 

 

MEMO

 

333 Date of Issue: Dec, 1982
© HONDA MOTOR CO” LTD.

reg $333? 24. TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START

   

POSSIBLE CAUSE

1. Check fuel flow In carbuvelov NOT REACHING CARBURETOR—>(II Fuel (ank empw
I2) Clogged Iuel tube or luel fllIEr
REACHING CAREURETOR (3} Sficklng float valve

(4) Faully fuel pump
(6) Pinched (uel rank vent nose

2. Perform a 3-polnl spark lesl WEAK on NO SPARK—>0) Faulty spark plugs
(2) Fouled spark plugs
Goon SPAFIK (:ll Faulty spark unlr
(4) Broken or shoned high unslon
wires

(5) Faulty spavk unlt
(6] Broken or shamed igniflon coil

(7) Faulty lgnilion swllon
(8) Faully pulse generator

3. Test cylinder compression LOW COMPRESSION ———>(I) Low banerv charge
(2) lmpvopervalve clearance (loo
COMPRESSIoN NORMAL small]

(a) Valye sruck open
(4) Worn eyllndor and pisren rlngs
(5) Damsgsd cylinder head gasket
(6) Seized valve

(7) Impropsrvalvellmlng

 

4, Stan by following novmal procedure ENGINE STARTS BUT STOPS——>(1) Improper choke opsrallon
[2) Cavburmor Incorrectly adjusted
ENGINE DOES NOT FIRE (3) Intake pips leaking

(4) Impropev ignilion timing
(Spark null or pulse generalor)
(5) Fuel comaminaled

 

5. Remove and inspacl spark plug WET PLUG ——>(1l Carburelor flooded
(2) Choke closed
(3) Thronle valve open
(Al Air cleaner dirty

 

Date of Issue; Dec, 1982 339
©HONDA MOTOR 00., LTD. 24'1

TROUBLESHOOTING

ENGINE LACKS POWER

1, Raise wheels off ground and spln by hand

WHEEL SPINS FREELY

2. Check lira pressure
PRESSURE NORMAL

3, Accelerele rapldlv Irom low [a second

ENGINE SPEED INCREASES PRO-
PORTIONALLY TO ACCELERATION
WHEN CLUTCH |S RELEASED

4. Accelrme lighlly

ENGINE SPEED INCREASES

5. Check igniridnrlming
CORRECT

6. Check valve clearance
CORRECT

7. Tool cylinder compression

NORMAL

8. check carourardr ior clogglng
NOT CLOGGED
I
9. Remove spark plug

NOT FOULED OR DISCOLORED

10, (Check oil level and condition
CORRECT

1 1. Rsmove cVIInder head cover and inspefl
lubrication

VALVE TRAIN LUBR ICATED
PROPERLY

11. Check (Dr engine Dverheallng

NOT OVERH EATI N G

13. Accelerate or run 3! high speed

ENGINE DOES NOT KNOCK

WHEELS DO NOT SPIN FREELY—DIII
(2)
(3)
(4)

PRESSURE LOW——>(1)
(2)

ENGINE SPEED INCREASES BUT MOTOR—F“)
CYCLE DOES NOT ACCLERATE WELL [2)
WHEN CLUTCH IS RELEASED I3)

ENGINE SPEED DOES NOT INCREASE —>(1I
(2)
(3)
(4)
(5)

INCORRECT—>(ll
(2)

INCORRECT—>(1)
(2)

TOO LOW h>(1)
(2)
(3)
(4)

CLOGGED _>(II

FOULED OR DISCOLOR ED—>lll
(2)

I3)

INCORRECT —>ll)
(2)
(a)

VALVE TRAIN NOT LUBRICATED——>(1)
PROPER LY (2)

OVERHEATINGfiH)

[2)
(3)

ENIGNE KNOCKS —-—>(II
(2)
(3)

(4)

HONDA
V65MAGNA

é

POSSIBLE CAUSE .
Brake draQQInQ
Worn or damaged wheel bearings
Wheel bearlng needs lubrlca‘ion
Final gear bearlng damaged

Punciured tire
Faulty lire valve

Clulch slipping
Worn ciulch disc/piare
Warped clutch disc/plate

Carburetor choke closed
Clogged alr cleaner
Restricted lual Ilow
Clogged muffler

Pinched Iuel (ank VBrIl hose

Fauliy spark uni:
Faully pulse aenaramr

lrnpmper valve adjustment
Worn valve seat

Valve stuck open
wdrn cylinder and pisipn rings
Leaking heed geskei

improper valve (lming

Carbureror noi serviced
irequentiy enough

Plugs nm serviced Irequsmly
enough

Spark plug wllh incorrect heat
range

Air cleener diriv

Oil level lop high
Oil level loo low
epnreminared oil

Clogged oil passage
Clogged oil eoniroi orlflce

Excessive ceropn build-up
in cDmhusliDn chamber
Use oi poor quality iuei
Clulch slipping

Warn plsion and cylinder
Wrong iype oi iuel
Excessive carbon buIId-up in
combusflnn chamber
lgnirion riming too advanced
(Faulty spark unil)

 

24-2

340

Date of Issue: Dec, 1932
©HONDA MOTOR 00., LTDV

HONDA
V65MAGNA

 

TROUBLESHOOTING

 

POOR PERFORMANCE AT LOW AND IDLE SPEEDS

INCORRECT—>1!)
(2)

l. Chack lanilion timing and valve clearance
CORRECT

2. check carburetor pilot screw adjustment
CORRECT

LEAKING——(1I
(2)

3r Chack for leaking lmake pipe
NO LEAK
WEAK OR INTERMITTENT SPARK—b (I)

(2)
(3)

4. Parforrn Spark (es!

GOOD SPARK

POOR PERFORMANCE AT HIGH SPEED

INCORRECT—>lli
[2)
(3)

I. Check lgn on liming and valve clearance
CORRECT

FUEL FLOW RESTRICTED—DH)
(2)
(3)
(4)
(6i

2. Disconnect iuel lube at carburetor

FUEL FLOWS RREELV

3. Remove carburetor and check for
clogged ier

N0 CLOGGED JETS

4, Check valve timing

POSSIBLE CAUSE
Improper valve clearance
Improper Ignition liming
(Faulty spark unir)

INCORRECT ———> See Fuel System Section

Delerloralad insulator o-rlng
Loose carburetor

Faulty or fouled spark plug

Faulty Spark unil
Faulty ignition coil

Improper valve clearance
Faulrv spark unir
Faulty pulse generaror

Lack of fuel in rank

Clogged Iuel line

Cloggad fuel tank breather hole
Clogged fuel valve

Faulty fuel pump

CLOGGED ———> Clean

INCORRECT———>Cam sprocket not installed
a

properly

CORRECT
5. Check Valve spring tension WEAK

NOT WEAKEN ED

POOR HANDLING —>Check tire pressure

 

(1i
(2)

1. If steering Is heaW

(I)
(2)
(3)
(4)

2. If either wheel I: wobbllng

 

-(6)
(6)

3. If the molorcycle pulls to one side ——>ul
(2)
(3)
(4)

——> Faully spring

steering lop thread m" 100 tight.
Damaged sreerlng head bearings

Excessive wheel bearing play
Bum rim

Improperly inerallecl wheel hub
SWingarm pivot bearing
excessively worn

Bant frame

Swingavm pivor adiusrlng boll me
right

Faulty shock absorber

Front and rear wheels not aligned
Bent front fork

Bsm swingarm

 

Date of Issue: Dec, 1982 341

© HONDA MOTOR 00., LTD.

24-3

fli‘gja; 134:? f 7114,? 0/26 [(3

flew /—/M~(//tt (Jam! 5’0 0 [on MEMO

é ()6 M, Emu/fl 511‘OME

(5, «(la ”Mr «do .6111 fwd} 76%) I'M:

5/557 btw (4.7/0 1/490 m1

flew [(414ng Aud- (Se/f7) 5/266 M;
0/6 U04»/V&5 +IO/M7-J ’7 ‘15"? IM} What. 327, k7
1'1 r L (a? / 5?;val’fi‘rim 9979 m' ,474/ GM

ANAL/fl 0745‘: /A (Mad (59,4 77)
LJLUM/ “Me/ o'flrcf vfik'fluy:

/,

QM 7." w V K L/ 00 m 1
CtJCL>Avl./2A.M(0// Gill/”Gm” K4527 Myw “A
/ fl .Duudé'lfl [QM/It“? Lifer/"i ”0/70 KM $5711
ff’W/If 7709. / 301W; ”4/
ants »» Z7va 417d
/5 ” Dun/4;” 37/5 Qualfijréy ”0/70 V/i?
[7/7 W/Ix/I‘fir [g 7'90 ”4,2
//, am] We»; Maw Mi ~7‘iL/fl/f- sas-
’r-Smlo/Aa / ““75
1‘: k/xcuuflflf Vuuq‘éP/ /L/ 52949 —fl/a/7 £7»;

/’ .
Aflhgfgofifi (we j

524’} F/Mf 5/”/( 5F/[L/ (flak ”JAM 55/
0.53:”,4—6eri wave» 9er]; Mfoo ””94
aawye/ Cal/(”WW /7§‘f0 M031

”PF/c Jul/f“ 3/116 /;;‘/V'“7 {fasff/Xti ¢5
f7 4

    

 

HONDA
V65MAGNA

 

342

Date of Issue: Dec, 1982
© HONDA MOTOR 00,, LTD.

HONDA.
V65MAGNA

 

SWITCHES

 

Remove the angle sensor (page 15~10L
Measure the resistance between the B/Y and the
GM leads,

RESISTANCE: 10—19 k ohms

Check the resistance between the w and G/W leads
while turning the sensor arm slowly from the left
to , the right. 'The resistance should increase
smoothly.

TURN SIGNAL SWITCH

Disconnect the cancel unit couplers

Turn the turn signal switch to the Ieit position
and connect a jumper wire to the B/Bk and Br/B
leads

The turn signal switch should return to the neutral
position.

PerIorm the same test for the right turn position.

SPE ED SENSO R

Disconnect the cancel unit coupler]

Check for continuity between the W/Bk and the
G lead terminals at the wire harness coupler while
turning the front wheel slowly.

RESISTANCE: 0 H w Alternately

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Date ol Issue: Dec, 1982
© HONDA MOTOR CO., LTD.

 

 

 

HONDA
V65MAGNA

 

SWITCHES

Remove the angle sensor (page 1510).
Measure the resistance between the RN and the
GM leads.

RESISTANCE: 10—19 k ohms

Check the resistance between the W and G/W leads
while turning the sensor arm slowly from the left
to the right. The resistance should increase

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

smoothly.
k .'
i
l
l
'l: TURN SIGNAL SWITCH
' Disconnect the cancel unit coupler.
l Turn the turn signal switch to the left position
and connect a jumper wire to the B/Bk and Br/B
l leads.
IL The turn signal switch should return to the neutral

position.

l Perform the same test for the right turn position.
i

l

 

SPEED SENSOR

r Disconnect the cancel unit Coupler,

Check for continuity between the W/Bk and the
(5 lead terminals at the wire harness coupler while
turning the front wheel slowly.

RESISTANCE: 0 «m Alternately

Date of Issue: Dec, 1982
© HONDA MOTOR (30., LTD.

 

51mm 22. WIRING DIAGRAM

INDICATOR LIGHT CLUSTER I2v3W><T
RTuRN SIGNAL INDICATOR
NEUTRAL INDICATOR

HIGH DEAM INDICATOR
L,TURN SIGNAL INDICATOR

OIL PRESSURE INDICATOR
STOP AND TAIL INDICATOR

  
   
 
 
 
    
  
 
        
 
   
   
   
   

FUEL RESERVE WARNING INDICATOR
IGNITION SWITCH

ILz
LI PA

A n REA
TACHOMETER LIGHT R STOP

 

LIGHT 5W” H
FUSEI SPARE c STARTING ST‘MER “EL“ FUSE JDA(MA|N)
MOTOR '
VUSEZ HEADLIGHT
FUSE] METER t

 
    
 

FMSEA TURN SIGNAL-
FRONT REAR DRAKEHORN III N

   

BATTERV

 

    
  

 

PusEs FRONT POSITIONA I2va 0
TE P METER LIGHT .
M WSW l2 METER LIGHT TAIL , ‘
TURN SIGNAL FUEL CuT MAIN RELAv R REAR TURN SIGNAL ImzCPmW)
FUN MOTOR RELAv RELAv FUEL PUMP

   

 

 

 

     
   
    

THERMO
SWITCH

 

 

 

 
   
  
   

L
r we a.

      
       
  
 
 
 
 
  
        

BROWN 5P ELACK

 

SPEEDOMETER LIGHT
Izvuw MfiD—BIIW

Lb Lh
n L
E: LICENSE LIGHT Izvaw
R FRONT TURN SIGNAL

—I:n—DI
I2v:2/3CP(23/3w)

STOP AND TAIL LIGHT
I2v32/30P(2T/sw)

HEADLIGHT
wen/55w

MW—DCl-Lb/W

    

O

 
  
 
 

 
  
 

PL.TURN SIGNAL
CHECK UNIT

 
 

SILICON CTIFIER

      
  
 

STOP & TAIL SENSOR

 

v was
FRONT STOPLIGHT
SWITCH

  
  

  
  

I
v
v

  

    

v AIII

   
    

    
   

L FRONT TURN SIGNAL
I2V32/JCP(23/8W)

       

5» WA 5? MI

M

  

6P NAT

      
     
 
 

L,REAR TURN SIGNAL I2V:20P(23WJ

 

 

Am
A

w L: LI: REGULATOR/RECTIFIER
DUAL HORN

       
   
 
     

  

   
 

     
     
 

L , n I CSHEAcéE
4-H” "UN" IGNI ION COILS W H ALTERNATOR
CLUTCH SWITCH TURN SIGNAL HORN swwcH E E smp T
SWITCH STARTER SWITCH SPARK UNITS FEUL RESERVOIR SENSOR