a HONDA. SHOP MANUAL V 3 D MAGNA VF5OOC AMERICAN HONDA MOTOR CO ,‘NC.1984 (”M-1301 Al! Rvgms F‘vwvvod A27008408 IMPIIRTANT SAFETY NOTICE*# Indicates a siren; possibilio’ of severe personal inf-try or loss aflife if Instructions are not followed. CAUTION Indicates a possibiliq' of personal injury or equipment damage if irmmétion: are not followed. NOTE: Gives helpful inlormation. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage 8 ve ice or render it unsafe Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, mus-t satisly himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected, V4HondaBBS.com HONDA V30 MAGNA HOW T0 USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environ- mental Protection Agency and California Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole motor- cycle, while sections 4 through 19 describe parts of the motorcycle, grouped according to locationr Find the section you want on this page, then turn to the table of comm on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to section 20, TROUBLESHOOTING. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR 00., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR (20., LTD. SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION .- LUBRICATION u MAINTENANCE ENGINE :u FUEL SYSTEM .- ENGINE REMOVAL/INSTALLATION a COOLING SYSTEM .3 CYLINDER HEAD/VALVE E. _n TRANSMISSION CHASSIS FRONT WHEEL/SUSPENSION/ n STEERING REAR WHEEL/BRAKE/SUSPENSION In HYDRAULIC BRAKES Il- ELECTRICAL BATTERY/CHARGING SYSTEM '3 IGNITION SYSTEM ll: LIGHTS/SWITCHES/INSTRUMENT l:- m TROUBLESHOOTING E:' Date of Issue: July, 1984 © HONDA MOTOR 60,, LTD. O HONDA V30 MAGNA I. GENERAL INFflRMATlflN GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES TOOLS CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEM 1—2 II 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. V, WARNING Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in your workhg area. SERVICE RULES The battery electrolyte contain: sulfuric acid. Protect your eyes, skin and clothing. In case of contact, flush thoroughly with water and call a doctor if electrolyte gets in your eyes. WWARNING The battery generates hydrogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery, especially while charging it. I. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda‘s design specifications may damage the motorcycle 2. Use the special toolsdesigned for this product. 3. Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling. 4. When torquing bolts or nuts, begin with larger-diameter or inner bolt first, and tighten to the specified torque diagonally in 2-3 steps, unless a particular sequence is specified. 5. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 6. After reassembly, check all parts for proper installation and operation. 7. Use only metric tools when servicing this motorcycle. Metric bolts, nuts. and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycle. 3‘ Route all electrical wires as shown on pages 1-9 through 1-12 Cable and Harness Routing. Date of Issue: July, 1984 © HONDA MOTOR CO, LTD‘ 1-1 HONDA V30 MAGNA GENERAL INFORMATION MflDEl IDENTIFICATIIJII ( ) COLOR LABEL BEGINNING FRAME N0. PC130'EM000028 ~ PCI31'EM000004 N (California) ENGINE NO‘ FORE—2000040" cover. The frame serial number is stamped on the steering head's The vehicle identification number (VIN) is on the steering right side. head's left side. ‘ D E -' 553% w \ . 1 l The engine serial number is stamped on the right side of ’ the upper crankcase. each carburetor. 1 2 Date of Issue: July, 1984 ' . © HONDA MOTOR (20., LTD‘ HONDA V30 MAGNA GENERALINFORMATION SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,200 mm (86.6 in) Overall width 735 mm (28.9 in) Overall height 1,180 mm (46.5 in) Wheelbase 1,500 mm (59.1 in) Seat height 780 mm (29.9 in) Foot peg height Ground clearance 335 mm (13.2 in) 130 mm (5.1 in) Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Maximum horsepower Maximum torque Oil capacity Coolant capacity Lubrication system Air filtration Cylinder compression Intake valve Opens Closes Exhaust valve Opens Closes Valve clearance (Cold) Dry weight 181 kg (399 lb) Curb weight 194 kg (428 lb) FRAME Type Double-cradle Front suspension, travel Telescopic fork, Travel 160 mm (6.3 in) Rear suspension, travel Swing arm, Travel 110 mm (4.3 in) Front suspension air pressure 0—40 kPa (0—0.4 kg/crn’, 0—6 psi) Gross vehicle weight rating 354 kg (780 lb) Vehicle capacity lead 159 kg (351 lb) Front tire size 100/9018 56H Rear tire size 130/9016 67H up to 90 kg Front 28 psi (200 kPa, 2.00 kg/cmz) Cold tire (200 lbs) '0“ Rear 28 psi (200 kPa, 2.00 kg/cmz) pressures up to vehicle Front 23 psi (200 kPa, 2.00 kg/cm’) capacity load Rear 36 psi (250 kPa, 2.50 kg/cm’) Front brake, lining swept area Single disc brake, lining swept area 490 cm“ (76 in“) Rear brake, lining swept area Drum brake, lining swept area 201 cm2 (31 in’) Fuel capacity 13.5 liters (4.4 US gal, 3.0 Imp gal) Fuel reserve capacity 3.5 liters (0.9 US 981, 0.8 Imp gal) Caster angle 58°30‘ Trail 112 mm (4.4 in) Front fork oil capacity 400 cc (13.5 fl. oz.) ENGINE Type Water cooled 4-stroke, DOHC engine 4 cylinder 9o°v 60.0 x 44.0 mm (2.36 x 1.73 in) 498 cc (30.4 cu. in) 11.0 : 1 Double chain drive & Rocker arm type 62HP/1,100 rpm 4.14 kg-m/9,000 rpm (30 ft. lbs) 3.0 liters (3.2 US qt, 2.6 Imp qt) 2.51iters(2.6 US qt.. 2.2 Imp qt.) after draining 1.8 liters (1.9 US qt, 1.81mp qt.) Wet sump Paper filter LOGO—1,400 kPa (10.0—14.0 kg/cm’, 140—196 psi) 3° (BTDC) 4e°24' (eroc) 42° (AEDC) . 103°02' (ABDC) 43° (5500) " 1 "‘m "“ 51°5o' teens) 7° (ATDC) 66°30 (ATDC) IN: 0.12 mm (0.004 in) EX: 0.I3 mm (0.005 in) at 0 mm lift Date of Issue: July, 1984 © HONDA MOTOR (20., LTD. 1-3 HONDA GENERAL INFORMATION V30 MAGNA ITEM SPECIFICATIONS ENGINE Engine weight lDryl 63.6 kg (140 lb) Idle speed 1,300: 100 rpm Cylinder numbering No. 1 ~ Left rear No. 2 — Left front Na. 3 — Right rear No, 4 - Right front CAR BURETION Carburetor type/throttle bore Identification number Pilot screw initial setting Float level VD—V4 Vertical 8i horizontal/32 mm (1.26 in) See page 4-1 See page 4-17 6.2 mm (0.24 in) DRIVE TRAIN Clutch Transmission Primary reduction Final reduction Wet, multi-plate type 54peed over drive 2.057 (72/35i 2.933 drive sprocket 15T driven sprocket MT Tail/stop light Turn signal Front (Left/Right) Flear (Left/Right) Speedometer light Tachometer light Temperature meter light Turn signal indicator (Left/Right) Neutral indicator ~ Overdrive indicator High beam indicator Oil pressure warning light Tail and stop light warning light Fuel reserve warning Gear ratio I 3308 (43/13) Gear ratio ll 2.167 139/1Bl Gear ratio I” 1.667 (35/21) Gear ratio IV 1375 (33/24) Gear ratio V 11154 (30/26) Over drive 1.000 (28/28) Gear shift pattern Left toot operated return system ELECTRICAL Ignition Full transistor Ignition timing “F" mark 15°/1,700 rpm Full advance 37°/3,000 rpm Starting system ELECTRIC MOTOR Alternator 0.28 kw/5,000 rpm Battery capacity 12V—12AH 593* ““9 NGK ND Standard DPRaEA-e xzaapnaue For cold climate (Below 5°C, 41°F) DPR7EA-9 X22EPR-U9 F.°' °x‘°"d°F‘. DPReEA-e X27EPR-U9 hIgh speed rIdIng Spark plug gap 03—03 mm (0.03—004 in) Firing order 1—4—3—2 Fuse/Main fuse 10A, ISA/30A (Main fusel LIGHTS Headlight [High/Low) 12V~60l55W lZV—CI/SZCP (8/27Wl SAE NO. 1 157 12V—32/32CP (23/23Wl SAE N0. 1034 12V—32/3ZCP (23/23Wl SAE N0. 1073 12V—3AW 1 2V—3Wx2 1 2V—3W 1 2V—3Wx2 l 2V—3W 1 2V—3W l 2V-3W 12V—3W 12V—3W 1 2V-3W 1-4 Date of Issue: October, 1984 © American Honda Motor 00., Inc. 1984 - All Rights Reserved if) HONDA V30 MAGNA GENERAL INFORMATION TURUUE VALUES ENGINE Item Thread dia. 1mm) Torque NAm (kgm, ft-lb) Remarks Cvlinder head cover Camshaft holder 6 mm bolt 8 mm bolt Cylinder head 8 mm bolt Valve adjuster nut Rocker arm shaft Cam sprocket bolt Spark plug Connecting rod nut Cam chain guide A Carn chain guide B Flywheel bolt Starter clutch cover Starter clutch bolt Clutch cenmr nut Gearshift return spring pin Drive sprocket bolt Oil pressure switch Neutral switch Oil pipe joint bolt Oil filter Oil drain bolt Crankcase bolt Oil pump driven sprocket bolt Oil pass pipe 8—12 (03—12, 6—9) 10-14 (1t0—1t4,7—10) 21—25 (2.1-2.5, 15—18) 30—34 130—34, 22—25) 9—12 (09—12, 6—9) 45—55 (45—55. 32—40i 18—20 (13—10, 13—14) 12—16(1.2—1.6,9—12) 30—34 (3.0—34. 22-25) 10—14 (1.0—1.4, 7-10) 10—1411.0—1,4. 7-10) 50—60 (6.0—60, 36—43) 26—30 (2.6—3.0, 19—22) 50—60 15.0-15.0, 36—43) 60—70 (GD—7,0, 43—51) 20—30 (2.0—3.0, 14-22) 8—12 (08—12, 6—9) 15—20 (1.5—2.0, 11—14) 10—14 (1.0—1.4, 7-10i 20-25 (2.0—2.5, 14—18) 15—20 (1.5-2‘0, 11—14) 35—40 (3.5—4 25-29) 10—14(1.0—1 4 —10) 21—25 (2.1— 5,15—18) 13—17(1.3-17 9—12) 10—14(1.0—L4, 7—10) Apply 3vBOND sealant or its equivalent to the bolt threads, FRAME Item Thread dia. (mm) Torque Nxm (kg-m, ft-Ib) Remarks 7 Steering stem nut Handlebar upper holder Front fork upper pinch bolt Front fork lower pinch bolt Front axle Front axle pinch bolt Front fork sorcket bolt Front fork cap Steering adjustment nut Rear axle nut Rear brake torque link 24 10 12 33 26 1 6 80—120 (BB—12.0, 58—87) 25-35 (ZS—3.5, 18—25) 9—13(O.9-1.3,7—9) 45—55 (4.5- 5, 32—40) 55-65 (5.5—6.5, 40—47) 15-25 (1.5—2.5, 11—13) 15—25 (1.5—2.5, 11—13) 15—30 (1.5—3.0,11—22) 19—23 (1.9—2.3, 14—17) 70-90 (7.0—9.0, 51—65) 13—25 (1.3—2.6, 13—13) See page 12-28. Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. 1-5 GENERAL INFORMATION HONDA V30 MAGNA Torque N~m (kg-m, ft-lbi Remarks Item Thread die. (mm) Shock abosrber mount bolt Upper 8 Lower 10 Swing arm left pivot bolt 25 Swing arm right pivot bolt 25 Swing arm pivot bolt lock nut 25 Front brake caliper bracket 10 Front brake caliper mount bolt 8 Front brake caliper pin bolt 12 Front brake disc 8 Brake hose oil bolt 10 Brake arm bolt Master cylinder holder bolt 6 Engine hanger bolt Front 10 Rear-upper 10 Hear-lower 10 Sub frame socket bolt Upper B Lower 8 Gear shift arm pinch bolt Front fork stabilizer bolt 3 Final driven sprocket 10 Exhaust chamber mount bolt 8 Clutch hose oil bolt 10 20—30 (2.0—3.0, 14—22) 30—40 (3.0—4.0, 22—29) 80—1 10 (ED—11.0. 58—80) 13—17 (1.3—1.7, 9—12) 80—110 18.0—11.0. 53—80) 30—40 (3.0—4.0, 22—29i 20—25 (2.0—2.5, 14—18) 25—30 (2.5—3.0, 18—22) 35—40 (3.5—4.0, 25—29) 25—35 (2.5—3.5, 18—25) 24—30 (2.4—3.0, 17—22) 10—14(1.0— 7—10) 25—32) 5, 25—32) 35—45 (35—45, 25—32) 35—45 (3.5—4.5, 25—32i 36—45 (3.5—4.5, 25—32) 20—28 (2.0—2.8, 15-20) 13—28 (1.8—2.8, 13—20) 60—70 (6.0—7.0, 43—51) 25—35 (15—15, 18—25) 25—35 (2.5—3.5, 18—25) Apply oil grease to the threads STANDARD TORQUE VALUES ' Tighten to 25 NM (2.5 k9~m, 18 ft-lb) first and loosen, then tighten to 13—17 N~m (1.3—1.7 kg-m, 9—12 ft-Ib). Item Torque valuves N-m (kom, ft-lb) Item Torque values N~m (kg-m, ft-lb) 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 4.5—5 (0.45—03. 3—4) 8—12 (0.8—1.2, 6—9) 18—25 (1.8—2.5, 13—18) 30—40 (3.0—4.0, 22—29) 50—60 (SD—6.0, 36—43) 5 mm screw 6 mm screw and flange bolt with 8 mm head 6 mm flange bolt and nut 3 mm flange bolt and nut 10 mm flange bolt and nut 3.5—5 (035—05, 3—4) 7—11 (0.7—1.1, 5—8) 10—14(1.0—1.4.7—10i 24—30 (2.4—3.0, 17—22) 35—45 (3.545, 25—32) 1-6 Date of Issue: July, 1984 HONDA MOTOR COI, LTD, HONDA V30 MAGNA 6 GENERAL INFORMATION TOOLS SP E C I A L DESCRIPTION TOOL NUMBER ALTERNATE TOOL TOOL NUMBER REF. SECTION Oil pressure gauge elrachrnem 075104220100 Equivalem commercially 2 Oil pleasure gauge 07606—3000000 1— available I" U'S‘A' 2 Oil iilrer wrench 07912—6110001 2 Vacuum gauge teiter 07404—0020000 Vacuum gauge reel-r M907la—021—xxxxx 3 (Ues.Ar only) Carburetor syncnrenizalion wrench 07900—KE70000 Equivalenr commercially available in u.s.A. 3 Pressure pump (U.S.A. only) ST—AH —255—MC7 4 Vacuum pump (U.S.A, only) ST—AH —260—MC7 4 Valve guide driver, 7 mm 07942—023000 4 (u.s.A. only) Snap ring pliers 07914—3230001 Equivalont commercially 7, 12, 14 available in U.s.A. Valve guide driver/removal, 5.0 mm 07942—MA00000 9 Valve guide reamer. 5.0 mm 07984—MA60000 9 Compression gauge anacnmem 07510—MBOD101 9 Bearing race remover 079464710500 12 Staaring srem driver 07946—M 300000 sreering stem driver 079464710601 12 IAttechment 07954—01500200 Fork ml driver 070074710101 12 Hex wrencn, 6 mm 079174230000 Equivalem commercially 12 available in USA. Run remover 079454710500 12 Race remover (UrS.A. only) 07953—MJ1000A 12 sreering stem socket 07916—3710100 12 Driver 079404710001 Driver 07949—3710000 12 Bearing rem-ml m. 30 mm 07936—8300100 Bearing remover, 30 mm 07936—8890300 13 Remover nendle 07936—3710100 13 Remover weighl 07936—3710200 13 Shock absorber compressor base D7959—M310000 13 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. 1-7 é HONDA GENERAL INFORMATION V30 MAGNA COMMON DESCRIPTION TOOL NUMBER ALTERNATOR 7001. TOOL NUMBER REF SECT|ON Valve adiusfing wrench 07703—0030400 3 Valve adjusting Wrench] 0 x 9 mm 077034030100 3 Heat level gauge 074014010000 4 Universal holder 07725—0030000 Eandslrap wrench 7, 3 (Equivalehx commercially available in 0.5.11.) Exrehslon bar 07715—0020500 Equivalehr commercially 7, 12 Lock nut wrench, 17 x 27 mm 07716—0020300 }m"ab'° i" U’S‘A' 7 Church eehrer holdar 07724—0050000 Equivalent commerclally hveileble In USA. 7 Flywheel pullar 07733—0020001 Flywheel puller 079324290001 0 Velve wing compressor 07757—0010000 9 Velve guide driver 07743—0020000 9 Driver 07740—0030100 11 Auuhmenr, :10 mm 07746—0030200 ‘ 11 Arreehrhehr, 37 x 40 mm 077404010200 12, 1: Aheehmehr, 42 x 47 mm mus—0010300 17, 13 Lack HUI wrench, 30 X 32 mm 077‘6—0020400 Equlvalem commercinlly available in U. A, 12 Pller, 15 mm 07746—0040300 12 Anni-mung 52 x 55 mm 07746700I0400 Aneehmehr 07946—3710701 12 orlver 0774970010000 12, la ‘1 searing remover xhsft 0774570050100 j 12, 13 Remover head, 15 mm 0774670050400 jei‘a‘jzzt'zrjgfmiaw ‘ 12 Remover heed, 17 mm mus—0050500 13 Remover head, 20 mm 07746—0050600 13 Pilot, 17 mm 0774641040400 13 P1lol,20 mm 07746—0040500 13 Shock absorber compraisor 079594200001 13 Date of Issue: July, 1984 1 ' 8 © HONDA MOTOR C0,, LTDV HONDA V30 MAGNA GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: e A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure it is secure. a Do not squeeze wires against a weld or the end of its clamp. 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. I Route harnesses so they are not pulled taut or have excessive slack, I Protect wires and harnesses with electrical tape X or tubing where they contact a sharp edge or 0 corner. Clean the attaching surface thoroughly @ Q before applying tape, 0 Do not use wires or harnesses with damaged insulation. Repair by wrapping them with a pro- tective tape or replace them. 0 Route wire harnesses to avoid sharp edges or corners. 0 Also avoid the projected ends of bolts and screws. 0 Keep wire harnesses away from 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 interfering with any moving or sliding parts. 0 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 interfere with adjacent or sur- rounding parts in all steering positions. Date of Issue: July, 1984 1 9 © HONDA MOTOR CO, LTD. - é HONDA V30 MAGNA GEN ERAL IN FORMATION HARNESS BANDS RIGHT HANDLEBAH SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE :0 1 1 0 Date of Issue: July. 1984 - © HONDA MOTOR CO, LTD. 53?.."233 GENERAL INFORMATION BRAKE HOSE CLUTCH HOSE BRAKE HOSE PULSE GENERATOR/OIL PRESSURE SWITCH WIRES P3; STARTER MOTOR CABLE Date of Issue: July, 1984 1 - 1 1 © HONDA MOTOR 00., LTD‘ é HONDA. V30 MAGNA GENERAL INFORMATION REGULATOR/ RECTIFIER WIRE ALTERNATOR WIRE TAILLIGHT LIGHT WIRES REAR LEFT TURN SIGNALWIRE REAR RIGHT TURN SIGNAL WIRE REGULATOR/ RECTIFIER WIRES SPARK UNITWIRES If) 1 1 2 Date of Issue: July, 1934 - © HONDA MOTOR 00,, LTD‘ /‘\. HONDA V30 MAGNA GENERAL INFORMATION EMISSION IIIINTRIIL SYSTEM The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify that their motorcycles comply with applicable exhaust emission standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Warranties for Honda Motorcycle Emission Control Systems is necessary in order to keep the emission warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subiected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor 60., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of lean carburetor settings, and no adjustments should be made except idle speed adjustment with the throttle stop screw. CRANKCASE EMISSION CONTROL SYSTEM This V30 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 drain tube which must be emptied periodically. See the Maintenance Schedule in Section 3. AIR CLEANER (:1 : FRESH AIR MAIN FRAME PIPE ' IBLOW‘BY GAS DRAIN TUBE DRAIN PLUG Date of Issue: July, 1984 © HONDA MOTOR co, LTD. 1 -1 3 HONDA V30 MAGNA GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California model) This model complies with California Air Resrouces Board requirements for evaporative emission regulations. Fuel vapor from the fuel tank is routed into a charcoal canister where it is absorbed and stored while the engine is stopped. When the motorcycle is running and the purge control diaphragm valve is open, fuel vapor in the charcoal canister is drawn into the engine through the carburetor. PU RGE CONTROL VALVE FUEL TANK FRESH AIR C . _,— DRAIN CHARCOAL CANISTER NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such devioe or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED T0 CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2. Removal of. or pUncturing of any part of the intake system. 3. Lack of proper maintenance. 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. Date of Issue: July, 1984 1 - 1 4 © HONDA MOTOR co” LTD. HONDA V30 MAGNA GENERAL INFORMATION 0 VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) The Vacuum Hose Routing Diagram Label is attached to the frame behind the left side cover. Route the vacuum hose: 3: shown on this label. VACUUM HOSE ROUTING DIAGRAM LABEL If (I o EMISSION CONTROL INFORMATION LABEL The Vehicle Emission Control Information Label is attached to the frame below the engine. EMISSION CONTROL IN FORMATION LABEL ‘e of Issue: July, 1984 7NDA MOTOR 00., LTD. 1 - 1 5 HONDA LUBRICATION V30 MAGNA O 15—20 N-m (1.5—2.0 kgm, 11—14 ft-lb) Turn the water pump shaft until the groove is vertical, then re- move the oil pump. WATER PUMP See Section 6 13—17 N-m (1.3—1.7 kn-m, 9—12 be) DRAIN BOLT NOTE: Do not forget to install F 35.40 N-m the thrust washer. E' (3.5—4.0 kg-m, 25—29 ft—lb) (2.5—35 kg—m, 18—25 ft < CHASSIS> FUEL LINES 3_4 DRIVE CHAIN 3-13 FUEL FILTER 3_4 BATTERY 345 THROTTLE OPERATION 3_5 BRAKE FLUID 3—16 CARBURETOR-CHOKE 3.5 BRAKE SHOE/PAD wEAR 3—16 AIR CLEANER 3_7 BRAKE SYSTEM 3-17 CRANKCASE BREATHER 3_8 BRAKE LIGHT SWITCH 3—13 SPARK PLUGS 3_8 HEADLIGHT AIM 3—13 VALVE CLEARANCE 3_3 CLUTCH 3-19 CARBURETORSVNCHRONIZATION 3—11 8'95 STAND 3-19 CARBURETOR IDLE SPEED 3—12 SUSPENSION 3—19 EVAPORATIVE EMISSION CONTROL NUTS: BOLTS. FASTENERS 3—20 SYSTEM 3—12 WHEELS 3-21 RADIATOR COOLANT 3—12 STEERING HEAD BEARINGS 3—21 RADIATOR CORE 3-13 SERVICE INFORMATION GENERAL 0 Engineoil See page 2-3 0 Engineoil filter Seepage 2-3 0 The cylinder numbering is given below: FRONT ® ® .— LEFT SPECIFICATIONS < Engine > Spark plugs: Standard For cold Climate (below 5°C, 41°F) For extended high speed riding NGK ND NGK ND NGK ND DPRBEA-Q XZ4EPFI-U9 DPR7EA-9 X22EPR-U9 DPHQEA-Q X27EPH-U9 Spark plug gap: 0.8—0.9 mm (0.03—004 in) Date of Issue: July, 1954 © HONDA MOTOR 00.. LTD. 3-1 HON DA MAINTENANCE V30 MAGNA Ignition timing At idle: 15° BTDC Advance starts: 15° BTDC at 1,700 rpm Full advance: 37° BTDC at 3,000 rpm Valve clearance Cold (Below 35°C, 95° F) Idle speed: Cerburetar synchronization: Throttle grip free play: Choke valve stroke < CHASSIS > Drive chain slack: Rear brake pedal free play Intake: 0.12 mm (0.004 in) Exhaust: 0.13 mm (0.005 in) 1,300 i 100 rpm All carburetors within 60 mm (2.4 in) Hg 2—6 mm (1/3—1/4 in) 6—7 mm (0.2—0.3 in) 15—25 mm (518—1 in) 20—30 mm (3/4—1-1/4 in) Tires: . . Front Rear Tire size 100/90-18 56H 130/90-1 6 67H Up to 90 kg (200 lb) lead 200 (2.00, 28) 200 (2.00, 28) Cold tire pressure, kPa (kg/cm“, psi) 90 kg (200 lb) load to vehicle capacity load 200 (2.00, 28) 250 (2.50, 36) Tire brand Bridgestone L303 6508 Dunlap F11 K627 Suspension air pressure: TORQUE VALUES Rear axle nut Valve adjuster nut TOO LS Special Vacuum gauge tester Carburetar synchronization wrench Common Valve adjusting wrench Valve adjusting wrench, 8 x 9 mm Front, 0—40 kPa (0—0.4 kg/cm‘, o—s psi) 70—90 N-m (7.0—9.0 kg-m, 61—65 ft-lb) 9—12 N-m (0.9—1.2 kg-m, 6—9 ft-lb) 07404—0020000 or M937B——O21—XXXXX (U.S.A. only) 07908—KE70000 Equivalent commercially available in U.S.A. 07708—0030400 07708—00301 00 3-2 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. HONDA V30 MAGNA MAINTENANCE MAINTENANBE SCHIJIILE Perform the PFIE-HIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE, A: ADJUST. L: LUBRICATE FREOUENcY WHICHEVER ODOMETER READING (NOTE 4) FIRST 595 :5 €55 t; \5 $5 $5 E V I \ K . I 1 é’d SSE” $31” {in .955? 35:" .352” Refer :0 ITEM EVERY page " FUEL LINES I I I 3-4 ' FUEL FILTER R 34 * THROTTLE OPERATION I I I I 3-5 m ' CAHBURETOR CHOKE I I I 3-5 5 " AIR CLEANER NOTE 1 R R R 3-7 I: CRANKCASE BFIEATHER NOTE 2 C c c c c C as 3 SPARK PLUGS R R R R R R 3-3 I- “ VALVE CLEARANCE I I I I 33 5 ENGINE OI L YEAR R R R R 2-3 3 ENGINE OIL FILTER YEAR R R R R 2-3 2 " CARBURETOR SYNCHRONIZATION I I I I 3-11 9 ' CARBUFIETOR IDLE SPEED I I I I I I I 3-12 3 RADIATOR COOLANT I I I 3-12 5 * RADIATOR CORE I I I 3-13 . COOLING SYSTEM HOSES & I I I I 343 CONNECTIONS . g/géJNRATIVE EMISSION CONTROL NOTE 3 I I I 342 DRIVE CHAIN I, L EVERY 300 mi 1500 km) 3-13 U, BATTERY MONTH I I I I I I I 315 E BRAKE FLUID z'flgggJR I I I ‘R I I “R 3-16 3 BRAKE SHOE/PAD WEAR I I l- I I I 3-16 E BRAKE SYSTEM I I I I 3-17 5 " BRAKE LIGHT SWITCH I I I I 3-13 I: ' HEADLIGHT AIM I I I I 3-13 5 CLUTCH FLUID ang‘RE‘ER I I I 'R I I 'R 3-19 2 CLUTCH SYSTEM I I I I 3-19 5 SIDE STAND I I I 3-19 2- " SUSPENSION - I I I I 3-19 g * NUTS, BOLTS, FASTENERS I I I I 3-20 " WHEELS I I I I 3-21 " STEERING HEAD BEARINGS I I I I 3-21 ' 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 RECOMMEND THAT THESE ITEMS BE SERVICED ONLY BY AN AUTHO- RIZED HONDA DEALER. NOTES: 1. SERVICE MORE FREQUENTLYWHEN RIDING IN DUSTY AREAS‘ 2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN 0R AT FULL THROTTLE. 3. CALIFORNIA TYPE ONLY, 4. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE. Date of Issue: July, 1934 © HONDA MOTOR 00., LTD. 3 ' 3 HONDA MAINTENANCE V30 MAGNA FUEL LINES Remove the seat and left side cover. Check the fuel lines and replace any parts which show deterioration, damage or leakage. FUEL FILTER Gasoline is flammable and is explosive under certain conditions Do not smoke or allow flames or sparks near the equipment while drainingfuel. Drain the fuel from the fuel tanks (Page 421), Remove the battery (Page 15-3). Remove the battery box Disconnect the fuel pump ooupler. Disconnect the fuel lines from the carburetor and sub tank. Remove the mounting nuts and fuel pump stay. ' m t, ‘ / . BATTERY CASE FUEL PUMP STAY FUEL FILTER Replace the fuel filter with a new one when indi~ cated by the maintenance schedule (Page 3-3). Reinstall the removed parts in the reverse order of removal. After installing, check that there are no fuel leaks. Date of Issue: July, 1954 3 - 4 © HONDA MOTOR 00., LTDr HONDA V30 MAGNA THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables (P396 2-10), It throttle operation is not smooth. Measure throttle grip free play at the throttle grip flange. Throttle grip free play can be adjusted at either end of the throttle cable. Replace any damaged parts before beginning this adjustment. Minor adjustments are made with the upper throttle cable adjuster. Adjust free play by loosening the lock nut and turning the adjusters. Tighten the look nut. Recheck throttle operation. Major adjustments are made with the lower adjuster. Adjust free play by loosening the lock nut and turning the adjuster. Tighten the lock nut. Recheck throttle operation. Replace any damaged parts. MAINTENANCE ADUSTER LOCK NUT LOWER ADJUSTER Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. MAINTENANCE CARBIIRETOR-CHDKE Check for smooth choke lever operation. Lubricate the choke cable as required. Pull die choke lever on the handlebar all the way down to lullv open. Make sure the choke valve is open by trying to move the choke lever on the carburetor. 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 clamp. Move the choke lever on the handlebar both ways and measure the choke valve stroke at each carbure- tor between the fully closed and fully open posi- tions. VALVE STROKE: 6—7 mm (0.2—0.3 In) Adjust if necessary, by loosening the choke cable clamp on the carburetor and moving the cable casing. HONDA V30 MAGNA 3-6 Date of Issue: July, 1984 © HONDA MOTOR CO‘. LTD, HONDA V30 MAGNA AIR CLEANER Remove the tank mount bolts and raise the fuel tank, Remove the bolt and front frame left cover, Remove three screws and air cleaner cover. Remove the air cleaner element. Discard the element in accordance with the main- tenance schedule. Also replace the element any time it is excessively dirty or damaged. CAUTION Because the paper filter is viscous type which contains oil, do not clean it by blowing with all Install a new element into the air cleaner case. Install the air cleaner case cover and secure it with the three attaching screws. Reinstall the fuel tank and front frame left cover. 5 MAINTENANCE AIR CLEANER CASE COVER AIR CLEANER ELEMENT (VISCOUS TYPE) Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA MAINTENANCE CRANKCASE BREATHER Remove the drain plug from the drain tube to empty any deposits. Install the drain plug. NOTE: Service more frequently when ridden in reln or at full throttle or if the deposit level can be seen in the transparent section of the drain tube. DRAIN PLUG SIDE ELECTRODE SPARK PLUGS l 0.8—0.9 mm RECOMMENDED SPARK PLUGS (0331—0035 in) NGK ND Standard DPRBEA»9 X24EPR-U9 For cold Climate (Below 5°C. 41°F) DPR7EA—9 X22EPRAU9 For extended high speed riding DPRDEAvQ XZ7EPR-U9 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: 0.8-0.9 mm (0.03—0.04 in) CENTER Adjust by bending the side electrode carefully. ELECTRODE With the plug washer attached, thread each spark plug in by hand to prevent crossthreading. Continue tightenlng by hand until the spark plug bottoms. Then, tighten the spark plugs another 1/2 turn with a spark plug wrench to compress the plug washer. Connect the spark plug caps. VALVE CLEARANCE NOTE: Inspect and adjust valve clearance whlle the engine is cold. (Below 35°C, 95°F) Lean the motorcycle to the right and left to drain the oil remaining in the cylinder head into the crankcase. Remove the right and left frame side covers by pull- , ing them straight off. SIDE COVER Remove the seat. 3 8 Date of Issue: July, 1984 ' © HONDA MOTOR 00,, LTD. HONDA V30 MAGNA MAINTENANCE Remove the fuel tank (Page 4-21). Remove the radiator (Page 66). Remove the front frame bar. Remove the cylinder head cover mount bolts and remove the front and rear cylinder head covers. Remove the clutch slave cylinder and final drive sprocket cover. NOTE: lt is not necessary to disconnect the clutch oil line. To prevent the clutch system from air con- tamination, and the slave cylinder piston from falling, squeeze the clutch level im- mediately after removing the slave cylin- der, and tie the lever to the handle grip with a string. Loosen the six bolts and remove the alternator cover. Remove the inspection hole cap from the right crankcase cover by loosening it. Rotate the crankshaft counterclockwise at the fly- wheel side and align the "TR" mark on the pulse rotor with the index mark on the right crankcase cover. Make sure that the No.1 piston is at TDC (Top Dead Center) on the compression stroket If not, turn the crankshaft counterclockwise 350 degrees (one turn) and re-align the "TR" mark with the index merk. Measure the intake and exhaust valve clearances for the No. 1 cylinder. VALVE CLEARANCES: INTAKE: 0.12 mm (0.004 in) EXHAUST: 0.13 mm (0.005 in) CLUTCH SLEAVE CYL // \ /.\\ Date of Issue: July, 1984 © HONDA MOTOR 60., LTD. MAINTENANCE Adjust by loosening the lock nut and turning the adjusting screw with valve adjusting wrench until there is a slight drag on the feeler gauge. Hold the adiustlng screw and timten the lock nut. Recheck the valve clearance. Rotate the crankshaft at me flywheel side counter- clockwise 90 degrees to align the "TF” mark on the pulse rotor with the index mark and check the valve clearances for the No. 4 cylinder. Adjust by using the procedures for the No. 1 cylinder. Rotate the crankshaft counterclockwise 270 degrees to align the “TR" mark with the index mark and check the valve clearance: for the No.3 cylinder. Adjust by using me procedures for the No. 1 cylinder. Rotate the crankshaft counterclockwise to align the "TF" mark with the index mark and check the valve clearances for the No. 2 cylinder. Adjust by using the procedures for the No. 1 cylinder. Install the removed parts in the reverse order of removal. Check the engine oil level. Fill the radiator with clean coolant to the specified levelt 3-10 VALVE ADJUSTING WRENCH, 8 x 9 mm 07708—0030100 HONDA V30 MAGNA VALVE ADJUSTING WFl ENCH 07708—0030400 \, .\ FEELER GAUGE VALVE ADJUSTING WRENCH, 8 x 9 mm 07708—0030100 M . ' VALVE ADJUSTING WRENCH 07703—0030400 Date of Issue: July, 1984 © HONDA MOTOR 00.. LTD, \, HONDA V30 MAGNA MAINTENANCE CARBIIRETIIR-SYNCHRIJIIIZATIOII NOTE: Svnchronize the carburetors with the engine at normal operating temperature, transmission in neutral and motorcycle on the centerstand. Lift the water hose and pipe and remove the No.4 cylinder head part plug. Remove the plug: from the No.1, 2, and 3 cylinder head ports and install the vacuum gauge adapters. Connect the vacuum gauges. NOTE: The No. 4 carburetor cannot be adjusted; It is the base carburetor. Start the engine and adjust the idle speed. IDLE SPEED: 1,300 t 100 rpm Check that all carburetors are within 60 mm (2.4 in) Hg, Synchronize to specification by turning the adjust- ing screws with carburetor synchronization wrench (07908—KE70000) Recheck the idle speed and synchronization. Remove the gauge adapters and install the pings. N0. 2 CYLINDER HEAD PORT ‘NOA CYLINDER HEAD PORT VACUUM GAUGE TESTER 07404—002000!) 0H M9373— 021—XXXXX (U.S.A. ON LY) Q ( ADJUSTING Qscruzws L \ \ CARBU RETOR SYNCH RON IZATION WRENCH 07908—KE70000 Date of Issue: July, 1984 © HONDA MOTOR (30., LTDt 3-11 MAINTENANCE CARBIJIIETOII IDLE SPEED NOTE: ' Inspect and adjust idle speed after all other engine adjustments are within specifica- tions. - The engine must be warm for accurate adjustment. Ten minutes of stop-and-go riding is sufficient. Warm up the engine, shift to neutral, and place the motorcycle on its center stand. Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,300 i 100 rpm EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) Check all tubes to be sure they are securely con- nected and are not kinked or clogged. Replace any damaged or deteriorated tubes. If a purge control valve problem is suspected, refer to test procedures on page 4.19, RADIATOR COULANT Remove the frame left side cover, Check the coolant level of the reserve tank with the engine runnlng at normal operating tempearture. The level should be between the "UPPER" and "LOWER" level lines‘ If necessary, remove the reserve tank can and fill to the "UPPER" level line with a 50/50 mixture of distilled water and anti-freeze. Reinstall the cap and frame side cover. HON IDA V30 MAGNA THROTTLE STOP SCREW V V N eqw 5WD LOWER LEVE L MARK 3-12 Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA RADIATOR CORE Check the air passage: for clogging or damage. Straighten bent fins and collapsed core tubes. Remove insects. mud or any obstruction with mm- pressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20% of the radlating surface. COOLINC SYSTEM HOSES & CONNECTIONS Inspect me hoses for cracks or deterioration, and replace if necessary. check the tightenees of all hose clamps. (CHASSIS) DRIVE CNAIN Clean the drive chain with a non-flammable or high flash point solvent that will not damage the O—rings and wipe dry. CAUTION Do not use a steam cleaner, high pressure washers or aerosol chain lubricants as these will damage the O-rings. MAINTENANCE f: ' KEROSENE k; WIPE DRY fl LUBRICATE ”73 SAE #80 OR SAE #90 GEAR OIL Date of Issue: July, 1984 © HONDA MOTOR 60., LTD. 3-13 MAINTENANCE Turn the engine off, place the motorcycle on its center stand and shift the transmission into neutral. Check slack in the drive chain lower run midway be- tween the sprockets. SLACK: 15—25 mm (5/8—1 in) CAUTION Excessive chain slack, 50 mm [2 in} or more, may damage the frame Adiust as tollows: Loosen the axle nut. Loosen the adjusting bolt lock nuts. Turn both adjusting bolts an equal number of turns until the correct drive chain slack is obtained. CAUTION Make Me that the same alignment marks on both adjuster align with the edge of the swingarm, Tighten the adjusting bolt lock mm. Tighten the rear axle nut. TORQUE: 70—90 N~m (7.0—9.0 kw", 51—65 ft—Ibl Heoheek chain slack and free wheel rotation. Lubricate the drive chain with SAE 80 or 90 gear oil. Check the chain wear label. If the red zone on the label and the index mark on me adjuster align or overlap after adjustment, the chain must be re- placed. REPLACEMENT CHAIN: D.|.D 50V3 or RKSOFO AXLE NU INDEX MARK HONDA V30 MAGNA LOCK NUT RVED‘ ZONE 3-14 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. HONDA V30 MAGNA MAINTENANCE Inspect the drive chain and sprockets for damage or wear. A drive chain with damaged rollers, loose pins, or missing O-rings must be replaced. Replace any sprocket which is damaged or excessively worn. DAMAGED WORN NOTE: Never install a new drive chain on worn spro< ckets or a worn drive chain on new sprockets Both chain and sprockets must be In good condition or the replacement ohain or spro— ckets will wear rapidly. BATTERY Remove the rlght frame side cover and inspect the battery fluid level. When the fluid level nears the lower level line, do the following: Remove the battery holder bolt, then swing the holder out of the way. Disconnect the negative cable at the battery, then disconnect the positive cable. Disconnect the battery breather hose from the battery. Pull die battery out, remove the filler caps and add distilled water to the upper level line. Reinstall the filler caps and the battery NOTE: Add only distilled water. Tap water will shorten the service life of the battery. m__.— 71Ie 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 medl- 0‘! m NORMAL cal attention. BATTERY HOLDER FILLER CAPS UPPER LEVEL LOWER LEVEL Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. MAINTENANCE BRAKE FLUID Check the front brake fluid reservoir level. It the level nears the lower level mark, fill the re- servoir with DOT-3 or DOT~4 BRAKE FLUID to the upper level mark. Check the entire system for leaks, if the level is low. DAUYION ' Do not remove the cover until the handle- bar has been turned so that the reservoir is level. o 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 14 for brake bleeding procedures. BRAKE SHOE/ PAD WEAR FRONT BRAKE PAD Check the brake pads for wear by looking through the slot indicated by the arrow cast on the caliper assembly. Replace the brake pads it the wear line on the pads reaches the edge of the brake disc (Page 14-5). CAUTION Always replace the brake pads in pairs to assure even disc pressure. REAR BRAKE SHOE Replace the brake shoes if the arraw on the wear indicator aligns with index mark on the brake panel when brake is applied. 1 INDEX MARK HONDA V30 MAGNA UPPER LEVE L 3-16 Date of Issue: July, 1954 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA MAINTENANCE BRAKE SYSTEM _ , BjiAKE HOSE Inspect the front brake hose: and fittings for deteioration, cracks or signs of leakage, Tighten any loose fittings. Replace hoses and fittings as required. Inspect the rear brake pedal and rod for loose connections, excessive play or other damage. Replace or repair if necessary. BRAKE PEDAL HEIGHT Adjust brake pedal height so the pedal is 10-20 mm (3/8—3/4 in) below the top of the foot peg. CAUTION Incorrect brake pedal height can cause brake drag. To Adjust: Loosen the stopper bolt locknut and turn the stopper bolt. Retighten the locknutt NOTE: After adjusting the brake pedal height, check the rear brake light switch and brake pedal free play and adjust if necessary. LOCKNUT BRAKE PEDAL FREE PLAY Measure the rear brake pedal free play from the top of the brake pedal. FREE PLAY: 20—30 mm(3/4—1-1/4in) Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD. 3 ' 1 7 MAINTENANCE HONDA V30 MAGNA To adjust, turn the adjuster nut. After adjustment, check the rear brake light switch and adjust if necessary. BRAKELIEHT SWITCH Adjust the brakelight switch by holding the switch body and turning the adjusting nut. Du not turn the switch body, Turn the adjusting nut clockwise if the brake light comes on too late. HEADLIEIIT AIM Adjust vertically by loosening the headlight case mounting bolts and moving the headlight. Adjust horizontally by loosening the headlight case bracket mount bolts and moving the headlight right or left. Tighten the bolts securely after adjustment. NOTE: Adjust the headlight beam as specified by loml laws and regulations. An improperly adjusted headlight may blind cumming drivers, or it may fall to light the road properly. ADJUSTE R NUT ADJUSTING NUT ME ERAKELIGHT SWITCH HEADLIGHT BRACKET MOUNTING BOLT IHEADLIGHT CASE MOUNTING BOLT 3-18 Date of Issue: July, 1984 © HONDA MOTOR C0,, LTD. HONDA V30 MAGNA CLUTCH Check the clutch fluid reservolr level. II the level nears the lower level mark, fill the reservoir with DOT-3 M4 BRAKE FLUID until the level is between the upper and lower level marksi Check the entire system for leaks, if the level is low. CAUTION ‘ Do not remove the cover until the handle- bar 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. a Do not mix different types of fluid, as they are not compatible. SIDE STAND Check the rubber pad for deterioration or wear. It wear extends to the wear line, replace the pad. check the side stand spring for damage and lost of mnsion. Check the side stand for damage and freedom of movement. Make sure the force required to hold up the side stand is within 3.0—5.0 kg (63—11.!) lb) when pull- ing with a spring scale. Lubricate the side stand pivot. SUSPENSION Do not ride a vehicle with faulty suspension. Loose, worn or damaged suspension parts MAINTENANCE UPPE R LEVEL WEAR LlNE NO GOOD lmpalr vehicle smbilior and control. FRONT Check the action of the front forks Ivy compressing them several times. Check the entire fork assembly for the leaks or damage. Replace damaged components whlch cannot be repaired. Tighten all nut: and bolts. Date of Issue: July, 1984 © HONDA MOTOR (20., LTD. MAINTENANCE Check the front fork air pressure with the forks being cold. Place the vehlcle on its center stand. Remove the air valve cap and measure the air pressure. AIR PRESSURE: 0—40 kPa (0—0.4 kg/cm’, o—s pal) REAR Place the motorcycle on its center stand. Try to move the rear wheel sideways to check for worn swingarm bearings. Replace the bearings it there is any looseness. check the shock Ibsorber for leaks or damage. Tighten all rear suspension nuts and bolts. NllTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to thalr correct torque values (Section 1) at the intervals shown in the Maintenance Schedule (pages 33). Check that all cotter pins. safety clips, hose clamps and cable stays are intact. HONDA V30 MAGNA 3-20 Date of Issue: July, 1934 © HONDA MOTOR C0,. LTD‘ HONDA V30 MAGNA MAINTENANCE WHELS NOTE: Tire pressure should be checked when tires are COLD. Check the tires for cuts, imbedded nails, or other damage RECOMMENDED TIRES AND PRESSURES: Front Heir Tire sire 100190-18 130/9046 56H 67H up to 90 kg Cold m. (200 m Ind 200 (2.0a 28) 200 (2.00, 28) 97"". summon,» “MW loadtovehlcle zoo (100,23) 15.012.50.35) , t cm ,on) upecitvlold ran 33%?" L303 6503 bl’lfld DUN LOP F11 K327 Check the front and rear wheel: for truenes: (Sec- tion 12 and 13L Measure the tread depth at the center for the tires. Replace the tires if the tread depth reaohes the following limits: Minimum tread depth: Front: 1.5 mm (1/16 in) Ru . 20 mm (3/32 in) STEERING HEAD BEARINGS NOTE: Check that the control cable: do not inter- fere with handlebar rotation. Raise the front wheel off the ground and week that the handlebar rotates frreely. If the handlebar moves unevenly, binds, or has vertical mouement, adjust the steering head bearing by turning the steering head adjusting nut. Date of Issue: July, 1984 © HONDA MOTOR CO“ LTD. 3-21 HONDA FUEL SYSTEM V30 MAGNA NOTE: After '84: Do not in‘archanga the jet needies, The No. I and No. 4 carburetors use differ- ’ ant iet needles from the No. 2 and No. 3 car- J buretars. Q b5 0 4 0 Date of Issue: October, 1984 " © American Honda Motor Co., Inc. 1984- All Rights Reserved HONDA V30 MAGNA 4. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING CARBURETOR REMOVAL VACUUM CHAMBER PILOT SCREW CARBURETOR SEPARATION CARBURETOR ASSEMBLY FLOAT, FLOAT VALVE AND JETS 4—1 4—2 4—3 4—4 4—5 4—10 4—12 CARBURETOR INSTALLATION PILOT SCREW ADJUSTMENT HIGH ALTITUDE ADJUSTMENT (USA only) PURGE CONTROL VALVE INSPECTION AIR CLEANER FUEL TANK/LINES/PUMP 4—16 4—17 4—18 4—1 9 4—20 H1 E SERVICE INFORMATIIJN GENERAL m Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Do not smoke or allaw flames or spark: in the work area. 0 When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reasembly, The float bowls have drain screws that can be loosened to drain residual gasoline. 0 After '84: The No. 1 and No. 4 carburetors use different jet needles than the No, 2 and No. 3 carburetors. Do not interchange the jet needles. TOOLS Special Valve guide driver, 7 mm Vacuum pump Pressure pump Common Float gauge SPECIFICATIONS 07942—8230000 (USA. only) ST-AH-ZSO-MC7 (USA. only) ST-AH-255~MC7 (USA. only) 07401—0010000 [IICAL Item Specifications Carburetor type VD-V4 Vertical 81 Horizonml Throttle bore 32mml1.26inl Venturl bore 11¢ Primary, 2945 Secondary Identification No. '34: vosaA [VDSSA] After 134: vossB [vessel Float level 8.2 mm (0.24 inl Main jet '84: *108 After ’84: #105 Jet needle ’34: All 2VE After '84: No. 1 and 4 carburetor: 2VF No. 2 and 3 carburetors 2VE Idle speed 1,300 2 100 rpm Throttle grip free play 2-6 mm (0.08—0.24 in) Pilot screw initial opening See page 4-17 Date of Issue: October, 1984 © American Honda Motor Co., Inc. 1984 - All Rights Reserved 4-1 FUEL SYSTEM HONDA V30 MAGNA TROUBLESHOOTING Engine cranks but won't start . No fuel in tank . No fuel to carburetors . Engine flooded with fuel . No spark at plug (ignition system faulty) . Air cleaner clogged . Intake air leak . Improper choke operation . Improper throttle operation muamawn- Hard starting or stalling after starting . Improper choke operation . Ignition malfunction . Carburetor faulty . Fuel contaminated . Intake air leak . Idle speed incorrect 0:0!me— Rough idle 1. Ignition system faulty 2. Idle speed incorrect 3. Incorrect carburetor synchronization 4. Carburetor faulty 5. Fuel contaminated Misfiring during acceleration I. Ignition system faulty Bee ' ‘ng 1. Ignition system faulty 2. Carburetor faulty Poor performance (drivubilityl and poor fuel economy 1. Fuel system clogged 2. Ignition system faulty Lean mixture 1. Clogged fuel jets 2. Faulty float valve 3. Float level low 4. Fuel cap vent blocked 5. Fuel strainer screen clogged 6‘ Restricted fuel line 7. Intake air leak 8. Flextricted or faulty fuel pump Riot: mixture , Clogged air jets , Vacuum piston stuck closed . Faulty float valve . Float level too high . Choke stuck or clogged . Dirty air cleaner mmbun—a Date of Issue: July, 1984 © HONDA MOTOR (20., LTD. HONDA V30 MAGNA FUEL SYSTEM CARBURETIJR REMOVAL Remove the seat. Remove the fuel tank (Page 4-21) and frame front cover, Remove the air cleaner element (Page 3-7). Remove the air cleaner case mounting bolts and case cover screws Pull out the air cleaner case and remove the case cover, Disconnect the choke and throttle cables at the carburetor. Disconnect the fuel line. Disconnect the purge lines from the canister at the PCV (California only). Loosen all the carburetor bands then remove the carburetors from the engine THROTTLE CABLE FUEL TANK d AIR C EANER CASE CARBURETOR Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD, FUEL SYSTEM VACUUM CHAMBER REMOVAL Remove the four vacuum chamber oaver screws and cover. Remove the compression spring, diaphragm and vacuum piston. Inspect the vacuum piston for wear or other damage. Make sure the piston maves up and down freely in the chamber. Push the needle holder in and turn it 60 degrees with an 8 mm socket. Then remove the needle holder, spring and needle from the piston NOTE: After '34: The No. l and Not 4 carburetors use different jet needles than the No. 2 and No. 3 carburetors Do not interchange the jet nee- dles. HONDA V30 MAGNA COVERS COMPRESSION SPRING DIAPHRAGM “ VACUUM PISTON NEEDLE HOLDER 4-4 Date of Issue: October, 1984 © American Honda Motor 00., Inc. 1984 - All Rights Reserved HONDA V30 MAGNA FUEL SYSTEM Inspect the needle for excessive wear or damage at the tip. Check for a torn or deteriorated diaphragm CAUTION After '84: The No. 1 and No. 4 mburetors use different let needles than the No. 2 and No. 3 carburetors Do not confuse the jet needles during inspection INSTALLATION Installation is essentially the reverse of removal but to keep from distorting the diaphragm, install the vacuum piston/diaphragm as follows: Insert the vacuum piston into the carburetor. Stick your finger into the carburetor bore and hold the vacuum piston in the full throttle piston, then turn down the diaphragm so its lip fits into the carburetor groove. Install the chamber cover, aligning its cavity vvith the hole in the carburetor, and secure with at least two screws before releasing the vacuum piston. DIAPHRAGM 030 NEEDLE NEEDLE HOLDER CARBUHETOR N0. '34 AFTER '84 No.1 zvs 2VF No.2 zvs 2VE No.3 ZVE 2VE No.4 2VE 2VF FLOAT, FLOAT VALVE AND JETS REMOVAL Remove the four float chamber screws and the float chamber. FLOAT HAMBER Date of Issue: October, 1984 © American Honda Motor Co., Inc. 1934 - All Rights Reserved 4-5 FUEL SYSTEM Remove the float pin, float and floatvalve. CAUTION Take care not to damage the float pin. F LOAT AND F LOAT VALVE INSPECTION Check the float for deformation or fuel inside the float. Inspect the float valve for grooves and nicks, Replace if necessary. FLOAT VALVE SEAT INSPECTION Remove the float valve seat and filter. Inspect the float valve seat and filter for grooves, nicks, clogging or damage. HONDA I V30 MAGNA FLOAT PIN FLOAT FLOAT VALVE \» FLOAT VALVE SEAT W" / 9%? FLOAT VALVE SEAT FILTER Date of Issue: July, 1984 © HONDA MOTOR C0., LTD. HONDA V30 MAGNA FUEL SYSTEM Remove the main jet, jet holder and slow jet, Remove the pilot screw (Page 4-8). NOTE: Before removing the pilot screw, turn it in carefully and note the number of turns until it seats lightly. CAUTION Damage to the pilot mew sea! will occurxjf the pilot mew is tightened against the seat. Blow all jet and body openings clean with com- pressed air. INSTALLATION Install the iet holder and main jet. Install the slow jet. Install the float valve seat and filtar. FILTER FLOAT VALVE SEAT FLOAT VALVE ' JET HOLDER MAdT SLOW JET VALV ‘SEAT JET HILDER AND FILTER Date of Issue: July, 1984 © HONDA MOTOR CO” LTD. 4-7 FUEL SYSTEM HONDA V30 MAGNA inspect the operation of the float valve. Install the float valve, float and float pin. FLOAT LEVEL Measure the float level with the carburetor inollned 16°41? from vertical and the float tang iutt eon— tacting the float valve. FLOAT LEVEL: 6.2 mm (0.24 in) Adjust the float level by carefully bending the float tang. Install the float chamber and secure it with the screws. FLOFLEVEL GAUGE 07401—001000!) PILIJT 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 misadjustrnent. 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. 4-8 Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD, L.-. ‘ HONDA V30 MAGNA FUEL SYSTEM 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 Be careful not to drill into the pilot screw. AII pilot screws must be replaced even if only one requires it for proper pilot screw adjust- ment (page 4-1 7]. Force a self-tapping 4 mm screw (H/C 0693994, P/N 93903—35410) into the drilled plug and continue turning a screwdriver until the plug rotates with the screw. Pull 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. CAUYION r__—— Damage to the pilot screw seat wiII occur if the pilot screw is tightened against the seat. Remove the pilot screws and inspect them. Replace them if they are worn or damaged. PILOT SCREW Date of Issue: July, 1984 © HONDA MOTOR (20., LTD. FUE L SYSTEM HON IDA V30 MAGNA INSTALLATION 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 4-17l. NOTE: Do not install new plugs until after adjust- ment has been made. If you replace the pilot screw in one car- buretor, you must replace the pilot screws in the other carburetors tor proper adjust- ment. CARBIIRETOR SEPARATION Bend the lock plate tabs dovm and remove the eight bolts. Remove the air cleaner base from the carburetor. Remove the cotter pins and washers and remove the choke link (No.2-to-No.3 carburetorlt Remove the link plate setting nuts reel washers and remove the choke links (No.1‘to-No.3 and No.2-to- No.4). LOCK PLATE ' ’ VAIR CLEANER BASE CHOKE IV.INI7(7 y VLJNKI’LATES NU? ' V ' "Wei-mks LINKS 4-10 Date of Issue: July, 1984 © HONDA MOTOR CO, LTD. HONDA. V30 MAGNA FUEL SYSTEM N0.1CARBURETOR NO. 2 CARBURETOR Carefully separate the No. 2 carburetor from the assembly. Then separate the No. 1 carburetor. CAUTION Separate the carburetor horizontally to pre- vent damage to the joint pipes. Disconnect the throttle link from the No. 3 and 4 carburetors by removing the cotter pins. THROTTLE LIN K FUEL JOINT PIPE _ NO.SCARBURETOR Carefully separate the No. 3 and No. 4 carburetors. T Noj'éARBURE'TOR " Date of Issue: July, 1984 © HONDA MOTOR (20., LTD. 4 ' 1 1 FUEL SYSTEM Pullout the collar. Remove the arm. Remove the choke valve nut, spring and valve. Check the choke valve for nicks, grooves, or other damage. GARBIIRETIIR ASSEMBLY Loosely install the choke valve, spring and ML Install the choke valve arm and spring by sliding the clevis of the choke valve arm onto the groove of the choke valve. Tighten the choke valve nut. Insert the collar to set the choke valve arm. COLLAR HONDA V30 MAGNA CHOKE VA'LVE'WJ? '7’“ ARM CHOKE VALVE SPRING ARM CHOKE VALVE ARM VALVE 4-12 Date of Issue; July, 1984 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA FUEL SYSTEM FUELJOINT PIPE Coat new O-rings with oil. Install the O-rings and washers on the fuel joint pipe. Install the fuel joint pipe to the No. 3 and No. 4 carburetors. Reconnect the throttle link between the No. 3 and No. 4 carburetors, using new cotter pins. No.4CARBURETOR No.3CARBURETOR FUEL JOINT PIPES Coat new O-rings with oil and install them on the fuel and air joint pipes. Put the No. l and No. 2 carburetors together with the ioint pipes. Date of Issue: July, 1984 © HONDA MOTOR CO, LTD, HONDA V30 MAGNA FUEL SYSTEM Loosen the synchronization adjusting screws until there is no tension. Install the synchronization springs. Install the thrust springs between the mrottle valve shafts. Make sure the fuel joint and air joint pipes are securely installed. * a i L , . . No.30AFlBURETOR THRUST RING No.3 CARBURETOR THHUST SPH|_N§ No.1CARBUHETOH no.3 SYNCH RONIZATION SPRING Install the choke link between No.2 and No.3 ' " f, carburetors using the washer: and new cotter pins. ’ Install the choke links between No.1 and No.3, and No.2 and No.4 carburetors using spring washers and nuts as shown. Install new O-rings onto the carburetors. O-RINGS 4 1 4 Date of Issue: July, 1934 “ - © HONDA MOTOR co., LTD, HONDA V30 MAGNA FUEL SYSTEM GROMMETS Install the dew] pins and grommets onto the air cleaner base. Make sure that the air vent pipe grommets are in place and are in good condition. Replace them with new ones if necessary. DOWE L PINS Place the air cleaner base over the carburetors aligning the dawel pins with the carburetor holes. Install the new lock plates and the eight bolts. Tighten the bolts and secure them by bending the lock plate tabs up. Reinstall the cover. Turn the throttle stop screw to align the No. 4 throttle valve with the edge of the bypass hole. ., filammmmm 11 v' V ....._ was— 2 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD, 4 '1 5 HONDA V30 MAGNA FUEL SYSTEM No.2 ADJUSTING SCREW No.3 ADJUSTING SCREW Align each throttel valve with the bypass hole edge \ at by turning the synchronization adjusting screws. Check the throttle linkage and throttle valve opera- tion by opening and closing the throttle lever. Check the choke linkage and choke valve operation by moving the choke arm. ' ' No.1 ADJUSTING SCREW CARBURETOH CYLIN DER HEAD BARBURETOR INSTALLATION Connect the choke and throttle cables to the car- buretor assembly. NOTE: Check the throttle and choke valve operation before installation. Remove the intake plpes from the front cylinder head, and install them on the front carburetors. Loosen the connecting hand; on the rear cylinder head intake pipes. Fit the carburetors into place on the cylinder heads and into the rear intake pipes. Tighten all intake plpe connecting bands. ONNECTING BANDS CHOKE CABLE CARBURETOR Make sure that the O—ring is in the groove of the air cleaner case. Install the air cleaner case cover by aligning the groove with the frame oenter pipe, slide the air cleaner case over and onto the air cleaner base. Tighten the air cleaner case mounting bolts and cover screws. Reinstall the removed parts in the reverse order of removal. Date of Issue: July, 1984 4 ' 1 6 © HONDA MOTOR 60., LTD. HONDA V30 MAGNA FUEL SYSTEM ’ PILOT SCREW ADJUSTMENT PiLOT SCREW IDLE DROP PROCEDURE (U.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 clockwise until it seats lightly and back it out to the specification given. This is an initial setting prior to the final pilot screw adjustment. INITIAL OPENING: 2-1/2 turns out THROTTLE STOP SCREW 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. 3. Attach a tachometer according to its manufac- turer's instructions. ’ 4, Adjust the idle speed with the throttle stop screw. IDLE SPEED: 1,300 i 100 rpm 5. Turn each pilot screw 1/2 turn out from the . initial setting. 6. If the engine speed increases by 50 rpm or more, turn each pilot screw out by successively 1/2 turn increments until engine speed drops by 50 rpm or less. 7. Adjust the idle speed with the throttle stop screw. 8. Turn the No. 1 carburetor pilot screw in until the engine speed drops 50 rpm. 9. Turn the No. 1 carburetor pilot screw 1 turn out from the position obtained in step 8. 10. Adjust the idle speed with the throttle stop screw. 11. Perform steps 8, 9 and 10 for the No.2, 3 and 4 carburetor pilot screws. 12. Drive new pilot screw plugs into the pilot screw bores with a 7 mm valve guide driver (P/N 07942—8230000l. When fully seated, the plug surfaces will be recessed 1 mm into the pilot screw bore. PILOT SCREW PLUG Date of Issue: July, 1984 HONDA MOTOR CO., LTD. 4' 1 7 FUEL SYSTEM Hllill ALTITUDE ADJUSTMENT (USA only) When the vehicle is to be operated continuously above 2,000 m (6,500 feet). the carburetor mutt 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. Flemove each pilot screw plug (page M). Turn each pilot screw clockwise 1-1/2 turn. Adjust the idle speed to 1,300 x 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 operation. Attach a Vehicle Emission Control Information Update label onto the frame as shown. NOTE: Do not attach the label to any part that can be easily removed from the vehicle. mama— Operation at an alititude lower than 1,500 In (5,000 feet) with the carburetors adjusted for high altitudes may cause the engine to idle roughly and stall. When the vehicle is to be operated continously 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 1,300 i 100 rpm. Drive new pilot screw plugs into the pilot screw bores (page 4-17). Be sure to do these adjustments at low altitude. HONDA V30 MAGNA VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL 4-18 Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA FORGE CONTROL VALVE INSPECTION (CALIFORNIA MODEL) NOTE: The purge control valve should be inspected if hot restart is difficult. check all fuel tank, Purge Control Valve (PCV). and charcoal canister hoses to be sure they are not kinked and are securely connected. Replace any hose that shows signs of damage or deterioration. Disconnect the PCV hoses, and remove the PCV from its mount. Refer to the routing label on the reverse side of the right side cover for hose connec- tions. Plug the connection that goes to the No. 2, 4 car- buretors. Connect vacuum pump to the 8 mm ID. hose that goes to the No, 1, 3 carburetors. Apply the specified vacuum to the PCV. SPECIFIED VACUUM: 250 mm (9.8 in) Hg The specified vacuum should be maintained. Replace the PCV if vacuum is not maintained. Remove the vacuum pump and connect it to the hose that goes to the No. 3 carburetor body (P.C. port). Apply the specified vacuum to the PCV. SPECIFIED VACUUM: 250 mm (9.8 in) H9 The specified vacuum should be maintained. Replace the PCV if vacuum is not maintained. Connect a pressure pump to the 10 mm ID. hose that goes to the charcoal canister. While applying the specified vacuum to the PCV hose that goes to the No. 3 carburetor body, pump air through the canister hose. Air should flow through the PCV and out the hose that goes to the No. 1, 3 car- buretor body. Replace the PCV if air does not flow out. CAUTION To prevent damge to the purge control valve. do not use high air pressure sources. Use a hand operated air pump only, Remove the pumps, install the PCV on its mount, and route and reconnect the hoses according to the routing label. FUEL SYSTEM VAOIIIII IIOSI IIIIIIIG IIIAEIIAI uumumm as I m nmmm ”Ill-ml Ilmllt mutt nuc ro CHARCOAL cmsrzn . ro No. 3 unauneroa now was: CONTROL VALVE To no I, a caneuREj'OflS WWW / gnummnm VACUUM PUMP ST-AH-ZGOMC7 (USA. only) PRESSURE PUMP . sT-AH-255-MC7 (USA. only) VACUUM PUMP ST-AH-ZSO-MC7 (U.S.A. only) Date oI Issue: July, 1984 © HONDA MOTOR 00., LTD. 4-19 HONDA ' FUEL SYSTEM V30 MAGNA AIR CLEANER CASE COVER AIR CLEANER CASE MOUNTING BOLTS REMOVAL Remove the fuel tank (Page 4-21). Remove the air cleaner case bolts and cover screws. Disconnect the breather tube from the air cleaner case‘ Remove the left frame cover. Remove the fuel tank stay bracket. Remove the air cleaner case bolts and cover screws. Lift up the air cleaner cover and remove the air cleaner case. BREATHER TUBE SCH EWS fAIR CLEANER COVER AIR CLEANER CASE SETTING PLATE ('34 only) 4-20 Date of Issue: October, 1984 0 American Honda Motor (.70., Inc‘ 1984 - All Rights Reserved HONDA V30 MAGNA FUE L SYSTEM FUEL TANK / lINES / PUMP , N . FUE‘L VALVE FUEL DRAlNING Do not allow flames or sparks near gasoline. Wipe up spilled gasoline at once. Turn the fuel valve OFF and disconnect the lower fuel tube‘ Connect a tube to the fuel valve outlet and drain the fuel into a clean container. Reconnect the fuel line to the fuel valve after draining FU_EL LINE FUELTANK FUEL TANK REMOVAL Remava the seat and the left and right side covers. Remove the fuel tank atmching bolts and pivot shaft. ATTACHING BOLT Lift the fuel tank and disconnect the fuel lines‘ Disconnect the purge line from the fuel tank (California model only). Remove the fuel tank. FUEL LINES Date of Issue: July, 1934 _ © HONDA MOTOR C0,, LTD 4 21 FUEL SYSTEM Remove the battery Remove the battery box and spark units. Remove the radiator coolant reservoir tank. Remove the relay bracket. Disconnect the low fuel warning unit wires. Remove the sub tank mounting boIL Then free the tank boss from the frame and lift it offl Disconnect the fuel line (mm the fuel valve on the tank side, and remove the sub tank. FUEL PUMP REMOVAL Drain the fuel from the fuel system (See page 4-21). Remove the followings: — seat — fuel tank — battery and box — reservoir tank and spark units — relay bracket and relays MOUNTING BOLT BATTERY HONDA V30 MAGNA COOLANT RESERVOIR SPARK UNI WIRES SUB TANK FUEL TANK $ 4-22 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD, HONDA V30 MAGNA FUEL SYSTEM Disconnect the fuel pump wirel Disconnect the fuel lines (sub tank-to-fuel pump and fuel pump-tourburetor). Remove the fuel pump mounting nuts and fuel pump assembly with fuel valve attached. MOUNTING NUTS ‘ FUEL FILTER Disconnect the fuel lines and disassemble the fuel pump, fuel filter and fuel valve from the bracket. FUEL PUMP FUEL PUMP INSTALLATION Connect the fuel lines as shown. Install the fuel pump, filter and valve on the pump bracket. Install the fuel pump in the reverse order of removal. FUEL FILTER FUEL PUMP NOTE: Note the fuel ne clamp Ioca ‘ons. FUEL VALVE TO SUB TANK ——> T0 CARBUHETOR Date of Isms: July, 1984 4 ' 2 3 © HONDA MOTOR (30., LTDt HONDA V30 MAGNA FUEL SYSTEM SUB TANK INSTALLATION Installation is the reverse order of removal. Check for leaks after installation. SUB FUEL TANK NOTE: Set the rubber mount into the detent portion of the frame schrely. FUEL TANK INSTALLATION Installation is the reverse order of removal. After installation, check that there are no fuel leaks. T0 SUBTAN K 4 2 4 Date of Issue: July, 1984 - © HONDA MOTOR co,, LTD. HONDA V30 MAGNA FUE L SYSTEM FUEL PUMP INSPECTION Do not allnw flames or spark: near gasoline. Remove the seat and right and left side covers. Disconnect the fuel pump relev coupler. Short the wire between the BI and W terminals of the harnees coupler. Disconnect the fuel line and hold a graduated beaker under the fuel line. Turn the fuel valve ON. Turn the ignition switch on and let fuel flow into the beaker for 10 seconds, then turn the ignition switch off. Multiply the amount in the beaker by 6 to determine the fuel pump flow capacity per minute. FUEL PUMP F LOW CAPACITV: 700 or: (0.74 us qt, 0.62 Imp qt) t 10%Iminute Connect the fuel lines. Flemove the iumper wire and connect the coupler to the fuel pump relay. Reinstall the removed parts. \ FUEL LINE \ FUEL PUMP RELAY JUMPER WIRE Date of Issue: July, 1984 © HONDA MOTOFl (30., LTD. 4-25 ENGINE REMOVAL/INSTALLATION é HONDA V30 MAGNA 7/” ‘16 /; 35—45 N~m (as—4.5 kgm, 25—32 mm) '12 20—28 N-m (IO-2.8 kg-m, 15—20 ft-lbb , 35—46 N-m 13.5—45 kgm, W" 25—32 ft»lb) (3.5—4.5 kg-m, 25—32 ft-lb) ‘3‘ 35—45 N-m '4‘ (3.5—4.5 kg-m, 25—32 ft-Ib) 8—12 N-m (0.8—1.2 kw", 6—9 ft-lb) 25-35 N‘m (2.5—3‘6 kg-m, 13—25 ft-lh) Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD. HONDA 5 ENGINE REMOVAL/INSTAIIAIIIIN v30 MAGNA _ SERVICE INFORMATION 5—1 ENGINE REMOVAL 5—2 ENGINE INSTALLATION 5-7 SERVICE INFORMATIIJII G E N E R A L O A floor jack or other adjustable support is required to support and maneuver the engine. - e The following parts or components can be serviced with the engine installed in the frame: ' Clutch - Alternator . Gearshift linkage ' Starter motor ' Front and rear cylinder heads ~ Carburetors SPECIFICATIONS Engine dry weight Approximately 63.6 kg (140 lb) Engine oil capacity 3.0 lit (3.2 US qt, 2.6 Imp qt) after disassembly 2.5 lit (2.6 US qt, 2.2 Imp qt) after draining Coolant capacity Radiator and engine Approximately 1.8 lit (1.9 US qt, 1.6 Imp qt) Reserve tank ’ Approximately 0.4 lit (0.42 US qt, 0.35 Imp qt) TORQUE VALUES Front engine hanger bolt 35—45 Nam (3.5—4.5 kg-m, 25—32 ft-Ib) Hear engine hanger bolt Upper 35—45 N~m (3.5—4.5 kg-m, 25—32 ft-Ib) Lower 35—45 N‘m (3,544.5 kg-m, 25—32 ft-Ib) Subtrame socket bolt Upper 35—45 N-m (3.5—4.5 kg-m, 25—32 ft-lb) Lower 35—45 N~m (3.5—4.5 kg-ITI, 25—32 ft-Ib) Exhaust chamber 25—35 N-m (2.5—3.5 kg—m, 18—25 ft-Ib) Drive sprocket bolt 8—12 N~m (QB—1.2 kg-m, 6—9 tt-Ib) Rear axle nut 70—90 Nam (7.0—9.0 kg-m, 51—65 ft-lb) Gearshift arm pinch bolt 20—28 Nrm (2.0—2.8 kg-m, 15—20 tt-lbI Date of Issue: July, 1984 5 1 © HONDA MOTOR 60., LTD. ' HONDA V30 MAGNA ENGINE REMOVAL/INSTALLATION ENGINE REMUVAL UEL TANK Remove the seat. Remove the frame left and right side covers. Remove the fuel tank (Page 4-21). Diwannect the negative cable from the battery. Drain the engine oil (Page 2-3). Drain the coolant and remove the radiator (Page 6-6). Remove the frame front covers‘ FHAME COVER 5 2 Date of Issue: July, l984 - © HONDA MOTOR 00., LTD. HONDA V30 MAGNA Remove the clutch slave cylinder cover. Remove the clutch slave cylinder. NOTE: It is not necessary to disconnect the clutch oil line. ' To prevent the clutch system from air con- tamination, and the slave cylinder piston from falling, squeeze the clutch lever im- mediately after removing the slave cylin- der, and tie the lever to the handle grip. Remove the gearshift linkage and left foot peg. Remove the drive sprocket cover. Loosen the axle nut and drive chain adjusters. Straighten the lock plate tabs and loosen the drive sprocket bolts. Remove the look plane, fixing plate, and the drive sprocket, Move the drive chain reamard. Loosen the left and right muffler band bolts. Remove the left and right mufflers. ENGINE REMOVAL/INSTALLATION CLUTCH SLAVE CYLINDER COVER FOOT PEG ' GSHEAHIFT CLUTCH SLAVE CYLINDER LINKAGE DHIVE SPHOCKET LOCK PLATE Date of Issue: July, 1984 © HONDA MOTOR CO., LTD, ENGINE REMOVAL/INSTALLATION HONDA V30 MAGNA Loosen the exhaust pipe joint nuts. Loosen the exhaust pipe bands and remove the exhaust pipes. Loosen the exhaust chamber mounting bolts. Loosen the rear exhaust pipe band bolts, then remove the exhaust chamber. MOUNTING BOLTS EXHAUST CHAMBER EXHAUST PIPE BANDS 5-4 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA ENGINE REMOVAL/INSTALLATION THERMOSTAT OUSING Loosen the hose band and dimnnected the sensor \ x , wire. . , Remove the thermostat housing. Disconnect the choke cable and throttle cable: from the carburetor; Disconnect the spark plug lapse Remove the front frame cross bar‘ Renuwe the air cleaner case. (Page 4-20). Date of Issue: July, 1934 © HONDA MOTOR (10., LTD. ENGINE REMOVAL/INSTALLATION Disconnect the fuel tube and remove the carburetor assembly (Page 4-3). Disconnect the alternator and pulse generator wires. Disconnect the starter motor cable from the starter motor. NOTE: Support the bottom of the engine with a jack or other adjustable support CAUTION Be careful not to bind the wire: and able: under the engine when removing the engine Remove the following: — three engine mount bolts. — four sub»trame socket bolts. — subframe. — engine from the left side NOTE: Do not lose the engine mount oollar. HONDA V30 MAGNA CARBURETOR ALTERNATOR AND Pu LSE GENERATOR me COUPLERS SUB-F HAME MOUNT BOLTS 5-6 Date of Issue: July, 1984 © HONDA MOTOR C0., LTD‘ HONDA V30 MAGNA ENGINE REMOVAL/INSTALLATION I ENGINE INSTALLATION Engine installation is essentially the reverse of re mavalt Use'e floor jack or other adjustable support to care- fully manuever the engine into place. CAUTION ' When installing the clutch slave cylinder, temporarily install it to the left crankcase cover, release the clutch lever from the handle grip. and then tighten the slave cylinda' mount bolts. - Do not forget to instalI the engine mount collar. ' Carefully align mounting points with the jack to prevent damage to mounting bolt threads, wire harnesses and (tables. Tighten all fasteners to the torque values given on page 5-1. NOTE: . Perform the following: - Route the wires and cables properly (pages 1-10thru1-12I. FIII the crankcase to the proper level with the recommended oil (page 2-1). Fill the cooling system (Page 64). Reform the falloaing inspection and adjustments: - Throttle operation (page 3-5). — Drive chain (Page 343). Date of Issue: July, 1934 5 7 © HONDA MOTOR co” LTDe ' COOLING SYSTEM HONDA V30 MAGNA 6-0 Date of Issue: July, 1984 © HONDA MOTOR (30.. LTD. HONDA V30 MAGNA 6. COOLING SYSTEM SERVICE INFORMATION TROUBLESHOOTING SYSTEM TESTING COOLANT REPLACEMENT THERMOSTAT 6—5 RADIATOR/COOLING FAN 6—6 WATER PUMP 6—11 SERVICE INFORMATION 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. Avoid spilling coolant on painted surfaces. SPECIFICATIONS Use only distilled water and ethylene glycol in the cooling system. A 50—50 mixture is recommended for maximum oorro- sibn protection. Do not use alchoI-based antifreeze. Add coolant in the reserve tank. Do not remove the radiator cap exoept to refill or drain the system. All cooling system service can be done with the engine in the frame. After servicing the system, check for leaks with a cooling system tester. Refer to Section 18 for fan motor thermostatic switch and temperature sensor inspections. Radiator cap relief pressure 75—105 kPa (0.75—1.05 kg/cm‘, 11—15 psi) Freezing point (Hydrometer test): 55% Distilled water + 45% ethylene glycol: —32°C (—25° F) 50% Distilled water + 50% ethylene glyool —37°C (—34°F) 45% Distilled water + 66% ethylene glyool: —44.5°C (—48° F) Coolant capacity: Radiator and engine 1.8 liters (1.9 US qt.1.6 Imp qt) Reserve tank 0.4 liters (0.4 US qt, 0.4 Imp gt) Total system 2.2 liters (2.3 US qt, 1.9 Imp qt) Thermostat Begins to open: 80° to 84°C (176° to 183°Fl Valve lift: Minimum of 8 mm at 95°C (031 in at 203°F) Boiling point (with 50—50 mixture): Unpressurized: 107.7°C (226°F) Cap on, pressurized: 125.6°C (258° F) TROUBLESHOOTING 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 . Faulty fan motor Namwa-t 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: July, 1934 © HONDA MOTOR 00., LTD. HON DA V30 MAGNA COOLING SYSTEM SYSTEM TESTING COO LANT Remove the seat and left side cover. Test the coolant mixture with an antifreeze tester. For maximum corrosion protection, a 50—60% solution of ethylene glycol and distilled water ls recommended. RADIATOR CAP RADIATOR CAP INSPECTION Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or it relief pressure is too high or too low. It must hold specified pres- sure for at least six seconds. NOTE: Before installing the cap on the tester, wet the sealing surfaces. RADIATOR CAP RELIEF PRESSURE: 75—105 kPu (0.75—1.05 kg/cm’, 11—15 psi) -’ ' RADIATOR CAP TESTER (COMMERCIALLY AVAILABLE m U.S.A) Pressurize the radiator, engine and hoses, and check for leaks. ' CAUTION Excessive pressure can damage the radiator, Do not exceed 105 km (1.05 kg/cm’, 15 psi). Repair or replace oomponents if the system will not hold speclfied pressure for at least six seconds. RADIATOR CAP TESTER (COMMERCIALLY AVAILABLE IN U.S.A) Date of Issue: July, 1934 6 ' 2 © HONDA MOTOR (10., LTD. l HONDA V30 MAGNA COOLING SYSTEM CIJIJLANT REPLACEMENT CAUTION The engine mus! be cool before servicing the cooling system, or severe scalding may result Remove the radiator cap, Remove the seat, fuel tank and frame side covers. Remove the battery (Page 153). Remove the battery box. Drain coolant from the reservair tank. Remove the reservoir tank. Reinstall the reservoir tank in the reverse order of removal. Install the removed parts. RESERVOIR TANK Date of Issue: July, 1984 © HONDA MOTOR C0,, LTD, COOLING SYSTEM Remove the drain bolts from the cylinder and sub frame and drain the coolant from the engine. Reinstall and tighten the drain bolts securely. Fill the system with a 50—60 mixture of distilled water and ethyelen glycol. Bleed air from the radiator. 0 Start the engine and run until more are no air bubbles in the coolant and the level stabilizes. a Stop the engine and add coolant up to the proper level if necessary. 0 Reinstall the radiator cap. a check the level of coolant in the reserve tank and fill to the correct level if the level is low. NOTE: Check the cooling system for leaks after replacing the coolant. LOWER LEVEL HONDA V30 MAGNA 6-4 Date of Issue: July, 1984 © HONDA MOTOR C0,, LTDt HONDA V30 MAGNA COOLING SYSTEM THERMIISTAT REMOVAL Remove the seat and frame side covers Drain coolant (Page 6-3). Remove the fuel tank attaching bolts and prop it up with the tank support. Remove the outer thermostat housing cover. Disconnect the temperature sensor wire connec- tor from the sensor. Loosen the hose band. Remove the thermostat housing mounting bolt. Remove the thermostat housing cover by remov- ing two bolts. Remove the thermostat from the housing‘ THERMOSTAT HOUSING COVER Date of Issue' July, 1934 © HONDA MOTOR C0,, LTD‘ 6-5 HONDA V30 MAGNA COOLING SYSTEM I NSPE CT I 0 N Inspect thermostat visually for damage. Suspend the thermostat in heated water to check its operation. NOTE: If the thermostat or thermometer touches the pan, you'll get a false reading. THERMOMETER Replaoe thermostat if valve stays open at room temperature, or if it responds at temperatures other than those specified. Technical Data Start to open so” to 84°C (176° to 183°Fl ’ ' __——__—, 8 mm minumum (031 in) Valve lift when heated to 95°C (203° F) for five minutes INSTALLATION Install the thermostat into the housing. Install the thermostat housing cover with a new O-ring. Connect the temperature sensor sire connector. Install the fuel tank, frame side covers and seat. Fill the cooling system (page 6-2l. RADIATOR/COOLING FAN REMOVAL Drain the coolant (page 6-3). Remove the seat and fuel tank attaching bolts and prop it up with the fuel tank stay. Remove the frame left and right covers Remove the left radiator cover. LEFT COVER Date of Issue: July, 1984 6 ' 6 © HONDA MOTOR 60., LTD. HONDA V30 MAGNA COOLING SYSTEM Remove the outer thermostat housing cover. Disconnect the cooling fan motor coupler. Loosen the hose bands and disconnect the upper and Iawar radiator hoses from the radlator. LOWER HOSE Dam of Issue: July, 1984 © HONDA MOTOR (30., LTD‘ 6-7 HONDA V30 MAGNA COOLING SYSTEM Remove the thermostatic switch cover. Disconnect the overflow tube. Disconnect the thermostatic switch wire. Remove the radiator mounting bolts and radiator. CAUTION Be curefixl not to damage the radiator fins, DISASSEMBLY Remove the screws and bolts, left and right covers and radiator grills RADIATOR GRILL BOLTS Date of Issue: July, 1934 6 ' 8 HONDA MOTOR 00., LTDi HONDA V30 MAGNA COOLING SYSTEM Loosen the hose bands and remove the upper and lower hoses, Remove the fan shroud with the fan and motor by removing two bolts and a nut. Remove the thermostatic switch it necessary, Be careful not to damage the radiator body. Remove the fan blade nut and washer, Remove the cooling fan from the motor shaft. Remove the fan motor from the xhroud by remov~ ing the three screws, UPPER HOSE MOUNTING BOLTS LOWER HOSE FAN éHR‘ou-f)‘ WASH E R THERMOSTATIC SWITCH NUT Date of Issue: July, 1984 © HONDA MOTOR co., LTD, COOLING SYSTEM RADIATOR INSPECTION Inspect the radiator soldered joints and seams for leaks. Blaw dirt out from between core fins with com- pressed air. If insects, etc., are clogging the radiator, wash them off with low pressure water. ASSEMB LY/INSTALLATION Assemble and install the radiator in the reverse order of removal. After installation, fill the cooling system (page 6-4). HONDA V30 MAGNA 6-10 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. HONDA V30 MAGNA COOLING SYSTEM WATER PUMP TELLTALE HOSE MECHANICAL SEAL INSPECTION Inspect the telltals hole for signs of mechanical seal coolant leakage. Replace the water pump as an assembly if the mechanical seal is leaking‘ REMOVAL Drain the coolant (page 6-3). Remove the gearshift linkage and left foot peg‘ LEFT FOOT PEG SLAVE CYLINDER COVER Remove the slave cylinder cover (page 7-4). ‘ ' - Z: " ’ n Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. 6 ' 1 1 COOLING SYSTEM Remove the clutch slave cylinder. NOTE: ' It is not necessary to disconnect the clutch oil line. To prevent the clutch system from air con- tamination, and the slave cylinder piston from falling, squeeze the clutch lever im- mediately after removing the slave cylin- der, and tie the lever to ehe handle grip. Remove the drive sprocket cover. Loosen the hose bands and disconnect the water hose from the water pump cover. Remove the four bolts and the water pump cover. Remove the hose clamp from the water hose; then disconnect the water hose from the water pump. Remove the water pump from the crankcase. NOTE: Further disassembly of the water pump can- not be done. HONDA V30 MAGNA SLAVE CYLINDER HOSE BANDS WATE R PUMP 6-12 Date of Issue: July, 1934 © HONDA MOTOR (10,, LTD. HONDA V30 MAGNA COOLING SYSTEM INSPECTION Check the water pump for mechanical seal leakage and bearan deterioration. Fleplaoe the water pump as an assembly if necessary. INSTALLATION Apply a coat of clean engine oil to a new 0~rlng and install it in the water pump groove. Align the water pump shaft groove with the oil pump shaft and insert the water pump in the crank- case. Connect the water hose to the water pump and attach the hose. Install the dowel pin on the water pump. Insert a new O-ring over the end of the water pipe. Connect the water pipe to the pump hose and water plpe cap. Install the dowel pins onto the water pump. O-RING WATER PUMP ASSEMBLY Date of Issue: July, 1984 © HONDA MOTOR C0., LTD. COOLING SYSTEM HONDA V30 MAGNA Install the drive sprocket cover. Install the clutch slave cylinder. NOTE: When installing the clutch slave cyllnder, tem- porarily install it on the left crankcase cover, release the cluwh lever from the handle grip and then tighten the slave cylinder mount bolts. Install the slave cylinder cover. Install the right foot peg and gearshift linkage. Fill the coaling system (page 64). DRIVE SPROCKET COVER , s ! , , GEARSH I FT LINKAGE 6-14 Date of Issue: July, 1984 © HONDA MOTOR cot, LTD. $33,121:? M EMO HONDA CLUTCH SYSTEM V30 MAGNA 26—35 N- (2.5—3.5 kg-m, 18—25 ft-Ib) E E 25—35 N-m (2.5—3.5 kg-m, 18—25 h-lb) 7 _ 0 Date of |ssue: July, 1984 © HONDA MOTOR 50., LTD, $3153.? 7. CLUTCH SYSTEM 13—17 N-m (1.3—1.7 kg-m, 9—12 ft-Ib) 30—70 Nvm (6.0—7.0 kg-m, 43—51 ft-lb) (5.0—6.0 kgm, 36—43 fblb) (LO—1.4 kg«m, 6—10 ft-Ib) Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HONDA CLUTCH SYSTEM V30 MAGNA SERVICE INFORMATION 7—2 RIGHT ORANKCASE COVER TROUBLESHOOTING 7_3 REMOVAL 742 CLUTCH FLUID REPLACEMENT/ STARTER CLUTCH 7—13 AIR BLEEDING 7—4 CLUTCH 7—18 CLUTCH MASTER CYLINDER 7—6 RIGHT CRANKCASE COVER CLUTCH SLAVE CYLINDER 7_9 INSTALLATION 7—25 SERVICE INFORMATION GENERAL 0 This section covers removal and Installation of the clutch hydraulic system, clutch and starter Clutch. 0 DOT-3 or 4 brake fluid is used for the hydraulic clutch and is referred to as Clutch fluid in the section. DO not use other types of fluid as they are not compatible. 0 Clutch maintenance can he done with the engine in the frame. SPECIFICATIONS STANDARD SERVICE LIMIT Clutch master cylinder Wlinder I.D. 14000—141143 mm (05512—05528 in) 14.06 mm (0.554 in) Piston 0.D. 13357—13384 mm (05496—05506 in) 13.94 mm (0.549 in) Clutch slave cylinder Cylinder I.D. 35700—35762 mm HADES—1.4079 in) 35.78 mm (1.409 in) Piston O.D. 35650—35375 mm (14036—131045 in) 35.62 mm (1.402 in) Clutch Outer bushing I.D. 29.000—29.021 mm (1.1417—1.1426 in) 29.06 mm [1.144 ml Outer guide 0.D. 28367—28380 mm (1.1404—1J4091n) 28.93 mm (1.139 in) Spring free length 35.420 mm (1.3945 in) 34.0 mm (1.34 in) Spring preload/length 19.3—24.2 kg/23.3 mm (44—63 Ila/0.92 in) —- Disc thickness A 2.3—2.9 mm (0.110—0.114 in) 2.6 mm (0.10 in) B 3.5—3.6 mm (0.137—0.141 in) 3.3 mm (0.13 in) Plate warpage — 0.30 mm (0.012 in) Starter clutch Driven gear 0.D. . 41175—42100 mm (1.809—1.814in) 42.16 mm (1.660 in) TORQUE VALUES Clutch hose Oil bolts Clutch level pivot nut Starter clutch bolt Clutch center lock nut Starter Clutch cover Oil pump driven sprocket bolt TOO LS Special Snap ring pliers Common Unversal holder Extension bar Lock nut wrench, 17 x 27 mm Clutch center holder 25—35 N~m (2.5—3.5 kg-rn, 18—25 ft-Ibl 5—7 NAm (0.5—0.7 kg-m, 4—5 ft-Ib) 50-60 N-m (5.0—6.0 kg-m, 36—43 ft-lh) 50—70 N-m (6.0—7.0 kg-m, 43—51 ft-lh) 26—30 N~m (2.6—3.0 kg-m, 19—22 ft-lb) 13—17 N-m (1.3—1.7 kg—rn, 0—12 ft-Ib) 07914—3230001 or equivalent in USA. 07725—0080000 or equivalent in U.S.A. 3313323333]- Or equivalent in USA. 0772441050000 or equivalent in USA. 7-2. Date of Issue: July, 1984 © HONDA MOTOFI C0., LTD. HONDA. V30 MAGNA CLUTCH SVST EM TROUBLESHOOTING Clutch lever soft or spongy 1, Air bubbles in hydraulic system 2. Low fluid level 3. Hydraulic system leaking (Hutch lever too hard 1. Sticking piston(s) Z. Clogged hydraulic system 3. Lifter mechanism damaged clutch slips 1. Hydraulic system sticking 2. Discs worn 3. Spring 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 Motorcycle creeps with clutch disengaged 1. Air bubbles In hydraulic system 2. Low fluid level 3. Hydraulic system leaking 4. Hydraulic system sticking 5. Plates warped cluwli operation feel: rough 1. Outer drum slots rough 2. Sticking pistonls) Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. 7-3 CLUTCH SYSTEM CLUTCH FLUID REPLACEMENT/ AIR BLEEDING DRAINING Remove the clutch slave cylinder cover. Remove the reservoir cap and diaphragm. CAUTION Avoid spilling fluid on painted surfaces. Place a rug over the fluid tank whenever the system is serviced. Connect a bleed hose to the bleeder velvet Loosen the slave cylinder bleeder valve and pump the clutch lever. Stop operating the lever when no fluld flows out of me bleeder valve. CLUTCH SYSTEM FILING NOTE: Do not mix different types of fluid. They are not compatible. If e mytyvac bleeder is not available, perform the following: Close the bleeder valve, fill the reservoir with brake fluid, and install the diaphragm. Pump up the system pressure with the lever until there are no air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt. Bleed the system as described on the next page. HONDA. V30 MAGNA SLAVE CYLINDER COVER BLEEDER VALVE BLEED HOSE 7-4 Date of Issue: July, 1986 © HONDA MOTOR COI, LTD. HONDA V30 MAGNA CLUTCH SYSTEM NOTE: check the fluid level often while bleeding the system to prevent air from being pump- ed into the system. ' Use only DOT-3 or 4 brake fluid from a sealed container. Do not mix fluid types and never reuse the contaminated fluid which has been pumped out during clutch bleeding. ' When using a clutch bleeding tool, follow the manufacturefs operating instructions. CLUTCH FLUID FILLING WITH MYTYVAC BLEEDER Fill the reservoir to near full with the recommended brake fluid. Connect the Mytyvac Bleeder or equivalent to the bleeder valve. Pump the bleeder and loosen the bleeder velvet Add fluid when the level in the master cylinder reservoir is low. NOTE: If air it entering the bleeder hose from around the bleeder valve thread, seal the threads with teflon tape. Check the operation of the clutch lever. If the clutch feels spongy, bleed the air from the system. AIR BLEEDING 1. Squeeze the clutch lever, then open the bleeder valve 1/2 turn and close the valve. NOTE: Do not release the clutch lever until the bleeder valve has been closed. 2. Release the clutch lever slowly and wait several seconds after it reaches the end of its travel. Repeat steps 1 and 2 until bubbles cease to appear in the fluid at the end of the hose. Fill the fluid reservoir to the upper level. Reinstall the slave cylinder cover. Date of Issue: July, 1954 © HONDA MOTOR C0,, LTD. 7 " 5 HONDA CLUTCH SYSTEM V30 MAGNA cwtcn MASTER cvuunm $3.?“me MASTERCYLWR REMOVAL Drain the clutch fluid from the hydraulic system. Remuve the clutch upper oil bolt. Remove the rear view mirror. Disconnect the clutch switch wires. Remove the master cylinder holder and clutch master cylinder‘ CAUTION A void spilling clutch fluid on painted :wfaces. Place a my over the file] tank whenever the clutch system is serviced. NOTE: When removing the oil bolt, cover the and of the hose to prevent contamination and secure the hose. DISASSEMBLY Remove the clutch lever and remove the clutch switch. Remove the push rod and boot. HOLDER CLUTCH SWITCH LEVER BOOT PUSH ROD 7-6 Date 0! Issue: July, 1984 © HONDA MOTOR CO‘, LTD HONDA V30 MAGNA CLUTCH SYSTEM CIRCLIP Remove the circlip from the master cylinder body. SNAP RING PLIEFIS 07914—3230001 EQUIVALENT COMMERCIALLY AVAILABLE IN U.S.A. PISTON WASHER Remcwe the washer, piston and spring from me master cylinder body‘ % o \x“ 5 SPRING CIRCLIP INSPECTION 0 MASTER CYLINEH I.D. Check the master cylinder for scores, scratche: or nicks‘ Measure the master cylinder I.D. SERVICE LIMIT: 14.06 mm (0.554 In) Date of Issue: July, 1934 7 7 © HONDA MOTOR col, LTD, ' CLUTCH SYSTEM HONDA V30 MAGNA 0 MASTER PISTON O.D. Measure the master piston 0.D. SERVICE LIMIT: 13.94 mm (0.549ln) Check the primary and secondary cup: for damage before assembly‘ ASSEMBLY CAUTION Handle the master piston, spring, primary cup and secondary cup as a set. Coat all parts with clean clutch fluid before assemb- ly. Install the spring, primary cup and piston CAUTION When installing the cups, do not allow the lips to rum inside out. Install the washer. Install the circlip, making sure it is seated firmly in the groove, Install the boot and push rod. Install the clutch switch. Install the push rod end piece into the clutch lever hole and install the clutch lever. RESERVOIR COVER I MASTER CLUTCH SWITCH 9 II DIAPHRAGM HOLDER CLUTCH LEVER PIVOT SPRING PRIMARY CUP PISTON AND SECONDARY CUP WSNAP RING Q’/BC)OT WASHER “7% g pusu aoo PUCH ROD END PIECE ,fil SIL|CONE GREASE 7-8 Date of Issue: July, 1934 © HONDA MOTOR 004, LTD, HONDA V30 MAGNA INSTALLATION Place the master cylinder an the handlebar and install the holder with the "UP" mark facing up and the two mounting bolts. Align the holder mating surface with the handlebar punch mark. Tiditen the top bolt first, then the bottom bolt. Install the oil hose with the bolt and its two sealing washers TORQUE: 15—35 N-m (2.5—3.5 Ito-m, 18—25 Nib) Connect the clutch switch wires to the switch ter- minals. Fill the reservoir and bleed the clutch system (page 7-4). CLUTCH SLAVE CYLINDER REMOVAL Remove the slave cylinder cover (Page 7-4). Remove the clutch oil bolt, than drain the clutch fluld from the clutch system. NOTE: Avoid spilling clutch fluid on palnted surfaces. Remove the clutch slave cylinder mounting bolts and clutch slave cylinder. Remove the gasket and dowel pins. Remove the clutdi lifter rod. "UP" MARK CLUTCH SYSTEM PUNCH MARK Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. 7-9 CLUTCH SYSTEM Remove the piston from the cylinder. If plston removal is hard, place a shop towel over the piston to cushion the piston when it is expelled, and posltion 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 piston. Remove the oil and piston seals. Clean the piston groove with clutch fluid. Check the plston spring for weakness or damage. INSPECTION o PISTON CD. Check the piston for soaring or scratches. Measure the outside diameter of the piston with a micrometer. SERVICE LIMIT: 35.82 mm (1.402 in) HONDA V30 MAGNA PISTON SEAL 7-10 Date of Issue: July, 1984 © HONDA MOTOR COT, LTD. HONDA V30 MAGNA CLUTCH SYSTEM o CYLINDER 1.0. Check the slave cylinder for soaring or scratches. Measure the inslde diameter of the cylinder bore. SERVICE LIMIT: 35.78 mm (1.409 in) \ 1 ASSEMBLY PISTON SEAL Anemble the slave cylinder In the reverse order of PISTON disassembly. The oil and piston seals must be OIL SEAL replaced with new ones whenever they have been removed. Lubricate the piston and piston seal with a medium grade of HiATempemure silicone grease or brake fluid before assembly. Be certain the piston seal is seated in the piston groove. Place the piston in the cylinder with the seal end facing out. ,6 SILICONE DOWEL PIN GREASE SLAVE CYLINDER CLUTCH L TER HOD we 3 INSTALLATION Install the clutch lifter rod with its dent side (gold plating side) facing the slave cylinder‘ Date of Issue: July, 1934 7 1 1 © HONDA MOTOR Co‘, LTD. - HONDA V30 MAGNA CLUTCH SYSTEM Install the two dowel pins and gasket onto the left crankcase rear cover. Install the slave cylinder. Connect the clutch hose with the oil bolt and the two sealing washers. TORQUE: 25—35 N~m (2.5-3.5 kom, 18—25 OHM Fill the clutch fluid reservoir and bleed the clutch system (also 7-4). Install the slave cylinder cover. SLAVE CYLINDER RIGHT FOOT PEG RIEHT CRANKGASE COVER REMOVAL Drain the engine oiL Remove the rear brake pedal and right foot peg BRAKE PEDAL ' Date of Issue: July, 1984 7 ' 1 2 © HONDA MOTOR CO‘. LTD HONDA V30 MAGNA CLUTCHSVSTEM Remove the bolts and right crankcase cover. Remove the gasket and dowel pins. STARTER CLUTCH REMOVAL Remove the starter idle gear shaft and near. Remove the alternator cover and hold the flywheel with universal holder. Remove the starter clutch bolt. Remove the starter clutch assembly. NOTE: If you are going to rebuild the starter clutch, loosen the starter clutch bolts with the starter clutch installed. \. —— UNIVERSAL HOLDER 07725—0030000 OR EQUIVALENT IN U.S.A. STARTER CLUTCH Date of Issue: July, I934 © HONDA MOTOR (30., LTDt 7-13 HON DA V30 MAGNA CLUTCH SYSTEM PRIMARY DRIVE GEAR Remove the thrust washer, collar and primary drive gear. WASH E R DISASSEMBLY Remove the starter driven gear and needle hearing from the starter clutch. STARTER CLUTCH Inspect the rollers for smooth operation. Remove the starter dutch cover by removing the three boll—st PLUNGER Remove the clutch rollers, plunger: and springs STARTER DRIVEN GEAR ROLLER STARTER CLUTCH COVER NEEDLE BEARING SPRING PLUNGER l NSPE CT I O N Check the rollers for excessive wear, and the springs for weakness or damage. , ' . I \ Date of Issue: July, 1984 7 ' 1 4 © HONDA MOTOR CO‘. LTD‘ HONDA. V30 MAGNA CLUTCH svs'TEM Inspect the driven gear for damage or excessive weer. Measure the driven gear O.D. SERVICE LIMIT: 4116mm (1.660 in) SPRING PLUNGER ASSEMBLY Inna“ the springs, plunger: and roller: into the starter clutch. STARTER CLUTCH ROLLER PLUNGER ROLLER CLUTCH COVER Install the dowel pin. Install the narter clutch cover aIlgning the dowel pin hole with the dowel pin and tighten the bolts, TORQUE: 26—30 N-m (2.8—3.0 Its-m, 19—22 Itvlh) NOTE: Apply a locking agent to the bolt threadst DOWEL PINS Date of Issue: July, 1984 © HONDA MOTOR (10., LTDt HONDA. CLUTCH SYSTEM V30 MAGNA Install the needle bearing. Install flue starter driven gear by turning it clock- wise. INSTALLATION Install the primary drlve geqr onto the crankshaft with the large chamfered side facing in‘ Install d1: collar and thrust washer onto the crank- shaft TH RUST WASHER Date of Issue: July, 1954 7 ' 1 6 © HONDA MOTOR Cot, LTD, HONDA V30 MAGNA Install the starter clutch by aligning the wide groove in the starter clutch with the tooth on the crank- shaft, Hold the flywheel with universal holder. “green the snner clutch bolt. TORQUE: so—eo Mm (5.0—6.0 kw, 36-43 mm Install the alternator cover. Install the starter idle gear and shaft by routing the starter clutch clockwim with a wrench, or by rotat- ing the idle gear clockwise to turn the starter motor thllft counterclockwise CLUTCH SYSTEM \ ,— UNIVERSAL HOLDER 0775—0030000 0R EQUIVALENT IN U.S.A. STARTER IDLE GEAFl Daterof Issue: July, 1984 © HONDA MOTOR COT, LTD. 7-17 HONDA V30 MAGNA CLUTCH SVST EM CLUTCH Voowa mus REMOVAL Remove the rimt crankcase cover (page 742). Remove the gasket and dowel pins. Remove the starter idle gear. Remove the starter clutch (page 743) GASKET STATER CLUTCH PRESSURE PLATE CAUTION ‘ To prevent the clutch system from air con- tamination, squeeze the clutch lever immadi- ately after removing the clutch pressure pbte, and tie the lever to the hand grip Remove the bolts and clutch springs. NOTE: Loosen the bolts in crisscross pattern in 2—3 steps. Remove the clutch pressure plate with the lifter guide and release bearing. LIFTER GUIDE RELEAS BEARING CLUTCH LIFTER ROD PLATES/DISCS Remove the clutch lifter rod, judder spring, seat, 0 clutch plates and discs. SPRING AND SEAT Date of Issue: July, 1984 7 - 1 8 © HONDA MOTOR C0,, LTD. HONDA V30 MAGNA CLUTCH SYSTEM CLUTCH CENTER HOLDER 07724—0050000 OR EQUIVALENT IN USA. - . u \L Hold the clutch center with a clutch center holder and remove the lock nut. Rumove the lock washer. EfirTSION BAR ' WRENCH, 17 x 2 mm 07716—0020500 o771e»0020300 0R EQUIVALENT IN U.S.A. OR EQUIVALENT IN USA. CLUTCH OUTER Remove the clutch center and clutch outer. Remove (ha oil pump driven sprocket and men remove the 0“ pump drive sprocket and clutch outer guide. DRIVENS' ROCKET Date of Issue: July, 1934 © HONDA MOTOR COE, LTD‘ .CLUTCH SYSTEM INSPECTION 0 CLUTCH SPRING Measure the clutch spring free length. SERVICE LIMIT: 34.0 mm (1.34 in) O CLUTCH DISC Replace the clutch disc: if they show Sims af scor- ing or discoloration. Measure the thickness of each disc. SERVICE LIMIT: A: 2.6 mm (0.10 in) B: 3.3 mm (0.13 in) Replace any disc that is thinner than the eerviee limit. 0 CLUTCH PLATE Check for plate werpage on a surface plate, using a feeler gauge. SERVICE LIMIT: 0.30 mm (0.012 in) .923 HONDA V30 MAGNA v.1 . ffi§4¢g_l an .u an 55 no no I! I; “JIIMII w a... IIIIIIIIIIIHIII IIIIMIIIHIIIM Ill-“:11”: 7-20 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA CLUTCH SYSTEM 0 CLUTCH OUTER AND OUTER GUIDE check the slots in the clutch outer for nicks, cuts or indentations made by the friction discs. Measure the ID. of the clutch outer bushing SERVICE LIMIT: 29.06 mm (1.1“ in) Measura tha OID‘ of the clutch outer guide. SERVICE LIMIT: 18.93 mm (1.139 In) INSTALLATION CLUTCH OUTER OIL PUMP GUIDE DRIVE SPHOCKET CLUTCH omen CLUTCH CENTER JUDDER SPR'NG SPRING SEAT CLUTCH PLATE LIFTER ROD w CLUTCH DISC a? 60—70 N~m (5.0—7.0 kg-m. 43—51 ft-Ib) PRESSURE PLATE Date of Issue: July, 1934 © HONDA MOTOR CO, LTD 7 ' 2 1 HONDA V30 MAGNA CLUTCH SYSTEM OIL PUMP DRIVE SPROCKET Install the clutch outer guide. Install the oil pump drlve sprocket and oil pump driven sprocket. Tighten the oil pump driven sprocket bolt. TORQUE: 13—17 N-m (1.3—1.7 ko-m, 9—12 ft-lb) OIL PUMP DRI EN SPROCKET OIL PUMP DRIVE SPROCKET Install the clutch outer onto the mainsheft, aligning the lugs on the cluuh outer boss with the grooves in the oil pump drive sprocket flange. Install the clutch centerl CLUTCH CENTER 7 22 Date of Issue: July, 1934 - © HONDA MOTOR C0,, LTD. HONDA V30 MAGNA CLUTCH SYSTEM Install the lock washer with the "OUTSIDE" mark facing out. Install the lock nut with chamfered side facing in VLOCK WASHER > LOCK NUT OUTSIDE Install the clutch center holder to hold the clutch center. Tighten the lock nut. TORQUE: 60—70 N-m (6.0—7.0 kw“, 43—51 ft-Ib) WRENCH, 17 x 27 mm EXTENSION EAR 07716—002030!) 07716—0020500 OR EQUIVALENT IN USA. On EQUIVALENT IN USA. Coat the 9 discs and 8 plates with clean engine oil DAMPER SPRING and install them as shown below. SPRING SEAT Install the spring seat and damper spring as shown. Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD 7 ' 2 3 HONDA V30 MAGNA CLUTCH SYSTEM LIFTER ROD Invert the lifter rod into the mainshafl with its dent side (gold plating side) facing to the slave cylinder. CIRCLIP RELEASE BEARING Make sure that the circlip is in place. Install the release bearing and lifter guide inta the clutch pressure plate. PRESSURE PLATE LIFTER GUIDE CLUTCH CENTER Install the pressure plate, aligning the "0" marks 1 -- ‘ -. v on the pressure plate and clutch center. NOTE: Before installing the pressure plate, release the clutch lever. ' ’2! "o" MARKS PRESSURE I’LATE Date of Issue: July, 1934 7' 24 © HONDA moron col, LTDe HONDA V30 MAGNA CLUTCH SYSTEM Install the clutch xprings and bolts and tighten the balls in a crisscross pattern in 2—3 steps. RIGHT BRANKCASE COVER INSTALLATION Install the starter clutch (page 7-16). Install the starter idle gear (page 7-17). Install a new gasket and the dowel pins. Install the right crankcase cover and tighten the bolts in a crisscros pattern. Fill the crankcase with recommended oil (page 2-3). Install the rear brake pedal and right foot peg Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HONDA ALTERNATOR/GEARSHIFT LINKAGE V30 MAGNA 0 50—60 N? g ‘ . , %/ ‘Seizi'ifi' >4 ‘ ‘Mp‘ (2.0—2.3 kgAm, 15—20 ft-lb) 8 0 Date of Issue: July, 1984 ' © HONDA MOTOR co., LTD. HONDA ALTERNATOR/ V30 MAGNA . GEARSHIFT LINKAGE SERVICE INFORMATION 8—1 TROUBLESHOOTING 8—1 FLYWHEEL REMOVAL 8—2 STATOR REMOVAL 8—3 STATOR INSTALLATION 8—4 FLYWHEEL INSTALLATION 8—4 GEARSHIFT LINKAGE REMOVAL 8—6 GEARSHIFT LINKAGE INSTALLATION 8—8 SERVICE INFORMATION GENERAL 0 This section covers removal and installation of the alternatorr 0 Refer to section 15 for troubleshooting and inspection of the alternator. o The gearshift spindle and stopper arms can be serviced with the engine in the frame. 0 If the shift forks, drum and transmission require servicing, remove the engine and separate the crankcase, TORQUE VALUE Flywheel bolt 50—60 N-m {SD—6,0 kg-m, 36—43 ft—lb) Gearshift arm pinch bolt 20—28 N-m (2.0—28 kg-m, 15-20 ft-Ib) TOO LS Gunman Universal holder 07726—0030000 or equivalent in USA. Flywheel puller 07733—0020001 or 07933—3290001 Hard to shift 1. Air bubbles in the clutch hydraulic system 2‘ Shift forks bent 3‘ Shift claw bent 4. Shift drum cam grooves damaged Transmission jumps out of gear 1. Gear dogs worn 2. Shift shaft bent 3. Shift drum stopper broken 4. Shift forks bent Date of Issue: July, 1954 © HONDA MOTOR col, LTD 8 - 1 HONDA V30 MAGNA ALTERNATOR/G EARSHI FT LINKAGE FLYWHEEL REMOVAL Remove the attaching bolts and slave cylinder cover, ’ Remove the cylinder (page 7-9L NOTE - It is not necessary to disconnect the clutch oil line. To prevent the clutch system from air con- tamination, and the slave cylinder piston from falling, squeeze the clutch lever im- mediately after removing the slave cylin- der, and tie the lever to the handle grip. / Remove the drive sprocket cover, gasket and dowel _ g ‘ ’ K.“ pin. ‘ > » j i ,- Remove the oil pipe clamp bolt. Place a container under the alternator cover to catch engine oil. Remove the alternator cover attaching bolts and alternator cover, Hold the flywheel with universal holder and remove the flywheel bolt. UNIVERSAL HOLDER 07725—0030000 OR EQUIVALENT lN U.S.A. Date of Issue: July, 1984 8' 2 © HONDA MOTOR CO., LTD, HONDA V30 MAGNA ALTERNATOR/GEARSHIFT LINKAGE FLYWHEEL PULLER 07733—0020001 0R 07933—3290001 Remove the flywheel with the flywheel puller‘ . ' ' ,‘ ‘ UNIVERSAL HOLDER 07725—0030000 OR EQUIVALENT IN USA. ALTERNATOR WIRE COUPLER STATflR REMOVAL Remove the seat Disconnect the alternator wire coupler. Remowe the alternator wire clamp. Remove the stator by removing four bolts, being careful not to damage the stator coil. Date of Issue: July, 1984 _ HONDA MOTOR 60., LTD‘ 8 3 HONDA V30 MAGNA ALTERNATOR/GEARSHIFT LINKAGE STATIJII INSTALLATION Install the stator on the left crankcase. Route the alternator wire properly, secure it with clamp and connect the alternator wire coupler. Install the stator wire clamp. lnstall the seat. FLYWHEEL INSTALLATION Clean the inside of the flywheel. Check the taper portion of the crankshaft and clean Install the flywheel onto the crankshaft. Hold the flywheel with the universal holder and tighten the flywheel boltt TORQUE: 50—60 N-m (5.0—6.0 kg-m, 36—43 ft—lh) Date of Issue: July, 1984 8 ' 4 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA Install a new gasket and the alternator covarl check the engine oil level and add if necessary (Page 2-3). Install a new gasket and the dowel pins. Install the drive sprocket cover. Install the clutch slave cylinder. NOTE: When installing the clutch slave cylinder, terns porally install it to the left crankcase cover, release the clutch lever from the handle grip and then tighten the slave cylinder mount bolts‘ Install the slave cylinder cover. ALTERNATOR/G EARSHIFT LINKAGE GASKET SLAVE CYLINDER COVER Date of Issue: July, 1984 © HONDA MOTOR 00., LTDi ALTERNATOR/GEARSHI FT LINKAGE HONDA V30 MAGNA GEARSHIFT llNKAGE REMOVAL Shift the transmission into neutral, Remove the right foot peg and gearshift arm. Remove the clutch slave cylinder covert Remove the clutch slave cylinder and drive sprocket Dover. NOTE: To prevent the clutch system from air con- tamination, and the slave cylinder piston from falling, squeeze the clutch lever immediately after removing the sieve cylinder, and tie the lever to the handle grip, Drain the coolant (Page 6-3). Drain the engine oil (Page 2-3)t Remove the water pump (Page 6-11). Remove the gearshift cover bolts. Remove the gearshift linkage case while pushing the gearshift spindle in‘ Remave the gasket and dowel pins‘ 8-6 Date of Issue: July, 1934 © HONDA MOTOR Cot, LTD. HONDA V30 MAGNA ALTERNATOR/GEARSHIFT LINKAGE GUIDEPL IE _ SPINDLE Remove the one nut and two bolts and remove the spindle. guide plate and spring as a set. Remove the drum shifter. Remove the neutral stopper arm and sprlng by removing the nut. NEUTRAL STOPPE R ARM Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA ALTERNATOR/G EARSHIFT LINKAGE Remave the drum stopper arm and spring. -7 6 DRUM STOPPEFI ARM INSPECTION Check the xtopper arms and springs for damage. Check the planetary gears on the gearshift spindle for wear or damage. Check the drum shifter for wear or damage. DHUM SHIFTER STOPPER ARMS check the ball bearing in the linkage case for damage or excessive play. GEAHSHI FT SPINDLE SPRING GEARSHIFT LINKAGE INSTALLATION Install the drum stopper arm and spring. DRUM STOPPR ARM Date of Issue: July, 1934 8 ' 8 © HONDA MOTOR C0., LTD, HONDA V30 MAGNA Move the gearshift drum to the neutral position. Install the neutral stopper arm and spring. Install the washer and nut, and tighten the nut. Assemble the drum shifter. Install the drum shifter with its punch mark aligned with the mark on the geraahift drum. Assemble the spindle and guide plate. Date of Issue: July, 1984 © HONDA MOTOR 60., LTDt ALTERNATOR/GEARSHIFT LINKAGE SPRING N 2 V SPINDLE GUDIE PLATE 4‘} ALTERNATOR/GEARSHIFT LINKAGE HONDA V30 MAGNA Install the spindle assembly. NOTE: - Align the center of the guide groove in the shift spindle with the center of the pint - Be careful not to shift the drum shifter from the neutral position. Tighten the bolts and nut. Install the return spring. Install the dowel pins and a new gasket. Install the gearshift linkage cover. Check the operation of the gearshift linkage. 8-10 PIN GUDIE GROOVE DOWEL PINS Q?" Date of Issue: July, 1984 © HONDA MOTOR CO” LTD HONDA V30 MAGNA Install the water pump (Page 6-13). Install the drive sprocket cover (Page 3-5). Install the clutch slave cylinder. NOTE: When installing the clutch slave cylinder, tam- porarily install it to the left crankcase rear cover, release the clutch lever and then tighten the slave cylinder bolts. Install the slave cylinder cover. Install the right foot peg and gearshift arm. ALTERNATOR/GEARSHIFT LINKAGE Date of Issue: July, 1934 © HONDA MOTOR 00., LTD‘ 8-11 HONDA CYLINDER HEAD/VALVE V30 MAGNA ' NOTE: 3—12 N~m NOTE. . . (0.8—1.2 kg-m, 6—9 bel Apply locking agent Do not forget to Install the washer. 45—55 N‘m (4.5—5.5 kg-m, 32—40 ft-Ibl 110314: N1" 7 ' , 33333;..." ( . .4 g-m,7—10ft-|b) 22—25mm 30—34 N‘m (3.0—3.4 kg-m, 22—26 ft-lbl Insert a pin when installing the cam chain tensionerl 21—25 N-m (2.1—2.5 kg-m. 15—18 ft-lbl (1.3—2.0 kg-m, 13—14ft-lbl 20—25 N-m (2.0—2.5 kg-m, 14—18 ft-lbl NOTE: The tightely would coils should face in‘ (2.0—25 kg-m,14—18 ft-lb) Date of Issue: July, 1984 9' 0 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA I ' SERVICE INFORMATION 9—1 VALVE SEAT INSPECTION/ TROUBLESHOOTING 9_2 REFACING 9—15 CAMSHAFT REMOVAL 9_3 CYLINDER HEAD ASSEMBLY 9—16 CYLINDER HEAD REMOVAL 9_8 CYLINDER HEAD INSTALLATION 9—13 CYLINDER HEAD DISASSEMBLY 9—10 CAMSHAFT INSTALLATION 9—20 VALVE GUIDE REPLACEMENT 9-14 CYLINDER COMPRESSION 9—24 SERVICE INFORMATION GENERAL I The cylinder heads can be serviced with the engine in the frame. 0 If the cam sprockem of either the front or rear cylinder are removed, the valve timing of both cylinder must be checked during reinstallation. e Camshaft lubricating oil is fed through the external oil lines. Be sure the oil lines are not clogged. 0 During assembly, apply molygdenum disulfide to the camshaft holder surfaces to provide initial lubrication. The cylinder numbering is given below: FRONT Q) G) (96) LE FT SPECIFICATIONS STANDARD SERVICE LIMIT Compression pressure 1200 i 200 kPa mung/cm“, 1701281031) — Camshaft Cam height IN 35.22—35.38 mm (1387—1393 in) 35.18 mm (1.385 in) EX 35.12—35.28 mm (1383—1389 in) 35.08 mm (1.381 in) Runout — 0.05 mm (0.002 in) Oil Both sides Inside 0.1 10—11190 mm (00043—00075 inl 0.194 mm (0.0076 in) ”WW “9mm“ Outside 0060—0126 mm (00024—00050 in) 0.130 mm (0.0051 in) One side tightened 0045—0106 mm (00018—00042 in) 0.110 mm (0.0043 in) Rocker arm Rocker arm I.D. 11000—11018 mm (04724—04731 in) 12.05 mm (0.474 in) Shaft O.D. 11366—11984 mm (04711-04718 in) 11.93 mm (0.470 in) Valve Valve stern 0D. IN 4375—4990 mm (01959—01965 in) 4.97 mm (0.196 inl EX 4355—4970 mm (01951—01957 in) 4.94 mm (0.1951nl Valve guide LD. IN/EX 5.000—5012 mm (01969—01973 in) 5.04 mm (0.198 Inl Stem-tD-guide clearance IN 0010—0037 mm (00004—00015 In) 0.07 mm (0.003 inl EX 0030—0057 mm (00012—00022 in) 0.10 mm (0.004 in) Valve seat width 0.90—1 .10 mm (0035—0043 in) 1.5 mm (0.05 in) Valve spring Free length Inner 32.35 mm (1.274 in) 30.65 mm (1.207 in) Outer 35.66 mm (1.404 in) 34.36 mm (1.353 in) Cylinder head Warpage — 0.10 mm (0.004 in) Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. 9-1 CYLINDER HEAD/VALVE TORQUE VALUES Cylinder head cover Cam sprocket bolt Rocker arm shaft Cylinder head Camshaft holder 6 mm bolt 8 mm bolt Oil pipe ioint bolt Oil pass pipe TOO LS Special Valve guide driver/remover, 5.0 mm Valve guide reamer. 50 mm Compression gauge attachment Common Valve spring compressor Valve guide driver TROUBLESHOOTING HONDA V30 MAGNA 8—12 N-m (03—12 kg-m, 6—9 ft-Ib) 0 kg-m, 13—14ft-lb) 5 kg-m, 32—40 ft-Ibi 4 kg-m, 22—25 ft-Ib) 4 kgm, 7-10 ft-Ib) s kg-m,15—18 ft—lb) 5 kg-m, 14—13ft-lb) 10—14 N~m (1.0—1.4 kg-m. 7—10ft-lbi O7942—MA60000 07984—MA60000 D7510—MBOD101 07757—0010000 07743—002000!) Engine topend 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 adiustment — Burned or bent — Incorrect timing — Broken spring 2‘ Cylinder head — Leaking or damaged head gasket — Warped or cracked cylinder head 3‘ Cylinder and piston (Refer to Section 10) Compression too Ilifli — Excessive carbon build-up on piston or combustion chamber Excessive noise . Incorrect valve adlustment . 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 . Warn rocker arm and/or shaft uranium»— 9-2 Date of Issue: July, 1984 © HONDA MOTOR C0., LTD‘ HONDA V30 MAGNA CAMSHAFT REMOVAL Remove the followings: From (he from cylinder head: — radiator (Page 6-6) — front frame cross bar — fuel tank From the rear cylinder head: — fuel tank — rear ignition coil Remove the spark plug caps. CYLINDER HEAD/VALVE Date of Issue: July, 1984 © HONDA MOTOR CO“ LTD‘ CYLINDER HEADNALVE Remove the four cylinder head cover bolts and the cover. Remove the four cam chain guide mounting bolts and the cam chain guide. Remove the tour bolts attaching the oil pass pipe and the pipe. Flemove the timing hole cap from the right flank case cover. Remove the alternator cover (page 8-2). Turn the crankshaft at the flywheel side counter- clockwise and align the "TF" mark for the front cylinder, or "TR" mark for the rear cylinder with the index mark on the right crankcase cover. HONDA V30 MAGNA CYLINDER HEAD COVER OIL PASS PIPE TF" or “TR"MARK Date of Issue: July, 1934 © HONDA MOTOR 00., LTD, HONDA V30 MAGNA Remove the intake and exhaust cam sprocket bolts. Turn the crankshaft counterclockwise 360° and remove the other cam sprocket bolts. Slide the cam sprockets with the urn chain off the camshaft tprooket flange. Remove the camshaft holder bolts and holders. NOTE: Mark all disassembled parts to ensure correct reassembly. Remove the camshaftt. cam chain. can sprockets and dowel pins from the cylinder head. CYLINDER HEAD/VALVE CAM SPROCKET BOLTS Date of Issue: July, 1984 © HONDA MOTOR (30,, LTD. 9-5 CYLINDER HEAD/VALVE INSPECTION 0 CAMSHAFT/CAM HOLDEH‘ Inspect the camshaft and holder iournal surfaces for scoring, scratches, or evidence of insufficient lubrication. . CAMSHAFT RUNOUT Check camshaft runout with a dial indicator. Support both ends of the camshaft with V-blaeks. Use 1/2 of the total indicator reading to determine mnout. SERVICE LIMIT: 0.05 mm (0.002 in) 0 CAM HEIGHT Using a micrometer, measure each cam lobe, Check for wear or damage SERVICE LIMITS: IN: 35.18mm (1,385 in) EX: 35.08 mm (1.381 in) HONDA V30 MAGNA CAMSHAFT HOLDER I v a Date 0' Issue: July, 1984 © HONDA MOTOR 00,, LTD‘ HONDA V30 MAGNA CYLINDER HEADNALVE O CAMSHAFT OIL CLEARANCE Wipe any oil from the Journals. Lay a strip of plastigauge lengthwise on top of each camshaft iou rnal. Install the camshaft holders and tighten in the sequence shown. NOTE: Do not rotate the camshaft when using plasti- gauge. Toncues: Fit—11‘] 30—34 N‘m (3.0—3.4 kg-m, 22-25 mb) -—|fl 21—25 mu (2.1—2.5 kn-m, 15—13 rub) BHEI 10—14 M."- (1.o—1.4 kg-m, 7—10 ft-lb) Remove the camshaft holders and measure the width of each plastigauge. The widest thickness determines the oil clearance, SERVICE LIMITS: A: 0.110 mm (0.0043 in) B: 0.130 mm (0.0051 In) C: 0,194 mm (0.0078 In) When the service limits are exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshaft halders if the clearance still exceeds service limits. Date 00 Issue: July, 1934 9 7 © HONDA moron co” LTD. , - CVLINDER HEAD/VALVE CYLINDER HEAD REMOVAL Remove the carburetor (page 4-3) and exhaust pipes (page 54). Remove the two bolts attaching to the water pipe and hose assembly being careful not to damage the O-rings. Remove the oil plpe bolt and sealing washers from the cylinder head. Remove the front and rear cam chain tensioner base mounting bolts. Pull the cam chain tensioner base up. Remove the slipper clip, washer and pin and remove the tensioner slipper from the tensioner arm. Remove the tensioner base. NOTE: Be careful not to let the clip. pin, washer or cam chain fall into the crankcase. v4. « TENSIONER ARM ‘ HONDA V30 MAGNA OI PIPE BOLT PIN WASHR ‘ Date of Issue: July, 1984 © HONDA MOTOR C0,, LTD. HONDA V30 MAGNA Remove the four cylinder head halts. Remove the cylinder heads using a screwdriver at the pry points‘ Remove the front and rear cylinder head gaskets and dowel pins. CYLINDER HEAD/VALVE Date of Issue: July, 1984 © HONDA MOTOR (20., LTD‘ CYLINDER HEAD/VALVE 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 for damage or excessive wear. Inspect the spring for proper tension‘ CYLINDER HEAD DISASSEMBLY Remove the rocker arm theft and rocker arms, Remove the rocker arm spring washer and O-rinfl from the shaft. TENSIONER SLIPPE R HONDA V30 MAGNA CLIP WASHER ROCKER ARM SHAFT ROCKER ARM SHAFT O»RING 0 SPRING WASHER 9-10 Date of Issue: July, 1984 © HONDA MOTOR COI. LTD. HONDA V30 MAGNA Remove the valve spring cotters, retainers, springs and valves. CAUTION - To prevent loss of tension, do not com- press the valve springs more than neces- sary to remove the corrers. ~ Thread the large retainer on the com- pressor attachment, so the compressor will not touch the cylinder head. NOTE: Mark all disassembled parts to ensure correct reassembly. Remove the valve stem sealsl and discard them. NOTE: Replace the stern seal: with newones when» ever they are removed. Remove carbon deposits from the combustian chamber and clean the head gasket surfaces NOTE: ' Avoid damaging the gasket surfaces. ~ Gaskets will come off easier if soaked in solvent. INSPECTION e CYLINDER HEAD Check the spark plug hole and valve areas for creeks. Check the cylinder head for warpage with a straight edge and leeler gauge SERVICE LIMIT: 0.10 mm (0.004 in) CYLINDER HEAD/VALVE VALVE SPRING COMPRESSOR 01757—0010000 ' FEELER GAUGE Date of Issue: July, 1984 © HONDA MOTOFl (20., LTD. CYLINDER HEAD/VALVE HONDA V30 MAGNA O ROCKER ARM SHAFT 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 ta rocker arm clearance. SERVICE LIMIT: 0.12 mm (0.005 in) Inspect the rocker arm shaft spring far wear or damage. 0 ROCKER ARM 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) O VALVE SPRING Measure the free length of the inner and outer valve springs. SERVICE LIMITS: INNER (IN, EX): 30.85 mm (1.207 in) OUTER (IN, EX): 34.36 mm (1.358 in) Replace the springs if they are shorter than the service limit. 9-12 Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA 0 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 OID. SERVICE LIMITS: IN: 4.97 mm (0.196 in) EX: 4.94 mm (0.195 In) NOTE: Ream the guides to remove any carbon build» up before checking clearance. Measure and record each valve guide I‘D. using a ball gauge or inside micrometers SERVICE LIMIT: 5.04 mm (0.198 in) Subtract each valve xtem on from the corres» ponding guide ID. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.07mmlo.oosinl EX: 0.10mm(0.0Min) NOTE: If the stem-to-guide clearance exceeds the service limits, determine ii a new guide with standard dimensions would bring the clear» ance within mleranoe. If so, replace any guldes as necessary and ream to fit. If the stem-toguide clearance exceeds the servlce limits with new guides, replace the valves also. NOTE: Reface the valve seats whenever the valve guides are replaced (page 9-15)l \ t '7 VALVE GUIDE FIEAMEFI 07984—MA60000 CYLINDER HEAD/VALVE Date of Issue: July, 1984 © HONDA MOTOR CO, LTD. CYLINDER HEAD/VALVE HONDA V30 MAGNA VALVE GUIDE REPLACEMENT Heat the cylinder head to 100°C (212°F). CAUTION ' Do not use a torch to heat the cylinder; it may cause warping. ' To avoid bums, wear heavy gloves when handling the heated cylinder head. Support the cylinder head and drive the old guide out from the combustion chamber side of the cylinder head CAUTION When driving the valve guide out, be careful] not to damage the head Adjust the tool setting depth by a pair of vernier calipers. DEPTH: 11.5 mm (0.46 in) Reheat the cylinder head to 100°C (212°FL Sup» port the cylinder head and drive new guides in from the rocker arm side of the cylinder head. VALVE GUIDE DRIVER D7942—MA60000 DEPTH —> .— % VALVE GUIDE DRIVER 07743—0020000 VALVE GUIDE DRIVER 07743—0020000 9-14 Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA CYLINDER HEAD/VALVE Ream the new valve guides after installation. NOTE: ' Use cutting oil on the reamer during this operation. Rotate the reamer when inserting and removing it. Refsoe the valve seat and clean the cylinder head thoroughly to remove any metal particles, VALVE SEAT lNSI’ECTIflII/REFAGING Clean all intake and exhaust valve: thoroughly to remove carbon depositx. Apply a light coating of Pmssian blue to each valve Iaoe. Lap each valve and seat using a rubber hose or other hand-lapping tool. Remove the valve and inspect the face, CAUTION The valve: cannot be ground. If the valve face is rough, worn unevenly, or contacts the seat improperly, the valve must be replaced. Inspect the valve seat. STANDARD: 0.9—1.1 mm (0.0354104! in) SERVICE LIMIT: 1.5 mm (0.06 in) If the seat is too wide, too narrow, or has low spots, the seat must be ground. SEAT WIDTH Date of Issue: July, 1984 © HONDA MOTOR 60,, LTD. 9-15 CYLINDER HEAD/VALVE NOTE: Follow the refacer 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 off the cylinder head and valve. OLD SEAT WIDTH CYLINDER HEAD ASSEMBLY NOTE: Install new valve stem seals when assembling. Lubricate each valve stem with molybdenum disul» iide grease and insert the valve into the valve guide. To avoid damage to the stem seal, turn the valve slowly when inserting. Install the valve springs and retainens‘. The spring's tigltly wound coils should face in. Install the valve cutters. CAUTION To prevent loss of tension, do not com» press the valve spring more than necessqry to install the valve cutters. ~ 711er the large retainer on the compres- sor attachment, so the compressor will not touch the cylinder head, 0|:D SEAT WIDTH VALVE SPRING COMPRESSOR 07757—0010000 HONDA V30 MAGNA 0.9—1 .1 mm (01335—0043 in) RETAINER COTTERS , 60 VALVE SPRING STEM SEAL SEAT 9-16 Date 0f Issue: July, 1954 © HONDA MOTOR 00.. LTD. HONDA V30 MAGNA CYLINDER HEAD/VALVE Tap the valve stems gently with a soft harnmer to firmly seat the cutters. NOTE: Support the cylinder head above the work bench surface to prevent possible valve damage. ROCKER ARM SHAFT 0-HING ' Install the O-ring and spring washer onto the rocker ‘_ ~ arm shaft. Apply engine oil to the rocker arm shaft and install the rocker arm‘ Apply liquid sealant to the thread at the rocker arm shaft. Install and tighten the rocker arm shaftt TORQUE: 45—65 N-m (4.5—5.5 kg-m, 32—40 h-Ib) ROCKER A M SHAFT Date of Issue: July, 1984 © HONDA MOTOR 80,, LTD, 9 ' 1 7 CVLINDER HEAD/VALVE HONDA V30 MAGNA CYLINDER HEAD INSTALLATION Clean the cylinder head surface of any gasket material. Install the dowel pins and new head gaskets. Install the cylinder head and head bolts but do not torque the bolts yet. Wlth the cam chain tensioner arm raised and lock plate lowered in the direction of the arrow, insert a pin or piece of wire in through the hale in the tensioner base and tsnsioner. DOWEL PINS PIN HOLE TENSIONER BASE TENSIONER ARlvl LOCK PLATE Date of Issue: July, 1984 © HONDA MOTOR Cot, LTDt HONDA V30 MAGNA 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. ~ Be careful not to drop the washer or clip into the crankcase. NOTE: ' Check the oil pass pipe and oil bolt for clogging, cracks or other damage. ' Do not forget to install the sealing washers. Install the oil pass pipe to the cylinder head with the oil belt. TORQUE: 20—25 N~m (7.0—2.5 ku-m, 14—18 ft-Ib) Install new OArings onto the ends of the water pipe. Install the water hose and pipe into the cylinder head with the two bolts. Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. CYLINDER HEAD/VALVE "5/ TENSIONEH ARM OlL BOLT WATER OSE/PIPE CYLINDER HEAD/VALVE CAMSHAFT INSTALLATION Lubrlcate the cylinder head cam bearing surfaces with molybdenum disulfide grease. Loosen the all valve adjusters. Check the camshaft marks so that you install each camshaft in its correct location. EX-F: Front cylinder exhaust Place with the locating ridge toward the left side. EX-Fl: Hear cylinder exhaust Place with the locating ridge toward the right side. IN-F: (Front cylinder intake Place with the locating ridge toward the left side. lN-R1 Rear cylinder intake Plaoe with the locating ridge toward the right side. ,lnstall each 'eamshatt fih sprocket into place "through the cam chaint HONDA V30 MAGNA LOCATING RIDGE INDEX MARK CAM SPROCKETS ' CAMSHAFT 9-20 Date of Issue: July, 1984 © HONDA MOTOR C0., LTD. r“ HONDA V30 MAGNA Remove the inspection hole cap from the right crankcase cover. Turn the crankshaft counterclockwise until the "TR" mark on the pulse rotor align: with the index mark on the right crankcase. Turn the rear cylinder camshaft so that the intake and exhaust cam lobes of the No. 1 cylinder face up. Install the rear cylinder intake and exhaust cam- shafts and sprockem throud'i the cam chain. Align the ”LE, 2.I" index line of the exhaust cam sproket with the top of the cylinder head‘ Aling the "1.|, Z‘E" Index line of the intake cam sprocket with me top of the cylinder head. Install the rear cylinder cam chain over the cam sprocket. Slide the sprockets onto the camshaft flanges, and install the sprocket bolt: in the exposed holes. I' {1 CYLINDER HEAD/VALVE INDEX MARK , . V “W” on “TR" MARK INTAKE CAMSHAFT he % EXHAUST CAMSHAFT i2 INTAKE CAM SPROCKET EXHAUST CAM SPF! OCK ET Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. 9-21 HON DA V30 MAGNA CYLINDER HEADNALVE 1‘: /_ h the front cylinder Camshafts so that the intake gr: lobe of the No. 4 cylinder faces down and the INTAKE CAMSHAFT exhaust cam lobe of the No. 4 cylinder faces up as shown. Align the "1.I, 2.E" index line of the exhaust cam sprocket with the top of the cylinder head. ENGIN RIGHT SIDE VIEW sprockets. CAM SPROCKET CAM SPHOCKET Slide the sprockets onto the camshaft flanges, and — install the sprocket bolts in the exposed holesl Align the “LE, 2.I" index line of the intake cam EXHAUST sprocket with the top of the cylinder head. CAMSHAFT Install the front cylinder cam chain over the cam EXHAUST INTAKE ENGINE LEFT SIDE VIEW Install the eight dowel pins to each cylinder head. Place the camshaft holders in the same locations noted during removali The groove in the bottom of m holder must align with the camshaft locating ridge. CAMSHAFT HOLDERS _ Date of Issue: July, 1984 ., “ © HONDA MOTOR 00., LTD. HONDA V30 MAGNA Turn the crankshaft counterclockwise 360 degrees and install the remaining cam sprocket bolts of the front and rear cylinders. Tighten the cam sprocket bolts. TORQUE: 18—20 M"! (1.8—1.0 kg-m, 13—14 ft-Ib) Install the oil pipe. lnstall the cam chain guide, Tighten all cylinder head bolts in the sequence shown. TOROUES: [I -— IE 30—34 M!!! (3.0—3.4 kown, 22—25 ft-lb) El — \E 21—25 N-m (2.1—25 kg-m,15—18 ft-lb) l_-1o—14 N-m (1.0—1.4 qum, 7—10 h-lb) Install the oil pass pipe, TORQUE: 10—14 N-m (1.0—1.4 kg-m, 7—10 fl-lb) Adjust the valve clearance (page 38). Lubricate the cam lobes with engine oil. CYLINDER HEAD/VALVE Date of Issue: July, 1984 © HONDA MOTOFl co., LTD. CYLINDER HEAD/VALVE Check the cylinder head oover gasket for damage or deterioration. NOTE: Clean the gasket before applying sealant. Apply sealant to the cylinder head cover gasket. Install the cylinder head oover. TORQUE: 8—12 N~m (0.8—1.2 kg-m, 8—9 ft-lh) Install the removed part in the reverse order of removal. CYLINDER COMPRESSION Warm up the engine. Stop the engine, then disconnect the spark plug caps and remove the spark plugs. Insert the compression gauge. Open the throttle all the way and crank the engine with the starter motor. NOTE: Crank the engine until the gauge reading stops rising. The maximum reading is usually reached within 4—7 seconds. COMPRESSION PRESSURE: 1,200 2 200 kPe (12.0 t 2.0 kg/cm‘, 170 s 20 psi) If compression is low, check for the following: — Improper valve clearance — Leaky valves — Leaking cylinder head gasket — Worn piston/ring/cylinder If compression is high, it Indicates that carbon deposits have accumulated on the combustion chamber and/or the piston crown. HONDA. V30 MAGNA CYLINDER HEAD COVER GASKET 9-24 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. HONDA V30 MAGNA MEMO . HONDA V30 MAGNA CRAN KSHAFT/PISTON 35—40 N‘m (3.6—4.0 kg-m, 25—29 ft-Ib) 30-34 N~m (2.1-2.5 kg.m_ (3.0—3.4 kg-m, 22—25 fl-Ib) 15—13 ft-Ib) 9 MOLYBDENUM DISULFIED 6 mm BOLT 10—14 N~rn (1.0—1.4 kg-m, 7—10 RAID) 8 mm BOLT 21—25 N-m (2.1-2.6 kg-m, 15—18ft-lb) 0 Date of Issue: July, 1984 1 ' 0 © HONDA MOTOR 60., LTD. 523.11% 10. CRANKSHAFT/ PISTON SERVICE INFORMATION 10—1 CRANKSHAFT REMOVAL 10—8 TROUBLESHOOTING 10—2 BEARING SELECTION 10—11 CRANKCASE DISASSEMBLY 10—3 CRANKSHAFT INSTALLATION 10—13 CONNECTING ROD REMOVAL 10—5 PISTON AND ROD INSTALLATION 10—13 PISTON REMOVAL 10—6 CRANKCASE ASSEMBLY 10—16 SERVICE INFORMATION G E N E R A L I The following parts must be removed before disassembling the crankcase. - Oil pan Refer to section 2 . Oil pump Refer to section 2 ~ Water pump Refer to section 6 ' Clutch/starter clutch Refer to section 7 - Gearshift linkage Refer to section 8 - Alternator Refer to section 8 - Cylinder heads Refer to section 9 ' Starter motor Refer to section 17 I All bearing inserts are select tit and are identified by color code. Select replacement bearings from the code tables. After insmlling new bearings, recheck them with plastigauge to verify clearance. 0 Apply molybdenum disulfied 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. SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Crankshaft Connecting rod big end side clearance 0.10—0.30 mm (0.004—0.012 in) 0.40 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 journal oil clearance 0028—0052 mm (00011—00020 in) 0.07 mm (0.003 in) Cylinder I.D. 60000—60015 mrn (23622—23628 in) 80.10 mm (2.366 in) Warpage — 0.10 mm (0.004 in) Piston Ring-togroove Top 0.015—0.045 mm (00006—00013 in) 0.10 mm (0.004 in) “3'3"“ Second ems—0.045 mrn (00006—00013 in) 0.10 mm (0.004 in) Ring end gap Top 0.10—0.30 mm (0.004—0.01200 0.50 mm (0.020 in) Second 0.10—0.30 mrn (0.004—0.012 in) 0.50 mm (0.020 in) Oil (Slide rail) 0.30—0.90 mm (0012—0035 in) 1.1 mm (0.04 in) Piston 0.0. 59.96—59.99 mm (13606—23618 in) 69.85 mm (2.356 in) Piston-to-cvlinder clearance OHIO-0,055 mm (00004-00022 in) 0.10 mm (0.004 in) Piston pin hole 16002—15008 mrn (06300—03302 in) 16.06 mm (0.632 in) Piston pin O.D. 15394—10000 mm (05297—0330 in) 15.98 mm (0.629 in) Piston-to-piston pin clearance 0.002—0014 mm (00001—00006 in) 0.04 mm (0.002 in) Connecting rod small end I.D. 10016—16034 mm (06306—06313 in) 16.08 mm (0.633 in) Piston pin-to-connecting rod clearance 0.016-0.040 mm (00006—00016 in) 0.06 mm (0.002 in) ©DaReiD‘N0fra'0’TgR1ggtLTD. 1 0 ' 1 CRANKSHAFT/PISTON HONDA V30 MAGNA TORQUE VALUES Oil drain bolt Connecting rod nut Crankcase 8 mm bolt 6 mm bolt TROUBLESHOOTING Excessive noise 1. Crankshaft - Worn main bearing - Worn rod bearing 2. Piston and Connecting Rod — Worn piston or cylinder — Worn piston pin or pin hole —- Worn rod small and Low compression or uneven compmslon 1. Worn cylinder or piston ring Excusive smoke 1. Worn cylinder, piston or piston rings 2. Improperly installed piston rings 3. Damaged piston or cylinder Overhutlnu 1‘ Excessive carbon build-up on piston head 2. Blocked or restricted flow of coolant 3. Sticking thermostat Knocking or abnormal noise 1. Worn pistons and cylinders 2. Excessive carbon build-up on piston head. 36—40 N-m (3‘5—O.D kg-m, 25—29 ft-lb) 30—34 N-m (3.0—3i4 kg-m, 22—25 ftAlb) 21—26 N-rn (2.1—2.5 kg-m,16—18ft-lbl 10—14 N-m(1.0—1i4 kg-m, 7—10 ft-lb) 102 Date of Issue: July, 1984 © HONDA MOTOR 00., LTDi . HONDA V30 MAGNA CRANKSHAFT/PISTON OIL BOLT ‘ BRANKGASE DISASSEMBLY Remove the oil bolt. Remove the oil pas pipe mounting bolt and the oil pass pipe. Remove the water pipe cap bolts. water pipe and caps. ”‘K‘x OIL PASS PIPE Remove the water pipe mounting bolt and the water pipe. ’ WATER PIPE Date of Issue: July, 1984 © HONDA MOTOR CO, LTD, CRANKSHAFT/PISTON Remove the seal plate. Remove the seven upper crankcase bolts. Turn the engine over and remove the eight lower crankcase bolts and fourteen crankshaft main journal bolls. NOTE: Remove the bolt: in two or more steps and in a crisscross pattern to prevent damage to the crankcase. Separate the lower crankcase from the upper crank- ca’se. NOTE: ' Do not pry the crankcase mating surface: apart. - Tap the crankcase lightly to loosen the crankcase. HONDA V30 MAGNA 10-4 Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA CONNECTING ROD BIG END SIDE CLEARANCE INSPECTION Check the connecting rod side clearance. SERVICE LIMIT: 0.40 mm (0.016 In) CONNECTING ROI] REMIJVAL Separate the crankcase (page 10-3). Remove the transmission. Remove the connecting rod bearing caps and note their locations. Push the connecting rods and pistons out through the top of the cylinder bores. Mark the rods, pistons, bearings end caps as you remove them to indicate their correct cylinder and position on the crankpins for reassembly. CONNECTING HDDS CHANKSHAFT/PISTON CDNNECTI NG FlOD/ PISTON ASSEMBLY Date of Issue: July, 1934 © HONDA MOTOR C0., LTD. CRANKSHAFT/PISTON PISTON REMflVAL Remove the piston pin clips. Push the piston pin out and remove the piston. Mark the piston pins to indicate their oorrect piston position. INSPECTION o PISTON RING Measure the piston ringto-groove clearance. SERVICE LIMIY: TOP/SECOND: 0.10 mm (0.004 In) Remove the piston rings and mark them to Indicate the correct cylinder and piston position. Using a piston, push the ring into the cylinder squarely and measure the end gap. SERVICE LIMITS: TOP: 0.50 mm (0.020 in) SECOND: 0.50 mm (0.020 in) OIL (Side rail): 1.1 mm (0.04 in) HON DA V30 MAGNA PISTON PIN 10-6 Date of Issue: July, 1984 © HONDA MOTOR CO, LTD, l HONDA V30 MAGNA o PISTON Clean the piston crown, removing all carbon de- posits. Inspect the piston for cracks or other damage and the ring grooves for excessive wear and carbon build-up. Measure the piston O.D. NOTE: Take measurements at 10 mm (0.4 in) from the bottom, and 90° to the piston pin hole. SERVICE LIMIT: 59.85 mm (23561») Measure each piston pin hole LD. SERVICE LIMIT: 13.061!!!“ (0.632in) o PISTON PIN Measure each piston pin O.D. SERVICE LIMIT: 15.98 mm (0.629 in) Calculate the piston pin-to-piston clearance. SERVICE LIMIT: 0.04 mm (0.002 In) CRANKSHAFT/PISTON Date of Issue: July, 1934 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA CRANKSHAFTIPISTON o CYLINDER Inspect the cylinder bores for wear or damage. Measure the cylinder ID. at three levels in X and Y axis. SERVICE LIMIT: 60.10 mm (2.366 in) Calculate the piston-to-cylinder clearance. SERVICE LIMIT: 0.10 mm (0.004 in) Check the cylinder top surfaces for warpege with a straight edge and feeler gauge. SERVICE LIMIT: 0,10mm (0.004 In) E TOP . . . . . . MI E Oversize pistons and piston rings are available In W" the following sizes: ”no" 0.25, 0.50, 0.75 and 1.00 mm _ " O CONNECTING ROD SMALL END Measure the connecting rod small end ID. If the reading exceeds the service limit, replace the rod. SERVICE LIMIT: 10.08 mm (0.633 In) Examine the rods for bends, cranks or other damage, Replace if necessary. Calculate the connecting rod-to-piston pin clear- ance. SERVICE LIMIT: 0.06 mm (0.002 In) CRANKSIIAFT REMOVAL Separate the crankcase (page 10-3). Remove the transmission. Remove the connecting rods and pistons (page 105). Remove the crankshaft and cam chains. CHAN KSHAFT Date of Issue: July, 1984 1 0' 8 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA CRANKSHAFT/PISTON INSPECTION O CHAN KSHAFT H UNOUT Support the No. 1 and No. 4 main bearing journals with V blocks. Set a dial indicator on the No. 3 or No. 2 main bearing journal. Rotate the crankshaft two revolutions and read the —r- runout. Actual runout is 1/2 of the total indicator reading. I SERVICE LIMIT: 0.03 mm (0.001 in) PLASTIGAUGE O CRANKPlN OIL CLEARANCE Inspect the bearing inserts for unusual wear or damage. Wipe all oil from the bearing inserts and crankpins. Put a piece of plastigauge on each crankpin. NOTE: Do not put the planigauge over the oil hole in the crankpin. Install the bearing caps and connecting rods on the correct crankpins, and tighten them evenly. TORQUE: 30—34 N-m (3.0-3.4 ka-m, 22—25 ft-lh) NOTE: Do not rotate the crankshaft and connecting rods during inspection. Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. 1 0' 9 CRANKSHAFT/PISTON Remove the caps and measure the compressed plastigauge on each crankpin. OIL CLEARANCE SERVICE LIMIT: 0.07 mm (0.003 In) 0 MAIN BEARING OIL CLEARANCE Inspect the bearing insert: for unusual wear or damage. Wipe all oil from the hearing inserts and journals. Reinstall the upper crankcase's main bearing inserts, then carefully lower the crankshaft in place. Put a piece of plastigauge on each journal. NOTE: Do not put the plastigauge over the oil hole in the main bearing journal of the crankshaft. Install the main bearing inserts on the correct journals in the lower crankcase, than assemble and tighten the bolts evenly in 2—3 steps in the se- quence shown. TORQUE 8 mm bolt: 21—25 N-m (2.1 —-Z.5 kw», 15—18 ftJb) 6 mm bolt: 10—14 Ill-III (1.0—1.4 kg—m, 7—10 h-Ib) NOTE: Do not rotate the crankshaft during inspec- (ion. PLASTIGAUGE HON DA V30 MAGNA 10-10 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. HONDA V30 MAGNA ORAN KSHAFT/PISTON Remove the lower crankcase and measure the compressed plastigauge on each journaL SERVICE LIMIT: 0,07 mm (04003 in) BEARING SELECTION CONNECTING ROD BEARING If a rod bearing clearance is beyond tolerance, select replacement hearing as follows: The code number (1, or 2) stamped on each con- necting rad identifies its inside diameter (I.D.). The code letter (A or B) stamped on each crank- shaft counter weight identifies the outside diameter (0.Dl) of its crankpin. I.D. CODE NUMBER Date oflssue:July,1984 © HONDA MOTOR CO‘. LTD, 10-11 CRANKSHAFT/PISTON Cross reference the crankpin and rod codes to select me correct replacement hearing. CONNECTING ROD LDI CODE NO. I 2 35.000— «5.003- 35008 mm 35.0I6 mm (I .3780- (um- 1.37mi") 137$in) 33333" 0 mm B ORANK- A (1.2595— (Vollow) (Green) SHAFT 1.2598 in) 0.0. DOD; 31.934— LETTER 3 31.992 mm a A n .2592— (Green) (Brown) 141595 in) BEARING INSERT THICKNESS: A (Brown): 1.494—1J98mm (03588—410590 in) B (Green): Lao—1.494 mm (03587—00588 in) C (Vellaw): 1.486—1A90 mm «10585—03587 In) MAIN BEARING The code letter (A or B) stamped on the rear por~ (ion of the upper crankcase identifies the inside diameter (LDJ of each main bearing journalt The code number (1 or 2) mmped on each crank— shaft counter weight identifies the outside diameter (O.D.) of its main iournal. HONDA V30 MAGNA COLOR CODES 10-12 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD‘ HONDA V30 MAGNA cRANKSHAFT/PISTON Cross reference the crankcase and crank journal codes to select the correct replacement bearing. CRANKCASE Ll). cop: LETTER , A B 777-. 35.000— 85.008— 35005 mm 35.016 mm “.3750- ".3783— 1.37mi") 1.3736 In) 33333" n c . mm Téflfi. 1 “.2575— (Vellow) (Green) NAL 11593:") on. . 3133“ 31.992mm c a (1.2592— (Green) (Brown) 4.25951") _—1___l BEARING INSERT THICKNESS B (Brown): LAM—Mos mm (moses—c.0590 in) c (Green): use—1.494 mm (03587—03588 D (Vellowl: Luis—1.490 mm (cases—0.0587 m) ORANKSHAFT INSTALLATION Install the main bearings into the upper and lower crankcases. Apply molybdenum disulfide grease to the main bearings. Install the cam chains onto the crankshaft. Place the crankshaft into the upper crankcase. c0LdR ODES MOLYBDENUM DISULFIDE PISTON AND ROD INSTALLATION clean the piston heads. ring lands, and skirts. ‘— I TOP Carefully install the piston rings onto the piston. ‘ NOTE: \ : I sscono Be careful not to damaee the piston andi rings during assembly. ' All rings should be installed with the mark- ‘ j OIL ings facing up. ' Space the ring end gaps 120 degrees apart. Do not align the side rail gaps. ' After installing the rings they should rotate freely, without sticking. ‘ ,7, 9 Date of Issue: July, 1934 1 0' 1 3 © HONDA MOTOR 00,, LTD. HONDA CRANKSHAFT/PISTON V30 MAGNA A fSPACER OIL ‘ 20_mm 0R_MORV / SIDE RAIL GAP “FRONT" "IN" MARK OIL HOLE Coat the rod's small and and pismn pin hole with molybdenum disulfide grease. FRONT CYLINDER Note that the front cylinder connecting rods are marked "MJfl-F". Install the plstons on the front connecting rods so that the intake "IN" mark is facing the same direc- tion as the oil hole in the rod. “MJB-F" MARK :J , 1984 1 o ' 1 4 gaaeoobjlgs/iulalO‘ll'JgR CO” LTD‘ HON DA V30 MAGNA CRANKSHAFT/PISTON HEAR CYLINDER "REAR” “IN" MARK OIL HOLE Note that the rear cylinder connecting rods are marked “MJB-R". Install the pistons on the rear cylinder connecting rods so that the intake "IN" mark is facing opposite 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. ,6" GROOVE MOLYBDENUM DISULFIEDS Install the bearing inserts on the connecting rods '1 ‘ ' ' and bearing caps, aligning the tabs on the inserts with the grooves in the rods and caps. Apply molybdenum disulfide grease to the connect- ing rod bearlngs. "MJB-R" MARK Coat the cylinders, piston rings/grooves and pistons with oil. To prevent damaging the crankshaft, slip short sections of rubber hose over the rod bolts before installation. Install the rod and plston 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 piston intake “IN" marks should be facing each other as shown. Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD‘ CRANKSHAFTIPISTON Compress the piston rings with a ring compressor and insert the piston and rod into the cylinder until the rod seats on the erankpin. NOTE: Be careful not to damage the pistons or rings during assembly. Apply molybdenum disulfied grease to the main bearings. Install the crankshaft. Install and torque the connecting rod caps. TORQUE: 30—34 N~m (3.0—3.4 kg-m, 22—25 ft-lb) NOTE: Be sure the bearing caps are installed in their correct locations as marked during removal. ~ Tighten the nuts in two or more steps. ' After tightening the bolts, check that the rods move freely without binding. CRANKCASE ASSEMBLY Clean the crankcase mating surfacest Turn the gearshift drum until the neutral switch is pushed by the drum. HONDA V30 MAGNA PISTON RING COMPRESSOR (COMMERCIALLY AVAILABLE IN U.S.AJ yr " :3 u—.... NEUTRAL SWITCH 10-16 Date of Issue: July, 1934 © HONDA MOTOR CO., LTD. HONDA V30 MAGNA Install the transmission. Move the 06, C5 and M3/4 gear: to the neutral position. Apply liquid sealant to the mating surface of the upper crankcase. CAUTION Do not apply sealant to the area near the main bearings. Install the dowel pin. NOTE: Make sure the oil control orifice is not clogged. Apply molybdenum disulfied grease ’to the crank- shaft main bearings. Applv liquid xealam to the mating surface of the lower crankcase. CAUTION Do not apply sealant to the area near the main bearings CRAN KSHAFT/PISTON 'M3/4 G EA R Wu DOWEL PIN Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD‘ 10-17 CRAN KSHAFT/PISTON Assemble the crankcase halves, aligning the shift fork claws with the gears. Tigmten the crankshaft main journal bolts to the specified torque diagonally beginning with the inner bolts first. TORQUE: 21—25 N-m (2.1—2.5 kgm,15—18 h-lb) Tighten the lower crankcase bolts to the specified torque diagonally, starting with inner bolts first. TORQUE: 3 mm eon: 21—25 N-m (2.1—2.5 kg-m, 15—13 ft-lb) 6 mm BOLT: 10—14 N-m (1.0—1.4 kg-m, 7—10 ft-lb) Tighten the upper crankcase bolts to the specified torque TORQUE: 8 Hum BOLT: 21—25 N-m (2.1—2.5 kg-m, 15—18 h-lb) 6 mm BOLT: 10—14 N~m (1.0—1.4 kq‘m, 7—10 h‘Ib) NOTE: Tighten the bolts in two or more steps and in a crisscross pattern. Install the removed parts in me reverse order of removal. HONDA V30 MAGNA 10-18 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. é HONDA V30 MAGNA MEMO HONDA. TRANSMISSION V30 MAGNA :51. :3 I E'u‘ W: a I : I; ;: / cs aoT 7' c3 (35T) ( ) c1 (4ST) M Date of Issue: July, 1984 © HONDA MOTOR C0., LTD. 11 I O HONDA V30 MAGNA 11. TRANSMISSION SERVICE INFORMATION TROUBLESHOOTING TRANSMISSION REMOVAL SHIFT FORK AND SHIFT DRUM TRANSMISSION ASSEMBLY 11—1 11—2 11—3 11—6 11—10 SERVICE INFURMATIIJN GENERAL 0 The gearshift linkage can be serviced with the engine in the frame (Section 8). O For internal transmission repairs, the crankcase must be separated (Section 10). a Note the installation directions and positions of the thrust washers when assembling the mainshaft and countershaft. SPECIFICATIONS STANDARD SERVICE LIMIT Transmission Gear I.D. M5. M6 gear 25.000—25.021 mm (03843—08861 in) 25.05 mm (0.936 in) C1 gear 23300—23021 mm (03055—03063 in) 23.05 mm (0.789 in) CZ, C3, C4 gear 28000—23021 mm (1.1024—1.1032 in) 28.06 mm (1.104 in) 1 Gear bushing M5 gear 24359—24980 mm (09826—09835 inl 24.92 mm (0.981 in) 09- M6 gear 24359—24380 mm (09326—09835 in) 24.92 mm (0,931 in) CI gear 22359—21980 mm (09039—03047 in) 22.92 mm (0.902 in) I32, CS, C4 QEBI’ 27359—27330 mrrl (1.1007—1.10163n) 27.92 mm (1.099 in) Gear bushing |.D. M5 gear 21385—21006 mm (08655—08664 in) 22.07 mm (0.869 in) C1 gear 20020—20041 mm (07832—07890 in) 20.11 mm (0.792 in) C2 gear 25330—25051 mm (09354—09363 in) 26.11 mm (0.939 in) Mainshaft 0.D. at MS gear 21359—21380 mm (03646-03654 in) 21.92 mm (0.863 in) Countershaft CD. at Cl gear 19387—20000 mrn (07869—07374 in) 19.95 mm (0.785 inI at CZ gear 25.002—25015 mm (03843-09843 in) 24.97 mm (0.983 in) Shift fork Claw thickness 5.93—6.00 mm (0234—0236 in) 5.60 mm (0.220 in) LB. 11000—12021 mm (04724—04733 in) 12.04 mm (0.474 in) Fork shaft O.D. 11966—11384 mm (0.4711—0.4718in) 11.90 mm (0.469 in) TOOLS Common Driver 07746—0030100 Attachment, 30 mm 07746—0030200 Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. 11-1 HON DA V30 MAGNA TRANSMISSION TROUBLESHOOTING Hard to shift . Bent gearshift fork Improper clutch system Bent gearshift fork shaft i Bent gearshift claw . Worn shift drum cam groove . Worn guide pin mmasap.. Transmission Jumps out of our 1. Worn gear dogs 2. Bent gearshift fork shaft 3. Damaged shift drum stopper 4. Bent gearshifl fork 1 1 2 Date of Issue: July, 1984 ' © HONDA MOTOR co., LTD. HONDA V30 MAGNA TRANSMISSION TRANSMISSION REMOVAL REMOVAL Separate the crankcase (Section 10). Remove the bearing setting plate. BEARING SETTING PLATE MAINSHAFT ‘ Remove the mainshaft assembly and oountershaft assembly. Remove the oil seal. COU NTE RSHAFT Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. 1 1 ' 3 HONDA V30 MAGNA TRANSMISSION Disassemble the mainshafl and countershaft. /@ ‘ y'EHSHAFT MAINSHAFT M1 @ INSPECTION 0 TRANSMISSION GEAR Cheek gear dogs, slots and gear teeth for excessive or abnormal wear. ar evidence of insufficient lubri- cation. Measure the ID. of each year. SERVICE LIMITS: M5, m gear: 25.05 mm (0.986 in) C1 gear: 23.05 mm (0.789 In) 02, ca. Cl near: 23.05 mm (1.104 In) Date of Issue: July, 1984 © HONDA MOTOR CO” LTD. 11 I uh HONDA V30 MAGNA O GEAR BUSHING Measure the OD. of each gear bushing. SERVICE LIMITS: M5, M6 gun 24.92 mm (0.981 in) C1 our: 22.92 mm (0.902 in) (:2, 03. C4 gar: 27.92 mm (1.099 in) Measure the ID. of each gear bushing. SERVICE LIMITS: M5 gear: 22.07 mm (0.869 in) 01 war: 20.11 mm (0.792 in) C: our: 15.11 mm (0.939 In) 0 MAINSHAFT/COUNTERSHAFT Measure the CD. of (he mainshaft and counter- shaft. SERVICE LIMITS: Maimhm (:1 M5): 21.92 mm (0.363 in) Countershtft (at C1): 19.95 mm (0.785 in) Countershaft (at C2): 4.97 mm (0.983 in) o BEARING check the mainshaft and oountershaft benrings for excessive play. ’ If the oountershaft bearing is damaged or has ex- cossive play, the oountershaft must be replaced. TRANSMISSION PLAY P LAY Date oI Issue: July, 1984 © HONDA MOTOR (30., LTD. 11-5 TRANSMISSION O SHIFT FORK SHAFT check the shift fork shaft far bems, scratches or scoring. Measure the shift fork shaft O‘D. SERVICE LIMIT: 11.90 mm (0.469 in) 0 SHIFT DRUM Inspect the shift drum and for scoring, scratches, or evidence of insufficient lubrication. Cheat the shift drum grooves for damage. 0 CRANKCASE Inspect the shift drum hole and shift fork shaft hole for scoring or scratches HONDA V30 MAGNA 11-8 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD‘ HON IDA V30 MAGNA TRANSMISSION INSTALLATION Install the shift drum. Install the bearing stopper plate and stopper arm pin and tighten the stopper arm pin, using two nuts. Install the shift forks and shift fork shaft. NOTE: Install the shift fork: so that their mark; face toward the right side of the engine. Rig“ shift fork: "R" mark Center shift fork: “C" mark Left shift fork: ”L" mark SHIFT FORKS MAR KS Date oflssue:Ju|v,1984 © HONDA MOTOR CO‘, LTD. 11-9 TRANSMISSION Install the shift fork shaft stopper with the bolt. TRANSMISSION ASSEMBLY COUNTERSHAFT Apply molybdenum disulfide grease to the slidlng surfaces of the oountershaft and each gear and bushing. Assemble the countershaft. NOTE: ' Check the gears for freedom of movement or rotation on the shaft ' Check that the snap rings are seated in the grooves HONDA V30 MAGNA SHIFT FORK SHAFT STOPPER 11-10 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD HONDA V30 MAGNA TRANSMISSION Install the (:3 and C4 gear bushings with the oil holes in the bushings and shaft alignedt OIL HOLES MAINSHAFT Apply molybdenum disulfide grease to the sliding surfaces of the mainshaft and each gear and bushing. Assemble the mainshaft. NOTE: ~ Check the gears for freedom of movement and rotation on the shaft. ' Check that the snap rings are seated in their grooves. 8’fi°o‘fi6§“fi3¥8h'§33 LTDt 1 1 ' 1 1 TRANSMISSION HONDA V30 MAGNA Align the oil hole in the M6 bushing with the oil hole in the mainsheft. Install the bearing set ring onta the upper crankcase. Install the mainshaft and countershaft onto the upper crankcase, aligning their locating points with the dowel pln and bearing set ring. OIL HOLES M6 BEARING BEARING SET RING 11-12 Date of Issue: July, 1984 © HONDA MOTOR (10., LTD‘ HONDA V30 MAGNA TRANSMISSION Install the bearing setting plate. NOTE: Before installing the lower crankcase, meek that the oil orifices are clear. Install the lower crankcase (Section 10). n n :J ©‘L‘oim‘flo33h'333 LTD 1 1 - 1 3 HONDA V30 MAGNA FRONT WH EEL/SUSPENSION/STEERING , 9 80—120 N~m Q‘ \ (an—12.0 kg-m, I » 58—87 ft-Ib) w\9—13 N-m (0.9—1.3 kg-m, 7—9 ft-Ib) FORK CAP 15—30 N‘m (LS—3,0 kg-m, 11—22 ft-Ib) E 13—28 N-m ‘4 5 5 5 k (1.8—2.8 kg-m, 13—20 ft-Ib) . — . g-m, 32—40 ft-Ib) 55—65 N‘m (515—63: kg-m, 40—47 ft-lb) 15—25 Nrm (1.5—2.5 kg-m, , 1 1—1 8 flvlh) " I,“ . 35—40 N-m (3-5—40 ks-m, 25—29 mm 3040 Nm SOCKET BOLT (3.0—4.0 kg-m, 22—29 ft-lb) 15-26 N-m (1.5—2.5 kgm, 11—18ft-lb) 1 2 O Dateoflsme:July,1984 - © HONDA MOTOR 60., LTD‘ HONDA V30 MAGNA FRONT WHEEL/ 1 2. SUSPENSlflN/STEERING SERVICE INFORMATION TROUBLESHOOTING HANDLEBARS FRONT WHEEL FRONT FORKS STEERING STEM 12—1 12—2 12—3 12—7 12—15 12—24 SERVICE lllFflRMll'Ilflll GENERAL 0 A jack or other support is required to support the motorcycle when you are working on the front wheel or fork. 0 Flefer to the Tubeless Tire Manual for tubeless tire repairs. SPECIFICATIONS STANDARD SERVICE LIMIT Axle shaft runout — 0.2 mm (0.01 in) Front wheel rim runout Radial 0.3 mm (0.01 in) max. 2.0 mm (0.08 in) Axial 0.3 mm (0.01 in) max. 2.0 mm (0.08 in) Wheel bearing play — 0.03 mm (0.001 in) Fork spring free length 450.1 mm (17.72 in) 441.1 mm (17.37 in) Fork tube runout — 0.2 mm (0.01 in) Front fork fluid capacity 400 cc - Front fork air pressure 0—40 kPa (0—0.4 kg/cm’, 0—6 psi) — TORQUE VALUES Handlebar upper holder Front axle Axle pinch bolt Front fork socket bolt Fork cap Steering adjustment nut Steering stem nut Brake disc Front fork upper pinch bolt Front fork lower pinch bolt Front fork stabilizer bolts Master cylinder holder bolt 25—35 N‘m (2.5—3.5 kg-m, 13-25 ft-lb) 55—65 N~m (5.5—6.5 kg-m, 40—47 ft-lbl 15—25 N~m (1.5—2.5 kg-m,11-18 ft-lbl 15—25 N~m (1.5—2.5 kg-m,11—IB ft-lb) 15—30 N-m (1.5—3.0 kg-m, 11—22 ft-lb) 19—23 N-m (1.9—2.3 kg-m, 14—17 ft-lb) See sequence page 12-28. 80-120 N-m (SD—12.0 kg-m, 53—87 ft-Ib) 3540 N~m (3.5—4.0 kg-m, 25—29 ft—lb) 9—13 N-m (0.9—1.3 kg-m, 7—9 ft-Ib) 45—55 N-m (4.5—5.5 kg-m. 32—40 ft-lb) 18—23 N-m (1.8—2.8 kg-m, 13—20 ft-Ib) 10—14 N-m (1.0—1.4 kg-m, 7—10 ft-Ib) Date of Issue: July, 1934 © HONDA MOTOR 00., LTD. 121 FRONT WHEEL/SUSPENSION/STEERING TOO L Special Hex. wrench, 6 mm Snap ring pliers Fork seal driver Race remover Race remover Steering stem driver Steering stern socket Driver Common Driver Attachment, 42 x 47 mm Pilot, 15 mm Lock nut wrench, 30 x 32 mm Extension bar Wheel bearing remover shaft Wheel bearing remover head, 15 mm Attachment, 37 x 40 mm Attachment, 52 x 55 mm TROUBLESHOOTING Herd steerlng 1. Steering bearing adjustment nut too tight. 2. Faulty steering stern bearings. 3. Damaged steering stern bearings. .4. Insufficient tire pressure. HONDA V30 MAGNA 07917—3230000 or equivalent in U .S.A. 07914—3230001 or Equivalent in U.S.A. 07947—3710101 07946—3710500 07953—MJ1000A lU.S.A. only) 07945—M300000 or 07946—3710601 and 07964—M 300200 07916—3710100 07949—3710001 or 07949—3710000 07749—0010000 07746—0010300 07746—0040300 07716—0020400 or equivalent in U.S.A. 07716—0020500 or equivalent in U.S.A. 07746—0050100 or equivalent in U.S.A. 07746—0050400 or equivalent in U.S.A. 07746—0010200 07746—0010400 or 07946—3710701 Soft suspension 1. Weak fork springs. 2. Insufficient fluid in front forks. 3. Front fork air pressure inoorrect. Hard suspension Steers to one side or does not track straight l. Unevenly adjusted right and left shock abosrbers. 2. Bent front forks. 3. Bent front axle; wheel installed incorrectly. Front wheel webbing 1. Bent rim. 2. Worn front wheel bearings. 3. Faulty tire. 4. Axle nut tightened properly. 1. Incorrect fluid weight in front forks. 2. Front fork air pressure incorrect. 3. Bent fork tubes. 4. Clogged fluid passage. 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. 12-2 Date of Issue: July, l984 © HONDA MOTOFl 60., LTD. HON DA V30 MAGNA HANDLEBARS REMOVAL Remove the wire harness bands. Disconnect the brake switch wires. Remove the front brake master cylinder, Remove the switch housing screws. Disconnect the throttle cables, then remove the switch. Remuve the switch housing. FRONT WHEEL/SUSPENSION/STEERING WIRE HARNESS BANDS ‘ BRAKE MASTER CYLINDER > BRAKE SWITCH WIRES SWITCH HOUSING Date of Issue: July, 1984 © HONDA MOTOR C0,, LTD. 12-3 FRONT WH EEL/SUSPENSION/STEE RING Disconnect the clutch switdi wires. Remove the clutch master cylinder socket bolts and clutch master cylinder. Remove the left switch housing mount screws and left switch housing. Remove the handle cover and upper holder caps. HONDA V30 MAGNA CLUTCH MASTER CYLINDER CLUTCH SWITCH WIRES LEFT SWITCH HOUSING 12-4 Date of Issue: July, 1984 © HONDA MOTOR CO” LTD‘ HONDA V30 MAGNA Remove the handlebar upper holder bola and handlebar upper holders. Remove the handlebar. INSTALLATION Place the handlebar on to the lower holder aligning the punch mark with the outside face of the lower holder‘ Place the upper holders on the handlebar with the punch marks facing forward. Tighten the toward bolts first, then tighten the rear bolts. TORQUE: 25—35 N-m (2.5—3.5 kg‘m, 18—25 h-Ib) FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR UPPER HOLDERS HANDLEBAR UPPER HOLDERS Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. FRONT WH EEL/SUSPENSION/STEER ING Apply grease to the throttle grip sliding surface and slide the throttle grip over the handlebar. Connect the throttle cables to the throttle grip. Align the right handlebar switch locating pin with the hole in the handlebar and install the :ight handlebar switch. Install the top portion of the switch and tighten its screws. Tighten the forward screw first, then tighten the rear screw. Place the front brake master cylinder on the handle— bar and install the master cylinder holder with the "UP" mark facing up. Align the holder mating surface with the punch mark on the handlebar, and tighten the upper bolt first then tighten the lower bolt. TORQUE: 10—1! N-m (1.0—1.4 kg—m, 7—10 tt»|h) Connect the front brake switch wires. HONDA V30 MAGNA THROTTLE GFlIP BRAKE MASTER CYLINDER HOLDER RIGHT HANDLEBAR SWITCH ,6». THROTTLE CABLE VPUNCH MAFlK “UP" MARK 12-6 Date of Issue: July, 1984 © HONDA MOTOR (20., LTD. HONDA V30 MAGNA FRONT WHEEL/SUSPENSION/STEERING LEFT HANDLEBAR SWITCH PIN Connect the choke cable to the choke lever. Align the left handlebar twitch locating pin with the hole in the handlebar and install the left handle- bar switch. Tighten the upper screw tint. then tighten the lower screw. CHOKE CABLE HOLE "UP” MARK PUNCH MARK Place the clutch master cylinder on the handlebar and install the master cylinder holder with the "UP" mark facing up. Align the holder mating surface with the punch mark on the handlebar. and tighten the upper bolt. Connect the clutch switch wires. Connect the left and right handlebar switch wire connectors. FRONT WHEEL REMOVAL Raise the front wheel off the ground by placing a support under the engine. Disconnect the speedometer cable by removing the set screw. , _.. it” , 4 a /; SET SCREW SPEEDOMETER CABLE Date of Issue: July, 1984 - © HONDA MOTOR (20., LTD. 1 2 7 FRONT WH EEL/SUSPENSION/STEER ING Remove the axle pinch bolt. Loosen and remove the front axle and remove the front wheel. NOTE: Do not operate the front brake lever after removing the caliper, To do so will cause difficulty in fitting the brake disc between the brake pads. INSPECTION I WHEEL BEARING Check wheel bearing play [W placing the wheel in a truing stand and spinning the wheel by hand. Replace the bearings with new ones if they are noisy or have excessive playr e WHEEL FllM Check the rim runout by placing the wheel in a truing stand. Spln the wheel slowly and read the runout using a dial indicator. SERVICE LIMITS: RADIAL RUNOUT: 2.0 mm (0.08 in) AXIAL RUNOUT: 2.0 mm (0.08 in) NOTE: The wheel cannot be repaired and must be replaced with a new one if the service limits are exceeded. HONDA V30 MAGNA AXLE PINCH BOLT PLAY 12-8 Date of Issue: July, 1984 © HONDA MOTOR (30., LTDI HONDA V30 MAGNA FRONT WHEEL/SUSPENSION/STEER ING e AXLE 86‘ the axle in V blocks and measure the runout. The actual runout is 1/2 of the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 In) SPEEDOMETER GEAR BOX D | SASSEM B LY Remove the speedometer gear box. Remove The brake disc socket bolts and disc. BRAKE DISC Date of Issue: Ju|v, 1984 © HONDA MOTOR 60., LTD. HONDA V30 MAGNA FRONT WH EEL/SUSPENSIONISTEER ING DUST SEAL Remove the dust seal and speedometer gear relainer. ‘ /, A SPEEDOMETEH GEAR HEATINER SIDE COLLAR Remove the side collar and dust sesI. ’ ”" _ ‘“ DUST SEAL BEARING REMOVER SHAFT 07746—0050100 0H EQUIVALENT IN USA. If the bearings need replacement, remove the bear- ings and distance collar. NOTE: Never reinstall old bearings: once the bearings are removed, they must be replaced with new ones. ,m L REMOVER HAND, 15 mm 07746—0050400 OR EQUIVALENT IN USA. D fl :J | ,1984 1 2 ' 1 0 ©altle()‘;\IDs/§ulslo¥0yfi COT, LTD. HONDA V30 MAGNA FRONT WHEEL/SUSPENSION/STEERING ASSEMB LY Do not 3:! grease on the brake disc or stop- pmg power will be reduced. 35—40 N~m (3.5—4.0 kg-m, 25—29 ftJb) NOTE: When torquing the bolts, apply oil or grease to the thread. NOTE: DRIVER ' The cast wheel has on rim band. , , , , 0774943010000 o The from wheel uses a tubeless tire. For ' ' tubeless tire repair, refer to the Honda Tubeless Tire Manual. Drive in the right bearing first and press the distance collar into place. NOTE: Be certain the distance collar is in position before installing the right bearing. Drive in the left bearing squarelyl NOTE: Drive the bearing into position, making sure - mat it is fully seated and that the mark side , 'i ." I is facing out. ATTACHMENT, 42 x 47 mm 07746—0010300 PILOT, 15 mm 07746—0040300 D n :Ju , - ©an°oonoiu§orgn1cggf LTD. 1 2 1 1 HONDA V30 MAGNA FRONT WH EEL/SUSPENS|0N/STEER ING COLLAR Install the dust seal and side collar, — - ' A DUST SEAL DUST SEAL Install the speedometer gear retainer in the left side of the wheel hub, aligning its tang: with the slots in the hub. Install the dust seal, Apply oil or grease to the brake disc bolt threads. Install the brake disc and tighten the bolts to the specified torque value. TORQUE: 35—40 N-m (3.5-4.0 ka-m, 25-29fl41b) L ‘ BRAKE else 1 2 - 1 2 éaézfléfiflgk 13(8): LTD. HONDA V30 MAGNA Install the speedometer gear box in the wheel huh, aligning the tangs with the slots. WHEEL BALANCING CAUTION Wheel balance directly affects the stability, handling and overall safety of the motorcycle, Always check balance when the tire has been removed from the rim. NOTE: For Optimum balance, the tire balance mark (a paint dot on the sidewall) must be located next to the valve stem. Remount the tire it necessary. Mount the wheel with brake discs and tire in an inspection stand. Spin the wheel, allow it to stop, and mark the lowest (heaviest) part of the wheel with chalk. Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop consistently in the same position. FRONT WH EE L/SUSPENSION/STEERING SPEEDOMETER GEAR BOX BALANCE MARK Date of Issue: July, 1984 © HONDA MOTOR CO” LTD. 12-13 FRONT WH EEL/SUSPENSION/STE ER ING To balance the wheel, install wheel weights on the highest side of the rim, the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it Is spun. Do not add more than 60 grams. INSTALLATION Place the wheel between the fork legs. Fit the disc carefully between the brake pads. Align the speedometer gear box with the boss an the left fork leg as shown. Install the axle and collar. Remove the support block from under the engine. Tighten the axle to the specified torque. TORQUE: 55-65 N-m (5.5-6.5 kg-m. 40—47 be) \ With the front brake applied, pump the front fork several times to seat the front axle. Tighten the axle pinch bolt to the specified torque. TORQUE: 15—25 N-m (1.5—2.5 Ito-m, 11—18 ft—lb) Install the speedometer cable and set screw. HONDA V30 MAGNA BALANCE WEIGHT SPEEDOMETER GEAR BOX» f. 12-14 Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. HONDA V30 MAGNA FRONT WHEEL/SUSPENSION/STEERING FRONT FORKS REMOVAL Remove the front wheel (page 12-7). Remove the brake caliper and bracket. BRAKE CALIPER F RONT F ENDER Pull off the bolt caps. " Remove the front fender and fork braoet Remove the bottom bridge cover. BOTTOM BRIDGE covER' 3’fi°o°ti$‘2“fid¥3k‘§83 m 1 2 -1 5 FRONT WHEE L/SUSPENSION/STEER ING Loosen the fork upper and lower pinch bolts. Pull the fork tubes down and out while Misting to remove them. D ISASSE MB LY Hold the fork tube in e vise with soft jaws or a shop towel. CAUTION Do not damage the sliding surface. Depress the air valve and release from fork air pres- sure CAUTION - If air pressure is not released before dis- assembling, the fork cap may become a projectile, ~ The cap is also under spring presswe. Use care when removing and wear eye and face protection. Remove the fork tube cap, LOWER PINCH BOLTS HONDA V30 MAGNA FORK TUBE CAP 12-16 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD, HONDA V30 MAGNA FRONT WHEEL/SUSPENSION/STEERING Remove the fork spring, spacer and washer. Force out the fork fluid by pumping the fork up and down several times. . < A SPRG WASTIER' " HEX WRENCH, 6 mm 079174230000 OR EQUIVALENT IN U.S.A. Hold the fork slider in a vise with soft jaws or a shop towel. CAUTION Do not damage the fork slider, Remove the socket bolt with a hex wrench. NOTE: Temporarily install the spring and fork tube cap if difficulty is encountered in removing the bolt. SOCKET BOLT PLASTIC WAsuEn Remove the dust seal, sponge seal and plastic washer. SPONGE SEAL DUST SEAL (Saiu‘oiiési‘fiéi'cih'ggi LTD, 1 2 ' 1 7 FRONT WH EEL/SUSPENSION/STEER ING HONDA V30 MAGNA Remove the snap ring. Pull the fork tube out until resistance from the slider bushing is felr. Then move it in and nut, tapping the bushing lightly until the fork tube separate: from the slider. The slider bushing will be forced our by the fork tube bushing. 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. See inspection on page 12-20. Remove the oil lock piece, fork piston and rebound spring. SNAP RING PLIERS 07914-3230001 0H EQUIVALENT IN U.S.A. OIL Lock PIECE SNAP RIN'G’ ‘ BACK-UP RING OIL SEAL FORK PISTON SLID’ER é’Js‘HING 12-18 Date of Issue: July, 1984 © HONDA MOTOR CO” LTD HONDA V30 MAGNA INSPECTION o FORK SPRING FREE LENGTH Measure the fork spring free length. SERVICE LIMIT: 441.1 mm (17.37 in) Replace the spring if it is shorter than the service limit. 0 FORK TUBE/FORK SLIDER/PISTON Check the fork tube, fork slider and piston for score marks, scratches, or excessive or abnormal wear. Replaoe any components which are worn or damaged. check the fork piston ring for wear or damage. Check the rebound spring (or fatigue or damage. 56! the fork tube in V blocks and read the runout. Use 1/2 of the total indicator reading to determine the actual runout. SERVICE LIMIT: 0.2 mm (0.01 in) FRONT WHEEL/SUSPENSION/STEERING PISTON RING PISTON § R EBOUND SPRING FORK TUBE SLIDER Date of Issue: July, 1984 © HONDA MOTOR C0., LTD‘ 12-19 HONDA V30 MAGNA FRONT WHEEL/SUSPENSION/STEER ING o BUSH lNG/BACK-UP RING Visually inspect me slider and fork tube bushings. Replace «he bushing if there is excessive scoring or scratching, or if the reflon is worn so that the copper surface appears on more than 3/4 of the BUSHING entire surface. Check the back-up ring. Replace it if there is any BACK—UP RING distorlsion at the point: shown. COPPER SURFACES CHECK POINTS ASSEMBLY Before assembly. wash all part: with a high flash point or non-flammable solvent and wipe them off completely. DUST SEAL AM WASHER FORK CAP BOLT % M F0 \‘§ PLASTIC WASHER § SNAP RING COLLAR ken SEAL BACK-UP RING .\) SLIDER BUSHING SPRING FORK SLIDER PISTON RING PISTON REBOUND SPRING §.\ SOCKET BOLT FORK TUBE BUSHING OIL LOCK PIECE 1 2 - 2 O Q’hia‘fiésfi‘fiéi’gh 1:933 no. HONDA V30 MAGNA Install the piston and rebound spring into the fork tube. Install the oil lock piece unto the fork piston and Place the fork slider in a vise with soft jaws or a shop towelr 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, spacer and fork tube cap to tighten the socket bolt. TORQUE: 16—25 N~m (1.5—2.5 kg-m, 11—18 ft-lh) Place the slider bushing over “12 fork tube and rest it on the slider. Put the back-up ring and an old bushing or equivalent tool on top. Drive the bushing into place with the seal driver and remove the old bushing or equivalent tooL Coat a new oil seal with ATP and install it mm the seal markings facing up. Drive the seal in with the seal driver until the snap ring groove appears com pletely. oiilfick PIéEE‘ ' FRONT WHEEL/SUSPENSION/STEERING FORK TUBE BUSHING "WSTO—N HEX WRENCH, 6 mm 07917—3230000 OF! EQUIVALENT IN U.S.A. SOCKET BOLT FORK SEAL DRIVER 07947—3710101 Date of Issue: July, 1984 © HONDA MOTOR (10., LTD. 12-21 HONDA FRONT WHEEL/SUSPENSION/STEERING V30 MAGNA Install the snap ring with it: radiuxed edge facing dawn. DUST SEAL Install the plastic washer, foam washer and dust seal. FOAM WASHER CIRCLIP OIL SEAL BACK-UP RING GUIDE BUSH SNAP RING PLIERS 07914—3230001 OR EQUIVALENT IN U.S.A. Pour the specified amount of ATP into the fork tuba. CAPACITV: 400 00 Install the spring. spring seat and collar. NOTE: Nate the spring direction; the small diameter and faces down. FORK TUBE CAP J 1 2- 22 amylasxfigllxwégi LTD, Install and torque the fork tube cap. TORQUE: 15—30 N-m (1.5-3.0 ka-m, 11—22 ft—lb) Install the air valve cap. HONDA V30 MAGNA FRONT WHEE L/SUSPENSION/STEER ING INSTALLATION Install the fork tube and align the groove in the fork tube with the upper surface of the top bridge. Tighten the fork upper pinch bolt. TORQUE: 9—13 N-m (0.9—1.3 kg-In, 7—9 ft-lb) Tighten the fork lower pinch bolts. TORQUE: l5—55 N-m (4.5-5.5 kg—m, 32—40 ft-Ib) Loosely install the front fork brace. the front fork plnoh bolts. Install the removed parts in the reverse order of removal. — front fender. — brake calipers. — front wheel. Tighten the front fork brace to the specified torque. TORQUE: 18—28 N-m (1.3-2.8 kg-m, 13—20 ft-Ib) Install the bolt caps. Fill me fork tubes with air to 0—40 kPa (0-0.4 kg/cm’, 0—6 psil. CAUTION - Use only a hand operated air pump to fill the fork tubes. Do not use compressed air, - Maximum pressure is 300 kHz (3 kg/crn’. 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 motorcycle on its center stand. Check the air pressure and adjust if necessary. FORK BRACE Date of Issue: July, 1984 © HONDA MOTOR 00., LTD, 12-23 FRONT WHEEL/SUSPENSION/STEERING BEARING REPLACEMENT Remove the upper and lower ball races using the tools listed. U PPE R : Race Remover Attachment 07953—MJ1000A (USA only) Attachment, 37 x 40 mm 07746—0010200 Driver 07949—3710001 or 07949—3710000 NOTE: Use side "A" of the race remover attachment 07053—MJ 1000A. LOWE R : Race Remover 07946—3710500 Attachment, 37 x 40 mm 07746—0010200 D river 07949—3710001 or 07949—3710000 Drive the upper and lower ball races into the steer- ing head using the tools listed. UPPE R 1 Attachment, 42 x 47 mm 07746—001 0300 Driver 07749—0010000 LOWE R: Attachment, 52 x 55 mm 07746—0010400 or 0794673710701 Driver 07749—0010000 Remove the lower bearing. HONDA V30 MAGNA BALL RACE REMOVER ATTACHMENT ATTACHMENT LOWER BEARING 12-26 Date of Issue: July, 198 4 © HONDA MOTOR CO” LTD, HONDA V30 MAGNA Loosely install the stem nut onto the steering stem. Remove the lower cone race and dust seal. Install a new washer and dust seal and then drive a new lower cone race in. Install the dust seal and lower bearing on the steering stem. Install the grease holder. BALL BEARING FRONT WHEEL/SUSPENSION/STEERING LOWER CON E RACE STEERING STEM DRIVER O7946-M800000 0R 07946—3710601 and 07964—M300200 CONE RACE GREASE HOLDER DUST SEAL Date of Issue: July, 1984 © HONDA MOTOR 60., LTD. 12-27 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Apply grease to the cone races ball races and bearing balls. Install the steering stern into the steering head pipe. Install the top inner raoefballs and dust cover. Install and tighten the steering stern adjusting nut. TORQUE: 19-23 N-m (1.9—2.3 kg-m, 14-17 ft-lb) Turn the steering stem lock to lock five times to seat the bearing. Retorque the steering stem adjustlng nut. TORQUE: 19—23 N-m (1.9—2.3 kg-m, 14—17ft-lb) Install a new look washer. Bend two apatite tabs down into the groove: of the adjusting nut. NOTE: Do not stall a used lock washer. Hand tighten the lock nut. Hold the adjusting nut and further tighten the Iodt nut only enough to align its grooves with the lock washer tabs. NOTE: If the lock nut groove: dannot be easily aligned with the look washer tabs, remove the nut, turn it over and reinstall it. Bend two lock washer tabs up into the lock nut QYOOVBS. DUST COVER HONDA V30 MAGNA TOP CONE RACE STEERING STEM SOCKET 07916—3710100 LOCK NUT LOCK WASHER 12-28 Date of Issue: July, 1984 © HONDA MOTOR C0., LTD. HONDA V30 MAGNA Install the fork tubes (page 12-23). Plaoe the fork tubes up through the steering stem and temporarily tighten the lower fork pinch bolts. Install the fork bridge and tighten the steering stern nut. TORQUE: 80—120 N-m (ED—12.0 ka-m, 58—87 ft-Ib) STEERING HEAD BEARING PRELOAD Insmll the front wheel (page 12-14). Place the stand under the engine and raise the front wheel off the ground. Position the steering stem in the straight ahead position. Hook a spring scale to the fork tube and measure the steering head bearing preload. NOTE: Make sure that there is no cable or wire harness interference. The preload should be within l.1—1,6 kg-m, (2.42— 353 lb) for right and left turnsr If the readings do not (all within the limit, lower the front wheel on the ground and adjust the bearing adjustment nut. After establishing the bearing correct preload. install the removed parts in the reverse order of removal. FRONT WH EEL/SUSPENSION/STEERING EXTENSION BAR 07716—002050!) 0R EQUIVALENT IN USA. LOCK NUT WRENCH, 30 x 32 mrh' 07716—0020400 0R EQUIVALENT IN USA SPRING SCALE Date of Issue: July, 1934 © HONDA MOTOR (30., LTD, 12-29 HONDA. REAR WHEEL/BRAKE/SUSPENSION V30 MAGNA 30—1 10 Nm (SD—11.0 kg-m, 58—80 ft-lb) 13—17 N-m / (1.3—1.7 kgm, % 9—12ft-lb) 20—30 N-m [2.0—10 kg-m, 14—22 ft-Ib) BRAKE ARM 24—30 N-m (2.4—3.0 kgm, 17—22 ft-Ib) 70—90 N‘m , I (7.0-9.0 kg-m, 61—65 fi-Ib) v 30—1 10 N~m (ac—11.0 kg-m, 58—80 ft-lh) (5.0—7.0 kym, 43—61 ft-Ih) 18—25 N-m (LS—2.5 kg-m,13—18 ft—lb) 30—40 N-m (3.0—4.0 kgm, 22—29 ft-lb) Date of Issue: July, 1984 1 3' 0 © HONDA MOTOR (30., LTD, HONDA 1 3 REAR WHEEL/ V30 MAGNA . BRAKE / SUSPENSION SERVICE INFORMATION 13—1 TROUBLESHOOTING 13—2 REAR WHEEL 13—3 REAR BRAKE 13—10 SHOCK ABSORBER 13—13 SWING ARM 13—16 SERVICE INFIJRMATIIIII GENERAL 0 For tubeless tire repairs, refer to the Tubeless Tire Repair Manual, SPECIFICATIONS STANDARD SERVICE LIMIT Axle runout — 0.2 mm (001 in) Rear wheel rim runout Radial — 2.0 mm (0.08 in) Axial — 2.0 mm (008 in) Rear shock absorber spring free length 255 mm (10.04 in) 249.9 mm (9.84 in) Rear brake dmm LD. ISO—160.3 mm (630—631 in) 161 mm (6.34 in) Rear brake lining thickness {9—5.0 mm (0.19—0.2inl 2.0 mm (0.08 in) TORQUE VALUES Rear axle nut 70—90 N-m (7.0—9.0 kgm, 51—65 ft-Ib) Brake torque link 15—25 N~m (1.8—2.5 kqm, 13—18 ft-Ib) Slving arm pivot bolt right" 13—17 Nim (1.3—1‘7 kg-rn, 9—12 ft-Ib) left 80—1 10 N-m (8.0—11.0 kg-m, 58-80 ft-lbl Swing arm pivot bolt lock nut 30—1 10 N-m (ED—11.0 kg-m, 58—80 ft—lb) Shook absorber mount bolt upper 20—30 N-m (lo—3‘0 kg-ml 14—22 ft-Ib) lower 30—40 N-rn (3.0—4.0 kg—m, 22—29 rt-lb) Final driven sprocket 60—70 N-m (6.0—7.0 kg»m, 43—61 ft-Ib) Brake arm bolt 24—30 N-m (2.4—3.0 kgm, 17—22 ft-Ib) " Tighten to 25 N-m (2.5 kg-m, 18 ft-lb) first, then loosen to the specified torque shown above. TOOLS Special Bearing remover set, 30 mm 07936—8890100 or Bearing remover, 30 mm 07936—3890300 Remover handle 07936—371010!) Remover weight 07935—3710200 Shock absorber compressor base 07959—M310000 Date of Issue: July, 1984 1 3 _ 1 © HONDA MOTOR C0.. LTD. REAR WHEEL/BRAKE/SUSPENSION Common Attachment, 37 x 40 mm Attachment, 42 x 47 mm Pilot, 17 mm Pilot. 20 mm Driver Bearing remover shaft Bearing remover head, 17 mm Bearing remover head, 20 mm shock absorber compressor TROUBLESHOOTING Oscillation . Bent rim Loose wheel bearings . Faulty tire . Loose axle . Tire pressure incorrect . Swing arm bearings worn . Worn tires umuunwp.‘ Soft suspension 1. Weak spring Hard suspension 1. Bent shock absorber Suspension noise 1. Shock case binding 2. Loose fasteners 07746—001 0200 07745—001 0300 07746—0040400 0774643040500 07749—001 0000 07746—0050100 07746—0050500 07746—0050600 07959—3290001 } or equivalent in U.S.A, HONDA V30 MAGNA 13-2 Date of Issue: July, 1984 © HONDA MOTOR C0,, LTDr HONDA V30 MAGNA REAR WHEEL REMOVAL Place the motorcycle on its center stand. Loosen and remove the axle nut. Loosen the chain adjuster lock nuts and adjusting nuts. Remove the cotter pin, nut, washer, rubber seat and bolt. Remove the rear brake rod adjusting nut and dis- connect the brake rod. Remove the chain cover. Move the rear wheel forward and remove the drive chain from the driven sprocket. Remove the axle shaft and collar from the wheel. Remove the rear wheel. INSPECTlON o AXLE Set the axle in V blocks and read the axle runout with a dial indicator. SERVICE LIMIT: 0.2 mm (0.01 in) ADJUSTING NUT/ LOCK NUT v REAR WHEEL/BRAKE/SUSPENSION AXLE N Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HON DA REAR WHEEL/BRAKE/SUSPENSION v30 MAGNA O REAR WHEEL BEARING Check the wheel bearing play by rotating the wheel by hand. Replace the bearings with new ones if they are noisy or have excessive play. PLAY 0 REAR WHEEL RIM RUNOUT Check the rim for runout by placing the wheel in a truing stand. Spin the wheel slowly, and read the runout using a dial indicator. SERVICE LIMITS: RADIAL RUNOUT: 2.0 mm (0.08 In) AXIAL RUNOUT: 2.0 mm (0.08 in) NOTE The wheel cannot be serviced and must be replaced it the above limits are exceeded. 0 FINAL DRIVEN SPROCKET Check the condition of the final driven sprocket teeth. Replace the sprocket if worn or distorted. NOTE If the final driven sprocket requires replace- ment, inspect the drive chain and drive sprocket. GOOD /—\ REPLACE A 13-4 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA REAR WHEEL/BRAKEISUSPENSION O BRAKE DRUM l.D. Measure the rear brake drum LD. SERVICE LIMIT: 161 mm (6.34 in) DISASSEMBLY Remove the brake panel from the wheel. Remove the collar from the final driven flange‘ Remove the final driven sprocket and driven flange together. NOTE Do not separate the driven sprocket and flange, unless replacement of the driven sprocket or flange is necessary. Replace the damper rubbers if they are damaged or deteriorated. :‘x" 'l DRMPEFnueBERs ‘ " Date of Issue: July, 1984 © HONDA MOTOR CO, LTD‘ 13-5 R EAR WHEE L/BRAKE/SUSPENSION If the bearing needs replacement, drive out the bearings and the distance collar. N OTE If the bearings are removed, they should be replaced with new ones. Remove the dust seal and circlip. Remove the center collar. If the bearing needs replacement, drive out the wheel bearing using the bearing remover 20 mm (07746—0050600) and remover shaft (07746— 0050100l or equivalent tools. N01'E If the bearing is removed, it should be re- placed with new one. HONDA V30 MAGNA REMOVER SHAFT 07746—0050100 OH EQUIVALENT IN U_S.A. / 11““!!! BEARING REMOVE—R HEAD, 17 mi.“ mus—0050500 on EQUIVALENT in USA. cmcup DUST SEALV CENTER COLLAR 13-6 Date of Issue: July, 1934 © HONDA MOTOR 00., LTD. HONDA ASSEMBLY NOTE The rear wheel use: a tubeless tire‘ For tubelesx tire repairs, refer to the Tubeless Tire Manual. a FINAL DRIVEN FLANGE / fan 60—70 N-m (6.0—7‘0 kg—m, 43—51 ft-lb) FINAL DRIVEN SPROCKET DAMPER Contaminated brake linings reduce stopping RUBBER power. Keep grease off the brake linings. Wipe excess grease off the cam. DR IVER 07749—001000!) Drive the left side bearing into the wheel hub first with the sealed and facing out. lnnall the dismnco collar into place. Drive ‘he right side bearing in squarely with the sealed and facing nut. , . , l . ATTACHMENT, 42 x 47 mm ATTACHMENT, 37 x 40 mm 07746—00I 0300 077464010200 PILOT, 17 mm 077464040400 PILOT, 17 mm 07745—0040400 V30 MAGNA REAR WHEEL/BRAKE/SUSPENSION Date of Issue: July, 1984 1 3 - 7 © HONDA MOTOR COT, LTD‘ HONDA V30 MAGNA REAR WHEEL/BRAKE/SUSPENSION DRIVER 0774945010000 Install the driven sprocket on the driven flange. YOROUE: 60—70 N-m [6.0—7.0 kg-m, 43—51 ft—lb) Drive the wheel bearing in squarely with the sealed end facing out. Install the circlip and dust seal. ATTACHMENT, 37 x 40 mm,07746—0010200 PILOT, 20 mm 0774e—omosoo CENTER COLLAR Install the center collar. Install the damper rubbers. Apply grease to a new O-ring and install it on the wheel hub. Install the final driven flange. Install the collar. Check wheel balance and repair it is necessary (Page 12-13). DAMPER Rueeen O-RING 8 Date of Issue: July, 1934 1 3" © HONDA MOTOR 80., LTD. HONDA. V30 MAGNA REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Install the brake panel onto the rear wheel. I R EAR BRAKE PANEL CHAIN ADJUSTER W Install the chain adjusters in the swing arm ends. Place the rear wheel ammbly between the rear fork legs, set the right side spacer and insert the rear wheel. Loosely install the rear axle nutl Install the drive chain on the final driven sprocket. Adjust the drive chain (Page 3-13). RIGHTSIDE COLLAR Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD. REAR WHEEL/BRAKE/SUSPENSION Install the rear brake torque link to the brake panel. Install the rubber spacer, washer and nut. TORQUE: 18—25 N-m (1.8—2.5 kg-m, 13—18 ft-Ib) Install a new cotter pin, Connect the brake rod with brake arm spring and adjusting nut. Adjust the rear brake (Page 3-17). REAR BRAKE Remove the rear wheel and remove the brake panel from the rear wheel. LINING THICKNESS INSPECTION Measure the rear brake lining thickness. SERVICE LIMlT: 2.0 mm (0.08 In) HONDA V30 MAGNA SPRING 13-10 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY Remove the brake arm and wear indicator. Remove the cotter pins and retainer plate. Remove the brake shoes and return springst Remove the brake cam. ASSE M B LY Apply grease to the anchor pins and brake cam. Contaminated brake linings reduce stopping pawn Keep grease off the brake lining. Wipe any excess muse 017' the cam Install the brake cam. Install the brake shoes and return springst Install the retainer plate and set the cotter pins. RETURN SPRING BRAKE SHOE RETA NE? PLATE ANCHOR PIN A \ BRAKE CAM COTTER PIN fl BRAKE CAM RETURN SPRING BRAKE SHOE BRAKE CAM ifimfi' con RPIN " Date of Issue: July, 1934 © HONDA MOTOR 80., LTD. PLATE , 13-11 HONDA V30 MAGNA REAR WHEE L/BRAKE/SUSPENSION Add xhe drop of oil to the felt seal and install it on the brake panel. Install the wear indicator on the brake arm. Install the brake arm, aligning the punch mark: and tights" dun brake arm bolr. TORQUE: H0 N-m (14—340 kn-m, 11—22 Mb) \ BRAKE ARM ‘ 1 3-1 2 gahfifié‘ifiélgh‘cggf no. HONDA V30 MAGNA REAR WHEEL/BRAKE/SUSPENSION SHOCK ABSORBER REMOVAL Remove the shock absorber upper and lower nuts and bolts and remove the shock absorber. SHOCK ABSORBER COMPRESSOR 07959—3230001 D | SASSEM B LY Set the shock absorber in the shock absorber oomr pressor and compress the shock spring. SHOCK ABSORBER COMPRESSOR BASE 07959—MB10000 UPPER JOINT Place the upper joint in a visa and pull the shock rod out. A Loosen the lock nut and remove the upper joint Loosen the compressor and remove the shock absorber from the compressor. LOCK NUT g“h°o°é$‘§‘fié¥3h'§<‘3i no. 1 3-1 3 HONDA V30 MAGNA REAR WHEEL/BRAKE/SUSPENSION SPRING FREE LENGTH Measure the rear shock absorber spring free length. SERVICE LIMIT: 249.9 mm (9.84 In) <— ASSEMB LY Place the spring adjuster, spring lower seat. spring, spring upper seat and stopper rubber on the damper. UPPER JOINT DAMPER SPRING ADJUSTER SPRING UPPER SEAT LOCK NUT SPRING LOWE R SEAT 1 3-1 4 5“fi°o°J$‘§‘fifi¥3h‘§8§ no. HONDA V30 MAGNA REAR WHEEL/BRAKE/SUSPENSION CAUTION Be sure the base is adjusted correctly for the shock spring seat and the clevl: pin is all the way in. Apply a locking agent to the rod threads and install the lock nut. Attach the shock absorber compressor, screwing in the compressor's base adjuster nut. Apply a locking agent to the damper rod threads and screw the upper joint on. Hold the upper ioint in a vise and tighten the lock nut securely. NOTE: Check that the lock nut is seated against the rod's bottam thread. Align the spring seat with the upper ioint while releasing the compressor. INSTALLATION Install the shock absorber onto the frame. Tighten the upper and lower mounts. TDRCIUES: Upper: 20—30 N-m (2.0-3.0 kg—m, 14—22 ft~lhl Lowerz30—40 N-m (3.0—4.0 kg~m, 22—29 ft-lb) UPPER JOINT p r, t N. itlgl‘r‘lTlTlt m , [Wee'uuflu LOCK NUT SHOCK ABSORBER COMPRESSOR BASE ADJUSTER NUT 07959—3290001 SHOCK ABSORBER COMPRESSOR CLEVlS PlN EASE 07959—MBIDOOO Date 0f Issue: July, 1984 © HONDA MOTOR cu. LTD. HONDA V30 MAGNA REAR WHEEL/BRAKEISUSPENSION SWINE ARM Remava the followings: — chain guard — rear wheel —- rear shock absorber lower mount bolt Loosen the lock nut and remove me pivot bolt and lock nut. Remove the left pivot bolt and swing arm‘ LEFT PIVOT BOLT ” 1 3 ' 1 6 gafieofléiufid¥gh 1%: LTD, HONDA V30 MAGNA D | SASSE M B LY Remove the mo xcrews and the chain slider, Remove the cotter pin and pivot nut and bolt. Remove this brake torque link. INSPECTION Remove the dust seals, bearings and grease holder. Check she bearing: for wear or damagel check the swing arm for cracks or damage. BEARING 91066-MC7—004 DUST SEAL,22X40X5 91 268-KE8—003 REAR WHEE L/BRAKE/SUSPENSION CHAIN SLIDER PIVOT BOLT/NUT COTTER PIN DUST SEAL GREASE HOLDER BEARING Date of Issue: July, 1934 © HONDA MOTOR (30., LTD. 13-17 REAR WHEEL/BRAKE/SUSPENSION PIVOT BEARING REPLACEMENT Remove and discord the bearing auter race. Drive in a new bearing outer race squarely. Install the grease holder. Apply grease to the pivot bearings and install them into the swing arm. Apply grease to the dust seal lip: and install the dust seals into the swing arm pivot. HONDA V30 MAGNA BEARING REMOVER SET, 30 mm 07936—8890100 0R BEARING REMOVER, 30 mm 07936—8890300 REMOVE R HANDLE 07936—3710100 R EMOVE R WEIGHT 07936—3710200 m \REMOVER, 30 mm o7else—sagoaoo Wu" « DRIVE R 07749—0010000 ' .. ATTACHMENT, 37 x 40 mm 07746—0010200 GREASE HOLDER BEARING DUST SEAL 13-18 Date of Issue: July, 1984 © HONDA MOTOR 60., LTD. HONDA V30 MAGNA ASSEMBLY Assemble the removed parts in the reverse order of disassemblv. INSTALLATION Set the swing arm and screw in the left pivot bolt. Loosely install the right pivot bolt and lock nut. Tighten the left pivot bolt. TORQUE: 80—1 10 Min (8.0—1 1.0 WM, 58—80 ft—lb) Tighten the right pivot bolt. Tigflen (0 25 N~m (2.5 kg—m, 18 ft—lb) first, then loosen to the specified torque. TORQUE: 13—17 N-m (1.3-1.7 kg-m, 9—12 h-lb) Tighten the lock nut while holding the pivot bolt to prevent it from turning. TORQUE: 80—1 10 Min (SD—11,0 kg-m, 58—80 fl-lb) REAR WHEEL/BRAKEISUSPENSION CHAIN SLIDER Date of Issue: July, 1984 © HONDA MOTOR C0,, LTD‘ HONDA V30 MAGNA REAR WHEEL/BRAKE/SUSPENSION Install the rear shock absorbers and chain sdlusters. Install the rear wheel (Page 13-9). Install the chain guard. 1 3 _ 20 Date of Issue: July, 1984 © HONDA MOTOR C0., LTD. HONDA V30 MAGNA MEMO HONDA HYDRAULIC BRAKES V30 MAGNA 25—35 N~m (2.5—3.5 kwn, 18—25 ft-lb) 25—30 N-rn (2.5—3.0 kgvm, 18—22 ft-ib) \m :9 % i\\\ J / ‘ ‘ “ \ ~ , 20—25 N-m /% 30“") N‘m (mo—2‘5 kg-m, (3.0—4.0 kg-m, 22—29 ft-lb) 14—18 ftAth 1 4 0 Date af Issue: July, 1984 ' © HONDA MOTOR 60., LTD. 533.1533 14. HYDRAULIC BRAKES SERVICE INFORMATION 14—1 TROUBLESHOOTING 14—2 BRAKE FLUID REPLACEMENT/AIR BLEEDING 14—3 BRAKE PAD/DISC 14—5 FRONT MASTER CYLINDER 14—8 BRAKE CALIPERS 14—11 SERVICE INFORMATION GENERAL The brake caliper: can be removed without disconnecting the hydraulic system. Bleed the hydraulic system if it is disassembled or if the brake feels spongy. Do not allow foreign material to ennr the system when filling the reservoir. Avoid spilling brake fluid on painted surfaces or instrument lenses, as severe damage can result. Always check brake operation before riding the motorcycle. SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Frontdisc thickness 4.8—5.2 mm (01889—01047 in) 4.0 mm (0.16 in) Front disc warpage — 0.30 mm (0012 in) Front master cylinder I.D. 14000—14043 mm (05512-05629 in) 14.05 mm (0.5533 in) Front master piston O.D. 13357—13384 mm (05495—05506 in) 13.945 mm (0.5490 in) Front caliper piston 0.D. 31348—31398 mm (l.2578~1.2598 ini 31.940 mrn (1.2575 in) Front caliper cylinder I.D. 31030—31080 mm (12610—132630 in) 32.090 mm (1.2634 in) TORQUE VALUES Caliper bracket mount bolt 30—40 N~m (3.0—4‘0 kg-m, 22—29 ft-lb) Brake caliper mounting bolt 20—25 N~m (2.0—2.5 kg-m, 14—18 ft-Ib) Brake caliper pin bolt 25—30 N.m (2.5—3.0 kg-m, 13—22 ft-Ib) Brake hose oil bolt 25—35 N-m (2.5—3.5 kg-m, 13-25 ft-Ib) Date of Issue: July, 1984 1 4-1 © HONDA MOTOR 00., LTD. HYDRAUUCBRAKES HONDA V30 MAGNA TOOL Special Snap ring pliers TROUBLESHOOTING Brake lever/pedal so“ or spongy 1. Air bubbles in hydraulic system 2‘ Low fluid level 3. Hydraulic system leaking Brake lever/pedal too hard 1. Sticking pistons 2‘ Clogged hydraulic system 3. Pads glazed or worn excessively Brake drag 1. Hydraulic system sticking 2. Sticking pistons Brakes grab I. Pads contaminated 2. Disc or wheel misaligned Brake chatter or squeal 1. Pads contaminated 2. Excessive disc runout 3. Caliper installed incorrectly 4. Disc or wheel misaligned 079144230001 or equivalent in USA. 14-2 Date of Issue: July, 1984 © HONDA MOTOR 60,, LTDl HONDA V30 MAGNA HYDRAULIC BRAKES BRAKE FLUID REPLACEMENT/ AIR BLEDIIIG BRAKE FLUID DRAINING Remove the reservoir cap and diaphragm. CAUTION Avoid spilling fluid on painted surfaces. Place a rag over [he fuel tank whenever the system is serviced. Connect a bleed hose to the bleeder valve. Loosen the oeliper bleeder valve and pump the brake leverl Stop operating the lever when no fluid flows out of the bleeder valve. CAUTION A contaminated brake disc or pad reduces stopping power. Defend contaminated pads and clean a contaminated disc with a high quality bmke cleaning agent. BRAKE FLUID FILLING NOTE: Do not mix different types of fluid. They are not compatible. lf a brake bleeder is not available, perform the following procedure. Close the hleeder valve. fill the reservoir. and install the dlaphragrn. Pump up the system pressure with the lever until there are no air bubble: in the fluid flowing out of the reservoir small hole and lever resistance is felt. Bleed the system as described on the next page. Date of Issue: July, 1934 © HONDA MOTOR C0., LTDi HYDRAULIC BRAKES NOTE: . check the fluid level often while bleeding the system to prevent air from being pump- ed into the system. - Use only DOT-3 or 4 brake fluld from a sealed oonteiner. . Do not mix brake fluid types and never reuse the contaminated fluid which has been pumped out during brake bleeding, because that would impair the efficiency of the brake system. - When using a brake bleeding tool, follow the manufacturer's operating instructions. BRAKE FLUID FILLING WITH BRAKE BLEEDEFl Fill the reservoir to near full with recommended brake fluid. Connect the Mvtvvao Brake Bleeder or equivalent to the bleed valve. Pump the brake bleeder and loosen the bleeder valve. Add fluid when the level in the master cylinder reservoir is low, NOTE: If air entering the bleeder hose from around the bleeder valve thread, seal the threads with teflon tape. Check the brake lever operation. It the brake feels sponev, bleed the air from the system. AIR BLEEDING 1. Squeeze the brake lever, then open the bleed valve 1/2 turn and close the velvet NOTE: Do not release the brake lever until the bleed valve has been closed. 2. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. Repeat Step: 1 and 2 until bubbles cease to appear in the fluid at the end of the hose. UPPER LVEL MAFIK HONDA V30 MAGNA 14-4 Date of Issue: July, 1984 © HONDA MOTOR (20., LTD, HONDA V30 MAGNA HYDRAULIC BRAKES BRAKE PAD/DISC FRONT PAD REPLACEMENT NOTE: Always replace the brake pads in pairs to assure even disc pressure. Remove the caliper mount bolt. Lift the caliper by pivoting it with the caliper pin bolt then remove the caliper. Remove the retain" bolt and retainer. Remove the pad pins from the caliper, Remove the pods from the caliper. PAD PINS Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD. HYDRAULIC BRAKES HONDA V30 MAGNA Push the caliper pistons In all the way. Position the pad spring in ma callper as shown. Install the new pads in m caliper. Install th- pad pins. 14-6 Date of Issue: July, 1984 © HONDA MOTOR C0,, LTDl HONDA V30 MAGNA Install the retainer. Tighten the retainer bolt. Make sure the pad spring on the caliper bracket is in place. Install the caliper to the bracket so the disc is posi- tioned between the pads, being careful not to damage the pads. Tighten the caliper mounting bolts. TORQUE: 20—25 N-m (2.0—2.5 kg-m, 14—18 h-lb) BRAKE DISC 0 DISC THICKNESS Measure the thlekness of each disc. SERVICE LIMIT: 4.0 mm (0.16 in) HYDRAULIC BRAKES Date of Issue: July, 1984 © HONDA MOTOR 00,, LTD, HONDA V30 MAGNA HYDRAULIC BRAKES o BRAKE DISC WARPAGE Measure the brake disc for warpage. SERVICE LIMIT: 0.30 mm (0.012 in) BRAKE HOSE MASTER CYLINDER FRONT MASTER CYLINDER REMOVAL Disconnect the iront brake switch wires. Remove the rear view mirror. Drain the fluid from the brake system (page 144). Disconnect the brake hose. Remove the front brake master cylinder holder and master cylinder. CAUTION Avoid spilling brake fluid on painted surface; Place a rag over the fuel tank whenver the brake system L7 being serviced. BRAKE SWITCH WIRES HEAR VIEW MIRROR 4K“ BRAKE SWITCH BRAKE LEVER NOTE: When removing the fluid hose bolt, cover the end of the hose to prevent contamination. Sewre the hose in an uplight position to prevent fluid from leaking out. D l SASSE M B LY Remove the brake lever from the master cylinder. Remove the brake switch from the master cylinder. Remove the boot. Date of Issue: July, 1984 8 © HONDA MOTOR CO, LTD. 14 HONDA V30 MAGNA HYDRAULIC BRAKES CIRCLIP PISTON Remove the circlip lrom the master cylinder body. I 1 , SNAP RING PLIERS 07914—3230001 OR EQUIVALENT IN U.S.A, MASTER CYLINDER BODY PISTON Remove the piston and spring from the master cylinder body. Clean the inside of the master cylinder and reservoir with clean brake fluid, ® SPRING CIRCLIP INSPECTION Measure the master cylinder I.Dt check the master cylinder for scores, scratches or nicks. SERVICE LIMIT: 14.055 mm (0553 in) Date of Issue: July. 1984 © HONDA MOTOR CO., LTD. 1 4 ' 9 HYDRAULIC BRAKES Measure the master piston 0.D. SERVICE LIMIT: 13.945 mm ( 0.5490 in) Check the primary and secondary cup: for damage before assembly. ASSEMBLY CAUTION Replace the mater cylinder piston, cylinder and wring a: a set; don't replace individual parts. HONDA V30 MAGNA Assemble the master cylinder. Coat all parts with claan brake fluid before assembly. Install the spring and primary cup together. CAUTION When installing the cups, do not allow the tip: to turn inside out and be certain the circllp ls firmly seated in the groove. Install the plston and circlip. Install the boot. Install the brake lever. Install the brake light switch. BRAKE FLUID ‘ DOT-3 or 4 ‘ PISTON Q BRAKE SWITCH BRAKE LEVER 14-10 Date of Issue: July, I984 © HONDA MOTOFI COI, LTD, HONDA V30 MAGNA INSTALLATION Place the matter cvllnder on the handlebar. Install the holder with "UP" mark facing upward. Install the two mounting bolts. Align the end of the holder with the punch mark on the handlebar. Tighten the top bolt first than tighten the lower bolt. Connect the fluid hose with the brake hose oil bolt and two sealing washers. TORQUE: 25—35 N>m (2.5—3.5 Ito-m, 13—25 ft-Ib) Install the mirrort Connect the brake light switch wires. Fill the reservoir to the upper level and bleed the brake system according to page 1L3. BRAKE CALIPERS FRONT BRAKE CALIPER REMOVAL Place a clean container under the caliper and dis- connect the brake hose from the caliper. c Aunou Avoid .rpflllng bmke fluid on painted surfaces Remove the caliper bracket mounting bolts. DISASSEMBLY Remove the fallowing: — brake pads (page 14-5). — pad spring. — caliper pivot collar and boots. HYDRAULIC BRAKES MASTER CYLINDER PUNCH MARK UP MARK BRAKE HOSE PIVOT DOLLAR Date of Issue: July, 1984 © HONDA MOTOR 60., LTD. 14-11 HONDA V30 MAGNA HYDRAULIC BRAKES Remove the pistons from the caliper. If necessary, apply compressed air to the caliper _. ,\ fluid inlet to get the piston out. Place a shop rag under the caliper to cushion the piston when it is forced out. Use the alr in short spurts. W1 WARNiNG Do not brln the nozzle roo close to the inlet. Examine the pistons and cylinder: for scoring, scratches or other damage and replace it necessary. Push the piston seals in and lift them out, then discard them. clean the piston seal grooves with clean brake fluid, CAUTION Be Mefill not to damage the piston sliding surfaces. INSPECTION o PISTON Check the pistons for scoring. scratches or other damage. Measure the piston diameter with a micro— meter. SERVICE LIMIT: 31.940 mm (1.2575 in) :J | , 1984 1 4- 1 2 gfiié‘fioign co., no. HONDA V30 MAGNA HYDRAULIC BRAKES o CYLINDER Check the caliper cylinder for scoring, scratches or other damage. Measure the caliper cylinder bore. SERVICE LIMIT: 32.090 mm (1.2634 in) , \\,,/ CALIPER BODY BOOT COLLAR BOOT the boots are seated in the collar and caliper grooves properly. Install the pad spring. Install the pads (page 146). ASSE M B LY The piston teal: must be replaced with new ones \ whenever they are removed. Coat the seals with _ silioone grease or brake fluid before assembly. v Install the pistons with the dished ends toward the pods. Then install the piston bootst Install the collar boots and collar making sure that O \ 691‘ P ‘ V: ‘C Y" OILSEALS PISTONS PADS RING CALIPEH PIVOT BOOT FRONT BRAKE CALIPER INSTALLATION Make sure that the retainer clip is in position on the caliper bracket Inspect the condition of the caliper pivot boot. Apply silicone grease to the caliper pivot boot, RETAINER CLIP 5‘L°o°r$$‘2”fié¥l¥k'§8§ LTD. 1 4 - 1 3 HONDA HYDRAULIC BRAKES V30 MAGNA Install the caliper assembly over the brake disc so that the disc is positioned between the pads. CAUTION Be ewe/id not to damage the pads, lnstall the caliper bracket mounting bolts and tighten them securely. Connect the brake hose tn the caliper with the bolt and two sealing washers. YOROUE: 25-35 N-m (2.5—3.5 kg-m, 18—25 fflb) Fill the brake fluid reservoir and bleed the brake system (Page 143). 1 4-1 4 (Saiieo'fil'afidi‘gh'ggf no, HONDA V30 MAGNA M EMO HONDA BATTERY/CHARGING SYSTEM V30 MAGNA BATTERY 1’ ALTERNATOR REGU LATOR/RECTIFIEFI BATTERY/CHARGING SYSTEM DIAGRAM FUSE so A RED/WHITE RED L > L 5 --——g IGNITION ; _3 SWITCH LE fl BLACK/RED F m > F VOLTAGE FUSE 15A SENSOR ALTERNATOR BLACK _: GREEN _ REGULATOR/RECTIFIER 1 5 0 Date of Issue: July, 1984 © HONDA MOTOR (20., LTDI 5:31:33 15. BATTERY/ CHARGING SYSTEM SERVICE INFORMATION 15—1 TROUBLESHOOTING 15—2 BATTERY 15—3 CHARGING SYSTEM 154 SERVICE INFORMATIUN GENERAL 0 Battery fluid level should be checked regularly. Fill with distilled water when necessary. 0 Quick charge a battery only in an emergency; slow-charging is preferrred. 0 Remove the battery from the motorcycle for charging. If the battery must be charged on the motorcycle, disconnect the battery cables. Do not smoke or allow flame: near a charging battery. The gas produced by a battery will explode If flamzs or sparks are brought near. o All charging system components can be tested on the motorcycle. 0 Alternator removal is in Section 8. SPEClFICATIONS Battery Capacity 12V lZAH Specific gravity 1‘280/20°C (68° Fl Charging rate 1.2 ampere: maximum Altemetor capacity 2,000 rpm 5,000 rpm 15,8A min. (No load) 18.5A min. (No load) Voltage regulator Transistorized nonvadiustable regulator g'h°§rl$’2“fié¥3h'§3‘ no 1 5-1 BATTERY/CHARGI NG SYSTEM HONDA V30 MAGNA TROUBLESHOOTING No. power — key turned on 1. Dead battery — Low fluid level — Low specified gravity — Charging system failure 2. Disconnected battery cable 3. Main fuse burned out 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 Intermittent power 1. Loose battery connection 2. Loose charging system connection 3. Loose starting system connection 4. Loose connection or short circuit in ignition system 5. Loose connection or short circuit in lighting system Charging system failure 1. Loose, broken or shorted wire or connection 2. Faulty voltage regulator/rectifier 3. Faulty alternator 15-2 Date of Issue: July, 1984 © HONDA MOTOFl ‘20., LTD. ; !i(JINII)IL V30 MAGNA BATTERY R E MOVA L Remove the seat and right side cover. Remove the battery holder boltt Disconnect the negative cable at the batteryl then disconnect the positive cable. Disconnect the battery breather hose from the battery. Remove the batteryi TESTING SPECIFIC GRAVITY Test each cell with a hydrometer. SPECIFIC GRAvnv: 1170—1190 (20°C, 68° F) BATTERY/CHARG ING SYSTEM 1170—1190 Fully charged Below 1.260 Undercharged NOTE: ' The battery must be recharged if the specific gravity is below 1.230. . The specific gravity varies with the tempe- rature as shown in the accompanying tablet Replace the battery it sulfation is evident or if the space below the cell plates is filled with sediment, HYDHOMETER R ELECTROLYTE \ The battery contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: Flush with water and get prompt medical attention. ‘3' ”M BATTERY TEMPERATURE vs SPECIFIC GRAVITY no me 1.23 L2, nu ma L255 SPECIFIC GRAVITY I_ c' 4r 5' w 15' 20' 25' so 35' 40' F 32' II' so 55' ee‘ 77' er 95' l04' ELECTROLYTE TEMPERATURE Date of Issue: July, 1984 © HONDA MOTOR (20., LTD‘ 15-3 HONDA V30 MAGNA BATTERY/CHARGI NG SYSTEM CHARGING Remove the battery oell caps. Fill the battery cells with distilled water to the upper level llne, if necessary. Connect the charger positive H) cable to the battery positive (4») terminall Connect the charger negative (—l cable to the battery negative (-) terminal. charging current: 1.2 amperes max. Charge the battery until specific gravity is 1.270— 1290 at 20°C (68° F). ' Before charging a battery, remove the cap from each cell. ~ Keep flames and sparks away from a charg- ing battery. ' Turn power ON/OFF at the charger, not at the battery terminals to prevent sparks ' Discontinue Margin; if the electrolyte temperature exceeds 45°Clll3°F). CAUTION - Quickchargr‘ng should only be done in an emergency; slowehargtng is preferred. ‘ Route the breather tube as shown on the battery caution label on the frame. After installing the battery, coat the terminals with clean grease. CllARlilllE SYSTEM CURRENT TEST NOTE: Be sure the battery is in good condition be lore performing this test. Warm up the engine. Remove the rigat side cover and seat. Remove the main fuse and connect the ammeter positive wire to the fuse holder negative terminal and ammeter negative wire to the fuse holder posi- tive terminal. Connect the voltmeter across the battery terminals. Start the engine, gradually increase engine speed and read the ammeter and voltmeter. The ampere and voltage should be controlled to 0A and 14—15V. If the readings do not meet the specifications, check the wires for loose connection and repair it neces- sary. If the wires are in good condition, replace the regulator/rectifier with a new one and retest. It the readings still do not meet the specifications, perform the alternator output test (9896 15-5), MAIN FUSE TERMINALS BATTERY 1 1 5 4 Date or Issue: July, 1984 - © HONDA MOTOR co., LTD. HON DA V30 MAGNA BATTERY/CHARGI NG SYSTEM ALTE RNATOR OUTPUT TEST Disconnect the regulator/rectifier coupler. Disconnect the black wire from the coupler and re- connect the coupler. Connect the ammeter and voltmeter as the same as the current test. Start the engine and gradually increase the engine speed. NOTE: Test while the fan motor is stopped. Engine speed 1,500 rpm 5,000 rpm Output LOA min. 5.0A max. STATOR CONTINUITY TEST Remove the seat. Disconnect the alternator and regulator/rectifier coupler. Check for continuity between the leads, and be- tween the leads and ground. Replade the stator if there is no continuity between the leads, or if there is continuity between the leads and ground. VOLTAGE REGULATOR/RECTI FIER TEST Remove the seat. Disconnect the regulator/rectifier couplers. Check‘ for continuity between the leads with an ohmmeter. MAIN FUSE TERMINALS BATTERY L ALTE FINATOR COUPLER Date of Issue: July, 1984 © HONDA MOTOR 00., LTDt 15-5 HONDA V30 MAGNA BATTERY/CHARGING SYSTEM NOTE: RED/WHITE The test results shown are for a positive ground ohmmeter and the opposite results 2 will be Obtained when a negative ground 9 ohmmeter is used. 5 E I: r. NORMAL DIRECTION: CONTINUITY 8 g 5 E .J W (3 probe (9 probe 3 d E I YELLOW GREEN g >' E II RED/WHITE YELLOW g I n‘ z REVERSE DIRECTION: NO CONTINUITY <5 @probe (—j probe GREEN I GREEN YELLOW || YELLOW RED/WHITE VOLTAGE REGULATOR PERFORMANCE TEST BLACK Connect a voltmeter across the battery. check regulator performance with the engine running. The regulator must divert current to ground when battery voltage reaches 14.0—16.0V. Date of Issue: July, 1984 1 5 ' 6 © HONDA MOTOR C0,, LTDt HONDA V30 MAGNA Paw _ MEMO HONDA V30 MAGNA IGNITION SYSTEM ENGINE STOP SWITCH PULSE GENERATOR SPARK UNITS IGNITION SYSTEM DIAGRAM ENGINE STOP IGNITION IGNITION COILS + SWITCH swrrcu 1_3 RUN ON I OFF OFF 2—4 BATTE RY -I|——||I|I|I|I|I SPARK PLUGS SPARIzUNITS PULSE GENERAROH 1 6 0 Date Of Issue: July, 1984 - © HONDA MOTOR COI, LTDV 33mm 16. IGNITION SYSTEM SERVICE INFORMATION 16-1 TROUBLESHOOTING 16—2 IGNITION COIL 16—3 TRANSISTORIZED IGNITION SYSTEM 16—4 IGNITION TIMING 16—5 SERVICE INFUIIMATIIJII GENERAL 0 A Transistorized Ignition System is used and n0 adjustments can be made. SPECIFICATIONS ND NGK Spark plug Standard X24EPR-U9 DPREEA-Q For cold climate Below 5°C (41°F) XZZEPH-UQ DPR7EA-9 For extended high speed driving X27EPR—U9 DPRQEA-Q Spark plug gap 03—09 mm (0.03—0.04 in) Ignition liming F mark 15°BTDC/1,700 rpm Full advance 37°BTDC/3,ooo rpm Pulse generator air gap Ola—0.9 mm (01112—01335 in) Date of Issue: July, 1984 _ © HONDA MOTOR C0., LTD‘ 1 6 1 IGNITION SYSTEM HONDA V30 MAGNA TROUBLESHOOTING The ignition system is two subsystems; one for the Not 1 and No. 3 cylinders and one for the No. 2 and No. 4 cylinders. Determinewhioh sub-system ls faulty, then proceed to the guide below. Engine-cranks but wIII not start 1. Engine stop switch OFF 2. No spark at plug a. Faulty transistorized spark unit 4. Faulty pulse generator No spark at plug 1. Engine stop switch OFF 2. 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 3. Faulty ignition coil 4. Faulty ignition switch 5. Faulty spark unit 6. Faulty pulse generator Engine stem but runs pooriy 1. Ignition primary circuit - Faulty ignition coil - Loose or bare wire - Intermittent short circuit 2. Secondary circuit ~ Faulty plug - Faulty high tension wire Timing advance incorrect 1. Faulty pulse generator 2. Faulty spark unit 16-2 Date of Issue: July, 1934 © HONDA MOTOFI (30., LTD. NEW IGNITION Cflll. REMOVAL 0 Front Remove the seat, fuel tank and front frame cover. Disconnect the spark plug caps and ignition coil wirest Remove the mounting bolts and ignition coil. 0 Hear Remove the seat and fuel tank. Disconnect the spark plug caps and ignition coil wires. Remove the mounting bolts, ignition coil and spark plug wires, CONTINUITY TEST Measure the primary coil resistance. RESISTANCE: 2.89 Check the continuity between the primary terminal and bracket, There should be no continuity. NOTE: ‘ Measure the resistance while the coil is cold, Measure the secondarv coil resistance. RESISTANCE: 12.6—15.4 kfl NOTE: Measure the resistance while the coil is cold, IGNITION SYSTEM IGNITION COIL Revised: February, 1935 ‘9 American Honda Motor 00., Incv 1986 7A" Rights Reserved MSV SE“ (8602) - '34-85 VF5DOC 16-3 HONDA V30 MAGNA IGNITION SYSTEM TRANSISTDRIZEIJ IGNITION SYSTEM PULSE GENERATOR TEST Disconnect the pulse generator coupler and measure the coil resistance. RESISTANCE: 315—385 0 2, 4 cylinders: Between white and blue leads 1, 3 cylinders: Between white and yellow leads NOTE: Measure while the engine is cold. Check the continuity between each lead and ground. There should he no continuity. PULSE GENERATOR REPLACEMENT Remove the right crankcase cover. (page 7-12). Remove the pulse generator mounting bolts and remove the pulse generators. Install new pulse generators, allgning the pin on the pulse generator with the hole in the crankcase. Install the right crankcase cover. check the ignition timing. CAUTION Be careful rm! to damage the pick-up on the starter clutch outer. 1 6 - 4 Date of Issue: July, 1984 © HONDA MOTOR 60., LTD. HONDA V30 MAGNA IGNITION SYSTEM SPARK UNIT REPLACEMENT If the pulse generators, ignition ooils and wiring are good, and the ignltion tlming Is not wlthin specifica- tion, replace the spark units with new ones and recheck the ignition timing. Remove the battery and battery box, then replace the spark unit. SPARK NITS INSPECTION HOLE CAP a IGNITION TIMING NOTE: ' The ignition system is transistorized and cannot be adiusted. It the ignition timing is incorrect, check the ignition coils, pulse generator: and wiring. Replace parts that are required. ~ 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. Warm up the engine. Connect the timing lid" to the high tension wire of the No.2 or 4 cylinder. Hemcve the inspection hole cap from the right crankcase cover. Start the engine and check that the "F" mark (adjacent “TF” mark) aligns with the index mark on the right crankcase cover at 1,700 rpm. Connect the timing ligit to the high tension wire of the No. 1 cr 3cylinder. Start the engine and check that the “F" mark (adjacent to "TR" mark) aligns with the index mark on the right crankcase ccver at 1,700 rpm TIMING LIGHT Date of Issue: July, 1984 © HONDA MOTOR CO, LTD HONDA v30 MAGNA MEMO WW“: I7. ELECTRIC STARTER SERVICE INFORMATION 17—1 TROUBLESHOOTING 17—1 STARTER MOTOR 17—2 STARTER RELAY SWITCH 17—5 CLUTCH DIODE 17—5 SERVICE INFORMATION GENERAL 0 The starter motor can be removed with the engine in the frame. SPECIFICATIONS STANDARD SERVICE LIMIT Starter motor Brush spring tension 630—920 g (24.0—325 oz) 545 g (19.2 oz) Brush length 12.0—13.0 mm (0.47—0.51 in) 6.5 mm (016 in) M ELECTRIC STARTER DIAGRA STARTER STARTER MOTOR RELAY SWITCH GREEN/RED STARTER RELAY COIL g IGNITION ' SWITCH 9 Q NEUTRAL INDIATOR NEUTRAL SWITCH GREEN GREEN 1 BATTERY ’ ' Starter motor will not turn Starter motor turns, but engine does not turn 1. Battery discharged 1. Faulty starter clutch 2. Faulty ignition switch 2. Faulty starter motor gears 3. Faulty starter switch 4. Faulty neutral switch . 5. Faulty starter relay switch fflézlmfitf‘rizm main: turns, but IMIM do” not scan 6. Loose or disconnected wire or cable ' 'ty 9 °" 5“" ° 7. Clutch diode open 2. Engine problems . 8. Faulty clutch switch _ Low °°mpr°55'°" — Fouled spark plugs Starter mater turns engine slowly 3‘ Faulty °,a'h”"e'°“ H r . 4. No fuel In tank 1. Low specmc grevrty in battery 2. Excessive resistance in circuit 3. Binding in starter motor. Date of Issue: July, 1984 _ © HONDA MOTOR CO., LTD. 1 7 1 HONDA V30 MAGNA ELECTRIC STARTER STARTER MOTOR REMOVAL With the ignition switch OFF, remove the negative cable at the battery before servicing the starter moron Remove the oil filter (page 2-3L Disconnect the starter motor cable from the starter motor by removing the nut. Remove the starter motor mounting bolts and the starter motor. STARTER MOTOR OIL FILTER BRUSH HOLDER BRUSH SPRING I ,‘ ¥ \\ I I, 0»RING 0000090 of HEAFICOVER SHIMS Q3 0" CABLE TERMINAL AND BRUSHES y F RONT COVER 1 7 2 Dale of Issue: July, 1934 - © HONDA MOTOR co., LTD. HONDA V30 MAGNA INSPECTION O BRUSH 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 sprlnq tension: 546 g (19.2 oz) 0 COMMUTATOR Remove the starter motor case. NOTE: Record the location and number of shims. Inspect the commutator bars for discoloration Bars discolored in pairs indicate grounded armature ooils. NOTE: Do not use emery or sand paper on the com- mutator, check for continuity between pairs of commutator bars. There should be continuityr Also, make a continuity check between individual commutator bars and the armature shaft. There should be no continuity. Date of Issue: July, 1984 © HONDA MOTOR (30., LTD. COMM UTATO R ELECTRIC STARTER BRUSH SPRING CONTINUITY BETWEEN COMMUTATOR BAR PAIRS: NORMAL NO cominuITv BETWEEN COMMUTATOR BARS AND ARMATURE SHAFT: NORMAL 17-3 HONDA V30 MAGNA ELECTRIC STARTER NO CONTINUITY BETWEEN ' CASE/BRUSH TERMINAL CABLE TERMINAL AND MOTOR CASE: NORMAL Check for continuity from the cable terminal to the motor case. There should be no continuity. Then check for continuity from the cable terminal to the brush. There should be continuity. Replace the starter motor if the terminal is shorted to the motor case. CONTINUITY BETWEEN W CABLE TERMINAL AND BRUSH WIRE (INSULATED): NORMAL BRUSH HOLDER NOTCH CASE ASSEMBLY Assemble the starter motor in the reverse order of disassemblv by noting followings: Align the case notch with the brush holder pint SLOT Install the rear cover aligning its slot with the brush holder pin. INSTALLATION Install the starter motor in the reverse order of removllr 1 7 - 4 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD HONDA V30 MAGNA ELECTRIC STARTER I~ STARTER RELAY SWITCH STARTER RELAY swncu INSPECTION Depress the starter switch button with the ignition ON. The coil is normal it the starter relay switch clicks. Connect an ohmmeter to the starter relay switch terminals. Connect I 12 V battery to the switch cable termi- nals. The switch is normal if there is continuity. CLUTCH DIODE REMOVAL Remove the fuel tank. Remove the clutch diode from the wire harness. INSPECTION Check for continuity with en ohmmeter. There should be continuity in the normal direction and no continuity in the reverse direction. Date of Issue: July, 1984 © HONDA MOTOR 60., LTD, 1 7 - 5 HONDA V30 MAGNA MEMO HONDA 1 8 LIGHTS/ SWITCHES V30 MAGNA . INSTRUMENT SERVICE INFORMATION 18—1 OIL PRESSURE SWITCH 18—11 HEADLIGHT 18—2 TEMPERATURE GAUGE 18—12 INSTRUMENT 18—4 TEMPERATURE SENSOR 18—12 FUSE HOLDER 18—5 THERMOSTATIC SWITCH 18—13 IGNITION SWITCH 18—7 TACHOMETER 18—13 HANDLEBAR SWITCH 18—9 FUEL PUMP RELAY 18-14 NEUTRAL/OD SWITCH 18—10 FUEL RESERVE SENSOR 18—14 BRAKE LIGHT SWITCHES 18—10 BRAKE/TAILLIGHT SENSOR 18—15 CLUTCH SWITCH 18—11 WARNING LIGHT CHECK RELAY 18—15 SERVIBE INFORMATION GENERAL 0 Some wires have different colored bands around them near the connector. These are connected to other wires which cor- respond with the band color. 0 All pastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. 0 The following color codes used are indicated throughout this section and on the wiring diagram, Bu = Blue 6 - Green LG = Ligtt Green R - Red BI = Black Gr - Grey 0 = Orange W = White Br = Brown LB - Light Blue P = Pink Y . Vellow e To isolate an electrical failure, check the continuity of the electrical path through the part A continuity check can usually be made without removing the part from the motorcycle simply disconnect the wires and connect a continuity tester or volt-ohmmeter to the terminal: or connections. 0 A continuity tester is useful to find out whether or not there is an electrical connection between the two points, An ohm- meter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance involved, or when checking for high resistance caused by corroded connections SPECIFICATIONS LIGHT Headlight (High/Low) lZV—GD/SSW Tail/stop light 12V—3/SZCP (8/27Wl SAE NO. 1157 Turn signal Front (Left/Right) 12V—32/32CP (23/23W) SAE N0. 1034 Rear (Left/Right) 12V—32/326P (23/23W) SAE NO. 1073 Speedometer light 12V—3.4W Tachometer light 12V—3Wx2 Temperature meter light 12V—3W Turn signal indicator (Left/ Right) 12V—3Wx2 Neutral indicator 12V-3W Overdrive indicator 12V—3W High beam indicator 12V—3W Oil pressure warning light 12V-3W Tail and stoplight warning light 12V—3W Fuel reserve warning 12V—3W FUSES Main fuse 30A Fuse 10Ax6,15Ax1 Date of Issue: Jul ,1984 © HONDA MOTCIIH C0., LTD‘ 1 8 ' 1 LIG HTS/SWITCH ES/INSTRUMENT HEAIJLIGHT REMOVAL Remave the headlight attaching screw. Pull out the headlight, Disconnect the headlight coupler and remove the headlight. HEADLIGHT BULB REPLACEMENT Remove the seal rubber. Remove the bulb set spring and replace the bulb. H EADLIGHT ASSEMB LY SET SPRING HONDA V30 MAGNA COUPLER 18-2 Date of Issue: July, 1934 © HONDA MOTOR (30,, LTD‘ HONDA V30 MAGNA LIG HTS/SWITCHES/INSTRUMENT Install the rubber seal. HEADLIGHT CASE REMOVAL Disconnect the all couplers and connectors. Loosen the adjusting bolts. Remove the headlight case mounting balls and headlight case. INSTALLATION Installation is the reverse order of removal. NOTE: ~ Route the wires properly (Page H 1). ' Adiust the headlight aim (Page 3-18). Date of Issue: July, 1984 © HONDA MOTOR 60., LTD‘ 18-3 LIGHTS/SWITCHES/lNSTRUMENT INSTRUMENT REMOVAL Remove the headlight and headlight case (Pages 132 and 18-3). Disconnect the speedameter cable. Remove the mounting nuts and instruments. D ISASSEMBLY Remove the three screws and lower cover. Remove the screw and disconnect the meter wires. Remove the indicator. SCREWS INDICATOR HONDA V30 MAGNA CONNECTORS 18-4 Date of Issue: July, 1984 © HONDA MOTOR C0,, LTD‘ HONDA V30 MAGNA Remove the screws and meter covers. Remove the meter bracket. BULB REPLACEMENT Pull out the bulb socket and replace the bulb. ASSEMBLY Assembly is the reverse order of removal. LIG HTS/SWITCHES/INSTRUMENT SCREWS Date of |ssue: July, 1984 © HONDA MOTOR (30., LTDr 18-5 LIGHTS/SWITCHES“ NSTRUMENT INSTALLATION Install the instrument in the reverse order af re- moval. After the installation, check the warning and indi- cator light for proper opeartion, FUSE HOLDER R E MOVA L Remove :he bottam bridge cover. Remove the screws and fuse holder cover. HONDA V30 MAGNA BOTTOM BRIDGE :1: ‘ scnsws 18-6 Date of Issue: July, 1984 © HONDA MOTOR C0,, LTD, HONDA V30 MAGNA LIGHTS/SWITCHES/INSTRUMENT Disconnect the horn wires. Remove the bolts and pull out the horns from the bracket. Disconnect the fuse holder couplers (red 4? and 6?). Remove the fuse holder from the bracket INSTALLATION Installation is the reverse order of removal, IGNITION SWITCH INSPECTION Remove the headlight (Page 18-2) and disconnect the ignition switch coupler {black 6?). Check continuity of terminals on the ignition switch coupler in each switch position. mgr“ lG BAT1 FAN TLi TL2 PA OFF ON C o o——o P c o Coloreode R/Bl R Bulo BrIW Br YIBI HOHNS Date of issue: July, 1984 © HONDA MOTOR CO., LTD, LIGHTS/SWITCHES“ NSTRUMENT HONDA V30 MAGNA Remove the headlight and headlight case (Pages 18-2 and 1&3). Remove the two bolts and ignition switch. CONTACT BASE REPLACEMENT Pry open the retainer. Insert the ignition key and turn it so is partway between the ON and OFF detent positions. Push in the lugs, that are locked In the slots, then pull the contact base from the switch. Assemble the ignition switch in the reverse order of disassembly. INSTALLATION Installation is the reverse arder of removal. IGNITION SWITCH LUG CONTACT BASE RETAI NE R 18-8 Date of Issue: July, 1984 © HONDA MOTOR CO., LTD. HONDA V30 MAGNA HANDLBAR SWITCH The handlebar cluster switches (lights, turn signals, horn, etc.) must be replaced as assemblies (Section 1 2)‘ Remove the headlight (Page 18-2) and disconnect the switch couplers (black 9P, red 9?). Continuity tests for the components of the handle- bar cluster switches folluw: Continuity should exist between the color coded wires in each chart when that position is selected. HEAD LIGHT Hl-LO SWITCH Posmgnm‘m' HL Ho HI Lo 0——o (NI 0 0 Hi C O COLOR Br/W W Bu H O R N B UTTO N Ho BAT: F REE PUSH O——O Color code Lg W/G TURN SIGNAL SWITCH W L R P PR PL LEFT 0—0 0—0 OFF 0 O RIGHT c o o Coloroode Gr 0 LB Br/W LB/W OIW STARTER SWITCH HEADLIGHT HI-LO SWITCH TURN SIGNAL SWITCH LIGHTS/SWITCH ES/INSTRUMENT HORN BUTTON ENGINE STOP SWITCH STARTER SWITCH ENGINE STOP SWITCH HLI HL2 IG ST IG BAT: FREE O——-O OFF PUSH O——O RUN O——O COLOR Bu/W Bl/R Bl/W V/R COLOR Bl/W BI Date of Issue: July, 1984 © HONDA MOTOR 60., LTD‘ 18-9 é HONDA LIGHTS/SWITCHES“NSTRUMENT V30 MAGNA NEUTRAL/OD SWITCH Remove the right side cover and disconnect the neutral/0D coupler. NEW Check the continuity between the Lg/R lead and ground with the transmission in neutral. There should be no continuity with the transmission in any gear. There should be continuity between the 6/0 lead and ground with the transmission in the OD posi- tion. There should be no continuity in any other gear. BRAKE lIGHT SWITCHES FRONT BRAKE SWITCH Disconnect the Trent brake light switch wires from the switch. There should be continuity with the brake lever applied and no continuity with the lever released‘ Replace the switch if necessary. REAR BRAKE SWITCH Remove the right frame side cover. Disconnect the rear brake light switch coupler. Check the continuity between the green/yellow and white/green leads. There should be continuity with the brake pedal depressed and no continuity with the pedal released. Replace the switch if necessary. Revised: November, 1984 1 8 - 1 o 0 American Honda Motor Co., Inc. 1934 - All Rights Reserved MSV BM 5 34" HONDA V30 MAGNA LIG HTS/SWITCHES/INSTRUMENT CLUTCH SWITCH Disconnect the clutch switch wires from the switch. Check the continuity between the switch termlnals. There should be continuity with the clutch lever applied and no continuity with the lever released. IJIL PRESSURE SWITCH WARNING CIRCUIT TEST Do an oil pressure check (page 2-4). Turn the ignition switch on; the oil pressure warning light should come on. If the warning light does not come on, turn the ignition switch OFF and disconnect the oil pressure switch wire. Turn the ignition switch 0N and ground the wire terminal to the engine. The warning light should come on. If the warning light comes on, replace the oil pres- sure switch. If the warning light does not come on, check the fuse, indicator bulb and wire connections. Replace or repair as necessary. Start the engine The warning light should go off, lf the warning light stays on, check the oil pressure and replace the oil pressure switch if oil pressure is normal. Apply liquid sealant to the switch threads. Install and tighten the switch. TORQUE: 15—20 N~m (1.5—2.0 kw“, 11-14 ft-lbl CAUTION Be mrefitl not to overtighten the switch to prevent damaging the threads of the engine covert Connect the switch wire to the switch. Install the rubber cover onto the switch. SWITCH WIRE Date of Issue: July, 1984 © HONDA MOTOR 00., LTD‘ 18-11 HONDA V30 MAGNA LIGHTS/SWITCHES"NSTRUMENT TEMPERATURE EAGlIE Disconnect the wire from the temperature sensor and short it to ground. Turn the ignition switch to ON. The temperature gauge needle should move all the way to the H. CAUTION Do not leave the temperature sensor wire ground for longer than a few seconds or the temperature gauge will be danwged, TEMPERATURE SENSOR Disconnect the green/blue wire from the tempera- ture sensor. Drain the coolant and remove the temperature sensor from the thermostat case. ' O TEMPERATURE SENSOR Suspend the unit in oil over a heater and measure the resistance through the unit as the oil heats up. 50°C 30°C 1oo°c 120°C Temperature 122a,: 1760': 2120,: 248%: TEMPERATURESENSOR Resistance 15451 523 279 160 m— . Wear gloves and eye protection. . Heated at! is highly flammable. Keep it away from open flames. NOTE: - Oil must be used as the heated liquid to cheek operation above 100°C (212°F). TH ERMOMETER ' You'll get false readings If either the thermometer or temperature unit touches the pan. 1 8- 1 2 8‘é%fi$2”fifi¥3fi'§$ LTD. HONDA V30 MAGNA LlGHTS/SWITCHES/INSTRUMENT THERMOSTATIC SWITCH The cooling fan motor is actuated by the thermo- satic switch located in lower the radiator, If the fan motor does not start, disconnect the switch coupler from the thermostatic switch and short coupler terminals together with a jumper wire as shown. Turn the ignition switch on. The cooling fan motor should start running. If it does not start, check for battery voltage from the black lead (positive) to black/blue (negative) of «is fan motor coupler. If there is no voltage, check for a blown or faulty fuse, loose terminals or connectors, or an open circuit. If it starts, inspect the fan thermostatic switch as follows: Suspend the switch in a pan of coolant (50—50 mixture) and check the temperatures at which the witch opens and closes, Make sure that there is no switch continuity with room temperature and gradually raise the coolant temperature. The switch should be continuity (close) at 98—102°C (208— 215 F). NOTE: o Keep temperature for 3 minutes before testing continuity. A sudden change of temperature will cause error of tempera- ture reading between the thermometer and the switch. - Do not let the thermometer or switch touch the pan as it will give a tales reading, Soak the switch in coolant up to its threads. TACHIJMETER If the tachometer does not work properly, replace the 1—3 spark unit with a new one and recheck the operation. If the problem still appears, replace the spark unit with the original one and replace the tachometer, TACHOMETER SPARK UNIT PU LSE GENERATOR Date of Issue: July, 1984 © HONDA MOTOR 60., LTD. 18-13 LIGHTS/SWITCHES/INSTRUMENT FUEL PUMP RELAY Remove the seat and fuel tank. Turn the ignition switch and engine stop switch 0N and check for continuity between the white termi- nal of the fuel pump relay coupler and ground. There should be no continuity. Start the engine for few minutes. Then, check that there is continuous battery voltage between the white wire terminal of the fuel pump relay coupler and the body grcnd. If the relay fails either check, replace it. FUEL RESEVE SENSOR Drain the fuel from the fuel tank. Turn the ignition switch ON, the fuel reserve warning light should come on. If the warning light does not come on, remove the seat, disconnect the Gr/Bl wire and ground it to the frame. The warning light should come on. If not, check the fuse, bulb and wire connection. Replace or repair as necessary. If the warning light still does not come on, replace the tensor. Fill the fuel tank with 3.5 lit (0.9 US gal) of fuel, and recheck the warning light. It should come on. The warning light should go out after a few seconds with the ignition turned 0N. If the warning light does not go out, replace the fuel reserve sensor. HONDA V30 MAGNA FUEL PUMP RELAY VOLTMETER FUEL SENSOR FUEL SENSOR 18-14 Date of Issue: July, 1984 © HONDA MOTOR 00., LTD. HONDA V30 MAGNA LIGHTS/SWITCHES" NSTRUMENT BRAKE/TAILLIGHT SENSOR Turn me 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) eres. VOLTAGE: 5V If there is no voltage, replace the sensor unit. WARNING EIGHT CHECK RELAY Turn the ignition switch on. The fuel and tail/brake warning lights should come on for few seconds, If the warning light does not come on, disconnect the check relay coupler. Check voltage between the BI/Br and G terminals. There should be battery voltage if no voltage, check the harness and fuse, and repair or replace if neoessarvt Disconnect the Gr/BI terminal from the fuel sensor and ground it. The fuel warning light should come one If the light does not come on, replace or repair the weming light bulb. If the bulb is good, replace the check relay. BHAfiE/TAl LLIGHT SENSOR TAIL/STOP SENSOR TAIL/BRAKE WARNING LIGHT FUEL SENSOR CHECK RELAY I. J J; J:- FUEL WARNING Lee . Br - El/Br J ' Bl/Br TAIL/BRAKE f LIGHT IGNITION = SWITCH BRAKELIGHT SWITCHS Date of issue: July, 1984 © HONDA MOTOR 00., LTD. 18-15 HONDA V30 MAGNA M EMO 5:31:33 19. WIRING DIAGRAM mum um: ansm Imllxl wan-IVE mm menu: new um menu um: mm mm m rim-E um M: m WWW U9“ mm sum mum) "m ""r 2mm arm Iwnmdan Lam-ml.) Imam swam) m no, new mac 51M m,m_ ml m‘m 1mm-nn«svm~awm rus: (mm momum mu \ ’ 4. ______ mnsilm mum W D : m. mm. w * w L 4 LJ U L iJ 95mm] um mu m ww- \ l n m m m unusxmm mmlmlm mm 5m! mus-um ' L m um sum "WW" 1—: n mums-"101 ’—— 1—7 ~ mm slam. mm m 5mm mm: sw- man smumuuuw smqq "mum wmm mm am. mm! mm 51mm mm m m a sron 1mm ...?(- IMWHM m mm m «an m: s. mu m you "man ?‘£F°P 1% mm mm mum) mu m: m. um "mama-t um nu: um (In m 003OZ—M18—6700 Date of Issue: April, 1984 © HONDA MOTOR C0,, LTD. 19-1 62mm 20. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 20-1 ENGINE LACKS POWER 20—2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 20—3 POOR PERFORMANCE AT HIGH SPEED 20—3 POOR HANDLING 20—3 ENGINE DOES NOT START OR IS HARD TO START POSSIBLE CAUSE 1, Check Iuol flow (0 carburetor NOT REACHING CARBURETOR——>(I) Fuel tank .1“pr (2) Clown! Iuel line or fuel filter REACHING CARBURETOR I3l Stlcklnq flour VIM l4) Fuultv fuel pump (5) Funky Ind pump mlly l6) Pinched fuel tank vln! has. 2. Perform a 3-point spark ten WEAK on NO SPARK—bu) Euulry spark plug: (2) Fouled Ipark plugs GOOD SPARK (3) Faulty spark unlr (4) Broken or shelled high tenslon wire: (5) Flulty spark mm (6) Broken or Ihorlod lgrrlriorr poll (7) Faulty lpniupn Mitch (a) Faulty pulse genemor 3. Ten cylindcr oompnnian LOW COMPRESSION —>Il) Low battery charge (2) lmpmpar vulva clear-nu (too COMPRESSION NORMAL small) (3) Valve nuck own (a) Worn cyllnaer and pinon rlngs (5) Dom-god cylinder head pike: (6) Seized vulva (7) Improper valve rlrnlng 4‘ sun by Iollowing normal procedure ENGINE STARTS au-r 9095*»(1) )mprpper choke opcrnion l2) Carbureror incorrectly odiuned ENGINE DOES NOT FIRE (3) Imikep clanking (4) lmprpp gnmonllming (Spurk null or pulse ganaralor) (5) Fuel connmin-Iod 5‘ Human Ind inspect Iplrk plug WET PLUG —-——-—>(I) Carburemr flooded (2) Carburttor choke axcastively cloud, (3) Cylinder "00de (4) Air clunar dirty Date of Issue: July, 1984 © HONDA MOTOR CO‘, LTD. 20-1 TROUBLESHOOTING EIIGIIIE UIL'KS PIIVIEII L Rnlse rear wheels off the ground and spin by mud WHEEL SPINS FREELV 2. crack (In plenum PRESSURE NORMAL 3‘ Anal-rue rIpIdly lrom low to mend ENGINE SPEED DECREASES WHEN CLUTCH IS RELEASED 4. Ace-lent. ”may ENIGNE SPEED INCREASES 5. Chock Ignition timing OORR ECT 3. Chuck vulva clmncl OORR ECT 7. TI" cylinder oompflulon NORMAL 3, Chock arbumov for plowing NOT CLOGGED 9r anovo .pnk plug NOT romeo on DISCOLORED IO. Chock oII IMI and condition CORR ECT IL Rum-w. cvlindov mad cow“ and Impact lubricltlon VALVE TRAIN LUBRICATED PROPERLY 12, check lor enuim overhauling NOT OVERHEATING 13. Mod-rm of run It hlflh spend ENGINE DOES NOT KNOCK WHEELS DO NOT SPIN FREELV——>(I) (Z) (3) (4) PRESSURE LOW _| (I) (2) ENGINE SPEED INCREASES —>(1) WHEN CLUTCH IS RELEASED (2i (3) ENGINE SPEED} DOES NOT INCREASE —>(‘I (2) (J) (4) (5) INCORRECT—DU) (2) "meanest—>11) (2) Too Lowhun (2) (3) (4) CLOGGED _—> FOULED OR DISCOLORED—DU) (2) INOORRECT —>(‘) (2) (3) VALVE TRAIN NOT LUBRICATED_—>(‘I PROPERLY (2) ——5 (I) (2) (3) (4) OVERHEATING (5) (6) ENGINE KNOCKS ———-—-—->(|) (2) (a) (4) 6 HONDA V30 MAGNA Possum CAUSE arm arming ~ Worn or damaged wnul burlng; Drive min (00 “gm Rm axle nu! ma tIgnL Purmur-d (in Funny (In vain Clutdl IIIwII-lg me chflch dine/pm. Wurp-d clutch disclaim carburetor chokt cloud Clown .lr alarm Rmricw fuol flow Claw“ mulllor Glow“ ml tank vent nol. Faulty spark unit Faulty puln .- mar Improper mm .djmmm Worn vulva an Vllw nuck open worn chindor Ind plnon rIngs LMkIrlg ma gum Improw um timing Carburetor no! mood fnqunmly enoulll Plug: not ”Mood mquontly enough Splrk plug wkn Income! hm ""99 Oil level too high 0i) Iml too low Contamlnltod oil Clogged oil pump. elm-d oll comrol orlflm Coolant law! low Fm molov not working (fan motor rally flulty) TIIIrmofln stuck cloud Exclaim carbon builddlv in combustion cnlmbev US. 0' pool tau-lily lull Cluxch gunning Worn plnorl and cyllndlr Wren] (vat of In.) EWIW carbon build-up in combustion cIIIInbOr Ignition (lining mo Idvlnood (Faulty spark lull!) 20-2 Date of Issue: July, 1984 © HONDA MOTOR C0., LTDV HONDA V30 MAGNA TROUBLESHOOTING POUR PERFIIRMANCE AT lflVl AND IDLE SPEEIIS FOSSIBLE CAUSE L cmk Ignition limlng .nd valv- clur-nce INCORRECT—>(1) minim my. clam-loo (2) impiow ignmon timing CORRECT (Faulty iplrk unit) 2. Chick urbuvflor piioi nor-w Idllmmunl INCORRECT —-—————> So. Fucl Synom Smion CORR ECT 3, Chock for Inkinfl inukl Div. LEAKING—>(II Dneviound inwlltor O-Ilng izi Loon amumor NO LEAK 4i Ptr'orm lplrk an WEAK 0R INTERMITTENT SPARK—DH) Flully, urban or W" found mm plug coon max (2) mm Inlrk unii (3) Funny ignition coil PllflR PERFIIRMANEE AT HIGH SPEED NOTE: Ignition to the No. 2 and No. 4 cylinders is cut-off at 12,000 rpm to prevent engine damage. L Cluck ignltion timing and VII" Clo-ran“ INCORRECT——-->(1) Impropu vulvo alt-rune. (2| Faulty tplvk link CORRECT (a) Faulty pulu Mentor 2, Dimnmfl fuul lin. n urbumor FUEL FLow RESTfilcrEo——>m Fuu tank empty (2) Clown! incl IIM FUEL FLows FREELY (a) Clown lmi unk hmtmr hell (4) Cloned fuel Volvo (5) Faulty fuel pump 3. minim urhumon and check lor CLOGG ED —-———> cmn clog-1 in: NO CLOGGED JETS 4‘ chuck v-lve liming INCORRECT—>cam ”rocket no! installed piowiy CORR ECT 5. Cluck vulva :prlng unslon WEAK—————> Faulty wring NOT WEAK ENED Palm HANBEINE —> Check tire and suspension pressures Sic-ring min wiumr run too light (2) DIM-god flaring head burilm 1‘ ll sminuilhlaw p“) (i) Emulvu mini tie-ring play (2) Ban: rim (3) Improplvly lnmllod whul (4) Swing arm plvoglmring axcussmly wom (5) Burn lulu. 2‘ If elmer wheel ls wobbllng 3. If tho motorcyclu pull: to one dd. —————-—-——>ll) Bm fum- I (2) FM! Ind ml whulx not tlignod (3) Sam iron: (wk (4) amt swing Inn Date of Issue: July, 1984 © HONDA MOTOR 00., LTD 2 O " 3 HONDA V30 MAGNA MEMO 3V0 (W