6 / HONDA SHOP MANUAL 1 VF7OOF/VF75OF k INTERCEPTDR IMPORTANT SAFETY NOTICE—— \« Indicates a strong possibility of severe personal iniury or loss of life i/ instructions are not followed CAUTION: Imlimm u /m.\.\i/wi/i1_|‘ ((I' perswml in/mr ur vquipim-m damagi- (f ins/mum’s are nu/ lillluu't'tl. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures. saletv principles and service operalions are not included. lt 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 a vehicle 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 oi each conceivable way, nor could Honda investigate all such wavs. Anyone using service \ procedures or tools, whether or not recommended by Honda mus! saris/y himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected. HONDA VF700/750 INTERCEPTOR HOW TO USE THIS MANUAL This manual is based on the VF750F. Any in- formation that differs between the VF700F and VF750F is called out in the text or in a note GENERAL INFORMATION ‘ .' LUBRICATION u MAINTENANCE n Follow the Maintenance Schedule (Section 3) FUEL SYSTEM .- recommendatlons to ensure that the vehicle is in peak operating condition and the emission ENGINE REMOVAL/INSTALLATION 1. levels are within the standards set by the US, Environmental Protection Agency Performing COOLING SYSTEM IE. the first scheduled maintenance is very impor- tant. It compensates for the initial wear that CLUTCH SYSTEM occurs during the break-in period Sections 1 through 3 apply to the whole motorr 'é‘ GEARSHIFT LINKAGE n cycle, while sections 4 through 20 describe a parts of the motorcycle, grouped according to E ALTERNATOR ‘I location, Find the section you want on this page, then CYLINDER HEAD/VALVE 'l:l turn to the table of contents on page 1 of that sections CRANKCASE II. Most sections start with an assembly or system PISTON /CRANKSHAFT IE- illustration, service information and trouble shooting for the section, The subsequent pages give detailed procedures. TRANSMISSION lfyou are notfamiliarwiththis motorcycle, read w FRONT WHEEL/SUSPENSION II. TECHNICAL FEATURES, section 22, a lfyou don’tknowthe sourceofthetrouble,goto 2 REAR WHEEL/SUSPENSION IE. section 23, TROUBLESHOOTING, 5 HYDRAULIC BRAKES II! All information, illustrations, directions and BATTERY/CHARGING SYSTEM specifications included in this publication are based on the latest product information 2‘ IGNITION SYSTEM available at the time of approval for prlntlng. 0 Honda Motor Co., Ltd. reserves the right to E make changes at any timawithout notice and '5 ELECTRIC STARTER without incurring any obligation whatever. E No pan of this publication may be repro- u-I SWITCHES E:l duced without written permission. HONDA MOTOR CO., LTD. Service Publications Office WIRING DIAGRAM n. TECHNICAL FEATURES m TROUBLESHOOTING m Date of Issue. October. 1984 ©Amencan Honda Motor Co , lnc 1984 , All nghts Reserved 3 HONDA v45 INTERCEPTOR I. GENERAL INEIIRMATIIIN GENERAL SAFETV 1—1 SERVICE RULES 171 ‘ MODEL IDENTIFICATION 1—2 SPECIFICATIONS 1—3 TORQUE VALUES 1—5 TOOLS 1-7 CABLE Bl HARNESS ROUTING 1—9 EXHAUST AND NOISE EMISSION CONTROL SYSTEM 1—13 ,I '84: EVAPORATIVE EMISSION CONTROL SVSTEM lCalifornia model only) 1—14 ‘ EMISSION CONTROL INFORMATION LABEL 1-15 GENERAL SAFETY m If the engine. must be running to do )ume work make 31er [he area is lvell-I-eliii'lmrrl. Never run Illr- (’Ilglllc m [I rinsed area. The exhausl l-mimillt polwlmm curlmli mmmxule gm‘. Gum/mu I.\ t’XI/‘t'l’fl'l‘ flammable and it erpluu'iia "Ill/(‘5’ vermin (audit/mu. ()1) "II! ,wka' W nllmvflumet (I! mar/t5 In your working area. SERVICE RULES The battery EIfl'lrn/yle L'lllllllin.\ sulfuric acid. Pram-i wmr arm. inn and rlulluug. In ('21? nfl‘olllm‘l, [Tm-ll Ilmmug/Ilil with miter am! all a (Itll'llll‘ if eli‘r-imlivw gels in ylmr (’yex. The Jinrrery gl‘lle‘mll‘b hydrogen gas which mil be highly explu w ”4! mil (make ur allow flumm or sparks near the I’ll/ll") , espwmliy while l-Imrgi'ng i'l 1. Use genuine HONDA or HONDArrecommended carts and lubricants or their equivalent. Parts that do not meet HONDA‘S design specifications may damage the motorcycle, 2. Use the special tools designed tor this product. 3. 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, 4, Install new gaskets, Orrings, cotter pins, lock plates, etc. when reassemhling. 5, When tightening bolts or nuts, begin With largendlameter or inner bolts first, and tighten to the specified torque diagonally, unless a particular sequence ls specified, 6, Clean parts in cleanlng solvent upon disassemblv, Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. Date of Issue: October, 1983 © HONDA MOTOR (30., LTD, 1-1 HONDA V45 INTERCEP'I'OR GENERAL INFORMATION MflllEL IDENTIFICATIIIN /. w BEGINNING Frame No. JH2RCiSD'DMDODOD1 ~ The color iabel is affixed to the rear fender] under the seat. EngineNo. RC15E—2w0001 N The frame serial number is stamped on the steering head's The vehicle identification number iVlN) is on the up!”r right side. right tube oi the frame V The engine seriai number is stamped on the right side of The carburetor identification numbers are stamped onto the upper crankcase. each carburetori Date of Issue: January, 1983 1—2 © HONDA MOTOR 00., LTD, é HONDA. VF700/750 INTERCEPTOR GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,160 mm (95.0 in) Overall width Overall height Wheelbase Seat height Foot peg height Ground clearance 770 mm (30.3 in) 1,215 mm (47.8 in) 1,495 mm (58.9 in) 820 mm (323 in) VF750F. 343 mm (13.7 in) VF700F2 343 mm (‘35 in) 155 mm (6.1 in) Dry weight '83-'84 VF750F, 221 kg (487 lb) '84 VF700F: 220 kg (485 lb) After '84 VF7OOF: 223 kg (492 lb) Curb weight 243 kg (536 lb) FRAME Type Double cradle Front suspenSIon, travel Telescopic fork 160 mm (6 3 In) Rear suspension, travel SWIngarm/Shock absorber, 120 mm (4.7 in) Front suspension air pressure 0—40 kPa (0—0.4 kg/cmz, 0—6 psi) Rear suspension air pressure 50—300 kPa (0.5 —3 O kg/cmz, 743 psi) Gross vehicle weight rating 413 kg (910 lb) Vehicle capacity load 168 kg (370 lb) Front tire size M120/80716 Tubeless Rrar tire size M130/EO-1B Tubeless up w 90 kg Front 32 psi (225 kF'a, 2.25 kg/cmz) Cold tire (200 lbs) load Rear 32 psi (225 kF’a, 2,25 kg/cmz) pressures Up to vehicle Front 32 psi (225 kPa, 2.25 kg/cmz) capacilv load Rear 40 [J51 (230 kPa, 2.8 kg/cm‘) Front brake, lining swept area Double disc 904 cm2 (140 sq in) Rear brake, lining swept area '83184: Single disc 490 cm2 (76 sq In) After ’84 VF700F: Single disc 452 cm2 (70 sq in) Fuel capaCIty 22 liters (5.3 us gal, 43 Imp gal) Fuel reserve capacity 4 liters (1.1 US gal, 09 Imp gal) Caster angle 28°10' Trail 96 mm (3.8 in) Front fork oil capacity VF750F: Right: 360 cc (12 2 oz), Left: 3130 cc (12.8 oz) VF700F' Right: 350 cc (119 oz), Left: 370 cc (12.5 oz) After ’84 VF7OOF: Right' 350 cc (11 9 oz), Left' 375 cc(13,2 oz) ENGINE Type Water cooled 4-stroke, DOHC engine Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Maximum horsepower Maximum torque Oil capacity Coolant capacity Lubrication system Air filtration Cylinder compression 4 cylinders 90°V VF750F’ 70 x 4B 6 mm (2.76 x 1.91 In) VF700F: 70 x 45.4 mm (2.76 x 1.79 in) VF750F: 748 cc (45.6 cu In) VF700F: 699 cc (42.7 cu In) 10.5 : 1 Silent, multirllnk chain drive and OHC with rocker arms VF750F 86 BHF/10,000 rpm VF700F' B1 BHP/10,000 rpm VF750F. 6,4 kgrm (46 3 trim/7,500 rpm VF700F' 6,2 kg-m (44.8 ft-Ib)/8,500 rpm 30 liters (3.2 US qt, 2.6 Imp qt) after disassembly 2.7 liters (2 9 US qt, 2,4 Imp qt) after draining 3 0 liters (3.2 US qt, 2.6 Imp qt) Forced pressure and wet sump Paper fllter 1,300 1 200 kPa (13.0 1 2.0 kg/cm2, 188 i 29 psi) Date oi Issue: October, 1984 ©American Honda Motor C0,, Inc 1984 . All Rights Reserved 1-3 GENERAL INFORMATION HONDA vr700/7so muncsnon Tall/stoplight Front turn signal/running light Rear turn signal Instrument lights Neutral Indicator Tum slgnal indlcztor ngh beam lndicaror ITEM SPECIFICATIONS ENG'NE '"lakeva've m m Opens 8°/ 5° IBTDCI 61°/ 58° (BTDC) Closes 40°/40°(ABDC] at 1 mm 107°/105°(ABDC) ztO Exhaust valve Opens 43743o IBBDC) Illt 96°/ 96° (BBDCI lift Closes 7°/ 5° IATDCl 74°/ 70°IATDcl I I C Id IN: V3“ ”mm 1 ° ) Ex~ 0,12 mm (0.005inl Englne weight (Dry) 81 5kg 1179] lb) Idle speed VF750F. 1,000 1 100 rpm VF7OOF:1,200 1100 rpm Cylinder numberlng No.1 7 Left rear No.2 7 Left front No, 3 7 nght rear No. 4 A Right front CARBURE- Carburetor type/throttle bore KEIHIN VD / 32 mm (1.26 in] TION IdenllflcatIon number Refer to page 41 Refer to page 4-1 PllOl screw initial setting See page 4-16 Float level 7.0 mm(0.281n) DRIVE Clutch Wet, multl-nlate TRAIN Transmission 5-speed Primary reductlon 2.152 Final reduction VF750F: 2.583 VF7OOF: 2.750 Gear ratio | 2733 Gear ratio |I L895 Gear ratio Ill 1.500 Gear ratlo IV 1.240 Gear ratloV 1.074 Gear shift pattern Left foot operated return system, I—N—2—3—445 ELECTRICAL Ignition Full transistor ignition Ignitlon tlming “F” mark VF750 0° BTDC at Idle VF700F215°BTDC at idle Full advance 37° BTDC at 3,300 rpm Starting system Startlng motor Alternator VF750F: snow/5,000 rpm VF700F: 350W/5,000 rpm Battery capacity 12V—14 AH Spark plug NGK ND Standard DPRBEAVQ X24EPFIvU9 For cold climate DPR7EA-9 X22EPR~U9 (Below 5°C, 41° F) For extended DPRQEA,9 x27EPReU9 hlgh speed rIdIng Spark plug gap 0.8—0.9 mm 10031—0035 in) Firing order 1—4—3—2 Fuse/maln fuse ISA/30A LIGHTS Headlight (hlgI’I/IOW beam) 60/55 w 8/27 W (3/32 cpl SAE NO, 1157 23/8 W (32/3 cp) SAE NOV 1034 23 W (32 cpl SAE N0. 1073 Date of issue: July, 1984 © HONDA MOTOR CO., LTD. HONDA v45 muncmon GENERAL INFORMATION TflRflllE VALUES o ENGINE Ham O’ty Thread Die—(mm) Torque Nm (kg-m, mp1 Remarks Cylinder head Cover 8 e 8—12l0.841.2.6~9) Cam holder 16 a 10714 (1.04.4, 77101 ‘ Cylinder head 8 8 2145 (2.1—2.5,15-18) ‘ 1a 9 33—37 (1347,2447) Alternator 1 Y2 80—100 18.0—10.0, 58-42) } Przmery or'we gaar 1 12 80»100 (80—100, 53—721 ‘ Ciutch lock out 1 22 62—63 (6245.8, 45—49) ( Crankcase 14 9 30—34 (3.04.4, 2245) 2 s 2145 (2.04.5, 1471a) 15 10414 (1.0—1.4,7710) Rockerarm shaft 8 1 22 45750 (4.54.0, 3246) 31:53::st 77‘ Cam sprocket a 1340 (1.840, 13—141 Starter clutch 3 26—30 (2.6—3.0, 19421 Shirt fork center 1 1 (640 (1.54.0, 12—141 Cam chain guide ban 1 12 ‘ 2145 (2.145, 15—10) 01(rr1ter 1 20 15—20 (1.540, 11714) Countershert peering homer 3 a 2145 (2.0—2.5, 14—18) Drive sprocket 1 10 50754 (5.0754, 36739! 1 Valve adjustment nuts (6 1 7 21—25 (2.14.5,157151 Drain plug 1 ‘ 12 35410 (3.5.4.0, 25 491 Connecting rod nuts 8 13 30—34 (3.0 -14 2245) Drum stopper Divot shaft 1 0 8—12 (0.3—1.2, 54) Applv S-Bond Sealant, 011 pressure switch 1 - 1540 (1.54.0,11—141 { or its equivalent, to the Spark plugs 4 12 12—10 (1.2—1.0, 942) "1’9““- Li a CHASSIS Item 1 (Fly ‘ Thread 01.1mm) Torque N»m (kg-m, (Mb) Remarks Steering stem nut I 1 24 90712019.0~12.0,65787| Steering bearing adjustment nut 1 26 10—12110—12779) '831page 1435) 194 31104.3,14—171 (page 14-35) Top bridge pinch mm 1 13 3040 (1.0-4.0, 2249) From ex1e holder 4 B 1845 11.914.513.401 Front axle nut 1 12 55—65 (5.5-6.5, 40747) From fark top pinch po1ts 2 9413 (0.9—1.3. 7—101 Front fork bottom cinch bolts 1 2 l 10 45—55 (4.5—5.5, 33-7401 Date of 1ssue: October, 1903 © HONDA MOTOR 00., LTD. 1 '5 GENERAL INFORMATION HONDA V45 INTERCEFTOR item O’tv Thread Dia (mml Torque N-m (kgrrn, ft-lbl Remarks Brake caliper bracket mount bolts (Rightl 2 10 EKG—4013.040, 22729) lLeft-upper) 1 10 30-40130—40, 22729) } Front brake calipers lLeft»lowerl 1 8 20725 (2.0725, 14—13) Brake caliper mount bolts 3 8 2072512072514718) } Front and rear Brake caliper pivot bolts 3 12 25-30l25-3.0,18722l brake calipers Front brake discs 12 8 35740 (1574.0, 25—29l Shock arm to frame bolts 2 10 40750 140-50, 29736) Shock link to shock arm bolt 1 10 40750 (4.0750, 29—36) Shock absorber mount bolts 2 10 40750 [4.0750, 139—35] Swingarm pinch bolt 1 8 20730 l2.0—3.0, 14—22)) Swingarm left pivot bolt 1 25 85-105 (85710.5, 61—76) Swingarm right pivot bolt 1 16 85—105(8.5710.5. 51776) Rear bra ke torque rod 8mm 1 8 18725 (1872.513718] 10 mm 1 10 30740 l3.0—4,0, 22729} Final driven sprocket 5 12 80—100l8.0710.0, 58—72) Rear brake disc 6 B 35740 13 5—4.0, 25—29) Rear axle nut 1 18 8571051357105617761 Sub-frame bolts (upper Apply oil to lower and lower) 4 10 35745 (3.5745, 25733) bolts Handlebar pinch bolts 2 8 30740 (3074.0. 22-29l Rear brake actuating 1 6 10715 (1.0—1.5, 7711) Side stand 1 10 35—45 (3.5—4.5, 25—33) Engine rear hanger bolts [upper and lower) 2 10 45755 14.5—55, 33—40l ‘ Engine center hanger bolts 6 8 24—30 (2.4730, 17722l l‘ Engine front hanger bolts 2 10 35745 135—45, 25—33l Gearshift pedal pivot bolt 1 10 35—45 135745, 25—33) Torque specifications listed above are for important fasteners. below. 0 STANDARD TORQUE VALUES Others should be tightened to standard torque valves listed Torque Values Torque Values 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 18—25 (1.8—2.5. 13718l 3040 (30—40, 22729) 50—60 (5.0—6.0, 3643) "9'" N-m lkg-m, ftrlb) "em N‘m (kgrm, me) 5 mm bolt and nut 4—6 (0.4—0.6, 3—4; 5 mm screw 3—5 (0.3—0.5, 24” 5 mm bolt and nut 8712 (0871.2, 6—9l 6 mm screw 7711 10771.1, 57Sl 6 mm flange bolt and nut 8 mm flange bolt and nut 10 mm flange bolt and nut 10—1411.0—1.4,7—10) 24730 (2.4731), 1772’Zl ‘ 35—45 (3.5745, 25733) 1-6 Date of Issue: October, 1983 © HONDA MOTOR CO” LTD. *v- HONDA TlllllS V45 INTERCEPTOR GENERAL INFORMATION o SPECIAL TOOL TOOL DESCRIPTION NUMBER ALTERNATETOOL NUMBER REF.PAGE Oil pressure gauge attachment 07510—4220100 T}Equivalent tool commercially 2-5 Compression gauge attachment 0751041000101 — available in USA 3-12 Carburetor pilot screw wrench 07900—4220201 3-11 Snap ring pliers 07914-3230001 Equivalent tool commercially 7 5, 14-21 available in USA. 14-27, 16-8 16-16 Steering stem socket 079154710100 14-32, 14-35 Hex Wrench, 6 mm 0791773230000 Equivalent tooI commercially 14-20 available in U.S.A, -07924—MC70001 Primary gear hoIder 07924—MC70002 or Gear holder modified - —E-07924-Mc70000 7-1 I, 7-22 0792441150000 Needle hearing remover 07931~MA70000 Not available in U.S.A1 15-15 Bearing race remover 0794673710500 14-33 Steering stem driver 07946~MEUOOUO — :‘izgimm ("W gzggjjggggo 14-34 Fork seal driver 079474630100 14-27 Driver 0794973710000 11-3 Ball race remover 07953-4250002 14-33 Oil seal driver attachment 079657MC70100 15-9, 15-10 Attachment ring 07965—ME70100 1510 Oil seal driver 07955-ME100100 15-10 Soar remover pump 07971-M01000A U.s,A. only 15-19 Valve guide reamer, 5 5 mm 0798472000000 1012, 1043 Ignition timing inspection cover 07998—M800000 or 07404—0020000 or 13-5 Vacuum gauge 07404—00301100 Vacuum gauge (U15.A.onlvi M937B-021exxxxx 3-10 on pressure gauge 07506—3000000 Equivalent tooI commerClallv 2-5 available In USA, Pressure pump ST— AH 455-17107 U.S.A. onIv—IncIudetI in Vacuum pump stem-26071007 Turbo kit 4'19 0 COMMON TOOL TOOL DESCRIPTION NUMBER ALTERNATE TOOL NUMBER REFPAGE Float level gauge 07401-0010000 4-6 Lock nut wrench, 10 x 12 mm 07708v0030200! Equivalent [00‘ 3.9 Lock nut wrench, 17 x 27 mm O77i6~00203007 commerCIally available 7-11, 7-19 Lock nut wrench, 30 x 32 mm 07716700204007 in U.S,A. 14-31, 14-36 Extension ems—00205007 7-11, 7-19 14-31, 14-36 Universal holder 07725—0030000 7-12, 7-19 Flywheel holder 0772570040000 Band strap wrench-commer- 972, 9.3 cIallyavaIlable in USA. Rotor puller 07733—0020001 Rotor puller 079334290001 9.2 Valve guide remover, 5.5 mm 0774270010100 Valve guide driver 07932 —3290l 00 10.13 Driver 07746—0030100— . , 13-9 Attachment, 25 mm ID. 07746—0030200—}D”"er 079454110200 13-9 Date of Issue: October, 1983 © HONDA MOTOR CO., LTD. HONDA V45 IN'I'ERCEPTOR GENERAL INFORMATION TOOL TOOL DESCRIPTION NUMBER ALTERNATE TOOL NUMBER HEFJ’AGE Attachment, 32 x 35 mm 07746—I0010100 15-5 Attachment, 37 x 40 mm 07746—0010200 746, 15-15 Attachment, 42 x 47 mm 0774643010300 1415, 14-33 Attachment, 52 x 55 mm 07746—0010400 ‘ 11-3, 14-34 156 Attachment, 62 x 68 mm 07746—Om0500 15-6 Pilot, 15 mm 07746—0040300 14—1 5 ‘Pilot, 17 mm 07746-00404“) 1545 Pilot, 20 mm 07745—0040500 15-6y l5~15 Pilot, 7.5 mm 07746-004060!) 15-6 Film, 35 mm 07746—0040700 716 Driver 07749—0010000 7-15, 14715 14-33, 14-34 15-6, 154 5 Valve spring compressor 07757 —001 0000 ‘ 10-10, 10-15 Baaling remover shaft 07746~005m00i Equivalent tool 14714, 155 Bearing remover oorreK, 15 mm 0774641050400? commercially svmlable 14-14 Bearing remover corret, 20 mm 07746—0050600— in USA. 155 Date of Issue: January, 1983 1 '8 © HONDA MOTOR CO, LTD. é HONDA V45 INTERCEP'I’OR CABLE & HARNESS liflllTlllG Note the following when routing cables and wire harnesses. A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure it is secure. 0 Do not squeeze wires against the weld or end of its clamp when a Weldon clamp is used. 0 Secure wires and wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses. 0 Route harnesses so they are not pulled that or have excessive slack. 0 Protect wires and harnesses with electrical tape or tube if they are contact a sharp edge or corner. Clean the attaching surface thoroughly befare applying tape. 0 Do not use wires or harnesses with a broken insulator. Repair by wrapping them with a pro- tective tape or replace them. 0 Route wire harnesses to avoid sharp edges or corners. 0 Also avoid the proiected ends of bolts and screws 0 Keep wire harnesses away from the exhaust pipes and ether hot parts. 0 Be sure grommets are seated in their grooves properly. 0 After clamping, check each harness to be certain that it is not interferring with any moving or sliding parts. 0 After routing, check that the wire harnesses are not twisted or kinked. I Wire harnesses routed along the handlebars should not be pulled taut, have excessive slack, be pinched, or interfer with adjacent or sur rounding parts in all steering positions. GENERAL INFORMATION >< em E O X k.& o><>< Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. HONDA 45 INTERCEPTOR GENERAL INFORMATION I , /‘ w '\ RADIATOR :9; 7:} \\5 OVERFLOWTUBE STARTER/ENGINE STOP , SWITCH COUPLER FUSE BOX / BRAKE COUPLER HOSES HEADLIGHT ’I ‘ , METER COUPLER ILLUMINATION \\\2 A \ C LUTCH P IFE FRONT BRAKE HOSES I ‘ / I’SPEEDDMETERCABLE \ K; , V C/ , THROTTLE CABLES CHOKE CABLE IGNITION COIL HIGH TENSION WIRES MAIN HARNESS THERMOSTAT , ' BRAKE HOSE OIL PRESSURE SWITCH THERMOSTATIC SWITCH W)RE 1 _ 1 0 Date of Issue: January. 1983 © HONDA MOTOR (20., LTD‘ HONDA v45 INTERCEPTOR GENERAL INFORMATION 0 TURN SIGNAL RELAY . ‘ ’/ “'UELCUT-OFF WW5" RELAY REGULATOR/ 7 i431”! I §Z¢Q‘)}£’ )E RECTIFIER \ ADIATOR A» RESERVE e @:;\\ TANK (5‘ ' REGULATOR/ .I"‘/ Vb A w \.- ’ - _ fi/i’lfi :RECTIFIER N7 ‘\ ,5" W COUPLER V /(Q :"' 3/” Q FAN/MANOR RELAY CLUTCH HOSE R / 3 IGNITION COIL \ ‘ ,» V @© STARTER RELAY SPARK PLUG BATTERY CABLE CAP OIL PRESSURE SWITCH D \ ‘ ' , «'7 :4 '\\P|JLSE o : 7, \ o / . \-\ \ , , \ BRAKE LIGHT : 7 .7; \_ ‘ )V/ , ,f‘é‘dE’UVSVESER/ATOR SWITCH WIRE R HEAR BRAKE HOSE GROUND CABLE 0 STARTER MOTOR ’ v I 5 icABLE RADIATOR BREATHER TUBE I BATTERY BREATHER TUBE Date of Issue: January, 1.983 1 - 1 1 © HONDA MOTOR C0,, LTD. HONDA V45 IN‘I'ERCEPTOR GENERALINFORMAHON HEADLIGHT / 1 FUSE Box COUPLER COUPLER / fl STARTER/ HEADLIGHT DIMMER/ 2:13;“ HOHN SWITCH COUPLER SWITCH COUPLER -, ‘ - TURN 7 ‘ -‘ COOLING FAN FUSE SIGNAL ‘ SWITCH COUPLER THROTTLE TURN SIGNAL ‘ CABLES WIRE ‘ . CHOKE CABLE C CHOKE CABLE COOLING FAN MOTORS IGNITION COILS HIGH TENSION WIRES RADIATOR HOSE MAIN HARNESS RESERVE TANK FUEL PUMP BRAKE AND TAIL LIGHT SPARK UNIT L. REAR TURN I A 56" LWIRE SPARK UNIT BRAKE AND TAIL LIGHT SENSOR _ 1 _ 1 2 Date of Issue: January, 1983 © HONDA MOTOR 00., LTD, HONDA V45 INTERCEP‘I’OR GENERAL INFORMATION EMISSIIIII BflNTRflL SYSTEMS \— The US. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certity that their motorcycles comply with applicable exhaust emissions standards during their uselul lite, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards tor 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 subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic, Honda Motor 00., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons. 3 EXHAUST EMISSION CONTROL SYSTEM :1 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. CRAN KCASE EMISSION CONTROL SYSTEM This engine is equipped with a crankcase emission control system which routes crankcase emissionsthroughthe aircleaner and into the combustion chamber. Condensed crankcase vapors are accumulated in a storage tank which must be emptied periodically See the Maintenance Schedule in Section 3. AI R C LE AN E R 'v :{> < :i ‘ FRESH AIR CARBUHETOR ‘— :BLOW~BY GAS B REATH E R SEPARATOR \' D RAIN TUB E \_, DRAIN PLUG \i Revised: July, 1984 0American Honda Motor Co,lnc,1984 - All Rights Reserved 1 ' 13 Msv 7227 B407 HONDA GENERAL INFORMATION V45 INTERCEPTOR I-EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) NEW This model complles with California Air Resources Board requirements for evaporative emission regulations. Fuel vapor from the iuel tank is routed into a charcoal canister where n is absorbed and stored while the engine is stopped. When the motorcycle ls running and the purge control diaphragm valve IS open, fuel vapor in the charcoal canister IS drawn into the engine through the carburetor. ONE WAY VALVE PURGE CONTROL VALVE FUEL TANK [ll NO, 1 ‘\ CANISTER r / I: FRESH AlR i @- 1 NO, 2CAN|$TER ONE WAY VALVE NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SVSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative bv any person, other than for purposes oi maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose at 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 alter such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing the muffler, battles, header pipes or any other component which conducts exhaust gases. 2 Removal of, or puncturing ol any part of the intake system 3. Lack of proper maintenance. 4. Replacing anv moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specilred by the manulacturer. Revised July, 1984 1 _ 14 oArnencan Honda Motor (:0, Inc 1984 - All Rights Reserved MSV 7227 8107 HONDA VF700/750 INTERCEPTOR EMISSION CONTROL INFORMATION [ABEL An Emtssuon Control InIormatton Label is located on the rear lender under the seat as shown It gives basic tune»up specifications EMISSION CONTROL INFORMATION UPDATE LABEL AIler making a highaltitude carburetor adjustment (page 4418), attach an update label on the rear fender under the seat as shown Instructions for obtaintng the update label are gtven In Service Letter No. 132 VACUUM HOSE ROUTING LABEL (After ’83 California model only) The Vacuum Hose Routtng Label is attached to the fuel tank below the seat. Route the vacuum hoses as described on this labeI. GENERAL INFORMATION EMISSION CONTROL IN FORMATION LABEL VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL vnmuumose ROUTING DIAGRAM tum mm — (Inmucl lumnmt mm 7 "III aural-u vtmtt m-un VACUUM HOSE ROUTING LABEL Date DI Issue October, 1984 © American Honda Motor Co, Inc 1984 , All Rtghts Reserved 1-15 LUBRICATION FRONT CYLINDER EX. CAMSHAFT FRONT CYLINDER ' |N. CAMSHAFT ITO REAR CVLINDER) OILORIFICE HONDA v45 muncmoa SHIFT FORK SHAFT ‘f H/ \ r r O \ OIL PUMP OILFILTER OILSTRAINER MAINSHAFT COUNTERSHAFT 2-0 Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. é HONDA VF700/750 INTERCEPTOR 2. LUBRICATION ENGINE OIL LEVEL SERVICE INFORMATION TROUBLESHOOTING ENGINE OIL & FILTER CHANGE OIL STRAINER CLEANING OIL PUMP OIL PRESSURE CHECK CONTROL CABLE LUBRICATION LUBRICATION POINTS SERVICE INFORMATION GENERAL To service the oil pump, it is necessary to remove the right side cover and water pump assembly. See section 6tor water pump removal and installation. SPECIFICATIONS Engine oil Oil capacity '837'84: 2.9 liters (3.1 US qt, 2,5 Imp qt) after draining After '84- 27 liters (2.9 US qt, 2,4 Imp qt) after draining 3.0 liters (3 2 US qt, 2.6 Imp qt) after disassembly Oil recommendation Use HONDA 4*STROKE OIL or equivalent. API SERVICE CLASSIFICATION, SE or SF. VISCOSITY. SAE 10W—40 Other viscosities shown in the chart may be used when the average temperature in your riding area is Within the indicated range. OIL VISCOSITIES Oil pressure (at oil pressure switch) 5.4 i 0 7 lug/cm2 (77 1 10 psi) at 5,000 rpm (80°C/176°F) Oil pump dellvery 478 liters (50 5 US qt)/min at 5,000 rpm of oil pump speed Oil pump service data STANDARD SERVICE LIMIT Rotor tip clearance 0.15 mm (0.006 In) 0.20 mm (0.008 in) Pump body clearance 01540.22 mm (0006—0009 in) 035 mm (o 014 in) F'u mp end clearance 00240.07 mm (0 001 —0 003 In) 0.10 mm (0004 in) Data at Issue October. 1984 © Amerlcan Honda Motor (20., Inc 1984 , All Rights Reserved LUBRICATION TORQUE VALUES Engine on draln plug Englne oil filler Oll pressure swrtch TOO LS Special Oil pressure gauge Oll pressure gauge anachmenr lRflUBLESHflflTINE on level too low 1, Exrernal orl leaks 2. Worn plslon rlngs 3. Worn valve gulde or seal Oil contamination é HONDA v45 INTERCEP‘I’OR 35—40 Nrm (3574 0 kg~m, 25—29 ll-Ib) 15—20 Nrm (1.572 0 kg-m,11—14fl-lb) 15720 N-m (1.5—20 kg-m,11—14flalb) owns—3000000 . A . 075104220100]— or equlvalent rools commerclauy available. 1, on or film nol changed olten enough 2, Head gasket faulty 3, Worn plsron rlngs Low oil pressure 1, Olllevellow 2‘ Pressure relief valve stuck open 3, Plugged oll pick-up screen 4. Oll Dump worn 5. Exlernal Oll leaks High oil pressure 1. Pressure rell‘ef valve sluck closed 2. Plugged orl fllrer, gallery, or mererlng orlflce 3. Incorrect oll belng used No oil prosxure 1 Oll level low 2, Oll pumpdrlve chain broken 3 Oll pump raulw 4. Internal OII leakage 2-2 Dale of Issue: January, 1983 © HONDA MOTOR CO, LTD. é HONDA v45 INTERCEP‘I’OR LUBRICATION ENGINE IIII. LEVEL Put the motorcycle on its center stand on level ground. Start the engine and let it idle for 2—3 minutes. Turn Off the engine. Remove the filler cap/dipstick, wipe it clean and insert it without screwing it in. Remove the filler cap/dipstick and check the oil level. If the level is below the lower level mark on the dipstick, fill to the upper level mark with recom- mended oil. Check the oil pressure with the oil pressure warnv ing light after the engine starts. The light should go off after one or two seconds. if it does not, stop the engine and check the oil pump output and/or oil circuit. EIIiiINE [III 81 FILTER CHANGE NOTE Change engine oil with the engine warm and the motorcycle on its center stand to assure complete and rapid draining. Stop the engine. Remove the oil filler cap/dipstick, oil drain plug and drain the oil. Remove the lower radiator cowl, lower radiator mounting bolts and brakcet. Swing the radiator away from the engine, but don’t disconnect its hoses. Remove the oil filter with a filter wrench and let the remaining oil drain out Discard the oil filter. Check that the sealing washer on the drain plug is in good condition and install the plug. Replace the oil filter with a new one, Check that the oil filter Orring is in good condition, and coat it with oil before installing it. Install the lower radiator mount bracket, lower radiator mount bolts and lower radiator cowl. Fill the crankcase with 2.9 liters [3.1 US qt, 2.5 Imp qt) of the recommended oil (page 2-1). Rein- stall the oil filler Cap/dipstick. Start the engine and let it idle for 2-3 minutes, then stop the engine. Make sure that the oil level is at the upper level mark on the dipstick. Make sure that there are no oil leaks. OIL FILLER CAP/DIPSTICK <- UPPER <- LOWE R OIL DRAIN PLUG LOWER RADIATOR OIL FILTER MOUNT BOLT MOUNT BRACKET Date of issue: January, 1983 © HONDA MOTOR (30., LTD. 2-3 LUBRICATION IJII. STRAINER BLEANINE NOTE: The oil strainer can be removed with the engine mounted t'n the frame. Remove the lower radiator cowl. Remove the exhaust chamber. Drain the englne oil [page 273), Remove the oil pan bolts and oil pan. Remove and clean the oil strainer. Check the operation of [he pressure relief valve. Make sure the O~ring is in good condition when- ever the relief valve is removed. Install the oil strainer and oil pan, Install the exhaust pipes. Fill the crankcase with the recommended oil (page 24). [Ill PRESSURE CHECK Warm the engine up to normal operatlng temper ature [approxlmately BO°CI176°FL Stop the engine and disconnect the all pressure switch wire. Remove the oil pressure switch and connect an oil pressure gauge ta the pressure switch hole (page 2-5). Check the Oil level. HONDA v45 muncmon OIL PAN RELIEF VALVE OILSYRAINER RELIEF VALVE 0»RING OIL PRESSURE SWITCH Date at Issue: January, 1983 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEP'I'OR LUBRICATION OIL PRESSURE GAUGE Start the engine and check the oil pressure at 5,000 rpm. OIL PRESSURE: 5.4 2 0.7 Iqi/cm2 177 i 10 psi) at 5,000 rpm iao°cn7e°Fl Stop the engine. Appiy 3-BOND® seaiant or equivatent to the pressure switch threads and instaii. TORQUE: 15—20 N-m (1.5—2.0 kg-m, 11—14fK-lbi Connect the oil pressure switch wire. Start the engine. Chew that the oil pressure warning indicator goes out after one or two seconds. If the DII pressure warning indicator stays on, stop the engine immediateiv and determine the cause. OIL PRESSURE GAUGE ATTACHMENT 07510—4220100 OR EQUIVALENT TOOL IN U,S.A. flll PUMP 3 REMOVAL NOTE The 0 pump can be removed with the engine mounted the frame Remove the lower radiator Drain the engine oil. Remove the exhaust system. Remove the right crankcase cover. Remove the oil pump driven sprocket by removing the bait and washer. Remove the all strainer (page 2-4) and the oil pass pipe, Make sure the O-rings are in good condition. Date of Issue: October, 1983 © HONDA MOTOR CO‘, LTD. HONDA LUBRICATION V45 INTERCEP'I'OR OIL PUMP Remove the oil pump by removing the mounting ‘ 1..) bolts. OIL STRAINER TUBE Straighten and remove the Cotter pin holding the oil strainer tube Remove the oil strainer stay. Remove the oil pump body cover. OIL PUMP BODY COVER DOWELPIN ORINGS Remove the dowel pin. Remove the inner rotor and drive pin. 9in INNER ROTOR Date of Issue: January, 1983 2‘6 ©HONDA MOTOR cot, LTD. HONDA v45 INTERCEPTOR Measure the rotor tip clearance. STANDARD: 0.15 mm (0.006 in) SERVICE LIMIT: 0.20 mm (0.008 in, Measure the pump body clearance. STANDARD: 0.15—0.22 mm woos—0.009 in) SERVICE LIMIT: 0.35 mm (0.014 in) Remove the rotor shaft and measure the pump end ciearance. STANDARD: 03240.07 mm (0001—0003 in) SERVICE LIMIT: 0‘10 mm (0.004 in) LUBRICATION Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. LUBRICATION ASSEMBLY Install the outer rotor into the body and insert the rotor shaft, Insert the drive pin into the rotor shaft, Align the slots in the inner rotor with the drive pin. Install the dowel pin and oil pump body cover. Make sure the oil strainer tube O-rings are in good condition Install the oil strainer tube with a new cotter pin. HONDA v45 INTERCEPTOR OUTER ROTOR ROTOR SHAFT DRIVE PIN DOWEL PIN |NNER ROTOR O-RINGS OIL PUMP BODY COVER OIL STRAINER TUBE CUTTER PIN Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. HONDA v45 INTERCEP‘I’OR LUBRICATION Install the orifice, O-rinq and dowel pin. Install the oil pump and 05] pipe NOTE Make sure the oil pipe gs are installed on the Install the oil strainer and oil pan, Place the oil pump driven sprocket into the drive chain. NOTE The ”IN” mark on the driven sprocket should face the crankcase, Install the washer and tighten the bolt. Install the dowel pins and a new gasket. Install the right crankcase cover. install the exhaust system. Fill the engine with the recommended oil (page 24). CflNTRIJL CABLE LUBRICATIIIN Periodically, disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially avail- able cable lubricant or a light weight oil. ORIFICE (4.3 mm ID) DOWEL PINS DRIVE CHAIN WASHER Date of Issue: January, 1933 ©HONDA MOTOR (10., LTD. LUBRICATION LUBRIBATIIIN PlllNTS a or E E LUBR|CANT THROTTLE AND CHOKE CABLE CLUTCH AND BRAKE LEVER PIVOTS 7! or CAB LE LUB R ICANT SFEEDOMETER ‘ \ CABLE HEAD BEAR|NGS WHEEL ’ BEARINGS (When replaced) fl PEDAL PIVOT I , l THROTTLE GRIP V HONDA v45 INTERCEPTOR SPECIAL LUBRICANT 0 SHOCK ABSORBER UPPER MOUNT BUSHING lpage15»1\) 0 SUSPENSION L|NKAGE NEEDLE BEARING (BUSHING FOR '33! 1page15-12) ,' I 7H Al REAR SHOCK ' ABSORBER ’ ,fii (AIFJ / I BRAKE ,1 V I I FOOT PEG ‘ / ,’ PIVOT & I I I SWINGARM ‘ ’ .PIVOT FOOT PEG WHEEL GEARSHAFT PIVOT *7: BEARINGS SPEEDOMETER PEDAL ‘2'ng (When replaced) DRIVE GEAR DRIVE CHAIN {Egg}; FORK ,fi. (SAE 80—90 GEAR OIL) ‘ ‘ ' SIDE AND CENTER STANDA PIVOT Date of Issue: October, 1983 © HONDA MOTOR 00., LTD. HONDA v45 INTERCEPTOR 3. MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM CYLINDER COMPRESSION DRIVE CHAIN BATTERV BRAKE FLUID BRAKE SHOE/PAD WEAR BRAKE SVSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SIDE STAND SUSPENSION NUTS, BOLTS, FASTENERS WHEELS STEERING HEAD BEARINGS 3—12 3—13 3—1 5 3—16 3—17 3—17 3—17 3—18 3—18 3—18 3—19 3—19 3—21 3—21 3—21 SERVICE INFORMATION 3—1 MAINTENANCE SCHEDULE 3—3 FUEL LINES 3—4 FUEL FILTER 3-4 THROTTLE OPERATION 3—5 CARBURETOR CHOKE 3—6 AIR CLEANER 3—6 I CRANKCASE BREATHER 3—7 SPARK PLUGS 3—7 VALVE CLEARANCE 3—8 CARBURETOR SYNCHRONIZATION 3-10 CARBURETOR IDLE SPEED 3—11 RADIATOR COOLANT 3—11 RADIATOR CORE 3—12 COOLING SYSTEM HOSES 8t CONNECTIONS 3—12 SERVIBE INFIJIIMIITIIIN GENERAL o Engine owl See page 273 0 Engine oIIfllIer See page 2-3 SPECIFICATIONS < Engme > Spark pIugs. Slandard For cold climate (below 5°C:41°F) For extended high speed nding NGK I ND NG K ND NGK ND DPRBEAVQ J xzaepnrue DPR7EA-9 X22EPR-U9 DPRQEA-Q X27EPR-U9 Spark plug gap: 0.3—0 9 mm (0031—0035 .n) Date of Issue: January, I983 _ © HONDA MOTOR coa, LTD. 3 1 MAINTENANCE lgmtion trm1ng At idle: Advance starts: Full advance: Valve clearance Cold (Below 35°C, 95°F): |d1e speed: Carburetor synchronization: Cyhnder com pression: Throtrle gnp free plays < CHASS|S> Drive chain slack: Tires: HONDA VF700/750 INTERCEP'I’OR VF750F: 10°BTDC VF700F: 15°BTDC 1,500 rpm 37°BTDC at 3,300 rpm Intake/Exhaust: 0.12 mm(010051n1 VF750F: 1,000 i 100 rpm VF700F: 1,200 i 100 rpm All carburetors within 60 mm (2.4 in) H9 of each other 1,300 x 200 kPa (1310 t 2.0 kg/cm‘, 185 t 28 psi) 2—6 mm [1/3—1/4 in) 15725 mm (5/3—1 in) ’7 ,, , Tire size Trre brand Cold tire pressure, kpa (kg/cmz, psi) 1,, load 90 kg 1200 lbs) load From Rear M120/ao—16 M130/80—1B , , ,,,i,_‘,—¥ U" ‘° 90 kg (200 'b" 225 (2.25, 32) 225 (2.25, 32) r to vehic1e capacity 1oad 72517-2532) 280 (2.30, 401 Br1dgestone 5511 6510 Dunlap i F11 K627 Suspension a3r pressure: Front, Rear, TOO LS Spatial Vacuum gauge Carburetor pilot screw wrench Compression gauge attachment Common Lock nut wrench, 10 x 12 mm 040 kPa (0—0.4 kg/cmz, 076 psi) 507300 We [0.54.0 kg/cmz, 743 psi) 0740440030100 or 07404—0020000 or M937B—0217XXXXX (U.S.A. only) 07908—4220201 07510—MBOO101 07708—0030200 or equivalent in U.S.A. Date of Issue: June, 1984 ©American Honda Motor C0,, Inn. 1984 ~ All Right: Rsssrwd é HONDA VF700/750 INTERCEPTOR MAINTENANCE MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance perIod, I: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY. C: CLEAN, R' REPLACE, A: ADJUST WHICHEVER ODOMETER READING (NOTE 4) FREOUEch COMES \ \ \ x x x x \ \ FIRST ‘5‘ gf‘ g5 85 5 5$ 55 1 $S$$$$ éi§ We ‘33 33:" N '5’ «9;? (3;? Refer to ITEM EVERv \ \ x \ \ \ Page ' FUEL LINES I I I 3-4 ‘ FUEL FILTER R 3-4 ' THROTTLE OPERATION I I I I 3-5 * CARBURETOR-CHOKE I I I 3-6 V, ‘ AIR CLEANER NOTE 1 R R R 3-6 5 CRANKCASE BREATHER NOTE 2 c C C c c c 3-7 ’2 SPARK PLUGS R R R R R R 3-7 E ' VALVE CLEARANCE I I I I 3-8 3 ENGINE OIL YEAR R R R R 2-3 ‘3; ENGINE OIL FILTER YEAR R R R R 2-3 5 ' CARBURETOR-SVNCHRONIzATION I I I I 310 a * CARBURETOR-IDLE SPEED I I I I I I I 3-11 g RADIATOR COOLANT I I -R 3-11 m ' RADIATOR CORE I I I 312 ~ COOLING SVSTEM HOSES 81 I I I I 3-12 CONNECTIONS 1 EVAPORATIVE EMISSION CONTROL SYSTEM NOTE 3 ' I ' 3'12 DRIVE CHAIN I EVERv 3-15 300 m1 (500 km) BATTERv MONTH I I I I I I I 3-15 9 BRAKE FLUID MONTH I I I I “R I I ‘R 3_17 E 2 VEARS “R E BRAKE PAD WEAR I I I I I I 3-17 “I: BRAKE SYSTEM I I I I 3-17 3 v BRAKE LIGHT SWITCH I I I I 313 E - HEADLIGHT AIM I I 1 I 3-1 a CLUTCH FLUID MONTH I . g “EARS ,R I I I R I I ‘R 3-13 5 CLUTCH SYSTEM I I I I 3-13 ”21‘ ' SIDE STAND I I I 3-19 <2 1 SUSPENSION I I I I 3-19 - NUTS, BOLTS, FASTENERS I I I I 3-21 " WHEELS I I I I 3-21 .. STEERING HEAD BEARINGS I l l I 321 “ SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESSTHE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLV QUALIFIED ” IN THE INTEREST OF SAFETY, WE RECOMMEND THATTHESE ITEMS BE SERVICED ONLV BY AN AUTHORIZED HONDA DEALER, NOTES 1. SERVICE MORE FREQUENTLV WHEN RIDING IN DUSTY AREAS. 2. SERVICE MORE FREQUENTLV WHEN RIDING IN RAIN OR AT FULL THROTTLE 3. CALIFORNIA TYPE ONLY (Alter ’83) 4, FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE. Dale 01 Issue OcIober, 1984 ©AmeIIcan Honda MoIor Co, Inc. 1934 - AII nghts Reserved 3-3 HONDA v45 muncmon MAINTENANCE FIIEL lINES Remove the seat and left side coverv Check the fuel lines and replace any parts which show deterioration, damage or leakage, FUEL LINES FIIEL FILTER anaemic mm Gasoline is flammable and is explosive under certain condition: Do not smoke or allow flame: or sparks in your working area Replace the fuel filter with a new one when indicat~ ed by the maintenance schedule (page 3-3). Remove the left side cover. Remove the electric panel mounting bolts and remove the coolant reserve tank. Unclip the fuel filter holder from the bottom of the electric panel. FUEL FILTER Disconnect the fuel outlet line from the fuel filter. Pull the fuel filter out then clip the inlet line closed, Disconnect the fuel inlet line Install the fuel filter. After installing] turn the fuel valve on and check that there are no fuel leaks. Date of Issue: January, 1983 3'4 © HONDA MOTOR co., LTD. é HONDA v45 INTERCEPTOR THRllTTLE UPERATIDN Check that the throttle grip opens smoothly to full throttle and fully closes automatically, in all steer- ing positions. Check the throttle cables and replace them it they are deteriorated, kinked or damaged. Lubrtcate the throttle cables [page 2-11), it throttle operation Is not smooth. Measure throttle grlD free play at the throttle grip flange. FREE FLAV12—6 mm (1/8—1/4 in) Adjustment can he made at either end of the throttle cable. Minor adjustments are made with the upper adjuster and major adjustments are made with the lower adjuster after removing the fuel tank and air cleaner easel Adjust the loosening the lock nut and turning the adjuster. Tighten the lock nut and recheck throttle operation. |nsta|l the air cleaner case and fuel tank, and check throttle free play once more. Also check for fuel leaks. MAINTENANCE LOCK NUT UPPER ADJUSTER LOWE R ADJUSTE R LOCK NUT Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. MAINTENANCE é HONDA v45 INTERCEP‘I’OR BARBURETOR BHllllE The V45 choke system uses a fuel enrichening circuit controlled by a bystarter valve. The by- staner valve opens the enrichening circuit via cable when the choke lever on the handlebar is pulled back. Check for smooth operation of the choke lever. Lubricate the choke cable, if the operation is not smooth. Pull the choke level on the handlebar all the way back to fully open. Make sure the choke valve is open by trying to move the choke lever on the carburetor, after removing the fuel tank and air cleaner case. There should be no free play. Adjust lr necessary, by loosening the choke cable clamp on the carburetor and movmg the choke cable casmg so the choke lever ls fully open Tighten the clamp. Push the choke lever up all the way to fully closed Make sure the choke valve is fully closed by check- Irlg for free play in the cable between the lever on the carburetor and cable casingv Relnstall the removed parts in the reverse order of disassembly. AIR CLEANER Remove the fuel tank Remove the air cleaner cover screws and the cover. CHOKE LEVER CLOSED CHOKE CABLE AIR CLEANER CASE COVER Date 0! Issue: January, 1983 © HONDA MOTOR 00., LTD, é HONDA v45 INTERCEP‘I’OR Remove the spring clip and the air cleaner element. Discard the element in accordance with the main- tenance schedule. Also, replace the element any time it is excessively dirty or damaged. Install a new element and secure it with the spring clip. Install the air cleaner cover and fuel tank, CRANKCASE BREATHER Remove the plug from the drain tube to empty any deposits, Install the drain plug. NOTE Service more frequently when riding in ram or at full throttle, or if the deposit level can be seen In the transparent section of the drain tube, SPARK PLUES RECOMMENDED SPARK PLUGS HT ‘ mg"? NE) Standard DPRsEArs lx24EPRru9 For cold Climate l— , lBeIow5°c,41”Fl DPR7EA79 IXZZEPRVUQ Forextended 7 ’ high speed riding DPRQEA-S X27EPR~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 USan a wire-type ieeler gauge. SPARK PLUG GAP: (LB—0,9 mm (01131—01335 inl Adjust by bending the side electrode carefully. With the plug washer attached, thread each spark plug in by hand to prevent crossthreading. Continue tightening by hand until the spark plug bottoms. Then, tighten the spark plugs another 1/2 turn with a spark plug wrench to compress the plug washer. Connect the spark plug caps. SE '. TSPRING AIR CLEANER ELEMENT DRAIN PLUG CENTER ELECTRODE SIDE ELECTRODE f (0.031 ~0.035 in) MAINTENANCE 0.8—0.9 mm Date of Issue: January, 1983 © HONDA MOTOR CO‘, LTD. MAINTENANCE VALVE CLEARANCE NOTE Inspect and adiust valve clearance while the engine iscold. (Below 35“c, 95°F) Remove the lower radiator cowl, Drain coolant from engine and lower radiator (page 6-3). NOTE Drain the coolant into a clean container for reuse. Scheduled coolant replacement is every 24,000 miles (38,400 km). Remove the seat and remove the left and right side covers. Turn the fuel valve off and remove the fuel tank. Remove the upper radiator (page 6-5). Remove the spark plug caps. Remove the front and rear cylinder head cover bolts and both cylinder head covers. Remove the alternator cover. INSPECTION Measure and adjust the intake and exhaust valve clearances as described below. Rotate the crankshaft counterclockwise to align the 713 mark with the crankcase mating surfacesc Make sure the No.1 piston is at TDC (Top Dead Center) on the compression stroke. 3-8 HONDA V45 INTERCEP‘I'OR REAR CYLINDER HEAD COVER No.36YLlNDEH No,1 CYLINDER FRONT CYLINDER HEAD COVER No. 4 CYLINDER T13 MARK REAR CRANKCASE MATING SURFACE Date of Issue: October, 1983 © HONDA MOTOR CO., LTD. MAINTENANCE VALVE CLEARANCE NOTE Inspect and a ust valve clearance wh e the eng ne cold. (Below 35°C, 95°F) Remove the lower radiator cowl. Drain coolant from engine and lower radiator (page 6-3). NOTE Drain the coolant into a clean container for reuse. Scheduled coolant replacement is every 24,000 miles (38,400 km). Remove the seat and remove the left and right side coverss Turn the fuel valve off and remove the fuel tank. Remove the upper radiator [page 65). Remove the spark plug caps. Remove the front and rear cylinder head cover bolts and both cylinder head covers. Remove the alternator cover. INSPECTION Measure and adjust the intake and exhaust valve clearances as described below. Rotate the crankshaft counterclockwise to align the T13 mark with the crankcase mating surfaces. Make sure the No.1 piston is at TDC (Top Dead Center) on the compression stroke, HON DA V45 INTERCEPTOR REAR CYLINDER HEAD COVER No.30VLINDER No,1 CYLINDER FRONT CVLINDER HEAD COVER No.2 CYLINDER REAR CRANKCASE MATING SURFACE Date of Issue: October, 1983 © HONDA MOTOR 00., LTD. all} i. HONDA v45 INTERCEPTOR Check the valve clearances for the No.1 cylinder using two feeler gauges for each pair of valves; one for each valve that shares a common rocker arm. VALVE CLEARANCE (m, EX): 0.1; mm (0.005 in) If adjustment is needed, loosen the lock nuts and turn the adjusting screws until there is a slight drag on both feeler gauges. Both feeler gauges should remain inserted during adjustment. Hold the adjusting screws and tighten the lock nuts. TORQUE: 21—25 N-m (2.1—2.5 kg-m/15—1B ft-lbl CAUTION The lock nut: will L’OMP loose ifnot tightened to the correct torque value. Recheck the valve clearance. Rotate the crankshaft 90° counterclockwise to align the T2.4 mark with the crankcase mating surfaces and check the valve clearances for the No.4 cylinder. Adjust using the procedures for the No. 1 cylinder. Rotate the crankshaft 270° counterclockwise to align the T13 mark with the crankcase mating surfaces and check the valve clearances for the No.‘ 3 cylinder. Adjust using the procedures for the No. 1 cylinder. Rotate the crankshaft 90° counterclockwise to align the T2.4 mark with the crankcase mating sur» faces and check the va|ve clearances for the No. 2 cylinder. Adjust using the same procedures as for the No. 1 cylinder. Install the rear cylinder head cover with its tabs racing forward. MAINTENANCE FEELER GAUGE LOCK NUT WRENCH, 10 x 12 mm 07708—0030200 TABS Date of Issue: October, 1983 ©HONDA MOTOR 00., LTD, HONDA VF700/750 INTERCEPTOR MAINTENANCE Install the front Cyllndef head cover wIth Its tabs H faCIng down Install the removed parts, except the radiator cap, ”1 the reverse order of dlsassemblyv Check the Engll’le all level. Fill the radiator wlth clean coolant to the specified V level, NOTE After filling the radiator, start the engine and rev lt at least three times to remove any air bubbles from the cooling systems Add more coolant mixture as necessary. lnstall the radiator cap NO.7CVL|NDER No.1 CYLINDER CARBURETflR SYNCHRUNIZATIDN HEADPORT HEADPOF‘T NOTE Synchronize the carburetors Wlth the engine at normal operating temperature, transmission in neutral and motorcycle on the centerstand. Remove the plugs from the No. l, 2, 3 and 4 \_, cylinder head ports and install the vacuum gauge adapters. Connect the vacuum gauges. VACUUM GAUGE 07404—0020000 or M93737021—XXXXX lU.S.A. onlyl ADJUSTMENT _ l U NOTE The No. 4 carburetor cannot be adjusted; It ls the base carburetor. Start the englne and adjust the idle speed, IDLE SPEED: VF750F: 1,000 i 100 rpm VF700F:1,200 t 100 rpm Check that all carburetors are within 60 mm (2.4 In) Hg. Date of Issue: June, 1984 3' 1 O ©Amencan Honda Motor Co., |nc,1984 ~All Right: Reserved HONDA vr7oo/7so INTERCEPTOR MAINTENANCE Synchronize to specification by turning the adr justing screws with carburetor pllol screw tench l07908—4220201lt Recheck the idle speed and synchronization. Remove the gauge adapters and install the plugs, EARBURETUR IDLE SPEED NOTE 0 Inspect and adjust idle speed aner all nther engine adlustments are within specifications. IThe engine must be warm lor accurate adjusts rnent. Ten mlnutes of stoprand-go riding is sufficient Warm up the englne, shift to NEUTRAL, and place the motorcycle on its center stand Turn the throttle stop screw as required to Oblaln the spectfled idle speed. IDLE SPEED: VF750F:1,000 1100 rpm VF700F: 1,200 i 100 rpm RADIATOR BlllllllNT Remove the frame left Slde cover. Check the coolant level of the reserve tank with the engine tuning at normal operating temperature The level Should be between the “UPPER” and "LOWER" level liness If necessary, remove the reserve tank cap and fill to the ”UPPER” level llne with a 50/50 mixture of distllled water and antHreeze. Reinstall the cap and frame side cover, V SCREW N92 ADJUSTING SCREW CARBURETOR PILOT SCREW No.3 ADJUSTING’ No.1 ADJUSTING SCREW THROTTLE STOP SCREW "UPPER” MARK W R ENCH 07908—4220201 ls. "LOWER" MARK Date ol Issue: July, 1984 © HONDA MOTOR C0,, LTD. 3-11 MAINTENANCE HONDA VF700/750 INTERCEPTOR RADIATOR CORE Check the air passages Ior clogging or damage Straighten bent fins and collapsed core tubes. Remove insects, mud or any obstruction with come pressed air or low water pressure. Replace the ISdlBlOI' if the air Ilow is restricted over more than 20% of the radiating surlace, COOLING SYSTEM HOSES & CONNECTIONS Inspect the hoses lor cracks or deterioration, and replace iI necessary, Check the tightness of all hose clamps. EVAPORATIVE EMISSION CONTROL SYSTEM (After '83 California model only) Check the luel tank breather tube between the tank cap and the canister, and the vacuumtube between the canister and the purge control valve lor deten- oration, clogging, damage or loose joints or con nections WATER HOSES PURGE CONTROL VALVE 3-12 Dale ol Issue October, 1984 (57 American Honda Motor Co , lnc 1934 - All Rights Reserved HONDA V45 INTERCEP‘I’OR Check the canisters for cracks or damage. CYLINDER BflMPRESSIflN Warm up theengine. 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: 1,300 2 200 kPa (13.0 t 2.0 kg/cm", 185 t 28 psi) If compression is low, check for the following: 7 Improper valve clearance - Leaky valves » Leaking cylinder head gasket — Worn piston/ring/cvlinder ii compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and/or the piston crown. Date of Issue: October, 1983 © HONDA MOTOR CO” LTD. MAINTENANCE COMPRESSION GAUGE ATTACHMENT 07510—M500101 or commercially available in USA, 3-13 HONDA v45 mmczwon MAINTENANCE DRIVE CHAIN Turn the engine 0“, place the momrcycle on its center stand and shift the transmission into neutral. Check flack in the drive chain lower run midway be tween the sprockets. SLACK: 15—25 mm (5/8—1 in) CAUTION ExEssive chain unaffilim {‘2 m) or mare, may damage the frame. 15/8—1 in) REAR END OF SWINGARM GRADUATED SCALE AXLE NUT Adjust as foilows: Locsen the axle nut. Loosen the adiusting bolt lock nuts. Turn both adjusting bolts an equal number of turns until the correct drive chain slack is obtained. CAUTION Make sure that the same alignment marks on both adjusting plate: align with the ends of the :wmgarm. Tighten the adjusting bolt lock nuts. Tighten the rear axle nut. TORQUE: 85~105 N-ml8t5—1D.5 kg-m, 61—76 ft-Ib) ADJUSTING BOLT LOCK NUT ADJUSTING PLATE Recheck chain slack and free wheel rotation. Lubricate the drive chain with SAE 80 or 90 gear oil. RED ZONE REAR END OF SWINGARM Check the chain wear label. If the red zone on the label align, or is beyond, the rear end of the swing- arm after the chain has been adjusted, the chain must be replaced. REPLACEMENT CHAIN: D.I.D. 50V or RKEDMO Date of Issue: October, was 3' 14 © HONDA MOTOR co., LTD. HONDA V45 INTERCEPTOR é 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 DAMAGED WORN sprocket which is damaged or excessively worn. NOTE Never install a new drive chain on worn spro» chets or a worn drive chain on new sprockets. Both chain and sprockets must be in good condition or the replacement chain or spro- ckets will wear rapidly. BATTERY Remove the right frame side cover and inspect the. battery fluid level. When the fluid level nears the lower level, remove the battery and add distilled water to the upper level line as follows: Remove the battery holder bolt, then swing the holder out of the way. Disconnect the negative cable at the battery, then disconnect the positive cable. Disconnect the battery breather hose from the battery, Pull the battery out, remove the filler caps and add distilled water to the upper level line. Reinstall the filler caps and the battery. NOTE Add only distilled water. Tap water will shorten the service life of the battery. m The battery electrolyte contains sulphuric acid Protect your eyes, skin, and clothing. If electrolyte gets in your eyes, flush them thoroughly wlth water and get prompt medi- cal attention. NORMAL UPPER LEVEL LOWER/LEVEL POSITEVE CABLE HOLDER BOLT FILLER CAPS EHEATHER HOSE NEGATIVE CABLE Date of Issue: October, 1983 © HONDA MOTOR (30.. LTD. 3-15 MAINTENANCE HONDA v45 Immcmon BRAKE FLUID Check the front brake fluid reservoir level. If the level nears the lower level mark, fill the re- servoir with DOT-4 BRAKE FLUID to the upper level mark. check the entire system for leaks, if the level is low. CAUYION Do not remove the cover until the handle» bar hax been turned to that the reservoir ix level. ' Avoid opemting the brake lever with the cap removed. Brake fluid will Squirt out if the lever is pulled. ’ Do not mix different type: offluid, ax they are not compatible Refer to section 16 for brake bleeding procedures. BRAKE PAD WEAR Check the brake pads for wear by looking through the slot indiCated bv the arrow cast on the caliper assembly. Replace the brake pads if the wear line on the pads reaChes the edge of the brake disc (page 16-5]. CAUTION Always replace the brake pads I assure even dxxt prexmre. BRAKE SYSTEM Inwect the brake hoses and fittings for deterio- ration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. BRAKE DISC UPPER LEVEL LOWER LEVEL UPPER LEVEL B RAKE PADS ARROW FRONT Q- LowEn LEVEL ARROW BRAKE DISC BRAKE PADS 3-16 Date of Issue: October, 1983 © HONDA MOTOR 00., LTD. HONDA V45 INTERCEPTOR MAINTENANCE BRAKE lIEHl SWlTCH BRAKE LIGHT SWITCH ADJUST‘NG NUT tut, Adjust the brake light switch so that the brake light will come on when the brake engagement begins. Adjust by holding the switch body and turning the adjusting nut. Do not turn the switch bodv. Turn the adjusting nut clockwise if the brake light comes on too late. HEADLIGHT AIM Adjust vertically by turning the vertical adjusting screwt Turn the adjusting screw clockwise to direct the beam down. Adjust horizontally by turning the horizontal adjusting screw. Turn the adjusting screw clockwise to direct the beam toward the right side of the rider. NOTE Adjust the headlight beam as specified by local laws and regulations, —, An impmperly adjum’d headlight may blind oncoming drivers, or i! may fail In light the roadfor a safe distance, I VERTICAL ADJUSTING SCREW CLUTCH UPPER LEVEL MARK check the clutch fluid reservoir level. if the level nears the lower level mark, fill the reservoir with DOT-4 BRAKE FLUID until the level is between the upper and lower level mark. Check the entire system for leaks, if the level ls low. CAUTION - Do not remove the cover until the hand- lebar hat been turned so that the rexervoir ix [weL . Avoid operating the clutch [ever with the cap removed. Fluid will squirt out if the l lever is pulled. - Do not mix different typex 0f fluid, as they are not compatible. LOWER LEVEL MAR K Date of Issue: October, 1983 ©HONDA MOTOR co., LTD. 3- 1 7 % HONDA v45 INTERCEP'I'OR MAINTENANCE SIDE STAND check the rubber pad for deterioration or wear, Replace ii any Wear extends to wear line as shown. Check the side stand spring for damage and loss of tension and the side stand assembly for freedom of movement. Make sure the side stand is not bent. GOOD NO 6000 NOTE / When replacrng, use a rubber pad with the 4—WEAHLINE mark "Ovei 260 lbs ONLY'C ~ Spring tension IS correct if the measure , merits lei within 2—3 kg [4.4—6.6 (b), l 0 when pulling the side stand lower end With L 7 a spring scaie. SUSPENSION Do not ride a vehicle with [nu/1y suspension, Loose, worn or damaged suspension pans impair vehicle stability and control FRONT Check the action 0f the frant forks by compressing them several times, Check the entire fark assembly for leaks in damage. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Check the front fork air pressure when the forks are Cold. Place the vehicle on its center stand. Remove the air valve cap and measure the air pressure. AIR PRESSURE: 0—40 kPa (0—0.4 kg/nml= 0—6 psi) AIR VALVE 3- 8 Date of Issue: October, 1983 1 © HONDA MOTOR (30., LTD. HONDA v45 INTERCEP'I'OR ANTIVDIVE SYSTEM INSPECTION Select a safe place away from traffic in perform this inspecrivn. Check the operation of (he anti-dive system by riding the motorcycle and firmly applying the brakes, Position Vfltifiivedamperffforce I LIGHT ANTI-DIVE || MEDIUM III HARD . Iv MAXIMUM ANTI-DIVE , Inspect and if necessary, repair Ihe Svslem (Reier to section 14). REAR Place the motorcche on Its center stand. Move the rear wheel Sideways wnh force to see if me swingarm bearings are worn. Replace Ihe bearings if there Is any looseness (page 1514). Check the shock absorber for leaks or damage. Tighren aIl rear suspension nuts and boils. Remove the frame lefi side cover. Remove the valve cap and measure the shock absorber air pressure. REAR SHOCK ABSORBER AIR PRESSURE: 50—300 kPI (0.5—3.0 kg/cm’, 7—43 psi) N9TI§ Check the air pressure when the shock ab- sorber is cold. MAINTENANCE AIR VALVE Date of Issue: October, 1983 © HONDA MOTOR (30., LTD. MAINTENANCE é HONDA v45 INTERCEP'I'OR NlITS, BfllTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (Section 1) at the intervals shown in the Maintenance Schedule (Page 33). Check all cotter pins, safety clips, hose Clamps and cable stays. WHEELS NOTE Tlre pressure should be checked when tires are COLD. Check the tires for cuts, imbedded nalls, or other sharp objects. RECOMMENDED TIRES AND PFIESSURES: 77777 FrorT ' 7' Rear Tire Slle MUD/8046 MlSO/BIHS Up to ‘ 90 kg Cold (ZOOlbsl l 225l2.25,32) 225l2.24,32l "’9 load l weir sure 90 k9 DSI lZOlesl kpa' loadm (kg/mi, vemcle 225l2.25,32) 280 (13,40) psi) CapacllV , a, "’35.. BRIDGE- l Tire (3511 0le brand two“: 7 i‘ DUNLOP K527A K627 Check the front and rear wheels for trueness lSec» tion14 and 15). Measure the tread depth at the center of the tires. Replace the tires if the tread depth reaches the following Ilmit: Minimum tread depth: Front: 15 mm (1/16 in) Rear: 2.0 mm (3/32 in) STEERING HEAD BEARINGS NOTE Check that the control cables do not interr fere with handlebar rotation. Raise the front wheel off the ground and check that the handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steerlng head hearing by turning the steering head adjusting nut (page 1484). 3-20 Date of Issue: October, 1983 © HONDA MOTOR (30., LTD. HON DA V45 INTERCEPTOR MAI NTE NANCE MEMO Date of Issue: chober, 1983 ©HONDA MOTOR 00., LTD‘ 3-21 FUEL SYSTEM HONDA v45 INTERCEPTOR 4-0 Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. HONDA vr700/7so INTERCEPTOR 4. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING CARBURETOR REMOVAL VACUUM CHAMBER FLOAT CHAMBER PILOT SCREW CARBURETOR SEPARATION CARBURETOR ASSEMBLY FUEL TANK AIR CLEANER FUEL PUMP (USA only) oestrous» awmmawna CONTROL SYSTEM CARBURETOR INSTALLATION PILOT SCREW ADJUSTMENT HIGH ALTITUDE ADJUSTMENT 2 EVAPORATIVE EMISSION 4—15 4—16 4—17 4—17 4713 4—18 (After '83 California model only) SERVICE INFORMATION GENERAL WWARNING or allow flame: or spark in [he work ma. Gasoline ix ewrrmelw flammah/e and is rvplasitiz under ('Pl‘lalrl t-ondi/iom. Work in a well ventilated area. Do n01 .tmokrr The front cylinders use down draIt carburetors When disassembling Iuel system parts, note the locations oi the Orrings. Replace them with new ones on reassembly. The lloat bowls have drain screws that can be loosened to drain residual gasoline. Fuel pump Inspection is in section 20. The No. l and No 3 carburetors use different jet needles (thinner) and shorterspringsthanthe No. 2 and No, 4 carburetors. Do not interchange these parts. TOOLS Special Valve guide driver, 7 mm Pressure pump Vacuum pump Common Float level gauge SPECIFICATIONS 0794278230000 (USA, only) STVAH72557MC7 (u.s,A. only) ST-AH-ZSO—MC7 to SA. only) 07401—0010000 '83 After '83 After '83 Cal Carburetor type KEIHIN VD Throttle bore 32 mm (1.26 in) Venturi bore 30 mm (1.18 In) ID, No. VF750F/VF700F VDSZB VDSZC/VDSZD VDOSA/VDOBB Mam m VF750F Front and rear' #123 Front: #112, Rear, #110 Front and rear: #128 VF700F Front. #112, Rear: #110 Front and rear: #122 Float level 7.0 mm (028 in) Idle speed VF750F: 1,000 1100 rpm, VF700F, 1,200 1100 rpm Throttle grip tree play 276 mm (008—024 in) Pilot screw initial opening See page 4-1 6 Date of Issue' October, 1984 © American Honda Motor Co, Inc 1984 - All nghts Reserved HONDA V45 INTERCEP‘I'OR FUE L SYSTEM BARBURETIIR REMflVAl AIR CLEANER CASE Turn the fuel Valve off. Remove the left and right side covers. Remove the seat and fuel tank. Remove the fairingt Disconnect the breather hose and remove the air cleaner case by removing five screws. BHEATHER HOSE CHOKE CABLE Remove the heat insulator plate Disconnect the choke and throttle cables from the carburetor. Loosen all carburetor bands and remove the car- buretor assembly from the intake pipes. V lNTAKE PIPES Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. FUEL SYSTEM Lift the carburetors out of the frame. Disconnect the fuel line from the carburetor. VABU‘IIM CHAMBER REMOVAL Remove the four vacuum chamber cover screws and cover. CANNON Do not interchange vacuum chamber covers, springs, piston: or iet needles between my- buretors. Remove the compression spring, draphragm and vacuum piston. Inspect the vacuum prston for wear, nicks, scratches’ or other damage. Make sure the piston moves up and down freely m the chamber. NOTEV No. 1 anti No. a carburetors use thinner jet needles and shorter springs than the No.2 and No.4 carburetors. HONDA V45 INTERCEFI'OR FUEL LINE COMPRESSION SPRING DIAPHRAGM VACUU PISTON 4-4 Date of ‘Issue: January, 1983 © HONDA MOTOR (20., LTD. HONDA v45 INTERCEP‘I’OR 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. Inspect the needle (or excessive weal at the tip and for bending, or other damage. Check for a torn diaphragm or other deterioration. INSTALLATION Installation is essentially the reverse of removal but to keep from distorting the diaphragm, install the vacuum piston/diaphragm as follows: Insert the vacuum piston into the carburetor. Stick your finger into the carburetor bore and hold the vacuum piston in the full throttle position, then turn down the diaphragm so its lip fits into the carburetor groove. Install the chamber cover, aligning its cavity with the hole in the carburetor, and secure with at least two screws before releasing the vacuum piston. NOTE Fug svsrem NEEDLE HOLDER DIAPHRAGM / SPRING . New”? NEEDLE HOLDER \ Be sure the thinner jet needles and shorter springs are installed in the No. 1 and No. 3 carburetors. CAVITV Date of Issue: October, 1983 © HONDA MOTOR (20., LTD. FU E L SYSTEM FUJAT CHAMBER REMOVAL Remove the four float chamber screws and the float chamber. FLOAT LEVEL Measure the float level with the carburetor inclined 15°—45° from vertical and the float tang just contacting the float valve. FLOAT LEVEL: 7.0 mm (0.28 in} Adjust the float level by carefully bending the float tang. F LOAT AN D JETS Remove the float pin, float and float valve. HONEA v45 INTERCEPTOR FLOAT CHAMBE R v SCREWS FLOAT LEVEL GAUGE 07401—0010000 FLOAT PIN 4-6 Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. HONDA v45 INTEICEP'I'OR FUEL SYSTEM VALVE SEAT Inspect the float valve for grooves and nicks. Inspect the operation of the float valver FLOAT VALVE F LOAT VALVE MAIN JET SEAT Remove the starter jet, maln jet and slow jet. Remove the float valve seat and filter. STARTER JéT' SLOW JET FILTER VALVE SEAT Inspect the float valve seat and filter for grooves, nicks or depositst ASSEM B LY Assemble the float chamber components in the reverse order of disassembly. ”Jr, Date of Issue: January, 1983 _ ©HONDA MOTOR car, no. 4 7 HONDA v45 INTERCEPTOR FUEL SYSTEM PILOT SCREW REMOVAL NOTE The pilot screws are factory preset and should not be removed unless the carbure tors are overhauledv I . The pilot screw plugs are factory installed l to prevent pitot screw misadiuslmenl, Do not remove the plugs unless the pilot screws are being removede \ ' Cover all openings with tape to keep metal ‘ particles out when the plugs are drilled. Center punch the pilot screw plug to center the drill point. Drill through the plug with a 4 mm (5/32 in) drill bit being careful not to drill into the pilot screw. CAUTION Be careful no! to grill into the pilot screw, All pilot screws mun be replaced even if only one requires it for proper pilo! screw all/us!- ment (page 4 Force a selirtapping 4 mm screw (H/C 069399, P/N 93903—35410) into the drilled plug and continue turning the screwdriver until the plug rotates With the screw, Pull on the screw head with pliers to remove the plug, Use compressed air to clean the pilot screw area and remove metal ShZVIngS. Date of Issue: January, 1983 4"8‘ © HONDA MOTOR CO., LTD. HONDA v45 INTERCEP'I'OR FUE L SYSTEM Turn each pilot screw in and carelully count the number of turns before it seats lightly. Make a note of this to use as a reference when reinstalling the pilot screws, CAUTION Damage [0 the pilot screw seat will 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. INSTALLATION Install the pilot screws and return them to their original position as noted during removals Perform pilot screw adjustment if new pilot screws are installed (page 4-16). NOTE Do not install new plugs until after adjust ment has been made. made. ~ It you replace the pilot screw in one car buretor, you must replace the pilot screws in the other carburetors for proper pilot screw adjustment CARBURETUR SEPARATIUN Remove the screws attaching the air chamber to the carburetors and separate the chamber and carbuv retorst WASHER Q \ PILOT SCREW AIR CHAMBER SCREWS Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. 4-9 HONDA FUEL SYSTEM V45 INTERCEPTOR CHOKE LEVERS AND RODS Remove the nuts, and remove the choke levers and rods. Remove the cotter pins and washers, and remove the choke rode CHOKE ROD SYNCHRONIZATION Na 1 FUEL No.3 SPRINGS CAHBURETOH JOINT PIPE CARBURETOR CarefulIv separate the Not I carburetor from the assembly. Then separate the No.2 carburetor, CANON! Separate the carburetors horizontally to pre- vent damage to the faint pipex , .4 No.2 TH‘RUST AIR JOINT No. 4 CARBURETOR SPRINGS PIPES CARBURETOR THROTTLE LINK Disconnect the throttle Iink from the No.3 and 4 caburetors by removing the cutter pins. 4- 1 Date of Issue: January, 1983 0 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEP'I'OR FUEL SYSTEM FUEL JO|NT PIPE No. 4 CARBURETOR ad»), No.3 CARBURETOR Carefully separate the No. 3 and No. 4 carburetors. CHOKE ARM SPRING COLLAR Remove the choke arm collar and remove the choke arm and spring. Remove the choke valve nut, spring and vaWe. CHOKE VALVE Check the Choke valve and spring for nicks, grooves, - or other damage. SPRING Date of ‘Issue: January, 1983 © HONDA MOTOR co., LTD. 4‘ 1 1 FUEL SYSTEM CARBlIRETflR ASSEMBLY install the Choke valve, valve spring and nut and tighten the nut. Install the choke arm and spring while hooking the arm to the aroma in the choke valve. Install the choke arm collar. Goa! the new O-rings with oil and install them on the fuel joint pipe for No. 3 and No. 4 carburetors. install the fuel joint pipe to the No.3 and No.4 carburetors. Reconnect the throttle linkage between the No. 3 and No. 4 carburetors, using new cotter pins. HONDA V45 INTERCEPTOR SPRING COLLAR FUEL JOINT PIPE OVRINGS THROTTLE LINK No.4CAREURETOR CUTTERPINS i' No.3cARBuRET0Fi 4-12 Date of Issue: January, 1983 ©HONDA MOTOR (30., LTD. HONDA v45 INTERCEP'I'OR Coat new Ovrings with oil and install them on the fuel and air joint pipes. Put the Na. 1 and No. 2 carburetors together with the joint pipest Loosen the synchronization adjusting screws until there is no tension, Install the synchronization springs. Install the thrust springs between the throttle valve shafts. Make sure the fuel joint and air joint pipes are securely installed. Date of Issue: January, 1983 © HONDA MOTOR 60., LTD. FUEL SYSTEM FUEL JOINT PIPE AIR JOINT PIPES THRUST SPRING No. 2 CARBURETOR 1 No.2 SYNCHFIDNIZATION SPRING No.1SYNCHRONIZATION N0. 3 SYNCHRONIZATION SPRING SPRING No.10ARBURETOR THRUST SPRING 3 CARBURETOR 4-13 FU E L SYSTEM HONDA V45 INTERCEPTOR Install the choke rods and levers, using the nuts and new cotter pins. Make sure the air chamber funnels, grommets and dowel pins are in place. Place the air chamber over the carburetors aligning the dowel pins with the carburetor holes. Attach the air chamber to the carburetors with the eight screws. 4-14 CHOKE RODS AND LEVERS FUNNEL CHOKE ROD GROMMETS \W/V DOWEL PINS \v sanws Date of Issue: January, 1983 © HONDA MOTOR 60., LTD. é HONDA V45 INTERCEP'I'OR FUEL SYSTEM BV-PASS HOLE ' Turn the throttle stop screw to align the No.4 F‘ throttle valve with the edge of the by-pass hole. No. 4 CARBURETOR THROTTLESi’OP SCREW No. 2 ADJUSTING SCREW Align each throttle valve with the bypass hole edge bv turning the synchronization adjusting screws. Inspect throttle operation as described below. ~ Open the throttle slightly by pressing the throttle linkage. Then release the throttle. - Make sure that it returns smoothly. \/ ' Make sure that there is no drag when opening and closing the throttle. Make sure that choke valve operation is smooth by moving the choke linkage. Close the choke valve by turning the choke linkage. Release the choke linkage and make sure that it ‘ I returns smoothly. ’ No. SADJUSTING scnew No.1ADJUSlNG SCREW BARBllRETflR INSTALLMIIIN Installation is essentially the reverse of removal. NOTE Route the throttle and choke cables properly (page 1 Oto 1 12. \—r Perform the following inspections and adjustments. ~ Throttle operation (page 3-5). ~ Carburetor choke (page 345). ' Carburetor idle speed (page 3-11). ~ Carburetor synchronization (page 3-10). Date of issue: January, 1983 ©HONDA MOTOR 00., LTD. 4' 15 6 r FUEL SYSTEM PlLllT SCREW ADJUSTMENT lDLE DROP PROCEDURE (USA. ONLY) NOTE ~ The pilot screws are factory preset an o—‘l adjustment is necessary unless the pilot screws are replaced (page 4~8l. - Use a tachometer With graduations of 50 rpm or smaller that Will accurately indicate a 50 rpm change, L 1. Turn each print 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 adiustment, INITlAL OFENING: VF7EOF: 2-1/2 turns out VF700F: 3 turn: out ,,7¥77 _l CAUYION l Damage to the pilot Screw seat will on r i if the pilot screw it lightened against the j L 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: vF750F: 1,000 a 100 rpm VF700F:1,200 i 100 rpm 5. Turn each pilot screw 1/2 turn out from the initial setting. 5. If the engine speed increases by 50 rpm or THROTTLE STOP SCREW 7 HONDA. vr7oor7so INTERCEPTOR PILOT SCREW more, turn each pilot screw out by successive 1/2 turns until engine speed drops by 50 rpm or less. . Adjust the idle speed with the throttle stop screw. 8. Turn the No. 1 carburetor pilot screw in until the engine speed drops 50 rpm, 9, Turn the No. l carburetor pilot screw 1 turn out from the position obtained in step 8. 10. Adjusl the idle speed with the throttle stop screw, Perform steps 3, 9 and 10 for the No. 2, Sand 4 carburetor pilot screws. 12, Drive new pilot screw plugs into the pilot screw bores with a 7 mm valve guide driverlP/N 07942 78230000). When fully seated the plug surlaces Will be recessed 1 mm into the pil0t screw bore. \l 1 . PLUG PILOTSCREW 4-16 Date of Issue: June, 1954 ©American Honda Motor 00., Inc. 1964 - All nghts Reserved HONDA V45 INTERCEPTOR FUEL SYSTEM FUEL IANK D4) no! 11/“) {flamet- w sparks new gasuline, Wipe up spilled gasoline at once. Check the vent hoIe of the filler cap for bIockage. - Check that tuel I5 flowmg out of the luel valv» lreely, Make sure that there are no tuel leaks AIR CLEANER CASE/CHAMBER Check the a'lr cleaner case seal rubbers for deteriora» (Ion. CRAN KCASE VENTILATION SYSTEM \_ Check [hat the breather tube IS not restlicledt AIR CLEANER COVER AIR CLEANER ELEMENT SEAL RUBBER L I J BREATHER _ ‘ BREATHER HOSE W SEPARATOR @/\ SEAL RUBBER ‘ SEAL RUBBER ' I» a a) / fl 2%; INLET AIR DUCTS AIR CLEANER CASE \ Date of Issue. January, 1983 OHONDA MOTOR CO, LTD. 4' 17 FUEL SYSTEM FUEL PUMP Remove the seat and left side cover. Disconnect the fuel pump coupler. Turn the fuel valve oft. Remove the breather separator. Clip the fuel inlet line] then disconnect the fuel inlet and outlet lines from the fuel pump. Remove the fuel pump mounting bolts and fuel pump. Install the fuel pump in the reverse order of removal. HIGH lllTlTllllE ADIUSTMENT (USA only) When the vehicle is to be operated continuously above 2,000 m (6,500 feet) the carburetor must be readjusted as follows to improve driveability and decrease exhaust emissions. NOTE This adjustment must be made at high altir tude to ensure proper hlgh altitude operation. Warm up the engine to operating temperature. Stop and go driving for 10 minutes is sufficrent. Remove each pilot screw plug (page 478). Turn each pilot screwclockwise 1 turn. Adjust the idle speed with the throttle stop screw. IDLE SPEED: VF750F: 1,000 $100 rpm VF700F: 1,200 i 100 rpm Drive new pilot screw plugs Into the pilot screw bores [page 4716). é HONDA vr7ool7so muncznon. FUEL PUMP COUPLER {WEATHER SEPARATOR 4-18 Date of Issue: June, 1984 ©American Honda Motor 60., lnc.1584 , All Rights Reserved NEW HONDA v45 INTERCEPTOR FUEL SYSTEM Attach a Vehicle Emission Control Information Update label onto the frame as shown. Reler to Service Bulletin #SLIBZ for inlormation on obtain» ing the label, NOTE: Do not attach the label to any part that can be easily removed from the vehicle. m—_ Operation at an altitude lower than L500 m (5,000 feet) with the carburetor: adjusted for high altitudes may cause the engine to idle roughly and stall. When the vehicle is to be operated continously below 1,500 m (5,000 feet), turn Each pilot screw counterclockwise 1 turn to its original position alter removing each pilot screw plug and adiust the L VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL idle speed to 1,000 it 100 rpm. Drive new pilot screw plugs into the pilot screw bores (Page 446M Be sure tqdo these adjustments at low altitude. PllRliE IIIINTIIIII. VALVE INSPECTIflN (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. NOTE: TO 3WAY JOINT PURGE CONTROL VALVE VACUUM PUMP ST»AH»260MC7 lU.S.A. only) located under the l strument Disconnect the PCV hoses from the 3—wayJomt, the No. 2 carburetor, and the right charcoal canister. Removethe PCV from its mount. Refer to the rout- mg label attached tothe luel tank belowthe seat for hose connections. Connect a vacuum pump to the 8 mm ID. hose that goes to the 3-way joint. Apply the specriied vacuum to the PCV, SPECIFIED VACUUM: 250 mm (9.3 in) Hg The specilied 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 carburetor body. Apply the specified vacuum to the PCV. SPECIFIED VACUUM: 250 mm (9.8 in) Hg The specified vacuum should he maintained. Replace the PCV if vacuum is not maintained. BODY VACUUM PUMP ST-AH-260Mc7 (USA. only) Revised: July, 1984 © American Honda Motor Co.. Inc 1984 . All Rights Reserved my 7227 3407 4-19 FUE L SYSTEM Connect a pressure pump to the 8mm LO. hose that goes to the charcoal canistert While applying the specified vacuum to the PCV hose that goes to the carburetor body, pump air through the canister hose‘ Air should flow through the PCV and out the hose that goestorhe 3-way‘ornt, Replace the PCV it air does not flow out. CAUTION: To prevent damage In the purge tantra] valve, du not use high air pressure sources. Use a hand operated air pump only, Remove the pumps, install the PCV on its mount, route and reconnect the hoses according to the Vacuum Hose Routing Label, Be careful not to bend, twist or kink the tubes when installing, ~ Slide the end of each tube completely onto itstitting and securewiththe hoseclamosr ~ Secure with the hose clamps whenev’er specified, . Check that the hoses are not contacting sharp edges or corners, é HONDA V45 INTERCEPTOR P RESSURE PUMP ST-AH~255~MC7 (USA only) VACUUM PU MP ST-AH-260-MC7 (UtS‘At only) VACULM HOSE ROUTING DIAGRAM mm mutt — (autumn mmnm mm _ um utlrmu mum my utvr 4-20 Revrsed July, 1984 ©Amerrcan Honda Motor (20., Inc 1984 - All nghts Reserved MSV 7227 3407 MEN HONDA v45 INTERCEP'I'OR FUEL SVSTEM MEMO Date of Issue: October, 1983 © HONDA MOTOR (30., LTD. 4-21 HONDA V45 INTERCEP’IOR ENGINE REMOVAL/INSTALLATION 45—55 N-m 145—55 kg-m, 33—40 mm 24,30 Nm (la—3.0 kg~m,17722fl»lb} 50—54 N-m (5.0—5.4 kgm, 36—39 ftrlbl 35—45 N-m (3.5—4.5 kgrm, 25—33 ftrlb) Dme of Issue: January, 1983 5‘0 ©HONDA MOTOR co., LTD. é HONDA V"°°’75°'N"RCE"°R 5. ENGINE REMOVAL INSTALLATION SERVICE INFORMATION ENGINE REMOVAL ENGINE INSTALLATION atrium O’N-l SERVICE INFORMATION GENERAL A Iloor Jack or other adjustable support is required to suppon and maneuver the engine. Applv a heatrresist and black paint if the black chrome plating is scratched or scored. The interceptor muffler IS chrome-plated black. To clean the muffler, use a soft sponge and flush With a sullicientwater, After washing, let it dry and coat With nonrcompounded silicon wax. The following parts or components can be servtced With the engine installed In the frame: Clutch Alternator Gearshift linkage Starter motor Front cylinder head Carburetors SPECIFICATIONS Engine dry weight 81 5 kg (180 lb) Oil capacity ’837’84: 30 liters (32 U S qtz) After '84: 2.7 liters (2.9 u.s. qt, 2 4 Imp Qt) TORQUE VALUES Drive sprocket bolt 50—54 N m (5.0-5.4 kg-m, 36739 hrlbl Engine rear hanger bolts 45'55 Nvm (4.5—5 5 kg-m, 33—40 ft-lbi Engine center hanger bolts 24—30 N m (2,473.0 kgrm, 17722 hrlbi Engine front hanger bolts 35—45 Nvm (35—4 5 kg-m, 25733 hrlb) Sub-frame bolts 35—45 N m (3,574.5 kgrm, 25*33 Itvlb) Date at Issue' October, 1934 ©Ametican Honda Motor Co, inc. 1934 - All Rights Reserved 5- 1 ENGINE REMOVAL/INSTALLATION EIllIIIlE REMflVAl Place the motorcycle on its center stand. Remove the seat and left and right side coverss Remove the fuel tank. Drain the engine oil (page 2-3) and coolant (page 6-3). Remove the upper and lower radiators (page 65). Remove the clutch slave cylinder. NOTE Do not operate the clutch lever after removing the clutch slave cylinder; It will cause difi ficultv when reinstalling the slave evlinder Remove the gearshift arm from the shift shaft. Disconnect the neutral switch wire connector and alternator wire couplera Remove the drive sprocket cover. HONDA v45 Immcmon CLUTCH SLAVE CYLINDER GEARSHlFT ARM ALTERNATOR WIRE COUPLER NEUTRAL SWITCH WIRE CONNECTOR DRIVE SPROCKET COVER \l 2 / f, I Date of Issue: Januarv,1983 © HONDA MOTOR C0,, LTDV HONDA V45 lN‘I'ERCEP'I'OR ENGINE REMOVAL/INSTALLATION DRIVE SPROCKET BOLT Remove the drive sprocket bah. Then remove the drive sprccket with the drive chain. DRIVE SPROKCET DRIVE CHAIN AIR CLEANER CASE Remove the air cleaner case and the carburetors (03924-3). Remove the spark plug caps from the spark plugs. Remove the right and left mufflers. MUFFLER Date of Issue: January, 1983 © HONDA MOTOR (30., LTD‘ HONDA v45 INTERCEP'I'OR ENGINE REMOVAL/INSTALLATION Remove the bolt attaching the exhaust chamber to the left side of the engine. Remove the bait attaching the exhaust chamber to the right side of the frame. Remove the rear exhaust pipe clamp bolts, Remove the front exhaust pipe attaching nuts at the from cylinder headsi Remove the exhaust chamber from the engine REAR EXHAUST PIPE CLAMP BOLTS STARTER MOTOR CABLE Disconnect the starter motor cable from the starter "IOYOT. 5-4 Date of Issue: January, 1983 © HONDA MOTOR CO, LTD. HONDA V45 INTERCEPTOR Disconnect the pulse generator wire coupler. Disconnect the water hoses and the temperature sensor wire from the thermostat. Remove the thermostat housing. Disconnect the battery negative cable from the battery terminal. Free the starter motor cable from the clamp. Place the floor jack or other adjustable support under the englne. NOTE The jack height must be cent‘muously adjust- ed to relieve stress from bolts that are being removed. Remove the engine hanger bolts from the right side, Remove the frame-to-sub-frame bolt. ENGINE REMOVAL/INSTALLATION PULSE GENERATOR WIRE COUPLER Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. ENGINE REMOVAL/INSTALLATION Disconnect the crankcase breather hose. Remove the engine hanger bolts and nuts from the left side. Remove the sub-frame bolts. Carefully lower the engine and remove it from the left side ENEINE lllSTllLLllTlllll Check the englne mount rubbers for damage and replace ll necessary. Install the engine mount rubbers. Engine installation is essentially the reverse of removal. Use a floor lack or other adlustable support to carefully manuever the engine into place cannon # Carefully align mounting points with the jack to prevent damage to mounting bolt thread: and wire harnesx and cab! Tighten all fasteners to the torque values given on page 5-1. NOTE ' Route the wires and cables prope y pages 1-10 thru 1 712l, ~ Fill the crankcase to the proper level With the recommended oil lPage 2% Fill the coollng system (Page 5-3). - Perform the following inspection and ad~ justments: Throttle aperation (Page 3-5), Clutch (Page 3-18). é HONDA v45 mmcmon SUB-FRAME \ V r CRANKCASE BREATHER HOSE SUBVFRAME BOLTS CENTER HANGER BOLTS FRONT HANGER REAR HANGER SUB-FRAME BOLTS BO LTS BOLTS Date of issue: October, 1983 © HONDA MOTOR (20., LTD. HONDA v45 INTERCEPTOR ENGINE REMOVAL/INSTALLATION MEMO Date of Issue: January, 1983 _ ©HONDA MOTOR (30., LTD. 5 7 COOLING SYSTEM HONDA V45 INTERCEPTOR 6-0 Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. HONDA v45 mum“ E. CUflLING SYSTEM SERVICE INFORMATION 6—1 THERMOSTAT 6—4 TROUBLESHOOTING 6—1 RADIATOR/COOLING FAN 6—5 SYSTEM TESTING 6’2 WATER PUMP 6—9 COOLANT REPLACEMENT 6—3 SERVICE INFURMATIIJN GENERAL Do not remove [he radio/m cap when /he engine is hot. The coolant is under pressure and severe scalding could result. The engine ml/s/ be my! before Servit'ing the cooling sysrs'm. Use only distilled water and ethylene glycol In the cooling system. A 50750 lelUf‘e is recommended for maximum corroe slon protection. Do not use alcohol-based antifreeze, Add coolant at the reserve tank Do not remove the radiator cap except to refill or drain the system. All Cooling system service can be done with the engine in the frame. Avoid spilling coolant on painted surfaces. After servicing the system, check for leaks with a cooling system tester. Refer to Section 20 for fan motor thermostatic switch and temperature sensor inspections. SPECIFICATIONS 55% Distilled water + 45% ethylene glycol: —3z°c l—25°F) Radiator cap relief pressure 7, 75—105 kPa (0.75—1.05 kg/cmz, 10.77149 usll l l 50% Distilled water + 50% ethylene glycol: —37°C (—34% Freezing point (Hydrometer test): 45% Distilled water + 55% ethylene glycol: 445°C has" Fl Diff Coolant capaclty: Radiator and engine Reserve tank Total system 2.5 liters (2.65 us qt) 0.4 liters lo.42 Us qtl 29 liters (3.07 US qt) Thermostat Begins to open. so“ [0 84°C (175° [0 lea°l=l 4 Valve l'f - Minimum of 8 mm at 95°C (0,315 in at 203°l=l #5 Unpressurized: 107.7“0 (226°F) L ,. Boiling point (With 50—50 mixture): Cap on. pressurlled: 125.6°C (258°Fl TRIJIIBLESIIIJIJTING Engine temperature too high Engine Ismaerature too low F 1, Faulty temperature gauge or gauge sensor 1. Faulty temperature gauge or gauge sensor 2. Thermostat stuck closed 2, Thermostat sluck open 3. Faulty radiator cap H 4. Insufficient coolant Coolant leaks 5, Passages blocked in radiator, hoses, or water jacket 1. Faulty pump mechanical seal 6. Fan blades bent 2, Deterlorated O-rlngs 7. Faulty fan motor I Date or Issue: January, 1933 © HONDA MOTOR 00., LTD. 6‘ 1 COOLING SYSTEM SYSTEM TESTING COOLANT Test the coolant mlxlure wlth an antlfreele tester, For maximum corrosion protection, a 50—50% solutlon of ethylene glycol and dlstllled water is recommended RADIATOR CAP INSPECTION Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low. It must hold specified pressure for at least SIX seconds NOTE Before installing the cap on the tester, apply water to sealing surfaces. RADIATOR CAP RELIEF PRESSURE: 75—105 kPa (0.75—1.05 kg/cm2, 10‘7—143 psi) Pressurlze the radiator, engine and hoses, and check for leaks‘ CAUTION Exeex e pressure can damage the radiamn Do not exceed 1. 5 kg/cm2 (14.9 [’in Repair or replace components if the system erI not hold specllied pressure for at least slx seconds. HONDA v45 muncmon AIMTIFREEZE TESTER COOLING SYSTEM TESTER (COMMERCIALLY AVAILABLE) RADIATOR CA.“ 6-2 Date of Issue: Januarv, 1983 © HONDA MOTOR CO., LTD. HONDA V45 INTERCEPTOR COOLING SYSTEM CHOU," REPLACEMENT RADIATOR CAP CAUYION wall g xymm, or severe soak! g may result. V Remove the radiator cap. Remove the lower radiator cowl. Drain the coolant from the radiator by removing the drain plug at the lower radiator. fig/(,1 ""f. LOWER RADIATOR COWL DRAiN PLUG Drain the coolant from the engine by removing the drain bolts at the water pump cover and cylinder heads. Replace the drain plug and bolts. Fill the system with a 50750 mixture ol distilled water and ethylene glycol. Bleed air from the radiator. I Start the engine and run until there are no air bubbles in the coolant, and the level stabilizes. I Stop the engine and add coolant up to the proper level if necessary. a Rsinstali the radiator cap. 0 Check the level of coolant in the reserve tank and fill to the correct level if the level is low. 0 Install the lower radiator cowl. DRAIN BOLT DRAIN BOLT Date of Issue. January, 1983 _ © HONDA MOTOR C0., LTD. 6 3 HONDA v45 INTERCEPTOR COOLING SYSYEM THERMUSTAT WIRE CONNECTOR REMOVAL Turn the fuel valve OFF. Remove the seat, frame side covers and Vuel tank. Drain the coulant (page 6-3), Disconnect the temperature sensor wire connectur from the sensor. TEMPERATURE SENSOR THERMOSTAT HOUSING COVER Remove the thermostat hOUSIng cuver by removing t,‘ two bolts. Remove the thermostat frum the housing HOUSING Date of Issue: January, 1983 6-4 © HONDA MOTOR C04, LTD‘ HONDA v45 muncmon COOLING SYSTEM INSPECTION Inspect thermostat visually for damage. Suspend the thermostat in heated water to check is operatlon . NOTE if the thermostat or thermometer touches the pan, you’ll get a false readm Replace thermostat if valve stays open at room temperature, or if it responds at temperatures other than those specified. Technical Data h Start to open 80° to 84°C (176° — 183°FI 8 mm minimum (031 in) Valve lift when heated to 95°C l203°Fl for five minutes. INSTALLATION Install the thermostat into the housing. Install the thermostat housing cover with a new O-ring. Connect the temperature sensor wire connector. Install the fuel tank, frame side covers and seat. Fill the cooling system (page 6-3). RADIATllR/CIIIJLINE FAN lREMOVAL Remove the lower radiator cowl and radiator drain plug and drain the coolant. O UPPER RADIATOR Loosen the upper hose clamp and disconnect the upper hose. THE RMOSTAT THERMOMETEH HOUSING UPFE R HOSE ' 1- l. HOSE CLAMP Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEP'I'OR COOLING SYSTEM Remove flie radiator grille and side covers. Disconnect the radiator overflow tube. Loosen the joint hose clamp and disconnect the joint hose from the upper radiator. Remove the fairing (page 143). Disconnect the fan motor wire couplers from the main harness at the right side. Remove the upper radiator mount bolts and remove the radiator from the frame. MOUNT BOLTS FRONT OWL 6-6 Date of Issue: October, 1983 © HONDA MOTOR CO” LTD“ HONDA V45 INTEICEPTOR COOLING SYSTEM JOINT HOSE o LOWER RADIATOR Loosen the joint hose clamp and disconnect the joint hose from the lower radiator. Loosen the lower hose clamp and disconnect the lower hose, LOWER HOSE MOUNT BOLT Disconnect the wires from the thermostatic switch. Remove the lower radiator mount bolt and remove the radiator from the bracket. TH E RMOSTATIC SWITCH DISASSEMB LY Remove the fan shrouds with the fans and motors. Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. COOLING SYSTEM Remove the fan from the motor by removing the nut. Remove the fan motor from the shroud by removr ing the three screws. RADIATOR INSPECTION Inspect the radiator soldered joints and seems for leaks. Biow dirt out from between core fins with com- pressed air, If insects, etc., are clogging the radiator, wash them off with low pressure water. NUT FAN MOTOR HONDA v45 INTERCEPTOR FAN SHROUD 6-8 Date of issue: January, 1983 ©HONDA MOTOR COV, LTDr HONDA. V45 INTERCEPTOR ASSEMBLY/INSTALLATION Assemble and install the radiators in the reverse order of removal. After installation, fill the cooling system (page 673). WATER PliMP MECHANICAL SEAL INSPECTION Inspect the telltale hole for signs of mechanical Seal coolant leakage. Replace the water pump as an assembly if the mechanical seal is leaking. REMOVAL Drain the coolant (page 6-3). Remove the clutch slave cylinder. NOTE Do not operate the clutch lever after removing the clutch slave cylinder. To do so will cause r difficulty in reinstalllng the slave cylinders Remove the gearshift arm from the shift shaft, Remove the drive sprocket cover. COOLING__SYSTEM Date of Issue: January, 1983 © HONDA MOTOR COV, LTD. 6-9 COOLING SYSTEM Disconnect the water hose from the water nump cover, Remove the water pump cover bolts and cover. Remove the water pipe clamp bolt. Loosen the water hose bands. Pull off the water pump from the crankcase. Remove the water pipe from the water pump. INSPECTION Check the water pump for mechanical seal leakage and bearing deterioration. Replace the water pump as an assembly if necessary. HONDA v45 INTERCEP'I’OR COVER BOLTS WATER PUMP COVER WATER PIPE O-RING WATER PUMP ASSEMBLY O-RING @ WATER PUMP COVER 9% 6-10 Date of Issue: October, 1983 ©HONDA MOTOR C0,, LTD. HONDA v45 muncmon lNSTALLATION Apply a coat of clean englne Oll (0 a new (lung and msxall it ln the water pump groove, Allgn [he waler pump shaft groove with the oll pump shaft and lnSerI the water pump m the crankcase. Insen a new Orrlflg over xhe end of the WatEr pipe. Connecx the Water plpe to the pump hose and water DIDe cap. Inslall (he dowel pins and lnstall a new O~rmg m the groove of the water pump cover. Install the water pump cover and torque the bolts. Connect the water inlet hose. Install the drive sprocket cover, gearshift arm and clutch slave cylinder, Fill me coollng system (page 673). O-RlNG COOLING SYSTEM OIL PUMP SHAFT WATER PUMP COVER Dale of lssue: January, 1983 ©HONDA MOTOR COV, LTD. 6-11 CLUTCH SYSTEM HONDA V45 INTERCEP‘I’OR (40 70kg-cm, 35 61n-Ib\‘i N % 7-0 Date of Issue: J aaaaaaa 1983 ©HONDA MOTOR (30., LTD. HONDA v45 INTERCEPTOR 7. CLUTCH SYSTEM I SERVICE INFORMATION TROUBLESHOOTING CLUTCH FLUID REPLACEMENT/ AIR BLEEDING CLUTCH MASTER CYLINDER CLUTCH SLAVE CYLINDER 62—68 N~m [6276.8 kg-m, 45—49 fl-Ib) aw soaoowm /}\ (8.0 10.0kgm, . 9 53 72mm Date of Issue: January, 1983 ©HONDA MOTOR CO, LTD. 7—2 7—3 IXQ CLUTCH COVER REMOVAL STARTER CLUTCH DISASSEMBLY CLUTCH DISASSEEMBLV CLUTCH ASSEMBLY STARTER CLUTCH A$EMBLV CLUTCH COVER INSTALLATION k% 9 @GM W’— 26—30 N- m (2. 6 3 0 kg m, 1972 ft-Ib) 7—17 7—20 7—22 I 7-1 CLUTCH SYSTEM SERVICE INFORMATIUN GENERAL HONDA V45 INTERCEPTOR 0 This section covers removal and installation of the clutch hydraulic system, clutch and starter clutch, 0 DOT~4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in the section. Do not use other types of fluid as they are not compatible. 0 Clutch maintenance can be done with the engine in the frame. SPECIFICATIONS If STAN DAR D SERVICE LIMIT Clutch master cylinder Cylinder I D. 14.000714043 mm (05512—05524 inl 14.06 mm (0.553 in) Piston 0D. 13957—13384 rnrn [05495705506 in) 13.94 mm 10.549 in) l Clutch slave cylinder Cylinder LD. 38100738162 mrn [15000—15024 in) 38.18 mm (1.503 inl Piston O_D. 38036738075 mm 11,4975—14990 in) 3802 mm 11,497 in) Clutch Outer guide |.D. 24395725012 mm 10.9841 —0.9847 in) 25.08 mm (0.987 in) Spring free height 4.1 mm (0.16 in] 3.9 mm (0.15 inl Clutch center B I.D, MAM—74.440 mm (29297719307 in] 74.47 mm (2.932 inl One way clutch inner 0.0. 57 710757.340 mm (22720722772 inl 57.60 mm 12.268 in) Disc thickness 3724.88 mm (0147—0153 in) 3.1mml0,12ini Plate warpage 0.30 mm [0.012 inl Pulse coil air gap 0.35—0.85 mm 10014—0033 in) Starter clutch l Driven gear O.D 47.175—47200 mm (18573713583 in) 47.16 mm (1.857 in) TORQUE VALUES Primary drive gear Clutch lock nut Starter clutch TOOLS special Snap ring pliers Gear holder Com mun E xtenslo n Lock nut wrench, 17 x 27 mm Driver Attachment, 37 x 40 mm Pilot, 35 mm Universal holder 80400 N-m (an—10,0 kg-m, 58—72 ft-lb) 62—68 N-m (6.2—6.8 kg-m, 45—49 ft-lb) 26730 N-rn (2.6730 kgrm,19722flrlbl 079247MC70002 or mvdified 070247MC70001 or 079247MC70000 or 07924—4150000 077l670020500 0771670020300 07749—0010000 07746—0010200 0774670040800 07725—0030000 or equivalent in USA 7-2 Date of Issue: January, 1983 © HONDA MOTOR (20., LTD. é HONDA v45 INTERCEPTOR TllllllBLESllllllllllli Clutch lever solt or spongy l, Air bubbles in hydraulic system 2. Low fluid level 3. Hydraulic system leaking Clutch lever ma hard l. Sticking pistonlsl 2. Clogged hydraulic system Clutch slips 1. Hydraulic system sticking 2. Discs worn 3‘ Springs weak Clutch will not dumgage . Alr bubbles in hydraulic system . Low fluid level , Hydraulic system leaking . Hydraulic system sticking . Plates warped u‘lthm CLUTCH SYSTEM Motocycle creeps with clutch disengagad 1. Air bubbles in hydraulic system 2. Low fluid level 3. Hydraulic system leaking 4. Hydraulic system sticking 5. Plates warped Excessive lever pressure 1. Hydraulic system sticking 2. Lllter mechanism damaged clutch operation feals mugh 1. Outer drum slots rough 2. Sticking pistonls) Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. 7-3 CLUTCH SYSTEM ELUTCH FLUID REPLACEMENT/ AIR BLEEDING Check the fluld level wllh the fluld reservoir parallel to the ground. CAUTION - lnstall the diaphragm on the reservoir when ‘ operating the clutch lever. Failure to do so will allow clutch flmd to squirt cm at the reservoir during clutch operation. ‘ ' AVDld spilling fluid on painted surfaces. ‘ Place a rag over the fuel tank whenever the system is serviced. CLUTCH FLUID DRAINING Connect a bleed hose to the bleed valve Loosen the slave cylinder bleed valve and pump the clutch lever. Stop operating the iever when no fluid flows out or the bleed valve CLUTCH FLUID FILLING NOTE Do not mix differemitypes of fluid since they may not be compatible. Close the bleed valve, fill the reservoir, and Install the diaphragm To prevent piston overtravel and clutch fluid see- page, keep a 20 mm (3/4 inl spacer between the handlebar grip and lever when bleeding the clutch system. Pump up the system pressure With the lever until there are no air bubbles in (he fluld llowing out of the reserv0ir small hole and lever resistance is felt, Then bleed the system, AIR BLEEDING NOTE Check the fluid level often while bleeding the clutch to prevent air from being i pumped into the system, Use only DOT 4 brake lluid from a sealed ‘ container. . Do not mix brake fluid types and never l reuse the fluid which has been pumped out during bleeding, or the Mummy of the l clutch system will be impaired. BLEED HOSE é HONDA V45 INTERCEP‘I'OR LOWER‘LEVEL BLEED VALVE 20 mm SPACE R 7-4 Date of Issue: January, 1983 © HONDA MOTOR COI, LTD. HONDA V45 INTERCEPTOR BLEED HOSE l) Squeele the clutch lever, open the bleed valve 1/2 turn then close the valve. NOTE Do not release the clutch lever until the bleed valve has been closed agaln. 2] Release the clutch lever slowly and wait several seconds after it reaches the end of its travel, Repeat the above steps until bubbles cease to appear in the fluid at the end of the hose. Tighten the bleed valve. TORQUE: 4—7 N-m (0.4—0.7 kg-m, 35—61 in-Ibl Fill the fluid reservoir to the upper level. CLUTCH MASTER CYLINDER DISASSEMBLY Drain clutch fluid from the hydraulic system. Remove the rear view mirror and clutch lever. Disconnect the clutch switch wlres and remove the clutch hose. CAUTION Amid willing clutch fluid an minim :urfaces. Place a rag over the file! rank whenever the clutch system is serviced. NOTE When removing the Oll bolt, cover the end of the hose to prevent contamination and secure the hose. Remove the master cylinder. Remove the push rod, boot and snap ring from the master cylinder body. CLUTCH SYSTEM BLEED VALVE: / SNAP RING PLIERS 07914—323000‘ OR EQUIVALENT OIL BOLT CLUTCH HOSE Date of issue: October, 1983 © HONDA MOTOR (20., LTD. HONDA v45 INTERCEP‘I'OR CLUTCH SYSTEM Remove the following: 7 piston and secondary cup. — primary cup and spring. T — clutch switch, if necessary. CLUTCH MASTER CY LIN DE R ‘x CLUTCH PRIMARY CUP SWITCH SECONDARY CUP p / PISTON MASTER CYLINDER |.D. INSPECTION Measure the master CYIiridel' |.DV check the master cylinder for scores, scratches or nicks. SERVICE LIMIT: 14.06 mm (0.553 in) \ MASTER PISTON O.D. INSPECTION V Measure the master piston 0D. SERVICE LIMIT: 13.94 mm (0.549 in) Check the primary and secondary cups Iur damage before assembiy \. Date of Issue: January, 1933 7-6 © HONDA MOTOR 00., LTD. HONDA v45 mmtcmon ASSEMBLY CAUTION Handle the master piston, spring, primmy cup and secondly); cup as a sex. Coat all parts with clean brake fluid before assemb- lvt Install the spring, primary cup and piston. CAUTION When installing the cum, do not allow [he lips to turn inside out. install the snap ring making sure it is seated firmlv in the groove, Then install the boot and push rod. Install the clutch swrtch, if it was removed. Place the master cylinder on the handlebar and install the holder with the "UP" mark facing up and the two mounting bolts. Align the mark of the holder with the handlebar punch mark, Tighten the top bolt first, then the bottom bolt. Install the oil hose with the bolt and Its two sealing washers. Install the push rod end piece into the Clutch lever hole and install the clutch lever, Connect the clutch switch wires to the switch terminals, Fill the reservoir and bleed the clutch system (page 7-4). CLUTCH SYSTEM RESERVOIR COVER /DIAPHRAGM m HOLDER f“ CLUTCH LEVER PIVOT BOLT IMARY CUP PR fisy® PISTON AND ’S/ECONDARV CUP SNAP RING BOOT /@@/Q ROD (S3 CLUTCH SWlTCH PUSH FIOD END PIECE PUNCH MARK OlL BOLT “UpumAnK CLUTCH HOSE Date of Issue: October, 1983 © HONDA MOTOR CO., LTD. 7-7 HONDA CLUTCH SYSTEM V45 INTERCEP‘I‘OR CLUTCH SLAVE CYLINDER smvzcvtmoen OIL eon DlSASSEMBLY Place a container under the slave cylinder, remove the oil bolt and disconnect the clutch hose. NOTE Avoid spilling clutch fluid on painted sur faces. Remove the slave cylinder. Remove the piston from the cylinders If piston removal is hard, place a shop towel over the piston to cushion the piston when it is expelled, and position the cylinder with the piston down. Apply compressed air to the fluid inlet [0 remove the piston. Use the air in short spurts. AIR NOZZLE SPRING Remove the spring from the slave cylinder. Remove the oil and piston seals. Clean the piston groove with clutch fluid. Check the piston spring for weakness or damage, " ' OILSEAL PISTON SEAL Date of issue: January, 1933 7‘8 ©HONDA MOTOR (30., LTD, HONDA v45 Imsncmon PISTON O.D. INSPECTION Check the piston for scoring or scratches. Measure the outside diameter of the piston with a micrometer. SERVICE LIMIT: 38.02 mm (1.497 in) CYLINDER |.D. INSPECTION Check the slave cylinder for scoring or scratches. Measure the inside diameter of the cylinder bore. SERVICE LIMIT: 38.18 mm (1.503 in) ASSEMBLY Assemble the slave cylinder in the reverse order oi disassembly. The oil seals must be replaced with new ones whenever they have been removed. Lubricate the piston and piston seal with a medium grade of HirTemperature 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 nut. —> / /—'\ CLUTCH SYSTEM OIL SEAL ,fil SILICONE GREASE PISTON SEAL PISTON ‘spnme § SLAVE CYLINDER BODY Date of Issue: October, 1983 © HONDA MOTOR (30., LTD. 7-9 g HONDA CLUTCH SVSTEM V45 INVERCEP'I'OR Install the insulator and slave cylinders Connect the clutch hose with the oil bolt and the two sealing washers. Fill the clutch fluid reservoir and bleed the clutch svstem (page 7-4)‘ CLllTCH COVER REMCVAl Drain the engine all. Remove the clutch cover, gasket and dowel pins‘ STARTER CLUTCH DISASSEMBLY Remove the starter 4dle gear shaft and gear. Remove the idler gear by rotating the starter clutch elockwrse with a wrench, or by rotating the idler gear clockwlse to turn the starter motor shaft counterclockwise. IDLER GEAR SHAFT Date of Issue: January, 1983 7' 10 © HONDA MOTOR 80., LTD. HONDA. V45 INTERCEPTOR CLUTCH SYSTEM Hold the primary gear with the gear holder and remove the bolt. Remove the starter clutcht Shift the primary driven sub gear with a screw- driver ta take preload off the primary drive gear and remove the primary drive gear. Remove the starter driven gear and needle bearing from the starter clutch, Inspect the rollers for smooth operation. Remove the starter clutch cover by removing the three bolts. Remove the clutch rollers, plungers and springs. Check the rollers for excessive wear. GEAR HOLDER 07924—MC70002 or modified STARTER DWVEN GEAR NEEDLE BEARING l STARTER CLUTCH SPRI ROLLER PLUNGER STARTER CLUTCH COVER Date of Issue: January, 1983 © HONDA MOTOR C0., LTD. 7-11 HONDA v45 Immunon CLUTCH SYSTEM STARTER DRIVEN GEAR INSPECTION - ' - Inspect the driven gear for damage or excessive wear, Measure the driven gear 0.D. SERVICE LIMIT: 4716 mm (1.857 in) \— \_— CLUTCH DISASSEMBLY CLUTCH LIFTER PLATE LIFTER GUIDE Remove the snap ring, clutch Iirter plate, bearing, lifter guide and lifter rod. \. vi SNAP RING BEARING CLUTCH‘SPRING SPRING SET PLATE Shift the transmission into 5an gear and apply the ‘- « rear brake. A ' ‘x, NOTE If EEEGe-is not in the frame, shift the transmission into gear and use the universal holder (0772570030000) to hold the drive sprocket. \‘ Remove the lock nut and lock washer. figmove the clutch spring set plate, clutch spring and two washers. \i 4 ' ’ LOCK NUT WRENCH, 17 x 27 mm EXTENSION 0771670020300 OR EQUIVALENT IN USA. _ 2 Date of Issue: January, 1983 7 1 © HONDA MOTOR co,, LTD. HONDA v45 INTERCEPTOR CLUTCH SYSTEM i DISCS AND PLATES CLUTCH PRESSURE PLATE \_. Remove the clutch pressure plate. , 3w ‘ " ‘ . 1., Remove the clutch plates and discs. y \. Remove dutch center 8 and the one-way clutch as an assembly. x Remove clutch center A and washers \. K. \ Date of Issue: January, 1953 © HONDA MOTOR 00., LTD. 7' 1 3 CLUTCH SYSTEM Remove the clutch outer and outer guide. INSPECTION o CLUTCH SPRING Measure the height of the clutch spring. SERVICE LIMIT: 3.9 mm (0.15 in) Replace the spring if it is shorter than the service limit. 0 CLUTCH DISC Replace the clutch dim; if they shew Signs of scoring 0( discoloration. Measure the thickness of each disc. SERVICE LIMIT: 3.1 mm (0.12 In) Replace any discs that are thinner than the service limit. HONDA v45 mtncmon 7'14 Date of Issue: January, 1983 © HONDA MOTOR C0,, LTD. \_, HONDA v45 INTERCEPTOR 0 CLUTCH PLATE Check for plate warpage on a surlace plate, using a IEBIM gauge. SERVICE LIMIT: 0.30 mm (0.012ln) 0 ONE WAV Cl UTCH INSPECTION Inspect the ane way clutch fur smooth operation. Check the rollers for excessive wear. Measure the ID, of clutch center B. SERVICE LIMI‘I: 74.47 mm (2.932 in) CLUTCH SYSTEM Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. 7-15 CLUTCH SYSTEM Measure The 0.0. of the one way clumh inner, SERVICE LIMIT: 5160 mm (2.268 in) INSPECTION o CLUTCH OUTER Check the slots in the clutch outer far nicks, cuts or indenmions made by the frictian discs. Check the clutch auter needle bearing for damage or excessive play. If the needle bearing is difficult to remove from (he clutch housing, use lhe following tools: Driver: 07749—0010000 Attachment, 37 x 40 mm: 0774670010200 Pilot, 35 mm: 07746—00408“) 0 CLUTCH OUTER GUIDE Measure the ID. of the clutch auter guide. SERVICE LIMIT: 25.08 mm (0387 in) 7-16 HONDA v45 m'rsncmon NEEDLE BEARING Date of Issue: January, 1983 © HONDA MOTOR 00‘, LTD. HONDA v45 INTERCEPTOR CLUTCH ASSEMBLY Insrall the clutch ouxer guide over the mainshafr. Install the needle bearing into the clutch outer. Align the holes in me clutch ourer with the pins on me on pump drive sprocket and install me clutch outer over the guide. Install Clutch center A and the washer. Place the clutch center B with the grooved side facing down, Install the one-way clutch into the clutch center B with its flanged cage facing up. 1nsta|l the clutch inner into the one-way clutch with its grooves facing up. Turn it counterclockwise as you install it. CLUTCH SYSTEM OIL PUMP DRIVE SPROCKET PINS r 1 s _, h CLUTCH 0U ER CLUTCH OUTER GUIDE CLUTCH CENTER WASHER c .5, GROOVES CLUTCH CENTER B ONE»WAY CLUTCH CLUTCH INNER Date of Issue: January, 1983 ©HONDA MOTOR 00., LTD. 7-17 CLUTCH SYSTEM Install the one»way clutch/clutch center B assembly over the mainshalt. NOTE Make sure the one way clutch assembly is installed correctly by turning the clutch center B. Theclutch center should turn clock- wise freely and should not turn counter clockwise, Coat the discs and plates with clean engine oil, and install them. Install the clutch pressure plate, I é HONDA v45 muncmon CLUTCH CENTER B (Turns clockwise) . E)" s k‘.‘ 7-18 Date of Issue: January, 1983 ©HONDA MOTOR (20., LTD. HONDA V45 INTERCEPTOR CLUTCH SYSTEM CLUTCH SPRING SET PLATE Install the clutch spring set plate, clutch spring, and / . . ‘ ' ‘\ washers. ’ NOTE Install the clutch spring with (he dished face towards the inside. y k» CLUTéH SPRING WASHERS CK WASHER Install the lock washer with its dished face towards L0 the inside. \, Place the transmission in 5th gear. \. NOTE if servicing the clutch with the engine out of the frame, shift the transmission into gear and hold the drive sprocket with the x i HOLDER 07725—0030000. TORQUE: 62—68 N-m (6.2—6.8 kg-m, 45—49 ft-lb) \' o —LOC|'< NUT WRENCH 17 x 27 mm 07716—0020300 0H EQUIVALENT IN USA. Date of Issue: January, 1983 ©HONDA MOTOR 00., LTD. 7'19 HONDA v45 INTERCEP'I'OR CLUTCH SYSTEM LIFTER ROD Install the clutch lifted rod. . Install the clutch lifter plate, Iilter guide and bear» ing. Install the snap ring. SNAP RING STARTER CLUTCH ASSEMBLY >l:F_i‘lMARYDRIVEN GEAR PRIMARY IDRl‘v’E GEAR . 1’ Install the primary drive gear onto the crankshaft 3‘ - \, while moving the primary driven gear with a screw— ' , driver. Install the thrust washer on the crankshaft. / THHUST WASHER 7 -20 Date of Issue: January, 1983 © HONDA MOTOR C0., LTD. HONDA V45 INTERCEP'I'OR CLUTCH SYSTEM ROLLER PLUNGER DOWEL PIN Install the springs, plungers and rollers into the staner clutch. Install the dawel pin. Install the starter clutch caver aligning the dowel pln hole with the dowel pin and tighten the bolts. TORQUE: 26—30N-m (2.6—3.0 kg-m,19—22fl-lbl NOTE Apply a locking agent to the bolt threads. CLUTCH COVER STARTER DRIVER GEAR Install the starter driven gear by turning it clockwise. . PUNCH MARK ‘ Allah the punch marks an the starter clutch and ‘» crankshaft and Install the starter clutch. Date of Issue: January, 1983 ©HONDA MOTOR 00., LTD. 7'21 HON DA. V45 IN'IERCEP'I'OI CLUTCH SVSTEM GEAR HOLDER 079247MC70002 or mudiiied D7924—MC'7ODO1 or 079247MC70000 or 07924—4150000 Hold the primaw gear with the gear holder (07924— ‘ L ‘ MC70002) and (ighten the primary gear bolt. TORQUE: 80—100 N-m (8.0—10‘0 kg-m, 58—72 rub) Install the starter idler gear and shaft. _ :- _n—d STARTER {DLER GEAR CLllTCH [iflVER INSTALLATIIIN _ GASKET lnsxall {he dowel pins and a new gasket. v UOWEL WNS Dale of issue: January, 1983 7-22 ©HONDA MOTOR C0,, LTD. HONDA mstaH (he dutch cover. Fill \he crankcase wixh 0“ (page 273L CLUTCH COVER CL UTCH SYSTEM Dateof!ssue:Januarv,1983 © HONDA MOTOR (10., LTD, 7-23 GEARSHIFT LINKAGE HONDA V45 INTERCEPTOR 8-0 Dale of Issue: January, 1983 © HONDA MOTOR CO” LTD, HONDA Mums-1cm: 8. GEARSHIFT LINKAGE SERVICE INFORMATION 8—1 TROUBLESHOOTING 8—1 GEARSHWT UNKAGE REMOVAL 8—2 GEARSHWT UNKAGEINSTALLANON 8—4 SERVICE INFORMATIUN GENERAL I 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, TROUBLESHflflTlNE n 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: January, 1983 © HONDA MOTOR (20., LTD, 8- 1 HONDA. v45 INTERCEP'I’OR GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMflVAL Drain the engine oil (page 273 Remove the gearshift arm from the shift shaft Remove the clutch cover and clutch assembly (Secnon 7). ' GEA‘RSHIFT ARM SHIFT SHAFT OIL PUMP DRIVE CHAIN OIL PUMP DRIVE SPROCKET Remove the oil pump driven sprocket boltr ». « -.~_ v - ‘ ,. 7 Remove the on pump drive chain, drive and driven sprockets, Remove the drum stopper arm nut, washer, sprung, collar, and arm. Date of Issue: January, 1983 8-2 © HONDA MOTOR 00., LTD. HONDA v45 Imancmon GEARSHIFT LINKAGE Remove the tab washer. Pull the gearshift spindle assembly out of the crank case. Remove the neutral stOFPBr arm bolt, arm and spring and washer. Date of Issue: January, 1983 © HONDA MOTOR co., LTD. 8'3 HONDA V45 INTERCEP'I'OR GEARSHIFT LINKAGE SHIFT DRUM CAM PLATE Remove me shift drum cam plate bolt and cam plate‘ GEARSHIFT LINKAEE INSTALLATIIIN DOWEL pm Install the dowel pin in the hole of the shift drum. Insert the five pins in the makes of the cam plale, Align the cam plate hole with the dowel pin on the shift drum and install the cam plate. Tighien the bolt securely. CAM PLATE HOLE PIN NEUTRAL STOPPER ARM Install the washer, neutral stapper arm, spring and arm bolt. Tighten the arm bolt securely. Dale of Issue: January, 1983 8-4 © HONDA MOTOR c0, LTD. HONDA v45 INTERCEP'I'OR GEARSHIFT LINKAGE Assemble the gearshift spindle and return spring and install as shown. Install the tab washer onto the stopper arm bolt. Install the drum stopper arm, collar. spring, washer and nut over the arm bolt. Tighten the nut securely. Rotate the gearshift spindle and check the linkage for smooth operation. Date of Issue: January, 1983 © HONDA MOTOR cow LTD. 8'5 GEARSHIFT LINKAGE 03L PUMP DRIVE CHAIN Insiall the oil puma drive and driven sprockets with drive chain and lighten the driven sprockei bait securely. NOTE: The driven sprocket has an “IN” mark that must face the crankcase. Install (he clutch assembly and cover (section 7]. Align the punch marks on the gearshift arm and gearshift spindle and install the gearshift arm on the shift shaft. Fill the crankcase with recommended oil (page 2-3). l GEARSHIFT ARM HONDA V45 INTEICEP‘I'OR DRIVE SPROKET “ii I , v SHIFT SHAFT Date of Issue: January] 1983 © HONDA MOTOR (30., LTD. HONDA v45 INTERCEPTOR GEARSHIFT LINKAGE MEMO Dateoflssue2Januarv,1933 © HONDA MOTOR (20., LTD, 8-7 ALTERNATOR 30—100 N-m (53.0—10.0 kg-m, 58—72 mm HONDA v45 INTERCEP‘I‘OR 9-0 Date of Issue: January, 1983 © HONDA MOTOR C0,, LTD. HONDA v45 mrsncmon ALTERNATUR L SERVICE INFORMATION FLYWHEEL REMOVAL STATOR REMOVAL ‘ STATOR INSTALLATION FLYWHEEL INSTALLATION 9—1 9—2 9—3 9—3 9—3 SERVICE INFflRMATlflN ,, GENERAL 0 This section covers removal and installation of the alternator. Refer to section 17 for troubleshooting and inspection of the alternator. TORQUE VALUE Alternator rotor/Flywheel bolt TOOLS Common Flywheel holder Rotor puller 80—100 N-m (8,040.0 kg~m, 58772 It-lb) 0772570040000 0773340020001 or 07933—3290001 Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. 9‘1 HONDA V45 INTERCEP‘I'OR ALTE RNATOR FLYWHEEL REMIJVAI. Place a comainer under the alternator cover to catch engine oil. Remove the allernator cover. FLYWHEEL HOLDER . 07725—0040000 Hold the flywheel Wlth lhe flywheel holder and remove the flywheel boll. ROTOR PULLER 07733—0026001 0R 07933—3290001 Remove the flywheel with lhe rotor puller, “I \ Remove lhe woodruff key from lhe crankshaft, \ FLVWHEEL HOLDER 077254)!)40000 9-2 Data of lssue: January, 1983 © HONDA MOTOR CO., LTD. é HONDA v45 INTERCEPTOR STATUR REMOVAL Remove the frame lefi side cover. Disconnect the alternator wire coupler and free the alternator wire from the clamp. Remove the stator by removing the bolts and wire clampt STATUR INSTALLATIUN lnstall the Stator and wire clamp. Route the alternator wire properly, secure it with clamp and connect the altevnatnr wire coupler to the main harness, Install the frame left side cover. FLYWHEEL lNSTALLATIflN Install the woodruff key into the cvankshaft. Install the flywheel by aligning its keywav with the key in the crankshaft. Hold the flywheel with the flywheel holder and torque the flywheel bolt. TORQUE: 80—100 N«m (so—10,0 k9~m, 58x72 ft-Ib) Install the alternator cover. Check engine oil level and add if necessary (page 23). Date of issue: January, 198_3 ©HONDA MOTOR CO., LTD, ALTERNATOR TERNATOR WIRE COUPLER WIRE CLAMP F LYWHEEL HOLDER 07725—0040000 . HONDA CYLINDER HEAD/VALVE V45 INTERCEPTOR 8—12 N-m (0.8712 kg-m, 6—9 h-lb) 10—14 N‘m (1071.4 kg-m, 7—10ftrlb) 21—25 NAm 111—25 kg-m,15—18f(-lb) 33742 N-m Ex (1.8—2.0 kgrm, 13— 14 ft-lb) Q 3% Lme ma®=® new 3“ um “ (3.8742 kgrm, Z7730 ftrlb) 1 0-0 Date of Issue: October, 1983 © HONDA MOTOR 00., LTD. HONDA v4sIN1=Rc=mR Ifl. CYLINDER HEAD / VALVE SERVICE INFORMATION 10—1 VALVE GUIDE REPLACEMENT 10—13 TROUBLESHOOTING 10—2 VALVE SEAT INSPECTION/ REFACING 10—14 CAMS‘HAFT REMOVAL 10—3 CYLINDER HEAD ASSEMBLY 10—15 CYLINDER HEAD REMOVAL 10*7 CYLINDER HEAD INSTALLATION 10—16 CYLINDER HEAD DISASSEMBLY 10~9 CAMSHAFT INSTALLATION 10—19 SERVIBE INFIJRMIITIIJN GENERAL 0 The from cylinderhead can be removed with the engine in the frame. 0 The rear cylinder head cannot be removed with the Engine in the frame; however its camshafts and rocker arms can be serviced with the engine in the frame. 0 If the cam sprockets of either front or rear cvlinder are removed, the Valve timing of both cylinders must be checked during reinstallation. O Camshaft lubricating oil is fed through the external oil lines, Be sure the oil lines are notclogged, During assemblv, appr molybdenum disulfide to the camshaft holder surfaces to provide initial lubrication. 0 The cylinder numbering is given below: m ® ® .— SPECIFICATIONS LEFT STANDARD SERVICE LIMIT Compression pressure 1,300 2 200 kPa e (13 t 2 kg/cmz, 184 1 28 psi) Camshaft Cam height ‘ IN 35.33.545.495 mm (1.3911~1,3974inl 35.3 mm (1.39 in) . i EX 35335735495 mm (13911713974 in) 35.3 mm (1.39 in) Runout 7 010 mm (0.004 in) End clearance 00570.25 mm (0.002—0.010 in) 0.30 mm (0.012 in) Oil clearance Center 0131—0191 mm (00052700075 in) 0.20 mm (0.008 in) ( Both ends 0020—0031 mm (0000840032 in) 010 mm (0.004 in) Rocker arm I Rocker arm LD. 12000—12013 mm (04724—04731 in) 12.05 mm (0.474 in) Shanoo 11966—11934 mm (04711704710 in) 11.93 mm 10,4701nl Valve Valve stern 0.0, IN 5475—5490 mm (02156—02161 inl 547 mm (0.215 in) EX 5455—5470 mm (0.2143—0.2154inl 5.45 mm (0.214 In) Valve guide LD. 550075.515 mm (02165—02171 in) 5.55 mm (0.219 in) Stem-to-guide clearance IN 001070.040 mm (00004—00016 in) 0.03 mm (0.003 in) EX 0030—0060 mm 10001240024 in) 0.10 mm (0.004 in) Valve stem runout — 0.05 mm (0.002 in) i Valve length IN 3955 mm (3.526 in) 89.05 mm (3.506 in) ( EX 8935 mm (3.513 ml 33.35 mm 13.493 in) g i Valve sear width 0.99—1.27 mm (0039—0050 in) 1.5 mm (0.06 in) Date of Issue: October 1983 ’ 10- 1 © HONDA MOTOR 00., LTD. CVLINDER HEAD/VALVE HONDA v45 INTERCEP'I'OR Valve sprlng Free length l Inner 41.6 mm (1.54 in) 40.25 mm (153 in) l Outer 43.7 mm (1.72m) 42.23 mm 11.66 in] . l Preload/lenath l Inner 7.427372 kg/342 mm (16.35—19.22 7 11 kg/34.2 mm lb/1.35 in) (15.67 lbrms in) Outer 129—151 kg/37.7 mm (28444329 12.29 kg/37,7 mrn lb/1.48 in) (27.09 |b/1.48 in) Cyl’lnder head l Warpage 0.1 mm (0.004 in) V V TORQUE VALUES Cvllnder head cover 8712 N-m (OE—1,2 kg-m, 679 lt-lbl Camshaft holder 6 mm 10714 N‘m l1.071.4 kg-m, 7>10 ft-lbl (The camshaft holder bolts ln each corner of the cylinder head are longer than the others.) Cam chain gulde A bDlI 21—25 N-m [2,172.5 kg-m115—18ft-lb) Cylinder head 9 mm 38742 N-m [3, —4,2 kg-m, 27730 ltrlbl Cylinder head 8 mm 21v25 Nrm (2,172.5 kgrm,15—18ftrlbl Rocker arm shaft 45—50 N-m (4. 45.0 kg-m, 33—36 ltrlbl Cam sprocket 18‘20 N»m (1.8720 kgrm, 13—14ftrlbl TOO LS Special Valve gulde reamer, 5.5 mm 07984—2000000 Common Valve sprlng compressor 07757—001000!) Valve gulde remover, 5.5 mm 07742—001010!) TRUUBLESHIJIJTINE Englne toprend problems usually affect englne performance, These can be dlagnosed by a compression test, or by tracmg nolses with a sounding rod or stethoscope. Low compression 1, Valves — Incorrect valve adjustment » Burned or bent valves 7 Incorrect valve tlrnrng a Broken valve spring 2. Cyllnder head — Leaklng or damaged head gasket 7 Warped or cracked cvlmder head 3, Cvllnder and olston (Refer to Sectlon 12) Compression too high 1, Excesslve carbon build-up on plston or combustion chamber Excessive nuke , Incorrect valve adjustment . Sticklng valve or broken valve sorlng . Damaged or worn camshaft Loose or worn cam chaln Worn or damaged cam chaln tensloner Worn cam sprocket teeth . Worn rocker arm and/or shaft ugolgeumd 10-2 Date of Issue: January, 1983 © HONDA MOTOR 00,, LTD, 1-10an ves INTERCEP’TOR CYLINDER HEAD/VALVE CAMSHAFT REMOVAL ‘ . _ F/ROhICVLINDER HEAD COVER NOTE The mshafts can be removed with the englne in the frame. Drain the coolant and remove the upper radiator (Section 6), Remove the front cylinder head cover. REAR CYLINDER HEAD COVER Remove the seat, frame side covers and fuel tank. Remove the rear cylinder head cover. Remove the oil line and cam chain guide mounting bolts, and the cam chain guide, Remove the alternator cover and rotate the crank- shaft counterclockwise until the cam chain has free play. Remove the oil line by pulling up the middle of the chain. Remove the alternator cover. OIL LINE Date of Issue: October] 1983 © HONDA MOTOR co., LTD. 1 0'3 CYLINDER HEAD/VALVE HONDA v45 mtsncmon Turn the crankshaft counterclockwise until the T13 mark aligns with the rear crankcase mating surfaces. Place rags or shop towels in the rear cylinder head to prevent parts from being dropped into the crankcase. Remove the rear cylinder Intake and exhaust cam sprocket bolts. Turn the crankshaft counterclockwise one turn (360°) and remove the other rear cylinder cam sprocket bolts. Turn the crankshaft counterclockwise until the T24 mark aligns with the rear crankcase mating surface. Clean the camshaft sprockets with Contact cleaner. Index the front cylinder camshaft sprockets with the top of the cylinder head. Use a water proof maker. NOTE Some camshaft sprockets may have perma» nent index dots as shown and will not require marking. _Remove the front cylinder intake and exhaust cam sprocket bolts. Turn the crankshaft counterclockwise one turn (360°) and remove the other cam sprocket bolts. Slide the cam sprockets and chains off the camshaft sprocket flange. Remove the cam chain from the sprockets and remove the camshaft holders. Mark the camshaft holders so that they can be reinstalled in their original locations. T13 MARK REAR MATING SURFACE INDEX MARKS FRONT CYLINDER CAMSHAFT SPROCKETS 10-4 Date of Issue: October, 1983 .HONDA MOTOR 00., LTD. HONDA v45 INTERCEPTOR CYLINDER HEAD/VALVE INTAKE CAMSHAFT DOWEL PINS v Remove the camshaft hoIder doweI pms and the intake and exhaust camshaft. V Remove the cam sprockets from (he namshahs. DOWELPINS EXHAUST CAMSHAFT CAMSHAFT HOLDER CAMSHAFT/CAM HOLDER INSPECTION Inspect the camshaft and holder iournaI surfaces for scoring scraches, or evudence of InsufficIeni IubrIcatIon CAMSHAFT RUNOUT Check camshait runout with a dial Indicator. Support both ends oi the camshaft with V-blocks. Use 1/2 of the tolaI Indbcator reading to determine runoul. SERVICE LIMIT: 010 mm (0.004 in) Date oI Issue: January, 1983 ©HONDA MOTOR (30., LTD. 10-5 HONDA v45 INTEncmon CYLINDER HEAD/VALVE CAM INSPECTION Using a micrometer, measure each cam lobe. SERVICE LIM|TS: IN, EX: 35.3 mm (1.39 in) Check for wear or damage. Wipe any oil from the journals. Lay a strip of plastigauge lengthwise on top of each camshaft journal. Install the camshaft holders and (Ighlen In a CVISSCI'OSS pattern, NOTE Do not rotate the camshaft when using plastigauge. The camshaft halder belts in each corner of the cylinder head are longer than the others. TORQUE: A: 6 mm BOLT: 10—14 N-m (1.0—1.4 kg-m, 7—«10 fl-Ib) B: 8 mm BOLT: 21—25 N-m (2.1—2.5 kg-m, 15—18fhlb) C: 9 mm BOLT: 38—42 N-m (3.8—4.2 kg-ln, 27—30 fhlb) _ Date of Issue: January, 1983 1 O 6 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEP‘I'OR CYLINDER HEAD/VALVE - Remove the camshaft holders and measure the . V Width of each strip of plestigauge. The widest . thickness determines the oil clearance. _ SERVICE LIMIT: 1 / . CENTER: 020 mm (0,008 in) BOTH ENDS: 0.10 mm (0.004 in) L When the service limits are exceeded, replace the camshatr and recheck the oil clearance. Replace the cylinder head and camshaft holders it the clearance still exceeds service limits. CYLINDER HEAD REMIIVAL NOTE The front cylinder head can be removed with the Engine installed. But (0 remove the rear cylinder head, you must remove the engine. WATER HOSE Loosen the water hose clamps. Remove the water pipes and hoses. Remove the water pipe O-rings. Remove the oil pipe and sealing washers. CAM CHAIN TENSIONER BASE l 5 O x . . c I Remnve the front and rear cam chain tensioner base mounting bolts. Pull the cam chain tensioner base up. Date of issue: January, 1983 ©HONDA MOTOR CO., LTD. 10‘? HONDA. CYLINDER HEAD/VALVE V45 INTERCEPTOR TENSIONEH SLIPPER cu? pm Remove the slipper clip, washer and pin and remove the tensioner base. Remove the cylinder head bolts Remove me cylinder heads using a screw driver at ‘he prv points. FRY POINT GASKET Remove ‘he front and rear' cylinder haad gaskets and dowel pins. .. DOWEL PINS 1 0-8 Date of Issue: October, 1983 © HONDA MOTOR (20., LTD. HONDA v45 INTERCEPTOR CYLINDER HEAD/VALVE FRONT CYLINDER CAM REAR CYL|NDER CAM CHAIN sLlI’PEI-‘I BASE CHAIN GUIDE Remave the front cylinder cam chain slipper base, ' and remove the rear cylinder cam chain guide by K removing the clip and washert ‘ Remove the front cylinder cam chain guide bolts 0 and guide. I . 0) NOTE » Do not drop the clip, washer and boIts into a ' the crankcase - 9 FRONT CYLINDER CAM CHAIN GUIDE TENSIONER GUIDE TENSIONER SLIPPER CAM CHAIN GUIDE AND CAM CHAIN TENSIONER INSPECTION Inspect the cam chain guide and tensIOner for damage or excessive wear. I Inspect the cam chain tensioner slipper fnr damage . k or excessive wear. " ~ I Inspect the spring for good tension, replace it necessary. 2 ' / / / TENSIONER SPRING ROCKER ARM ROCKER ARM SHAFT BOLT CV‘LINDER HEM] DISASSEMBLY Remove the rocker arm shaft and rocker arms. Remove the rocker arm spring and O-ring from the shaft bolt ROCKER ARM, SPRING O-RING SHAFT BOLT Date of Issue: October, 1983 © HONDA MOTOR co., LTD. 10'9 HONDA v45 INTERCEP‘I'OR CYLINDER HEAD/VALVE To keep the valve spring compressor from interfer ing wlth the cylinder head, remove the large retainer from the compressor attachment. Remove the valve spring cutters, retainers, springs and valves. WHOM To prevent a loss of tension, do not compress the valve spring: more than necessary to remove the callers. NOTE Mark all disassembled parts to ensure correct reassembly. Remove me valve stem seals, VALVE SPRING COMPRESSOR 07757401 0000 Remove carbon deposlts from the combustion chamber and clean off the head gasket surfaces NOTE Gaskets will come off easier if soaked in solvent. caunou Do not damage the gasket mrfacex. J CYLINDER HEAD INSPECTION Check the spark plug hole and valve areas for I "r cracks. Check the cylinder head for warpage with a stralght edge and ieeler gauge. SERVICE LlMlT: 0.1 mm (0.004 in) Date of Issue: January, 1983 1 0‘ 1 0 © HONDA moron co., LTD. HONDA V45 mmczproa ROCKER ARM INSPECTION Inspect the rocker arms for wear or damage to the camshaft contact surface or for a clogged oiI hole. Measure the ID. of each rocker arm. SERVICE LIMIT: 12.05 mm (0,474in) ROCKER ARM SHAFT AND SPRING INSPECTION Measure each rocker arm shaft 0D. SERVICE LIMIT: 11.93 mm (0.470 in) Inspect the shaft for wear or damage and calculate the shaft to rocker arm cIearance. SERVICE LIMIT: 0.12 mm (0.005 in) Inspect the rocker arm shaft spring for wear or damage. VALVE SPRING INSPECTION Measure the free length of the inner and outer valve springs. SERVICE LIMIT: INNER (IN, EX): 40.25 rum (1.58 ml OUTER (IN, EX): 42.23 mm (1.66 in) CYLINDER HEAD/VALVE Date of Issue: October, 1983 © HONDA MOTOR (30., LTD, 10‘11 CYLINDER HEAD/VALVE VALVE STEM-TO-GUIDE CLEARANCE Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide and measure and record each valve stem O.D. SERVICE LIMITS: N: 5.47 mm (0.215 in) EX: 5.45 mm (0.214 in) NOTE Ream the guides to remove any carbon bund- up before checking clearances. Measure and record each valve guide |.D. using a ball gauge or inside micrometer. SERVICE LIMIT: 5.55 mm “1215“” Subtract each valve stem CD. from the corres- ponding guide ID. to obtain the stem to guide clearance. SERVICE LIMIT: IN: 0.08 mm (0.003 in) EX: OJO mm (0004 in) NOTE If the stem-to-gulde clearance exceeds the service IimIIS, determine if a new guide would bring the clearance within tolerance. if so, replace any guides as necessary and ream to fit. If the stem’mrgmde clearance exceeds the service limits with new guides, replace the valves. NOTE fim—fi Reface the valve seats whenever the valve l gumes are replaced (page 10713). i % HONDA v45 [mammal VALVE GUIDE REAMER 07984 —2000000 10-12 Date of Issue. January, 1983 © HONDA MOTOR (20., LTD. HONDEP? V45 INTERC OR cvuuoen HEAD/VALVE VALVE GUIDE HEMOVER, 5,5 mm VALVE [illlIDE REPLACEMENT , J 07742—001010: Heat the cylinder head to 100°C (212°Fl with a hot plate or oven. CAUYION Do not use a torch to heat [he cylinder,- " may cause warping. - To avoid bums, wear heavy gloves when handling the heated cylinder head. Support the cylinder head and drive out the old guides from the combustion chamber side of the cvlinder head. VALVE GUIDE REMOVER, 5.5 mm 07742—0010100 Drive new guides in from the rocker arm side of the cylinder head. NOTE Cylinder head heat should still be at 100°C (212°F) for installation of the new guides. VALVE GUIDE REAMER 07984—2000000 Let the cylinder head cool to room temperature and ream the new valve guides. NOTE ‘ Use cutting oil on the reamer during this operation. - Rotate the reemer in the same direction when inserting and removing, Reface the valve seats (page 10-14) and clean the cylinder head thoroughly (0 remove any metal particles. Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. 10- 13 CYLINDER HEAD/VALVE VALVE SEAT INSPECTIIJN/ REFACINE Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of valve Prussian blue to each valve lace, Lap each valve and seat using a rubber hose or other hand-lapping tool. Remove the valve and ”15990! the face. CAUTION The valve: cannot be ground. If [he valve face is rough, warn unevenly, or canmcrs the seat improperly, the valve mus! be repIAced. Inspect the valve seat. II the seat is too wide, too narrow, or has low spots, the seat must be ground. NOTE Follow the refacer manufactur struc on operating After cutting the Seal, apply lapping compound to the valve face, and tap the valve using light pressure. After lapping, wash any residual compound 0" the cylinder head and valve. IN: CUTTER 28 mm EX:CUTTEFI 25 mm OLD SEAT WIDTH IN, EX: CUTTER 30 mm OLD SEAT WIDTH HONDA v45 INTERCEP‘IOR SEAT WIDTH: 0.99—1.27 mm (0039—01750 in) SERVICE LIMIT: 1.5 mm (0.06 in) IN: CUTTER 29 mm EX:CUTTER 24.5 mm 0.99427 mm (0039—0050 in) 10-14 Date at Issue: October, 1983 © HONDA MOTOR CO., LTD. \ HONDA v45 lmncmon BYLINBER HEM] ASSEMBlY NOTE Install new valve stem seals when assembling, Lubricati each valve stem wl'th molybdenum disulfide grease and Insert the valve into the valve guide. To avoid damage to the stem seal, turn the valve slowly when lnsertlng. Install the valve springs and retainers. The springis tightly wound coils should face toward the head. Install the valve cutters, CAUTION. To prevent 11 lax: 0f tension, (In nut cum- prexs the valve spring more than necessary In Mall the valve keepe . Tap the valve stems gently with a soft hammer to firmly seat the cotters, NOTE Sunport the cylinder head above the work bench surface to prevent possible valve damage. 7 CYLINDER HEAD/VALVE VALVE STEM SEAL " I B X l 1/ VALVE COTTE RS RETAINER VALVE SPRING COMPRESSOR 07757—0010000 Date of Issue: January, 1983 © HONDA MOTOR C0,, LTD. 10-15 HONDA CYLINDER HEAD/VALVE V45 INTERCEPTOR ROCKER ARM ROCKER ARM SHAFT BOLT Install the Orrlhg and sprlng onto the rocker arm ' shaft, Apply LOCTITE® to the rocker arm bolt threads. Apply engme oil to the rocker arm shaft and Install the rocker arm, Install and tlgl’lten the rocker arm shaft bolt. TORQUE: 45—50 N-m (4.5—5.0 kg-m, 33—36 I\~Ibl SPRING O-RING IIYLIIIIIEII HEAD INSTALLATIIIN Clean the cyllnder head surface of any gasket material. REAR CYLINDER FRONTCYLINDERCAM CAM CHAIN GUIDE CHAIN SLIPPER BASE Install the rear cylinder cam chain guide with the Washer and Clint Install the front cylénder cam chain guidel Install the front cylinder cam chain slipper base, NOTE Be careful not to drop the washer, clip or bolts to the crankcas O u FHONTCYLINDER CAM CHAIN GUIDE 1 O— 16 Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEPTOR Install the dowel pins and new head gaskets. With the cam chain tensioner ralsed ln the direction of the arrow, insert a pm or piece of wire through the hole in the tensioner base and tensioner, Place the cylinder head on the cylinder, \ Pass the cam chain through the cam chain tensioner and lnslall the tensioner slipper as shown. NOTE Check that the lower end of the slipper fits in the slipper base correctly. CYLINDER HEAD/VALVE _— GASKET x1. DOWEL PINS TENSIONER BASE HOLE TENS|ONER TENS1ONER SLIPPER CLlP PIN ‘1 TENSIONER BASE Date of Issue: October, 1983 © HONDA MOTOR (20., LTD. 10-17 HONDA CYLINDER HEAD/VALVE V45 INTERCEP‘I'OR Loosely tighten the cylinder head bolts. NOTE Tighten the cylinder head bolts to the speci» fied torque after all cylinder head bolts are installed Install the exterior OII pipe with washers onto the cylinder and cylinder head. \ OIL PIPE WATER HOSES Install the water pipes and hoses and tighten the - hose clamps securely. . ‘ _' ,7 WATER PIPES OIL PIPE 1 O' 1 8 Dale of Issue: January, 1983 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEP'I'OR CAMSHAFT INSTALLATION CVLINDER HEAD/VALVE CAUYION Follow this procedure from beginning to end, even if you are only servicing one cylinder head. Check the camshaft markx :0 that you inxtail each camshaft in its correct location The marks on the camshaft mean: EXRR, ER: Rear cylinder eths! IN RR, IR: Rear cylinder intake EX FR, EF: Front cylinder exhaust IN FR, [F‘ From cylinder intake ' The camshaft sprOCkets are interchangeable. INDEX MARK Lubricate the cylinder head cam bearing surfaces with molybdenum disulfide grease. 0 Rear Cylinder Camshafts Turn the crankshaft couterclockwise until the T1-3 mark on the flywheel rotor aligns with the rear crankcase mating surfaces, the cam chains don’t 1am at the cam chum tensionerx or at the crankshaft - ' , T18 MARK Date of Issue: October, 1983 © HONDA MOTOR (30., LTD. CYLINDER HEAD/VALVE Install the intake and exhaust Camshafts and sprockets through the rear cylinder cam chain as shown. Turn the camshafts so the camshaft marks face up. NOTE It the front cylinder camshatts were not removed, check that the front camshaft marks face up. If not, turn the crankshaft counterr clockwise 360 degrees (one turn). If a valve clearance adjuster keeps the camshaft from seating fully in the cylinder head, back the adjuster out all the way. CAUTION If you force a valve open while installing the camshaft holders, you may damage the holers or the camshaft bearing surfaces Place the camshaft holders in the same locations noted during removal. The groove in the bottom of the holder must align with the Camshaft locating ridge. Install the camshaft holder bolts, but do not tighten them yet. NOTE The camshaft holder bolts in each corner of the cylinder head are longer than the others. HONDA V45 INTERCEPTOR CAMSHAFT HO LDER 10-20 Date of Issue: October, 1983 © HONDA MOTOR 00., LTD. HONDA v45 INTERCEP'I'OR If the cylinders were not removed, lock the cam chain tensioner lor minimum tension: push the lock plate down while pulling or prying the tension arm up; hold the arm pin up while you insert a pin or wire through the lock holes. Check that the camshaft marks are still facing up, then align the sprocket index lines with the top of the rear cylinder head Place the cam chain on the sprockets. Slide the sprockets onto the camshaft flanges, and install the sprocket bolts in the exposed holesr Check that the sprocket index lines align at T1-3. Unlock the cam chain tensioner. CYLINDER HEAD/VALVE LOCK PLATE SPROCKET BOLTS 'l INDEX LINES Date of Issue: October, 1983 © HONDA MOTOR CO., LTD, 10-21 CYLINDER HEAD/VALVE 0 Front Cylinder Camshafts NOTE 7 7, Fnstall the rear cylinder head camshafts efore you install the front camshafts, If the front cylinder camshaft sprockets were not indexed during removal and are not marked as shown follow the procedure below; Clean the sprockets with contact cleaner and wipe dry. On a piece of paper, draw two lines perpendlcular to each other 190°). Use a protractor and draw two diagonal lines at a 45° angle. Center the sprocket on the lines with the original punch marks aligned on the horizontal line. Make new index marks on the sprocket where the 45° diagonal lines cross the sprocket NOTE It is not necessary to make new lndex marks 1 for the rear cylinder’s camshahs sprockets. Rotate the crankshaft counterclockwise 90 degrees [1/4 turn), until the T274 mark aligns with the rear crankcase mating surfaces. CAUTION 7 7 When turning the crankshaft, make mre the cam chain doesn’t jam at the cam chain tensinner or at the crankshaft, Install the intake and exhaust camshaft: and sprockets through the front cylinder cam chain as shown. Turn the Camshafts so the camshaft marks face up. Rotate each front camshaft conterclockwise 45 degrees (1/8 turnl to seat the cam fully in the cylinderhead. If a valve adjuster keeps the camshaft from seating fully in the cylinder head, back out the adjuster all the way. install the front cylinder camshaft holders and bolts, as described for the rear cylinder head. Do not tighten bolts at this time. Lock the cam chain tensioner for minimum tension. 6 HONDA V45 INTERCEPTOR ’ “l, ‘., 7 _/et/- /~3 l [‘( ‘90 Lb“ / WDRAwmiDEX MAR) DRAWINDEX MARKS ORIGINALINDEX MARKS REAR CRANKCASE MATING SURFACE u ‘. I T24 MARK INTAKE CAMSHAFT EXHAUST CAMSHAFT 10-22 Date of Issue: October, 1983 © HONDA MOTOR C0,, LTD. HONDA v45 INTERCEPTOR CYLINDER HEAD/VALVE Align the permanent index dots or new index mark on the front cylinder cam sprockets with the top of the cylinder head (viewed from the left side of the enginel. NOTE There should be a total of 46 pins between the index marks on the intake and exhaust cam sprockets as shown. Slide the sprockets onto the camshaft flanges, and install the sprocket balm in the exposed holes (rotate the crankshaft counterclockwise a little if necessary). Check that the sprocket index dots align at T24. Unlock the cam chain tensioner. . Valve Timing Inspection Check the front-to-rear cylinder camshaft timing as follows. 0 When the T1-3 mark aligns with the rear crank~ case mating surface, the index lines on all cam sprockeu should align with the top of the cylinder heads. a All camshaft marks will either face up or down. Turn the crankshaft as required to install the remaining sprocket bolts at all four Camshafts. Tighten the camshaft sprocket bolts to the speci~ fied torque. TORQUE: 18—20 N-m (1.8—2.0 kg-m,13—-14ft~lb) Tighten the tensioner base bolts securely. 46 PINS PERMANENT INDEX DOTS OR NEW INDEX MARK [lg/V" INDEX LlNEs Date of Issue: October] 1983 © HONDA MOTOR CO” LTD. CYLINDER HEAD/VALVE Turn the crankshaft counterclockwise until there is maximum cam chain free play, then install the oil pipes under the cam chain. Install the cam chain guide on the oil pipe base plate. Tighten the cylinder head bolts in a crisscross pattern in 2»3 steps. TORQUE: 9 mm: 33—42 N-m (3.8—4.2 kg-m, 27—30 it-lbl a mm121—25 N-m (2.1—2.5 kg-m,15—18fl-lb) 6 mm: 10—14 N-m (1.0—1.4 kg-m, 7—10 mm Lubricate the cam lobes with oil. Adjust the valve clearance (page 3-8]. install the new cylinder head cover gasket. NOTE Clean the gasket before applying sealant. Apply sealant to the cylinder head cover gasket. lnstall me rear cylinder head cover with its tabs facing forward, and install the front cylinder head cover wide its tabs facing down. Tighten the cylinder head cover bolts. TORQUE: 8—12 N-m (0.8—1.2 kg-m, 6—9 ft-Ib) Install the remaining parts in the reverse order of removal. HONDA v45 INTERCEPTOR FRONT CVLINDER HEAD COVER IR - f1 '7' w REAR CYLINDER HEAD COVER 10-24 Date of issue: October, 1983 ©HONDA MOTOR 00., LTD. HONDA v45 INTERCEP‘I'OR CYLINDER HEAD/VALVE MEMO Date of Issue: January, 1983 © HONDA MOTOR co., LTD. 10-25 HONDA CRANKCASE V45 INTERCEP'I'OR 8 mm 21—25 Nvm (2.1—2.5 ky'm, 15718 ft-lb) ® é 6mm 10714 Nrm (1.0—1.4 kgrm,7—10ft~lb) / E 33$; 30—34 N-rn (30—3/1 kgrm, 22—25 ft-lb) Date of Issue: January, 1983 1 1-0 ©HONDA MOTOR CO., LTD. HONDA v45 mmcmon IL CRANKCASE SERVICE INFORMATION 11—1 CRANKCASE DISASSEMBLY 11—2 CRANKCASE ASSEMBLY 11—3 SERVICE INFORMATION GENERAL 0 To service the pistons, crankshaft, connecting rods and transmission, the crankcase halves must be separated. a 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 Secllun 6 Clutch/starter clutch Refer to Section 7 Gearshift linkage Refer to section 8 Alternator Refer to section 9 Cylinder heads Refer to section 10 Starter motor Refer to section 19 TORQUE VALUES 9 mm bolt: 30~34 N-m 6.0—3.4 kgrm, 22—25 ftrlb) 8 mm bolt: 21725 N-m (21725 kg-ml l5—1Bft-lb) 6 mm bolt: 10—14 N-m(1.0~1.4 kg-ml 7—10mb) TOO LS SPecial Driver 0794973710000 Common Attachment, 52 x 55 mm 07746—0010400 Date of Issue: October, 1983 _ ©HONDA MOTOR 00., LTD. 1 1 1 HONDA v45 INTERCEPTOR CRAN KCASE BRANKBASE DISASSEMBLY Refer to Service Information [page “-1) for re moval of necessary parts belore disassembling crankcase. NEUTRAL SWITCH COVER Remove the countershalt bearing cover. Remove the neutral swixch cover and the switch (page 203), COUNTERSHAFT BEARING COVER MAINSHAFT BEARING HOLDER Remove the mainshaft bearing holder by removing ‘ ' v the screw and bolts. Remove the upper crankcase bolts. Date cf Issue: October, 1983 1 1'2 © HONDA MOTOR (20., LTD. HONDA. V45 INTERCEPTOR Turn the engine over and remove the iower crank- case bo‘lts. NOTE: Remove the bolts in two or more steps and in a crisscross pattern to prevent distorting the crankcase. Separate the crankcase. Remove the following parts: 0 Piston and connecting rods [Section 12). o Crankshaft (Section 12). 0 Shih {ork and shift drum (Section 13]. o Transmissuon (Section 13). Drive the countershaft bearing out of the case. CRANKCASE ASSEMBLY Drive the countershaft bearing into the crankcase. CRAN KCASE COUNTEHSHAFT BEARING ATTACHMENT, 52 x 55 mm 0774670010400 0794973710000 Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. 11-3 C RAN KCASE Install the IoHowmg parts: Shih fork and shift drum (Section 13% 0 Transmission (Section 13). o Crankshaft (Section 12)» o Piston and connecring rods (Section 12). Apply molybdenum disulfide grease to the shut fork gmoves of the M2/3, (34 and ()5 gears. HONDA V45 INTERCEPTOR .A.____o C5 GEAR C4 GEAR 11-4 Dale of Issue: January, 1983 ©HONDA MOTOR (30., LTD. HONDA. v45 INTERCEPTOR CRAN KCASE Clean the crankcase mating surfaces Apply liquid seaiant to the mating surface of the lower and upper crankcase. CAUYION Do not apply seabznt (u the area near the main bearings, D0 new con THIS ' AREA, Install the dowel pin into the lower crankcase. Assemble the crankcase haives, aligning the shift forks with the gears. Tighten the heirs to the specified torque values in the sequence shown, TORQUE VALUES: 9 mm bolt: 30-34 N-m [lo—3.4 kg-m, 22—25 “417) 3 mm bolt: 21—25 N-m (2.1—2.5 kg-m, 14—18ft—lb) 6 mm bolt: 10-44 N-m (1.0—1.4 kn-m, 7—10ft-lb) Tighten the bolts in a crisscross pattern and in 2~3 steps. . T/ '3;- K {v —-9 mm BOLT Date of Issue: October, 1983 © HONDA MOTOR (30., lTD. 11-5 CRANKCASE Tighten the upper crankcase bolts to the speCIfied tovque in a crisscvoss pattern and In 2—3 steps TORQUE: 8 mm: 21—25 N-m (2‘1—25 kg-m, 15—18 ft-lb) 6 mm: 10~14 N-m (1.0—1.4 kg-m, 7—10 ft-lb) NOTE Make sure that the plain washers are under the 8 mm bolt heads and the battery ground cable is under the 5 mm bolt head as shown. Install the malnshaft bearing holder and tighten the screw and bolts. Install the neutral switch and cover (page 2073)l Install the dowel pins and a new gasket on the countershaft bearing cover mounting surface. HONDA V45 INTERCEP‘I’OR 6 mm BOLT ' 6 mm BOLT AND BATTERY GROUND CABLE 3 mm BOLT AND PLAIN WASHERS MAINSHAFT BEARING HOLDER U DOWELPlNS 11-6 Dale of Issue: October, 1983 © HONDA MOTOR C0,, LTD. HONDA v45 INTERCEPTOR CRANKCASE COUNTERSHAFT BEARING COVER Apply grease to (he countershaft oil seal lip ln (he countevshaft bearing Coven then install it being careful not to damage the oil seal lip. OIL SEAL Date of Issue: October, 1983 _ © HONDA MOTOR (30., LTD. 1 1 7 HONDA CRANKSHAFT/PISTON V45 INTERCEPTOR ft-lb) Dale of Issue: January, 1983 1 2-0 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEPTOR 12 CRANKSHAFT/PISTIIN SERVICE INFORMATION 12—1 BEARING INSPECTION 12—8 TROUBLESHOOTING 12—2 BEARING SELECTION 12—10 CONNECTING ROD REMOVAL 12—3 CRANKSHAFT INSTALLATION 12—12 PISTON REMOVAL 12—4 PISTON AND ROD INSTALLATION 12—12 CRANKSHAFT REMOVAL 12—7 SERVICE INFURMATIUII GENERAL 0 Ali bearing inserts are select fit and are identified by color code. Seiect replacement bearings from the code tables. After installing new bearings, recheck them with plastigauge to veriIv clearance. 0 Apply molybdenum disulfide grease to the main journals and crankpins during assembly. 0 Before removrng the piston and connecting rod assemblies, clean the top ol the cylinder of any carbon deposits. 0 For servicing the piston, connecting rod and crankshaft, the crankcase assembly must be separated (Section 1 1i, SPECIFICATIONS ITEM STANDARD SERVICE LIMIT CrankshaIt Connecting rod big end side clearance 01070.30 mm (000470.012 in] 0.40 mm (0,0101ni Runout i— 0.03 mm (0.001 in) Crankpin oil clearance 002870.052 mm (00011700020 in) 0.08 mm (0.003 in) Main journal oil clearance 0020—0044 mm (00008—00017 in) 0.00 mm (0.002 in) Cylinder 1.0. 70000—70015 mm (2755—2750 in) 70.10 mm (270 in] Warpage _ A 010 mm (0.004 in) Piston 7 7 Hingltorgroove Top 0015—0045 rnrn (0.0006~0.0013 in) 0.10 mm (0.004 in) C'ea’am Second 0015—0045 mm (00006—00010 in) 0.10 mm (0.004 in) Ring end can a Top 0204.35 mm (0008—0014 in) 0.55 mm (0.022 in) Second 020—035 mm (o.0oa—o.o141ni 0.55 mm (0.022 in) 011 [Side rail) 0.20—0.90 mm (0008—0035 in) 1.1 mm (0.04 in) Piston 0.0. 7 69900—69990 mm (275472.755 in) 69.85 mm (2.750 in) Eonrtcrcylinder clearance 0.01—0.055 mm (00044002 in) 0.10 mm (0.004 in) Piston pinKore fl 7 13002—18009 mm (07037—07090 in) 19.00 mm (0.71 in) Piston pin 00. 17994—18000 mm (07084—07086 inl 17.93 mm (0.70 in) Piston- * on pin ciearance 0002—0014 mm (00001—00000 in) 0.04 mm (0.002 in) Connec 00 small end (.0. 18016718034 mm (0.7093—0.71001ni 10.03 mm (0.712 in) Plslon prn-toEnnecting rod clearance 0010—0040 mm (0.0006» 0.0016 in) 0.000 mm (0.00241ni Cam ciiain Length at 13 kg (29 lb) tenston 32355—32430 mm (127:0- 7711) 326.120 mm (1234 in) TORQUE: Crankoin: 30—34 Nrm (3.0—3.4 kg-m, 22—25 (no) Date of Issue: January, 1983 ©HONDA MOTOR co., LTD. 12‘ 1 CRAN KSHAFT/PISTON TRflflBlESHflflTINE Excessive noise 1. Crankshaft - Worn main bearing 0 Worn rod bearing 2, Piston and Connecting Rod o Worn piston or cylinder 0 Worn piston pin or pin hole 0 Worn rod small and Low compression or uneven compression 1. Worn cylinder or piston ring Excessive smoke it Worn cylinder, piston or piston rings 2. Improperly instalied piston rings 3' Damaged piston or cvlinder Overheating 1‘ Excessive carbon buildup on piston head 2. Biocked or restricted flow of coolant 3t Sticking thermostat Knocking or abnormal noise 1. Worn pistons and cylinders 2. Excessive carbon burldrup on piston head. 6 HONDA v45 INTERCEPTOR 12-2 Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. HONDA V45 INTERCEPTOR CRANKSHAFT/PISTON DflNNECTINE Rfll] REMflVAL Separate the crankcase assembly [Section 11L Check the connecIing rod side clearance. SERVICE LIMIT: 040 mm (0.016 in) Remove the connecting rod bearing caps and note their Vocationsl Push the connecting rods and pistons out through the top of the cylinder bores. CAUTION 0n engine: with high mileage, inspect the cylinder: for a ridge lust above the highest point of ring travel. Any ridge must be re- moved wirh an aulamotive Iype ridge reamer lye/are removing the pislon: to allow the pistons and ring: [0 pass through the cylinder, CYLINDER WEAR RIDGE Date oI Issue: October, 1983 © HONDA MOTOR co., LTD. 12-3 HONDA v45 INTERCEPTOR CRAN KSHAFT/PISTON Mark the rods, pistons] bearings and caps as you remove them to indicate the correct cylinder and position on the crankpins. PISTflN REMllVAl PISTON PIN cup Remove the piston pin clips. Push the piston pin out and remove the piston. Mark the piston pins to indicate their correct piston position. PISTON/PISTON RING INSPECTION Measure the piston ring~togroove clearance. SERVICE LIMIT: 0.10 mm (0.004 in) (TOP/SECOND) Remove the piston rings and mark them to indicate the correct cyilndel and piston position. 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, A =’ Date of Issue: January, 1983 12'4 © HONDA MOTOR co, LTD. HONDA V45 INTERCEPTOR CRANKSHAFT/PISTON Uslng a piston, push the rlng mm the cylinder squarely and measure the end gap, SERVICE LIMITS: TOP: 0.55 mm (0.02 SECOND: 0.55 mm (0.02 DIL [Side rail): 1.1 mm (0.04 in) Measure the DISlOn OD. NOTE: Take measurements 10 mm (0.4 in) from the bonam, and 90° to (he plslon pin hole. SERVICE LIMIT: 69.85 mm (2,750 in) InspeCI the cylinder bores for wear or damage. Measure the? cylinder ID, at three levels in X and Y axis, SERVICE LIMIT170.10 mm (2.76 in) Calculate the piston-to-Cylinder clearance. SERVICE LIMIT: 0.10 mm (0.004 in) 10? Oversize pistons are available in the following sizes: 025, 0.50. 0.75 and 1.00 mm MlDDLE sorrom Date of Issue: January, 1983 1 2 5 © HONDA MOTOR (20., LTD HONDA v45 INTERCEP'I'OII CRANKSHAFT/PISTON Measure each piston pin hole l.D. SERVICE LIMIT: 13.06 mm (0.71 ill) Measure each piston pin O.D. SERVICE LIMIT: 17.98 mm (0.70 in) Calculate the piston pin-to-piston clearance. SERVICE LIMIT: 0.04 mm (0.002 in) Measure the connecting rod small end I.D. II the reading exceeds the service limit, replace the rod. SERVICE LIMIT: 1E.08 mm (0.712 in) Date of Issue: January, 1983 12-6 © HONDA MOTOR (30., LTD. HONDA v45 INTERCEPTOR IIIIAIIKSHAFT IIEMflVAL Remove the crankshaft and cam chains. CRANKSHAFT INSPECTION Set the crankshaft on a stand or Vee blocks. Set a dial indicator on the center main bearing journal. Rotate the crankshaft two revolutions and read the runcut, Actual runout Is 1/2 of the total indicator reading. SERVICE LIMIT: 0.03 mm (0.001 In) CAM CHAIN LENGTH INSPECTION Place the cam chain on the camshaft sprockets with the index lines positioned as indicated. Secure one camshaft sprocket and apply 13 kg [29 lbs) of tension to the other, Then measure the distance between the index lines as shown. SERVICE LIMIT: 326120 mtn (12.84inl NOTE The Ildex lines should be parallel to each other. Replace the cam chain it it is longer than the service limit. CRANKSHA FT/PISTON CAM CHAIN (REAR CVLINDERI CRANKSHAFT CAM CHAIN (FRONT CYLINDER) INDEX LINES Date of Issue: October, 1983 © HONDA MOTOR (20., LTD. 12-7 HONDA V45 INTERCEP'I'OR CRANKSHAFT/PISTON BEARING INSPECTION MAIN BEARING Inspect (he bearing inserts for unusual wear or damage. Reinstall the upper crankcase’s main bearing inserts, then carefully lower the crankshaft in place. Wlpe all oil from the bearing inserts and journals. 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 hearings on the correct journals in the lower crankcase, then assemble and tighten the bolts evenly In 2—3 steps in the sequence shown. TORQUE VALUES: 5 mm boll: 10-14 Mar (1.0—1.4 kg-m, 7—10fblb) 9 mm boll: 30—34 N-m (3.0—3A kg-m4 22—25 h-lbI NOT Do not rotate the crankshaft during inspecV on, Remove the lower crankcase and measure the com pressed plastigauge on each journal. OIL CLEARANCE SERVICE LIMIT: 0.06 mm (0.002 In) Date of Issue: January, 1983 12'8 ©HONDA MOTOR co., LTD. HONDA v45 INTERCEPTOR PLASTIGAUGE CRANKSHAFT/PISTON Inspect the bearing inserts for unusuat wear or damage. Wipe all oil from the bearing inserts and crankpins. Put a piece of plastigauge on each crankpzn. NOTE ' Do not put the plastigauge over the oil hole in the crankpin. ~ The bearing tabs should face toward the exhaust ports‘ Remember the front and rear cylinder exhaust ports face opposite directionss Install the bearmg caps and rods on the correct crankpins, and tighten them even‘y TORQUE: 30—34 N-m (3.0#3.4 kg—m, 22-25 flrlb) NOTE Do not rotate the crankshaft during mspec- tion. Remove the caps and measure the compressed plastigauge on each crankpin. OIL CLEARANCE SERVICE LIMIT: 0.08 mm (0,003 in] CRAN KSHAFT/PISTON Date of Issue' January, 1983 © HONDA MOTOR C0,, LTD, CRANKSHAFT/PISTON BEARINB SElEflTlllN CONNECTING ROD BEARING lf rad bearing clearance is beyond tolerance, select replacement bearings as follows: The code numbers (1, 2, or 3) stamped on each con necting rod identifies its inside diameter II.D.). The code letters (A, B, or C) stamped on each crankshaft counter weight identifies the outside diameter (0D,) of its crankpin. Cross reference the crankpin and rod codes to select the correct replacement bearing, 5392— 35.9347 15,975- 343mm 1m 15.984 mm c (Ercwnl a (Black) E [Vellnw) e icy-ml A ism-l BEARING INSERT THICKNESS: A (Blue): 1502—1506 mm (00591—03593 in) B (Black): 1498—1502 mm (0.0590—0.0591 in) C (Brown): 1,494—1A93 mm (0.0583w0.0590 in) D (Green): 1.490—1494 mm (0.0587410588 in) E (Vellow): 1‘435—L490 mm (0.0585A0,0587 in) HONDA V45 INTERCEPTOR . CODE NUMBER 0D. CODE LETTERS CO LOR CODE 12-10 Date of issue: January, 1983 © HONDA MOTOR CO', LTD. é HONDA v45 INTERCEPTOR MAIN BEARING The code letters (A, B, or c) stamped on the rear portion of the upper crankcase identifies the inside diameter (LDJ of each main bearing journal, from left-to-right. In this example, the LB. code for the right main journal is ”A". The code numbers (1, 2, or 3) stamped on each crankshaft counter weight identifies the outside diameter (0.0.) of its main journal. Cross reference the crankcase and crank jouranl codes to select the correct replacement bearing. SELECTlDN TABLE (ENGINE Nu. ~ Rclsz 2001586) um mm (m) mum JOURNAL r 2 a G D CODE ,7 NUMBER 35992 35000 35 9114735992 35375735334 use I n n ma- 1141677 n ma. CODE LETTERS Mm) tenor r are» 39000-39008 A H 5354.1 5257! maum cram") 5 (mm B 3500555016 Clsmwnl BlBl-ckl A lBluel n 5357.. 53m :9 or 549.024 (1535145354) a mum A mm.) A lam-l SELECTION TABLE (ENGlNE NO RCISE zunlae7~l Um! mm rm) MAlNJDURNAL 1 2 3 ounces NUMBER 35000-36008 35992-35000 35934-35992 CASE 1 u u my mum 1.41577 cone LETTERS mm 1417:!) 14170) 39130049303 A (15354-153571 Equllow) Blame“) Elli-awn) asoaaaams ”as“ aw) man-"r Clamwn) BlBI-ekl 3’ “'3‘“ ”7‘ c lewnl a tel-ck) A lame) (I 536M sassy MAIN BEARING INSERT THICKNESS: A (Blue): 11306—1510 mm (0.0593—0.059 B (Black): 11502—1506 mm (03591—0059 C (Brown): 1498—1502 mm (03590—00591 In) D lGreen): 1,49471,498 mm (00588700590 in] E (Vellow): 1490—1494 mm (00537—00588 inl ORAN KSHAFT/PISTON |.D. CODE LETTERS O.D. CODE NUMBERS COLOR CODE Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. 12-11 HONDA v45 muncmon GRAN KSHA FT/PISTON ERANKSHAFT INSTALLATIIJN Install the main bearings into the dimer crankcase, Apply molybdenum disulfide grease to the upper and lower main bearings. Install the crankshaft with the cam chainst The weight code is stamped on the connecting rod by the alphabetical code. When replacing the connecting rod, perform the weight selection between the No. 1 and 2 con- necting rods, or No. 3 and 4 connecting rods in accordance with the selection table. NOTE: It is not necessary to perform the weight selection between the No. 1 and 3, or No. 2 and 4 connecting rods The "a“ mark in the table indicates that the matching is possible in the crossed codes. l ~ The cylinders are arranged in the order of No. 1,134 from the alternator side, WEIGHT CODE (ALPHABETICAL CODE) SELECTION TABLE #1, #2 CONNECTING nous J #3, #4 CONNECTING RODS #2 ROD CODEVli fi’fii 7' 7; #4 ROD (1007777 {f a c o E A B c D E i1 non coma , ‘ i are ROD cone A Lo“ 70 A 7 : ' o o —¥Bii l 1 d ‘l 337 B l ‘ o o o c ‘ r o 0 To I c 7 i o ‘ o o 0 ID Iolo oi ‘ in ”of, 010 E lo lo l i e o lOl l Date of Issue: October, 1983 1 2' 1 2 ©HONDA MOTOR CO., LTD. HONDA VF700/750 INTERCEPTOR PISTDN AND RDD INSTALLATIDN Clean the piston domes, ring lands, and skirts Carefully install the piston rings onto the piston. Stagger the ring end gaps as shown, NOTE: piston rings during assembly. ‘ All Hngs should be installed With the markings racing LID‘ ~ After Installing the rings they should rotate treery, wlthout Sticking Coat the rod's small and with molybdenum disullrde grease. Rear cylinders: Note that the rear cylinder connecting rods are marked ”MBDVF" or ”MBZVH" for the VF750F, and ”MBI~F" for the VF7OOV Install the pistons on the rear connecting rods so that the intake "lN" mark is facing opposite the oil hole in the rod. Be careful not to damage the piston and ORAN KSHAFT/PISTON \ A jSPACER wgwflsironz/ SIDE RAIL mmwm ,, TOP SECOND SIDE HAIL """ GAP REAR CYLINDER "IN” MARK l OIL HOLES IDENTIFICATION MARK VF750F shown, VF700F: MBl-F Date of Issue: June, 1984 ©American Honda Motor 00., Int: 1984 - All nghls Reserved HONDA VF700/750 INTERCEP'I’OR CRANKSHAFT/PISTON From cylinders: FRONT CYLINDER "IN" MARK IDENTIFICATION MARK Note that the front cylinder connecting rods are marked "MBOR" or "MHZ-F" for the VF750F, H H VF750F and MEI-R for lheVF7GO. shown. Install the plstons on the front rods so that the VFVOOF: intake "IN” mark ls faclng the same directlon as (he MEI-R OII hoIe in (he rode NOTE' Do not Interchange the HISIOI’ISI piston pins or connecllng rods. ~ Make sure that the DISlOn pln cllps are ’ properly seated OIL HOLES Ahgn the hole ln the connectlng rod bearlng Insert , Wlth the hole ln the connectmg rod and lnstaIl the lnserl OIL HOLE Install the COI’VnECUnQ rod cap bearrng Insert Apply molybdenum disulfide grease to the connect ing rod bearings. CONNECTING ROD BEARING ©Amarican Honda Motor 60., Inc. 1954 , AII Rights Reserved Date of Issua: June, 1984 1 2- 14 é HONDA V45 INTERCEMOR CRANKSHAFT/PISTON “IN" MARKS Coat the cylinders, piston rings/grooves and piston with oil. To prevent damaging the crankshaft, slip short sections of rubber hose over the rod bolts before installation. Install the rod and piston assemblies into the cylinders from the top of the crankcase, Be sure each assembly is returned to its original position as noted during removal. NOTE The piston intake "IN” marks should be facing each other as shown. A. PISTON RING COMPRESSOR (Commercially avallable) Compress the piston rings with a ring compressor and insert the piston and rod into the cylinder until the rod seats on the crankpin. NOTE Be careful not to damage the pistons or rings during assembly. |_— 7 Flip the upper crankcase over. Install and torque the connecting rod caps. TORQUE: 30—34 Nam (3.0734 kg-m, 22A25 ft-lb) NOTE ,— 7 - Be sure the bearing caps are installed in their correct location as marked during removal. Tighten the nuts in two or more steps. After tightening the bolts, check that the rods move freely without binding. Assemble the crankcase (See page 11-3). Date of Issue: October, 1983 ©HONDA MOTOR 00., LTD. 1 2' 1 5 1-101“:le TRANSMISSION V45 INTERc "on 21—25 N-m (2.1—2.5 kgrm,15—1Bft-lb) 16—20 N~m Date nflssue:Januarv,1983 13‘0 © HONDA MOTOR co‘, LTD. HONDA v45 mmcmon 113. TRANSMISSIIIN SERVICE INFORMATION 13—1 TROUBLESHOOTING 13—2 TRANSMISSION DISASSEMBLY 13—3 SHIFT FORK AND SHIFT DRUM 13—6 TRANSMISSION ASSEMBLY 1349 SERIVIBE INFORMATIIIN 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 111. SPECIFICATIONS STANDARD SERVICE LIMIT Transmission Backlash Ist 004740.142 mm 10.0019—0.0056 In) 0.20 mm 10.000 in) 2nd 0064—0123 mm 10.0025—00050 in) 0.17 mm 10.007 in) # 3rd, 4th, 5m 0063—0136 mm 10.0027—00054 in) 0.18 mm 10.007 in) Gear 1.0. M4, M5 gear 20000—23021 mm 11.1024—1 1032 in] 28.04 mm 11.1041n) C1 gear 26000—20021 mm11.0236—1.02441n) 20.04 mm 11,025 in) 1:2, (:3 gear 31000431025 mm 11.2205_1.2215 In) 3104 mm 11.222 in) Saar bushing M4, M5 gear 27359—27.an mm (1.100741.10161n1 27.94 mm 11.100 in] 070- 01 gear 25.959725.an mm 11.0220—10223 in) 25.94 mm 11.021 in) 02. ca gear 30950—30975 mm 112135412195 in) 30.93 mm 11.213 1nI Gear bushing M4 24895725016 mm (0.9840~0.98491n) 25.04 mm 10,980 in) '-D- C) 22020422041 mm 103009—00678 in) 22.00 mm (0.8691n] Mainshaft OD. (at M4] 24977—24390 mm (08333—03839 in) 24.92 mm (0.981 in) flurerimrgn; 1agc1_1_ 7 _ 21.979721000an(03653—03661 in) 21.96 mm 10.005 In) Gear-tar M4, M5 0020—0062 mm (00003—00024 in) 0.10 mm 10.004 in) 1:53:39“ 01 0020—0062 mm (00003—00024 in) 0.10 mm 10.004 in) W (:2, 03 0025—0075 mm 10.0010-00030 in) 0.11 mm 10.0041nI BushIng-tor M4 0005—0047 mm 100002410019 in) 0.00 mm 10.002 in) “‘3“ “93'3”“ c1 (102043.062 mm (00000430024 in) 0.10 mm 10.004 in) Shift fork Claw thickness 5.43—6.50 mm (025340.256 in) 6.1 mm (0.24 in) 10 Left and right 14.000-14.021 mm 10.5512—05520 in] 14.04 mm 10.553 in) Fork shaft 00, 13366—13034 mm 10.54987055051n) 13.90 mm 10.547 in) 335133511313"; 307,953.). 1 3- 1 HONDA. V45 INTERCEP‘I'OR TRANSMISSION TORQUE VALUES Countershaft bearing holder 21—25 N-m [2.1725 kgm, 15-18 ft-Ib) Shift fork center 16—20 NAm(1‘6—2.0 kg-m,12714 mm TOO LS Cnmmon Driver 07746—003010!) ‘ Attachment, 25mm 07746—0030200 “mm 079454710200 TRDUBLESHUCITINE Hard to shift 'v‘ 1‘ Clutch slave Cylinder sticking 2. Shift fork bent 3. Shift shaft bent 4V Shift claw bent 5t Shift drum cam grooves damaged Tnnsmission jumps out of gear 1. Gear dogs worn 2. Shift shaft bent 3, Shift drum stopper broken 4, Shin forks bent _ Date of Issue: Januarv,1983 1 3 2 © HONDA MOTOR co., LTD‘ HONDA v45 INTERCEFTOR TRANSMISSIUN DISASSEMBLY Separate the crankcase (Section 11). Remove the dowel pins from the crankcase. Inspec‘ the backlash of each year. SERVICE LIMIT: 1“: 0.20 mm (0.008 in) , 2nd: 017 mm (0.007 in) 3rd, 4th, am: 0.18 mm (0.007 in) MAINSHAFT Remove the mainsham Remove the countershaft bearing holder bolts. TRANSMISSION Date of Issue: January, 1983 © HONDA MOTOR CO, LTD 13-3 HONDA v45 INTERCEP'I’OR TRANSMISSION C3 GEAR C4 GEAR Pull the countershaft out 01 the crankcase while removing CI, C4, ()2, C3, and the spline washers and bushings. A...A' CI GEAR ‘ ' 1 C2 GEAH TRANSMISSION INSPECTION Check gear dogs, dog holes and gear teeth for ex- cessive or abnormal wear, or evidence of insufficient lubrication. Measure the ID. of each gear. SERVICE LIMIT: M4, M5 gear: 23.04 mm (1.104 (III 01 year: 26.04 mm (1.025 in) 02, C3 gear: 31.04 mm (1.222 in) Measure the CD, of the gear bushings. SERVICE LIMIT: M4, M5: 27.94 mm (1.100 in) C1: 25.94 mm (1.02 02, C3: 30.93 mm (1.218 in) Calculate the clearance between the gear bushings and the gears. SERVICE LIMIT: M4, M5: 0.10 mm (0.004 in) CI: 0.10 mm (0.004 in) CZ, ca: 0.11 mm (0.004 in) Date 01 Issue: January, 1983 13-4 © HONDA MOTOR (30., LTD. HONDA v45 INTERCEP'I'OR Measure the ID. of the gear bushings. SERVICE LIMIT: M4 gear bushing: 25.04 mm (0.986 in) C1 gear bushing: 22.06 mm (0.869 in) Measure the CD. of the mainshsft and countershaft. SERVICE LIMIT: Mainshafl (at M4 bushing): 24,92 mm (0,981 in) Countershah (at C1 bushing): 21.96 mm (0.865 in) " Calculate the clearance between the bushing and shaft. SERVICE LIMIT: M4 bushing-tasks“: 0.06 mm (0.002 in) C1 bushing-toahafl: 0.10 mm (0.004 in) TRANSMISSION Date of Issue: January. 1983 © HONDA MOTOR C0., LTD. 13-5 TRANSMISSION SHIFT FIJRK MID SHIFT DRUM REMOVAL Bend the lock washer tab down and remove the center fork mounting bolt. Remove the shift Iork shaIt and shifl Iorks. Remove the bearing stopper pIates, Remove the shift drum, GEAR SHIFT DRUM AND SHIFT FORK INSPECTION Inspect the SM" drum and for scoring, scratches, or evidence oI insumcient lubrication. Check the shift drum grooves Ior damage HONDA v45 INTERCEP‘I‘OR RIGHT FORK ' CENTER FORK LEFT FORK FORKSHAFT LOCK WASHER SHIFT DRUM \ u 4 . BEARING STOPPER PLATES 13-6 Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. HONDA v45 Iunncmon Inspect the shift drum hole and shiff fork shaft hole for scoring or scratches. Measure the shift fork shaft 0.0. at right and left shift fork surfaces. Check for scrafches, scoring or evidence of insuf- ficient lubrication. SERVICE LIMIT: 13.90 mm (0.547 in) Measure the right and left shin fork LD. ’ SERVICE LIMITS: LD. (right and Ian fork): 14.04 mm (0.553 in) TRANSMISSION Dale of Issue: January, 1983 © HONDA MOTOR 00., LTD. 13-7 HONDA V45 INTERCEP'I'OR TRANSMISSION Measure the shift fork claw thickness. SEFIVICE LIMIT: 6.1 mm (0.24 illI '83 ONLY INSTALLATION Install the shift drum, Apply a locking agent to the screw threads and install the bearing stopper plates «.04 s BEARING STOPPE H PLATES SHIFT FORK SHAFT OIL HOLE Install the shift fork shalt so that the oil hole and is toward the right. Install the shift forks onto the shaft. Install a new look washer and the bolt to the center shift fork and tighten the bolt. TORQUE: 13—20 N-ln (1.6—2.0 kg-m, 12—14 fl-Ib) Bend up the lock washer's tabs. 1 3_ Date of Issue: October, 1983 8 © HONDA MOTOR C0,, '_TD. HON DA V45 INTERCEPTOR TRANSMISSION DRIVER TRANISMISSIUN RSSEMBIY mus—0030100 on 079454710200 MAINSHAFT Install the mainshaft bearing with the special tooIs. ATTACHM’ENT, 25 mm ID. 07746—0030200 Check the gears for freedom of movement or rotar tion on the shaft. Check that the snap rings are seated in the grooves. MAINSHAFT Date of Issue: January, 1983 © HONDA MOTOR 00., m1 13'9 HONDA v45 muncmon TRANSMISSION COUNTERSHAFT Before installing the countershaft in the crankcase, install the CS gear and snap ring. Install the CS gear and spline collar. Install the stopper washer whlle alignlng the tab of the stopper washer with the groove in the spline collar, Assemble the C2, C4 and C1 gears, washers and . collars. ‘ , SPLINE COLLAR STOPPER WASHER Date of Issue: January, 1983 13-10 ©HONDA MOTOR C0,, LTD. HONDA v45 INTERCEPTOR TRANSMISSION COUNTERSHAFT BEARING HOLDER - I \ Install the countershafl bearing holder bolts and tighten them. TORQUE: 21—25 N-mI2‘1—2.5 kg-m,15—18h-Ib) Check that the oiI orifice is clear. OILORIFICE MAINSHAFT Install the mainshaft, then reassemble the upper and Iower crankcase (see Section 11). Date of Issue: October, 1983 © HONDA MOTOR CO., LTD. 1 3- 1 1 HONDA V45 INTERCEP‘I’OR FRONT WHEEL/SUSPENSION 90—120 N»m (9.04 2.0 mm. 65—87 ft-Ib) (3.04.0 kg-m, 22729 ft-lb) , « ‘ (3.0—4.0 kg-m, E F’ ' 22—29 ft-Ib) \ , .. . ‘ ‘ See page \- . > 14—35 9—13 N-m k7 (0.941 .3 kg-m,/Dm 7—1 0 Mb} 4555 Nm (4.5—5.5 kg-m, 33—40 ft-lbl 30740 N-m (3.044.!) kg-m, 22—29 ftrlb) 30740 N-m (3 0—4.0 kg-m, 22—29 ft—lb) 4% 55455 Nrm / (5.5—6.5 kg—m, ADHW ltrlb) / 18—45 N«m (1,872.5 kg-m, 13—18 ft»lb) 12.0»25 kgrm, 14~18 ft-lb) 1 4_ 0 Date of Issue: October, 1983 © HONDA MOTOR c0,, LTD. HONDA vr7oor7so INTERCEPTOR 14. FRONT WHEEL/SUSPENSION SERVICE INFORMATION TROUBLESHOOTING HEADLIGHT INSTRUMENTS FUSE HOLDER REPLACEMENT 14_1 14—2 1 4-3 14—3 14—5 IGNITION SWITCH HANDLEBARS FRONT WHEEL FRONT FORKS STEERING STEM 14—6 14—7 14—11 14—18 14—31 SERVICE INFORMATION GENERAL A jack or other support is required to support the (rant 0! the motorcycle when your are working on the front wheel or Iork, SPECIFICATIONS STANDARD SERVICE LIMIT Axle shaft runout — 0.2 mm (0.01 in) Front wheel rim runout Radial - 2,0 mm (0.08 in) Axial — 2.0 mm (0.08 in) Fork spring Iree length 4793 mm (18.87 in) 470 mm (18.5 in) Fork tube runout 7 0,2 mm (0.01 in] Front Iork Iluld capacitv R' ht VF75OF: 360 cc (12.2 oz), VF700F: 350 cc (1 1,9 01) '9 After ’84 VF700F: 35o cc(11.9 oz) ’ Left VF750F: 380 so (128 01), VF700F: 370 cc (12.5 oz) ; AIter '84 VF700F: 375 cc (12.7 oz) Front (ork air pressure 0740 kPa (0704 kg/cm’, 076 p5!) — TORQUE VALUES Steering stem nut 90-120 N‘m (SO—12,0 kgrm, 65 -87 lt-Ib) Steering bearing adjustment nut ’83: 10712 N m (I .07 2 kg-m, 7—9 ft-lbl After '83' 19723 N m (1,972.3 kg-m, 14717 ft-lb) Fork bridge pinch bolt Front axle holder Front axle nut Fork top pinch bolts Fork bottom pinch bolts Handlebar pinch bolts Front brake caliper mount bolts Anti-dive piston pin bolt Front brake dISC 30710 Nvm (3.0710 kg-m, 22—29 h-Ib) 18725 Nrm (1372.5 kg-m, 13—18 (t-Ib) 55765 N-m (5576.5 kg-m, 40—47 (t-Ib) 9713 Nm (0.9713 kg-rn, 7710 (t-lbl 45755 N-m (4.5755 kg-m, 33—40 (t-Ib) 30—40 Nm (3 074.0 kg-m, 22—29 ft-Ib) 30—40 N-m (3.0—4.0 kgrm, 22729 (Mb) 20725 N in (2072.5 kg-m, 14—18 (t-Ib) 35740 N In (354.0 kg-m, 25—29 (t-Ib) Date 01 Issue: October, 1984 ©American Honda Motor Co.,1nc, 1984 - All Rights Reserved 14-1 FRONT WHEEL/SUSPENSION TOOLS Special Hex. wrnech, 6 mm Snap ring pllel‘s Fork seal driver Steering stem socket Bearlng race remover Ball race remover Steering stem driver Common Driver Attachment, 42 x 47 mm Pilot, l5 mm Lock nut wrench, 30 x 32 mm Extension Attachment, 52 x 55 mm Bearing remover shaft Bearing remover head, 15 mm TRGHBLESHBUTINE Hard steering 1, Steering bearing adjustment nut too tight 2 Faulty steering stem bearings 3 Damaged steering stem bearings 4, Insufficient tire pressure Steers to one side or does not track straight 1. Bent forks 2. Sent front axle 3. Wheel installed incorrectly Front wheel wobbling ‘l. Bent rim 2. Worn front wheel bearings 3, Faulty Dre 4. Axle nut tightened improperly Soft suspension 1 Weak fork springs 2 Insufficient fluld in forks 3. Fork aIr pressure incorrect Hard suspension 1. incorrect fluid weight In forks 2, Fork air pressure incorrect 3. Bent fork tubes 4. Clogged fluid passage 5 Clogged antirdive orifice Front suspension noise 1. Worn slider or gurde bushings 2. Insufficient fluid in forks 3. Loose front fork fasteners 4. Lack of grease in speedometer gearbox é HONDA v45 Immcmon 0791773230000 or equivalent 07914—3230001 or equivalent in U.S.A. 0794774630100 07916—3710100 0794673710500 0795374250002 y 079467M 800000 or-[Steering stem driver 07946~3710601 Attachment 07964—M800200 07749—0010000 07746—0010300 07746—0040300 ¥ 07716—0020400 or equivalent in U.S.A. 07716—0020500 or equivalent in USA. 07746—0010400 07746$050100 or equivalent in U.S.A. 07746—0050400 or equivalent in U.S.A. x. \1 \— 14-2 Date of Issue' October, 1933 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEP'I'OR HEADLIGHT REMOVAL/INSTALLATION Remove the fairing. Remove the headlight rim and headlight by remov- ing the three screws. Disconnect the headlight coupler. install the headlight in the reverse order of removal. Check the headlight aim and adjust it if necessary (page 3-18). INSTRUMENTS REMOVAL Remove the fairing. Remove the headlight with its bracket by removing the mount bolt and nuts. FAIRING FRONT HEADLIGHT WHEE L/SUSPENSION Date of Issue: October, 1983 © HONDA MOTOR CO” LTD. FRONT WHEEL/SUSPENSION Disconnect the instrument wire coupler and the speedometer cable. Remove the mount nuts and remove the instrument assembly from the bracket. DISASSEMBLY Remove the odometer reset knob. Remove the instrument pod from the instrument panel. Remove the instrument bulb sockets. Replace any burnt bulbs. If the bulb does not light, inspect the wiring for an open or short circuit. HONDA v45 Innncmon SPEEDOMETERCAELE INSTRUMENT WIRE COUPLER ODOMETER RESET KNOB INSTRUMENT POD INSTRUMENT PANEL 1 44 Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. HONDA VF700/750 INTERCEP'I’OR FRONT WHEEL/SUSPENSION INSTRUMENT ASSEMBLY/ INSTALLATION Assemble and install the instruments in the reverse order ol disassembly and removalr FUSE HOLDER REPLACEMENT Remove the headlight brackel (page 1473), Disconnect the luse holder wire coupler. Remove the fuse holder cover Remove the two altaching screws and remove the luse holder from lhe fork bridge. |nsta|l (he Vuse holder In lhe reverse order ol re moval, NOTE FUSE HOLDER COVER '83-'84: After '84 Be sure to rout the (use holder WIre properly (pages 1-10 xhru 1»1 2), FUSE HOLDER . Dale of Issue October, 1984 © American Honda Motor Co, Inc 1984 - All nghls Reserved 1 4-5 FRONT WHEEL/SUSPENSION IGNITlflN SWITCH REMOVAL/INSTALLATION Remove the headlight and the instruments (page 143). Remove the fuse holder cover. Disconnect the ignition switch wire coup|er. Remove the ignition switch mounting bolts, and remove the ignition switch. Install the ignition switch in the reverse order of removal. D ISASSEMBLY/ASSEMBLY Pry open the retainer. Insert the ignition key and turn it so it is partway between the ON and OFF detent positions. HONDA v45 mmcmon IGNiTION SWITCH MOUNTING BOLTS RETAINER 14-6 Date of Issue: January, 1983 © HONDA MOTOR C0,, LTD. HONDA v45 INTERCEP‘I’OR FRONT WHEEL/SUSPENSION SLOTS Push in the lugs, that are locked in the slots, then pull the contact base from the swntch. Assemble the ignition switch in the reverse order of disassembly. HANULEBARS FRONT BRAKE MASTER CYLINDER REMOVAL Disconnect the front brake switch wires. Remove the from brake master cylinder. RIGHT HANDLEBAR SWITCH Remove the right handlebar switch. Date of Issue: January, 1983 - ©HONDA MOTOR (20., LTD. 14 7 HONDA. FRONT WHEEL/SUSPENSION V45 INTERCEPIOR CLUTCH MASTER CYLINDER Disconnect the clutch switch wires. Remove the clutch master cylinder. LEFT HANDLEBAR SWITCH Remove the left handlebar switch. CHOKE LEVER Disconnect the choke cable from the choke lever. CHOKE CABLE 14-8 Date of Issue: January, 1983 © HONDA MOTOR CO , LTD, HONDA v45 mmzcmon FRONT WHEEL/SUSPENSION STOPPER RING Remove the left and right handlebar retainer rings. Loosen the left and right handlebar pinch bolts. Remove the handlebars From the fork tubes. Remove the throttle grip from the right handlebar. INSTALLATION Apply grease to the throttle grip sliding surface and slide the throttle grip over thehandlebar. RETAINER RING Install the handlebars onto the fork tubes and on the handlebar spacers, aligning the pin on the bottom of the handlebar with the hole in the spacer. Tighten the handlebar pinch bolts. TORQUE: 30-40 N-ln (33—40 kg-m, 22—29 Vl-lbl Install the handlebar retainer rings, SPACER PINCH BOLT Date of Issue: October, 1983 © HONDA MOTOR (30., LTD. 14-9 HONDA V45 INTERCEPTOR FRONT WHEEL/SUSPENSION Align the right handlebar switch locating pin with the hole in the handlebar and install the right handlebar switch. install the top portion of the switch and tighten its screws. Tighten the forward screw first, then tighten the rear SCI’EW. 253‘ LOCATING PIN FRONT BRAKE MASTER CVLlNDEH “UP" MARK Place the front brake master cylinder on the handle- bar and install the master cylinder holder with the "UP” mark facing up. Align the index mark on the holder with the punch mark on the handlebar, and tighten the upper bolt first then tighten the lower bolt. PUNCH MARK INDEX MARK HOLDER Connect the choke cable to the choke lever, Align the left handlebar switch locating pin with the hole in the handlebar and install the left handle bar switch. Tighten the upper screw first, then tighten the lower screw. LOCATING PIN 14- 1 0 Date of issue: January, 1983 © HONDA MOTOR (20., LTD. HONDA v45 INTERCEF'I'OR FRONT WHEEL/SUSPENSION “up“ MARK CLUTCH MASTER CYLINDER Place the clutch master cylinder on the handlebar and install the master cylinder holder with the "UP” mark facing up. Align the index mark on the holder with the punch mark on the handlebar, and tighten the upper bolt Connect the clutch switch wires. INDEX MARK PUNCH MARK FliflNT WHEEL REMOVAL Remove the right front brake caliper from the fork leg. Remove the right axle holder. NOTE If you squeeze the front brake lever after the caliper is removed, the caliper piston will move out and make reassembly difficult. //‘ ‘. / AXLE HOLDER RIGHT FRONT CALIPER LEFT FRONT CALiPER Remove the speedometer cable set screw and dis- ~~ \ connect the speedometer cable. Remove the left front caliper from the fork leg and anti-dive piston case. Remove the left axle holder. AXLE HOLDER SPEEDOMETER CABLE Date of Issue: January, 1983 _ © HONDA MOTOR co., LTD. 14 1 1 FRONT WHEEL/SUSPENSION DISASSEMBLY Remove the front axle nut and axle. SPACER Remove the spacer from the right side. Remove the speedometer gear box from the left side. BRAKE DISC Remove the left and right brake disc mounting bolts and discs. Remove the dust seal from both sides. Remove (he speedometer retainer from the left side. SPEEDOMETER GEAR BOX 14-12 Date of Issue: January, 1983 © HONDA MOTOR C0,, LTD, HONDA v45 INTERCEP‘I'OR WHEEL BEARING INSPECTION Check wheel bearing play by placing the wheel in a truing stand and spinning the wheel by hand. Replace the bearings with new ones if they are noisy ar have excessive play, WHEEL, iNSPECTIUN Check (he rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout using a dial indicator. SERVICE LIMITS: RADIAL HUNDUT: 2.0 mm (0.08 in) AXIAL RUNOUT: 2.0 mm (0.08 in) NOTE The wheel cannot be repaired and must be replaced with a new one if the service limits are exceeded. AXLE INSPECTION Set the axle in V blocks and measure the runoul. SERVICE LIMIT: 0.2 mm (0.01 in) FRONT WHEEL/SUSPENSION L PLAY Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. 14-13 FRONT WHEE L/SUSPENSION WHEEL BEARING REMOVAL It the bearing need replacement, remove the bearr ings and distance collar. NOTE Never reinstaH old bearings; once the bearings are removed, they must be replaced with new DDESV ASSEMBLY HONDA V45 INTERCEPTOR BEARING REMOVER SHAFT 07746—0050100 BEARING REMOVER HEAD 07 746400 50400 Do not get grease on the brake dist or snipp- ing power will be reduced. NOTE . The cast whee! has no rim band, ~ The from wheel uses a tubeless tire. For tubeless lire repair, refer to the Honda Tubeless Tire Manual. 14‘14 Date of Issue: October, 1983 © HONDA MOTOR CO., LTD. HONDA v45 INTERCEPTOR Pack all bearing cavities with grease. Drive in the right bearing first, sealed side facing out, then press the distance collar into place. NOTE Be certain the distance collar is in position before installing the left bearing. Drive in the left bearing squarely, making sure that it is fully seated and that the sealed side is facing out. Install the speedometer gear retainer in the left side of the wheel hub, aligning its tangs with the slots in the hub. install the leftdust seal. Place new gaskets on the disc mounting flange, then install the left disc with its "L” mark facing out. Tighten thedisc mounting bolts. TORQUE 3540 N-m (3.5—4‘0 kg-m, 25—29 ftJb) FRONT WHEEL/SUSPENSION DRIVER 077494010000 ATTACHMENT, 42 x 47 mm 07746—001030!) PILOT, 15 mm 07746—0040300 SPEEDOMETER GEAR RETAINER "L” MARK Align BRAKE DISC DUST‘ SEAL Date of issue: January, 1983 © HONDA MOTOR 60., LTD. HONDA v45 INTERCEPTOR FRONT WHEEL/SUSPENSION "R" MARK SPACER Install the right dust seal, ,‘ ‘ Place new gaskets on the disc mounting flange, then ’ “ ’ install the right disc with its "Fl" mark facing out. Tighten the mounting bolt to the same torque as 0 left side. ’ Install the spacer. . . 4 DUST SEAL SPEEDOMETER GEAR DRIVE GEAR Fill the speedometer gearbox with grease and install the plain washer and drive gear. Install the speedometer gearbox in the wheel hub, aligning the tang: with the slots. m TANGS SLOTS AXLE NUT Install the front axle and axle nut. Tighten the axle ' \\ nut. (a ) TORQUE: 55—65 N‘m (5.5—6.5 kq-m. 40—47 h-lbl ’ NOTE There are flats on the opooslte end of the axle, so YOU can hold the axle While torquing (, the axle nut. Clean the brake discs with a high quality degreaslng agent. Date of Issue. January, 1983 14- 16 ©HONDA MOTOR (20., LTD. HONDA v45 letcmon INSTALLATION Position the wheel between the lork legs. Lower the engine so the fork legs rest on the top of the axle. Position the hang on the speedometer gear box against the lug on the left fork leg. Install the axle holders with the arrow pointing lorward. install the right front caliper and tighten the mount bolts. TORQUE: 30—40 Nrm (3.0—4.0 kg~m, 22—29 fl-lbl Tighten the right axle holder nuts [0 the specified torque, starting with the forward nut. TORQUE: 18—25 N-m (1.8—2.5 kgm, 13—18 ft-Ibl Install the left lront caliper. Tighten the anti-dive pivot bolt. TORQUE: 20—25 N-m (2.0—2.5 kg-m, 14—18 ft-Ih) Tighten the caliper mount bolt. TORQUE: 30—40 N-m (3.0—4.0 kg~m, 22‘29 h-Ib) Connect the speedometer cable and secure it with the set screw. Measure the clearance between each surface of the left brake disc and the left caliper holder with a 0.7 mm (0.023 in) feeler gauge. If the gauge inserts easily, tighten the forward left axle holder nut to the specified torque, then tighten the rear nut. If the feeler gauge canna‘t be inserted easily, pull the left fork out or push it in until the gauge can be inserted. After installing the wheel, apply the brake several times, then recheck both discs for caliper holder to disc clearance. M Failure to provide adequate dist m caliper holder clearance may damage the brake disc and impair brake efficiency. FRONT WHEEL/SUSPENSION ARROW MARK CALIPER MOUNT EOLT CALIPER MOUNT BOLT " ._ .. CALIPER HOLDER BRAKE DISC Date of issue: October, 1983 © HONDA MOTOR 60., LTD. 14-17 HONDA V45 INTERCEP‘I’OR FRONT WHEEL/SUSPENSION FRGNT FIIRKS REMOVAL Remove the following parts: — fairing. - headlight. — instruments. 7 handlebars. —— front wheel. - handlebar spacers. Remove the front fender and fork brace. FRONT FENDER UPPER PINCH BOLTS Loosen the fork upper and lower pinch bolts. LOWER PINCH BOLTS 1 4_ 1 Date of Issue: January, 1983 8 ©HONDA MOTOR (20., LTD. HONDA v45 lN'I'ERCEP'I'OR FRONT WHEEL/SUSPENSION Pull each fork lube out of the top bridge, NOTE Because of the friction caused by theair joint O-rings, you'll have to turn the tubes while pulling down. Remove the fork stop rings. FORK STOP RING Pull each fork tube out of the fork bottom bridge. If repIacement of the air joint is necessary, remove the two screws which attach the fork air joint to the top bridge, Date of Issue: January, 1983 © HONDA MOTOR C0., LTD. 14- 19 FRONT WHEEL/SUSPENSION DISASSEMBLY Hold the fork tube in a visa, with soft jaws or a shop towel and remove the fork tube cap. CAUTION Du not damage the 3 mg surface. Remove the fork spring, spacer and washer. Drain the fork fluid by pumping the fork up and down several times, Hold the fork slider in a vise with soft jaws or a shop towel. Remove the socket bolt with a hex wrench. NOTE Temporarily install the spring and fork cap if difficulty is encountered in removing the socket bolt. The piston and rebound spring can be removed frum the right fork. FORK CAP SPRING HONDA v45 INTERCEPTOR SPACER WASHER HEX WRENCH (6 mm) 0791773230000 OR EQUIVALENT 14-20 Date of Issue: January, 1983 © HONDA MOTOR CO‘, LTD. HONDA vr70017so INTERCEPTOR '83-'84: Remove Ihe dusl seal, loam seal and plastic washerv Discard the (cam seal and plastic washer. Do not reuse or replace After '84: Remove Ihe dust seal, Remove the snap ring. Pull The lork lube out until resislance (mm the slider bushing Is (all. Then move il in and out, tapping the bushing Ilghlly until the (ark tube separates (mm the slider, The slider bushing will be (arsed out by the lork lube bushingv Remove the oil lock piece lrom inside the slider‘ PLASTIC WASHER ’83—’84 Shown FRONT WHEEL/SUSPENSION FOAM SEAL DUST SEAL SNAP RING PLIERS 07914—3230001 OR EQUIVALENT lN U.§ A n if?” SNAP RING FORK TUBE FORK SLIDER Dale ol Issue Omober, 1934 ©Amencan Honda Motor Co, Inc 1934 , All ngms Reserved 1 4-21 FRONT WHEEL/SUSPENSION Remove the oil seal, back-up ring and slider bush- ing(s) from [he fork lube NOTE Do not remove the fork tube bushings unless it Is necessary to replace II with a new one. On the IeIl Iork, remove the circllp, on] lock valve, spring, and spring seal from [he piston. Remove [he prston and rebound spring from the Iork tuber INSPECTION FORK SPRING FREE LENGTH Measure [he Iork spring Iree length. SERVICE LIM": 470 mm (185 in) '83-'84: SLIDER BUSHING OIL SEAL BACK-UP RING FORK TUBE BUSHING PISTO N VF700/750 INTERCEPTOR é HONDA After ’84: OIL SEAL SLIDER BUSHING BACK-UP RING FORK TUBE BUSHING SPRING SEAT CIRCLIP OIL LOCK VALVE SPRING 1 4-22 ©Amer|can Honda Mmor Cor, Dale oI Issue‘ October, 1984 Inc. 1984 - All Rights Reserved EONDA v45 INTERCEPTOR FORK TUBE/FORK SLIDER/PISTON Check the fork lube, Iork slider and piston for score marks, scratches, or excessive or abnormal wear. Replace any components which are worn or damaged. Check the fork piston ring lur wear or damage. Check the rebound spring lnr fatigue or damage. FORK TUBE Set the fork tube in V blocks and check its runout. SERVICE LIMIT: 0.20 mm (0.038 in) BUSHING/BACK-UP RING Visually inspect the slider and fork tube bushings. Replace the bushings i! there is excessive scoring or scratching, or it the teflon is worn so that the copper surface appears on more than 3/4 of the entire surface. Check the backup ring; replace it if there is any distortion at the points shown. FRONT WH EEL/SUSPENSION PISTON HING PISTON REBOUND S? H ING Ii FORK was ‘ SLIDER l BUSHING BACKUP RING I r “1 q \ CHECK POINTS COPPER SURFACES Date of issue: January, 1983 © HONDA MOTOFI C0., LTD. 14-23 é HONDA FRONT WHEEL/SUSPENSION “700/750 'NTERCEPTOR ANTI-DIVE CASE '33-'34: Ahsr '94: Remove [he 'our socket bolts and remove the anti? dive case. '83-'84: Remove the piston and spring Remove the boots, pivot boll collar and stop rubber. After '84: Remove the piston and spring, Remove Ihe boot, plvot bolt collar and rubber bushing. Check the spring and plSlOl" for wear or damage '83<'84 PISTO N SPRING PIVOT BOLT COLLAR STOP RUBBER ’83«'34: % After '84: RUBBER BUSHING PISTON PIVOT BOLT COLLAR After ’84: 9f, % 1 4-24 Dale 0! Issue: chber, 1984 ©American Honda Motor Co. (nc 19B4 - All Rights Reserved HONDA vr700/7so INTERCEPTOR é '83-'84: Remove leit side washer, stopper ring and orifice, Check the orifice ior clogging by applying com» pressed arr Also check the orifice for damage and replace If necessary Remove the check valve setting screw, valve spring and check ball After ’84: Remove the screw attaching the antrdrive adjuster knob, knob and orifice, Remove the check ball screw, spring and ball, Check the orilice lor clogging, scoring, excessive wear or damage Replace il necessary Assemble the anti~dive case in the reverse order of disassemblv NOTE Apply a Thread Lock Agent to the threads oi the screws and socket bolts beiore assemblv‘ Applv ATF to the piston and piston O-ring. Apply silicone grease to the pivot bolt oollar Install the pivot bolt collar boot holder as shown Check the operation oi the collar and piston, ’83-’84: FRONT WH BEL/SUSPENSION After ’84: CHECK BALL ORIFICE ORIFICE ADJUSTER “$2 KNOB VALVE SPRING SPRING STOPPER RING CHECK BALL BOOT HOLDER '33-'94 After '84: Dale oi Issue' October, 1984 © American Honda Motor (20., lnc 1984 - All Rights Reserved 1 4-25 FRONT WHEEL/SUSPENSION VF700/750 INTERCEPTOR é HONDA ASSEMBLY Belore assembly, wash all parts with a high flash point or non-flammable solvent and wipe them off completely CAP BOLT FORK SPACER SPRING Insert the rebound spring and piston Into the lork tube, 0n the left fork, install the spring seat, valve spnng, OII lock valve and circlip on me piston Place the oil lock piece on the end of the pislun, NOTE 0n the rtght lork, Install the all lock piece, aligning the "at sides of the oil lock piece and piston end. DUST SEAL SNAP RING a; @ <3 FORK TUBE REBOUND BUSHINGlS) NOTE: Only one bushing is used after '84 PlSTONVi 753mm; SEAT T i“ \ CIRCLIP OIL LOCKVALVE SPRING OIL SEAL BACKUP RING SLIDER BUSHING SLIDER Q After '84: FORK BRACE ANTIVDIVE CASE \3 Q & FLAT SIDE 1 4-26 Date of Issue' October, 1984 ©Amerlcan Honda Motor (30., Inc 1984 ~ All nghls Reserved é HONDA vr1oo/1so INTERCEPTOR Insert the Iork tube into the slider. N OTE Align the cutout ol the oil lock piece with the drain bolt in the slider. Place the tork slider In a vise with soft jaws or a shop towel. Apply a locking agent to the socket bolt and thread it into the piston, Tighten With a 6 mm hex wrench. NOTE Temporarily install the Iork spring and Iork cap bolt to tighten the socket bolt. TORQUE: 15—25 N.m (1.5—2.6 kg BOTTOM TOP FORK TUBE CAP 7 1 4-28 Revlsed: February, 1985 ©Amencan Honda Motor m, Inc was - All Rights Reserved ' msv 9341 8602 ‘83 - '35 VF700/750F HONDA V45 INTERCEPTOR FRONT WHEEL/SUSPENSION INSTALLATION mm“ the forks and temporarily tighten date bot- tom pinch bolts. Install the fork stop rings in the grooves in the fork tube. Push the fork tubes up until the stop rings contact the air joints. FORK STOP RING TOP PINCH BOLTS Tighten the bottom pinch bolts. TORQUE 45—55 N-m (45—55 kg-m, 33—40 ft-lh) Tighten the top pinch bolts. TORQUE: 9—13 N‘m (0.9—1.3 kg-m, 7—10 fl-lb) Date 01 Issue: January, 1983 © HONDA MOTOR (20., LTD. FRONT WHEEL/SUSPENSION Loosely install the fark brace. Install the removed parts in the reverse order of removal. 7 front fender. — handlebar spacers. 7 handlebars. — front wheel. 7 headlight. — instruments. 7 fairing. With the front brake applied, pump the forks up and down several times. Tighten the front fork brace mounting bolts. Fill the fork tubes with air. RECOMMENDER PRESSURE: 0—40 kPa (0—0.4 kg/cm‘ , 0—6 psi) CWYION - Use only a handoperaled air pump la fill the fork tubes. Do not use compressed air. - Maximum pressure is 300 kPa {3 kg/CM2, 43 psi). Do not exceed [his or fork tube componenl damage may occur. With the front brake applied, pump the forks up and down several times. Place the motorcycle on its center stand. Check the air pressure and adjust if necessary. HONDA v45 INTERCEP'I'OR FRONT FORK BRACE FRONT FENDER 14-30 Date of Issue: Januarv, 1983 © HONDA MOTOR (30., LTD. HONDA v45 INTERCEPTOR FRONT WHEEL/SUSPENSION STEERING STEM REMOVAL Remove the Vollowing component; — fairing. e headlight, — instrument, — handlebars, — from wheel. — ignition switch. > 7 brake hose 3-way joint. BRAKE HOSE 3~WAV JOINT LOCK NUT WRENCH, 30 x 32 mm 07716—0020400 or EQUIVALENT IN U.S.A. Loosen and remove the steering stem nut. Remove the forks. ‘ I EXTENSION 0771670020500 0R EQUIVALENT U.S.A. TOP BRIDGE Loosen the top bridge pinch bolt and remove the tap bridge with the fork air joint. \ PINCH BOLT AIR/JOINT Date of Issue: October, 1983 ©HONDA MOTOR co., LTD. 14 -31 HONDA v45 INTERCEP'I'OR FRONT WHEEL/SUSPENSION LOCK WASHER LOCK NUT Straighten the lock washer tabs and remove the lock nut and lock washer, STEERING STEM SOCKET 07916—3710100 Loosen the bearmg adjustment nut and remove the steering stem‘ ’83 shown Check the steering stem bearings for damage or wear. BEARING REPLACEMENT NOTE Replace the bea g and bearing race as a set. Remove the grease retainerv Remove the bearing Inner race and dust seal from the steering stem. DUST SEAL BEARING Date of Issue: October, 1983 1 4 -32 © HONDA MOTOR 00., LTD. é HONDA VF700/750 INTERCEPTOR FRONT WHEEL/SUSPENSION Remove the upper bearing race with the special BALL RACE REMOVER tool. 07953—4250002 BALL RACE REMOVER Remove Ihe lower bearing race with the special 079534250002 tool. ». NOTE If the motorcycle has been Involved in an accident, examIne the area around the steerr Ing head for cracks. BEARING RACE REMOVER 0794673710500 ’83: After ’83: , LOCK NUT “fl WLOCK WASHE R —/’§ @J‘EARING ADJUSTMEN ® NUT 1‘ /® \DUST SEAL .<-UPPER BEARING INNER % QM RACE @XUPPER BEARING PPER BEARING OUTER/ RACE Q \ / GREASE RETAINER g LOWER BEARING OUTER”.§ RACE .‘LOWER BEARING @‘LOWER BEARING INNER-'Q \RACE /® DUST SEAL Dale oI lssue. October, 1984 ©Amencan Honda Molor C0,, Inc 1984 - All Flights Reserved 1 4-33 FRONT WHEEL/SUSPENSION Drive the upper bearing outer race into the steering head Drive the lower bearing outer race Into the steering head. Install a dust seal onto the steering stem and press the lower bearing inner race over the stem with the special tool. INSTALLATION Pack the bearing cavities with hearing grease. ’83: Install the grease retainer on the steering stern, then insertthe steering stem intothe steering head Install the bearing retainer and upper bearing/inner race, AIter '83: Inslall the lower bearing and grease retainer onto the steeing slem, then insert the steering stem into the steering head. Install the upper bearing and inner race. DRIVER J7749—0010000 ATTACHMENT, 42 £47 mm 07746-001 0300 HONDA VF700/750 INTERCEPTOR A‘I'I'ACHMENT, 52 x 55 mm 07749-0010400 \ \e \, DRIVER 0774940010000 l STEERING STEM DRIVER ‘ 07946—7MBOOOOO on 079454710601 AND 07964411500230 \r i '83 SHOWN UPPER BEARING/ _ INNER RACE ‘83 SHOWN \ \1 y .g‘ , i g > : y 1 4-34 Date oi Issue. October. 1984 © American Honda Motor Co , Incv 1984 - All Rights Reserved HONDA V45 INTERCEPTOR FRONT WHEEL/SUSPENSION STEERING STEM SOCKET 07916—3710100 Install and tignten the adjusting nut to the specified torque. TORQUE: ’83: 10—12 N-m (1.0—1.2 kg-m, 7—9 ft-lb) ’84: 19—21 N-m (1.9—2.1 kg-m, 14—151‘t-lb) Turn the steering stem lock~t07|0ck 4—5 times to seat the bearings, then tighten the nut to the same torque. ’83: Again turn the steering stern lock-to-loek 5 times to seat the bearings, then tighten the adjust- ment nut to the same torque. Install a new bearing adjustment nut lock washer aligning the tabs with the grooves in the nut. Bend two opposite tabs down into the grooves, NOTE LOCK NUT DO NOT install a used bearing adjustment nut lock washer, Hand tighten the lock nut. Hold the adjustment nut and further tighten the lock nut only enough to align its grooves with the lock washer tabs, NOTE l7 u If the lock nut grooves cannot be easily a gned w h the lock washer tabs remove the nut, turn it over and reinstall Bend two lock washer tabs up into the lock nut grooves. LOCK WASH E R Date of Issue: October, 1983 © HONDA MOTOR CO, LTD. 14-35 HONDA FRONT WHEEL/SUSPENSION V45 INTERCEPTOR EXTENSION . , 0771670020500 or EQUIVALENT IN U.S.A. instali the top bridge with the fork alr jorm. InstalI the front forks 10399 14—29). Instzil and tighten the steering stem nut. TORQUE: 90—120 N-m (9.0—123 kg~m, 65—87 ft-lhI LOCK NUT WRENCH, 30 x 32 mm 0771670020400 or EQUIVALENT IN U.S.A. STEERING HEAD BEARING PRELOAD lnstaIl the from wheel (page 14-17). Piace a stand under the engine and raise the from wheei off the ground. SPRING SCALE Position the Sleel’lng stem to (he sn’aighl ahead (commerciauy available) position. Hook 3 spring scale m the fork tube and measure the steering head bearing preload. NOTE Make sure that there is no cable and wrre harnes nterference. The preload shouid be within 1.0—1.6 kg 122173.53 lb) for right and Ieft turns. If the readings do not fail within the range, iower the front wheei and adjust the bearing adjustment nut. Aher maklng sure the bearing preioad is acceptable, instaii (he removed parts in the reverse order of removaI. Date of Issue: October, 1983 14‘36 © HONDA MOTOR 00., LTD. HONDA v45 Imncmon MEMO FRONT WHEEL/SUSPENSION Data of Issue: January, 1983 ©HONDA MOTOR 00., LTD, . HONDA REAR WHEEL/SUSPENSION V45 INTERCEPTOR 40—50 N-m (4.0-5.0 kg~m, 29—36 ft-lb) 85—105 N»m (8540.5 kg-m, 61 —76 fl-lb) (4,0~5.0 kg-m, 18725 N~m [1.8—2.5 kg-m, 13—18 frlbb “Eb 80v1 OD N4m (8,040.0 kgm, V 40—50 N-m N '- 53772 ftrlb) [40—51) kg-m my" 2946 ft-lb) \' 20730 N~m (2.0-30 kgrm, \. 14—22 mm 357105 N~m 'V (8.5—10‘5 kg-m, 61—76 ftrlb) Daxe of Issue: January, 1983 © HONDA MOTOR 00., LTD. 15-0 HONDA v45 INTERCEP'I'OR 15. REAR WHEEL/SUSPENSIIIN SERVICE INFORMATION TROUBLESHOOTING REAR WHEEL SHOCK ABSORBER SWINGARM 15—1 15—2 1573 15—8 15—13 SERVICE INFURMATIUII GENERAL 0 The rear wheel uses a tubeless t'lre, For tubeless t'lre repairs, refer to the TUBELESS TIRE MANUAL, SPECIFICATIONS STANDARD SERVICE LIMIT Axle runout 7 02 mm (0.01 inl Rear wheel rim runout Radial , — 2.0 mm (0.08 in) Axlal — 2.0 mm 10.08 in) Shock absorber air pressure J 507300 kPa (0.5—30 kg/sz, 7—43 psi! 7 TOROUE VALUES Shock arm-to-frame bolts Shock linkrto-shock arm bolt Rear shock absorber mount bolts Swingarm pinch bolt Swingarm pivot bolts Rear brake torque rod 8 mm 10 mm Final drlven sprocket Hear brake dlSC Rear axle nut TOO LS Speual Needle bearing remover Oil seal dl'lvef attachment Oil seal driver attachment rlng Oil seal drlver Common Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 52 x 55 mm Attachment, 62 x 68 mm Not, 17 mm Film, 20 mm Pilot, 25 mm Driver Bearing remover shaft Bearing remover head, 20 mm 40—50 Nam (Alto—5.0 kg-m, 29736 fr-lb) 40—50 N-m 14,0750 kgrm, 29736 Ma) 40750 N-m Ian—5.0 kg~m, 29736 Mb) 20730 N-rn (IO—3.0 kg~m, 14—22 ftrlb) 857105 N~m18t5—10.5 kg-m, 61776 ft-lbI 18—25 Nm (1372.5 kgrm, 13718 ftrlb) 3040 Nm (3.0—4.0 kg-m, 2249mm 80—100 N~m (8.07100 kg-m, 58772 ft-lb) 35—40 Nrm (3,574.0 kgrm, 25—29 ft-lbl 857105 Nvm 1857105 kgrm, 61776 ft-lbl 079317MA70000 079657MC70100 07965—ME70100 07965—M 300100 0774670010100 0774670010200 0774670010400 07746—0010500 0774670040400 0774670040500 0774670040600 0774970010000 07746—0050100 or equivalent in U.S.A. 07746—0050600 or equivalent in U.S.A. Date of Issue: October, 1983 © HONDA MOTOR C0., LTDV 15-1 REAR WHEEL/SUSPENSION TRflIHEIlESHflflTING Oscillation 1. Bent rlm 7.. Loose whee! bearings 3. Faulty tire 4. Loose axle 5‘ Tire pressure incorrect 6. Swingarm bearings worn 7. Worn tires Soft suspension 1. Weak spring 2. Insufficientfluid in shock absorber 3. Shock absorber air pressure incorrect Hard suspension 1‘ Incorrect fluid weight in shock absorber 2. Bent shock absorber 3. Shock absorber air pressure incorrect Sumunsion noise 1. Shock case binding 2, Loose fasteners HONDA v45 mrincmon 15-2 Date of Issue: January, 1983 ©HONDA MOTOR CO., LTD. HONDA v45 INTERCEP'I’OR REAR WHEEL/SUSPENSION REAR WHEEL LOC'K NUT ALXE NUT REMOVAL Place the motorcycle on its center stand. Loosen the drive chain adjusting bolts luck nuts and the adjusting bolts. Remove the axle nut and axle. Push the wheel forward and remove the drive chain from the driven sprocket and remove the rear wheel. NOTE If you cleaves: the brake pedal after the rear wheel is removed, the caliper piston will move out and make reassembly difficult. DlSASSEMBLY Remove the rear brake disc. Remove the dust sealv DUST SEAL FINAL DRIVEN SPROCKET Remove the final driven sprocket and driven flange together. NOTE Do not seiTarate the driven sprocket and flange, unless replacement of the driven sprocket or flange is necessary. Remove the dust seal from the final driven flange. Date of Issue; January, 1983 © HONDA MOTOR CO., LTD. REAR WHEEL/SUSPENSION INSPECTION AXLE Set the axle in V blocks and read the axle runout with a dial indicator. SERVICE LIMIT: 0.2 mm (0.01 in) REAR WHEEL BEARING Check the wheel bearing play by rotating the wheel by hand. Replace the bearings with new ones if they are noisy or have excessive play, HEAR WHEEL RIM RUNOUT Check the rim for runout by placing the wheel in a truing stand. Spin the wheel slowly] and read (he runout using a dial indicator. SERVICE LIMITS: RADIAL RUNOUT: 2,0 mm (0.08 in) AXIAL RUNOUT: 2.0 mm (0.03 in) NOTE 7 HONDA V45 INTERCEP'I’OR PLAY l The wheel cannot be serviced and must be replaced if the above limits are exceeded. 15-4 Date of Issue: January, 1983 © HONDA MOTOR 00., LTD HONDA v45 INTERCEPTOR FINAL DRIVEN SPROCKET Check the condition of the final driven sprocket teeth. Repiace the Sprocket if worn or distorted. NOTE REAR WHEEL/SUSPE NSION if the final driven sprocket requires replace- ment, inspect the drive chain and drive sprocket‘ DAMPER RUBBERS Replace the damper rubbers if they are damaged or deteriorated‘ BEARING REPLACEMENT Remove the wheel bearings. Drive the driven flange side bearing out. NOTE GOOD R EPLACE Never reinstali old bearings; once the bearings are removed, they must be replaced with new ones. Date of Issue: Octaber, 1983 © HONDA MOTOR (20., LTD. DAMPER RUBBER BEARING REMOVER SHAFT 0774641060100 BEARING REMOVER HEAD, 20 mm 07746—0050600 15-5 REAR WHEEL/SUSPENSION Pack all bearing cavities with grease. Press distance collar into place from the left side. Drive the right bearing in first, then the left bearing with the following tools. DRlVER 07749—0010000 ATTACHMENT, 52 x 55 mm 07746~0010400 Pl LOT, 20 mm 0774670040500 Drive the driven flange bearing in with the follawlng tools. DRIVER 07749—00l0000 ATTACHMENT, 62 x 68 mm 07746—0010500 PILOT, 25 mm 0774643040600 CAUTION Drive the bearing: in squarely With the :ealedi end facing 0141, making sure [hey are fully Seated. ASSEMBLY NOTE The rear wheel uses a tubeless tire. For tube- less tire repairs, refer to the Tubeless Tire Manual, 35—40 N-m (3.54.0 kg-m, & 25—29 ft-Ibl “WARNING Do not get grease on the brake disc or stop- puwer will be reduce . HONDA v45 INTERCEP‘I'OR DRIVER ¥ \ ATTACHMENT & PILOT \_, 807100 N-m (8040.0 kg-m, 58—72 lel V \ FINAL DRIVEN SPROCKET DAMPER RUBBER \. 15-6 Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. HONDA. V45 INTERCEI’T"R HEAR WHEEL/SUSPENSION DRIVEN FLANGE DRIVEN SPROCKET Install the rear axle sleeve, final driven flange and driven sprocket. If the driven sprocket was removed from the flange, tighten the driven sprocket nuts to the specified torque. TORQUE: 80—100 N-m (SD—10.0 kg-m, 58—72 lt-lb) Installthe dust seal, DUST SEAL REAR BRAKE DISC Install the brake disc and tighten the bolts, TORQUE: 35-40 N-m (3.5—4.0 kg-m, 25—29 ft-lh) Install the dust seal, DUST SEAL LEFT SIDE SPACER RIGHT SIDE SPACER Install the left and right side spacers. Date of Issue: January, 1983 © HONDA MOTOR co., LTD. 15'7 HEAR WHEEL/SUSPENSION INSTALLATION Install the rear wheel in the reverse order of re- moval. NOTE When installing the wheel, carefully fit the brake disc betv‘veen the brake pads. After installing the wheel, apply the brake several times. Then check that the wheel rotates freely. Recheck wheel installation if the brake drags or if the wheel does not rotate freely. Tighten the rear axle nut. TORQUE: 85—105 N-m (85—105 kg-m, 61—76 ftlhl Adjsut the drive chain slack Ipage 3713ir SHIllill ABSIIRBER REMOVAL Place the motorcycle on its center stand. Remove the seat and left frame side cover. Remove the breather separator and the electric panel. Remove the shock absorber lower mounting bolt. Remover the shock absorber upper mounting bolt, tilt the shock absorber rearward and remove it from the frame by pulling it up. 6 HONDA V45 INTERCEP'I'OR BREATHER SEPARATOR l l ELECTRIC PANEL LOWER MOUNTING BOLT UPPER. MOUNTING BOLT 15-8 Date of Issue: January, 1953 © HONDA MOTOR 00., LTD. HONDA V45 INTERCEPTOR OIL SEAL REPLACEMENT Remove the shock case boot. Remove the air valve cap and release the air pressure by depressing the air valve stem, Press the back-up ring 10—20 mm (DIM—0.03 in) in with the Oil Seal Driver and attachment. CAUTION BOOT Do nor press in the back-up ring exeexxively, since it can came the guide bushing to [am into the shock ease, making guide bushing removal difficult. Remove the stop ring, Hold the shock absorber upright in a vise. Fill a high pressure grease gun with ATF lAutomatic Transmission Fluid) and connect the attachment hose to the shock absorber air valve. Keep the shock upright, Wrap a shop towel around the oil seal. Pump ATF into the shock absorber through the attachment hose to force the oil seal and guide bushing out. The ATF will also come out. Let the shock absorber stand for another 10 min» utes to allow all of the ATF to drain from the outer case. Do not tilt the shock absorber or ATF will flow out of the damper case. ATTACHM ENT O7965rM070‘l DO STOP RING -ACK-UP RING OIL SEAL GUIDE BUSHING REAR WHEEL/SUSPENSION STOP RING AIR VALVE SHOP yowu GREASE GAN FILLED WITH ATF Date of Issue: October, 1983 © HONDA MOTOR CO., LTD. 15-9 REAR WHEEL/SUSPENSION Turn the shock absorber upside down as soon as all the ATF has drained from (he outer Case Fill (he damper case with the specified amount of ATF. SPECIFIED AMOUNT: 120 or: (4.06 US 01, 3.38 Imp oz) Install the guide bushing Into the damger case. To prevent seal damage, wrap a piece of tape around the groove at the end of the shock absorber. Dip the oil seal in ATF and install it onto the damper. CAUTION Be carefixl not to damage rm 0’ real during installation. Press the oil seal into the shock absorber with a hydraulic press umll the oil seal driver stops at the edge of the outer case. 15-10 OIL SEAL DRIVER 07965vMBOfl100 ATTACH ME NT 07965—MC70100 1-10an v45 INTEKCEPTOR L DAMPER OIL IATF OR EQUIVALENT) OILSEAL TAPE ATTACH ME NT 079657MC70100 ‘ TTACHME NT RING 07965~ME70100 OIL SEAL GUIDE BUSHING Date of Issue: October, 1983 ©HONDA MOTOR 00., LTD. HONDA V45 INTERCEI’TOR REAR WHEEL/SUSPENSION Install the back-up ring. . t BOOTS STOP RING Install the stop rlng, belng certain that it is fully seated in the ring groove in the outer case. Do not forget to install the stop ring; the ROOVE shock can come apart without this ring. G /\ BACK-UP RING Install the boot. Install the boot clip with the edge facing down. UPPER MOUNTING BOLT INSTALLATION Apply paste grease (containing more than 45% of molybdenum) to the upper mounting bushings‘ NOTE Use paste grease [containing more than 45% of molybdenum) as follows: 'MOLYKOTE G-n PASTE manuiactured by Dow Corning, U.StA. 'Locol Paste manufactured by Sumico Lubricant, Japan, 'Other lubricants of equivalent quality, Install the shock absorber in the frame and tighten the upper and lower mounting bolts. TORQUE: 40—50 N-m (4,0—53 kg-rn, 29—36 fl-lb) Date of Issue: October, 1983 © HONDA MOTOR (30., LTD. 15- 1 1 LOWER MOUNTING BOLT REAR WHEEL/SUSPENSION Install the electric panel and crankcase breather separator. NOTE Route the wires, hoses and tubes properly [pages 1-101hru 12). Install the left Irame slde cover and seat. Adjust the an pressure (page 3718), SHOCK ABSORBER LINKAGE REMOVAL Remove the Ielt and right mulllers Remove the shock link by removing the shock absorber lower mounting bolt, shock linkrloVshock arm bolt. swingarm pinch bolt, and shock llnk shaft. Remove the shock arms from the frame. LIN KAGE PIVOT INSPECTION Check the linkage needle bearings (bushings lor ’83) and collars for wear or damage. Inspect the dust seals Ior damage. Replace parts as necessary SHOCK LINKAGE INSTALLATION ’83. Apply paste grease (containing morethan 40% molybdenum) to the bushings and dust seals. See note on page 15-11. Alter '83’ Apply molybdenum disullide grease to the needle bearings and dust seals. 6 HONDA VF700/750 INTERCEPTOR SWINGARM SHOCK LINK SHOCK ABSORBER PINCH BOLT SHAFT LOWER MOUNTING BOLT s SHOCK LINK LINK-TO-ARM SHOCK ARM BOLT ’83 SHOWN: Q) 0%) 15-12 Date of Issue: October, 1954 ©Amencan Honda Motor Co, Inc 19B4 - All Rights Reserved HONDA v45 INTERCEP'I'OR REAR WHEEL/SUSPENSION Infiall the shock arms and shock link and tighten each bolt in the order listedv TORQUE: SHOCK ARM-TO-FRAME: 40a50 N-m (4.0—5.0 kn-m, 29—36 fl-Ib) SHOCK LlNK-TO-SHOCK ABSORBER 40—50 N-m (4.0—5!) kg-m, 29—36 ft-lb) SHOCK LINK-TO-SHOCK ARM: 40—50 N-m (4.0—5.0 kg-m, 29—36 ft-lb) SWING ARM PINCH BOLT: 20—30 N‘m (lo—3,0 kg-m, 14—22 ft-lb) mm“ the mufflers, SWINEMIM REMOVAL Remove the rear wheel (page 15-3). Remove the right muffler. Remove the shock link pinch bolt and shock link shaft. Remove the left and right swingarm pivot bolts. SWINGARM PINCH BO LT SHOCK LlNK—TO-SHOCK ABSORBER BO—LT SHOCK LINK LINKVTOV ARM BOLT FRAME BOLT SHOCK LINK PINCH BOLT SHOCK LINK SHAFT LEFT PIVOT BOLT RIGHT PIVOT BOLT Date of Issue: October, 1983 © HONDA MOTOR 60., LTD, REAR WHEEL/SUSPENSION Remove the lock pin from the rear brake torque rod bolt and remove the torque rod bolt. Remove the swingarm from the frame. Remove the drive chain slider from the swingarm. PIVOT BEARING REPLACEMENT Remove the pivot collar Vrom the swingarm's right pivot. Remove the dust WEI. Remove the snap ring and drive out the right pivot bearings. HONDA v45 INTERCEP‘I‘OR LOCK PIN TORQUE ROD BOLT DRIVE CHAIN SLIDER DUST SEAL PIVOT COLLAR SNAP RING 15-14 Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. HONDA v45 INTERCEPTOR REAR WHEEL/SUSPE NSION NEEDLE BEARING REMOVER O793’l-MA7OOD NOT AVAILABLE IN U.S.A. Remove the dust seal from the swingarm’s left V . pwat. Remove the Ieh pivot needle bearing with the specialtoal. k \_ DRWER WOODEN 077490010000 BLOCK Drive a new needle bearing into the swingarm left . pivoL CAUTION ——‘.—'———T To prevent swmgarm damage, mpport the xwingarm as shown. \_, ATTACHMENT, 32 x :15 mm 0774670010100 PILOT, 20 mm 07746—0040500 DRIVER 07749—0010000 Drive new ball bearings into the swlngarm right \ pivot. ATTACHMENT, 37 x 40 m 07746—0010200 PILOT, 17 mm 0774641040400 Date of issue: Oc‘cber. 1983 © HONDA MOTOR 60., LTD. 15- 15 REAR WHEEL/SUSPENSION Install the snap ring in the right swingarm pivot. Install the oil seals both plvots. Install the pivot collar into the right pivot. INSTALLATION Install the drive chain slider, Install the sw‘mgarm in the frame. Make sure [hat the rear brake mrque Iod’s flanged washer is ins(a|led ln the swingarm pivot. Connect the rear brake torque rod to the swingarm and tighten the pivot bolt. TORQUE: 18—25 N-m (1.9—2.5 kg-m,13—18k—lb) Secure the bolt with the |ock pin. C, HONDA v45 mmcmon SNAP RING PIVOT COLLAR DRIVE CHAIN SLIDER Jan-‘4’ " LOCK P|N 15-16 Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. H°¥¥#R V45 INT RC 0 REAR WHEEL/SUSPENSION Install the left and right pivot bolts. Tighten the right pivot bolt. TORQUE: 85—105 N-m(8.5—1D.5 ku-m, 61—76 ft-lb) Tighten the left pivot bolt. TORQUE: 85—105 N»m (Bis—40.5 ka-m, 61-76 ft-lhl SHOCK L!NK PINCH BOLT SHOCK LINK SHAFT Connect the swingarm and shock link and install the shock link shaft and shock link pinch bolt. Tighten the shock link pinch bolt. TORQUE: 20—30 N‘m (2.0—3.0 kg«m,14—22 ft-lhl install the right muffler, Install the rear wheel [page 15%], Date of Issue: January, 1983 15- 1 7 © HONDA MOTOR C0., LTD. HONDA HYDRAULIC BRAKE V45 INTERCEPTOR Q 3040 N-m \ m % (104.0 kg-m, V W 22—29 it-Ib) w 30—40N~m 3 (3.0—4.0 kg-m, 0}“ find» 1 "3% 25—40 N‘m (2574.0 kg-m. (2.573.!) kg-m, 18729 ft-lbl 18—22 be) (2,072.5 kg-m, 14-18 ftrlb) (lo—2.5 kgrm, §© 14—18ft-lb) 1 6'0 Date of Issue: January, 1983 © HONDA MOTOR CO‘, LTD. HONDA V45 INTERCEPTOR IB. HYDRAULIC BRAKES SERVICE INFORMATION 167 1 TROUBLESHOOTING 16— 2 BRAKE FLUID REPLACEMENT/AIR BLEEDING 16— 3 BRAKE PAD/DISC 16— 5 FRONT MASTER CYLINDER 16— 8 BRAKE CALIPERS 16—10 REAR MASTER CYLINDER 16—14 G E N E RA L o The brake calipers can be removed without disconnecting the hydraulic system. 0 Bleed the hydraulic system if it is disassembled or if the brake feels spongy. 0 Do not allow foreign material to enter the system when filling the reservoir. a Avoid spilling brake fluid on painted surfaces or instrument lenses, as severe damage can result. 0 Always check brake operation belore riding the motorcycle. SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Front disc thickness 4.5—5.2 mm (017770.205 in) 4,0 mm (0.157 in) Front disc runout 0.30 mm (0.012 in) Front master cylinder 1 D. 15870715913 mm (06248—06265 in) 15.925 mm (0,62701n) Front master piston 0 D. 15827—151354 mm (06231706242 in) 15.815 mm (0.6226 in) Front caliper piston 0.D. 31348—31998 mm (12578—12598 ini 31.940 mm (1.2575 in) Front caliper cylinder LD, 32030732080 mrn (12610-12630 in) 32.090 mm (1.2634 in) Rear master cylinder 1 D, 14000—14043 mm (0.551270.5529 in) 14,055 mm [0.5533 in) Rear master piston O D, 13.957713.984 mm (05495—05506 in) 13.945 mm (0,5490 inl Hear caliper cylinder I,D. 27.000727050 mm (10630—113650 in) 27.060 mm (1.0654 in) Hear caliper piston O.D. 26918726968 mm (1.0598—10617 in) 26.910 mm (1.0594 in) Hear disc thickness 6.5772 mm (0256—0283 in) 6,0 mm (0.236 in) Rear disc runout 0.30 mm (0.012 in] TORQUE VALUES Front brake caliper bracket mount bolt (Right) Front brake caliper bracket mount bolt (Left-upperi Brake caliper mount bolt Brake caliper pivot bolt Brake hose oil bolt Rear brake actuating arm (Left-lower) 30—40 N-m (3.0740 kg»m, 22—29 ft-Ibi 30740 N-m (3.0—4.0 kg-m, 22729 ft-lbl 20725 N-m (2.0—2.5 kg-m, 1471B ft-lbi 20725 N-m (2.0—2.5 kg-m, 14718 ft-Ibi 25730 N-m (2.5730 kg-m, 18722 ft~|bi 25—40 N-m (2.5740 kg»m, 18—29 ft-Ibi 10715 N-m(1.071.5 kg~m, 7711 ftrlbi Date of Issue: January, 1983 ©HONDA MOTOR CO., LTD. HYDRAULIC BRAKE TOO L Special Snap ring pliers TRllllBLESillflflllNE Brake lever/pedal soft or spongy 1. Air bubbles in hydraulic system 2. Low fluid level 3. Hydraulic system leaking Brake lever/pedal too hard 1. Sticking piston“) 2. Clogged hydraulic system 3. Pads glazed or worn excessiveiv Brake d rag i. Hydraulic system sticking 2, Sticking pistonlsl HONDA v45 INTERCEPTOR 0791473230001 or equivalent in U.S.A. Brakes grab 1. Pads contaminated 2. Disc or wheel misaligned Brake charter or squeal l. Pads contaminated 2. Excessive disc runout 3. Caliper inslailed incorrectly 4, Disc or wheel misaiigned 16-2 Date of issue: January, 1983 © HONDA MOTOR CO., LTD. HONDA v45 mmtcmon BRAKE FLIIIII] REPLACEMENT/ mom AIR BLEEDING ’ Check the fluid level with the fluid reservoir parallel to the ground, CAUTION - Install the cover on the renewal? whenever operating the brake [ever or pedal, Failure to do so will allow brake fluid to squirt out 0 f the reservoir during brake operation. Avoid spilling fluid on painted surfizces. Place clean Shop towels over the fuel tank whenever the system is being serviced BRAKE FLUID DRAINING Connect a bleed hose to the bleed valve to avoid spilling fluid. A brake fluid canmminaled brake disc or pad reduces stopping power, Discard pads and dean a contaminated disc with a high quality brake degreasing agent. Loosen the mliper bleed valve and pump the brake lever or pedal. Stop operating the lever or pedal when fluid stops flowing out of the bleed valve BRAKE FLUID FILLING erent types of fl may not be compatihl Close the bleed valve, fill the reservoir, and install the cover. To prevent piston overtravel and brake fluid see- page, keep a 20 mm [3/4 in) spacer between the handlebar grip and lever when bleeding the front brake system. When bleeding the rear brake system depress the pedal only as far as its normal travelt Pump up the system pressure with the lever or pedal until there are no air bubbles in the fluid flowing out of the reservoir small hole and lever or pedal resistance is felt. UPPER LEVEL ‘REAR HYDRAULIC BRAKE UPPER LEVEL LOWER LEVEL Date of issue: October, 1933 © HONDA MOTOR CO., LTD. HVDRAULIC BRAKE AIR BLEEDING NOTE ' Check the fluid level often While bleeding the brakes to prevent air from being pumpr ed into the system. ' When using the Mityvac Brake Bleeder, follow the manufacturer's instructions. CAUTION ‘ Ute only DOT4 brake fluid from a sealed container. - Do not mix brake fluid types and never re- use the contaminated fluid which has been pumped out during brake bleeding, because this will impair the efficiency of the brake system. Pump the brake lever or pedal to bring the caliper pads in contact with the discs Remove the master cylinder cap and fill the re- servoir to near full. Connect the Mityvar: Brake aleeder or equivalent to the bleeder valve. Pump the brake bleeder and loosen the bleeder valve. Add fluid when the fluid level in the master cylinder reservoir is low. Repeat above procedures until air bubbles do not appear in the plastic hose. NOTE If air is entering the bleeder from around the bleeder valve threads, seal the threads with teflon tape. If a Mityvac Brake Bleeder or equivalent not avail- able, bleed the system as follows: 1) Connect a bleeder tube to the bleeder valve. 2) Squeeze the brake lever or depress the brake pedal, open the bleed valve 1/2 turn and then close the valve. NOTE Do not release the brake lever or pedal un the bleed valve has been close 3) Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel. Repeat steps 1 and 2 until bubbles cease to appear in the fluid at the end of the hose. Fill the fluid reservoir to the upper level mark. A brake fluid contaminated brake disc or pad reduces stepping power. Discard contamin- ated pads and clean a contaminated disc with a high quality brake degreaxing agent. HONDA v45 INTERCEPTOR MITYVAC BRAKE BLEEDEH #GBQOCommercially Available in U S A, RUBBER HOSE BLEEDER VALVE MITVVAC BRAKE BLEEDER #GBBOVCommercially Available in U.S.A. 16-4 Date of Issue: January, 1983 © HONDA MOTOR CO” LTD. HONDA v45 INTERCEP‘IOR HVDRAULIC BRAKE BRAKE PAD/DISL‘ ' RIGHT CALIPER LEFT CALIPER FRONT PAD REPLACEMENT 4 NOTE Always replace the brake pads pairs to ‘ aSure even disc pressure. Remove the pad pin retainer bolt. Right caliper: Remove the caliper bolt and pivot bolt. Left caliper: Remove the caliber pivot bolt and anti-dive link bolt. Remove the caliper from the bracket. ‘ . PAD PlNS Remove the pad pin retamer and pull the pad pins out of the calipert Remove the brake pads. PAD SPRING Position the pad spring in the caliper as shown. Push the caliper pistons in all the way. Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. 16'5 HONDA v45 mmcmon HYDRAULIC BRAKE PAD PIN Install the new pads in the caliper. Install the pad pins, one pad pin first, then install the other pin by pushing the pads against the caliper to depress the pad spring. Place the pad piin retainer over the pad pins. Push the retainer down to secure the pins. RIGHT CALIPER Install the pad pin retainer bolt. Install the caliper to the bracket so the disc is positioned between the pads, being careful not to damage the pads, Right caliper: Tighten the caliper bolt and pivot bolt. Left caliper: Tighten the caliper pivot bolt and anti-dive link bolt. Date of Issue: January, 1983 16'6 ©HONDA MOTOR col, LTD. HONDA v45 INTERCEP'I'OR REAR BRAKE PAD REPLACEMENT Loosen the caliper bolt and remove it from the caliper bracket. Pivot the caliper up out of the way. Replace the rear brake pads using the same method as used for front brake pad replacement Dl‘SC THICKNESS Measure the thickness of each disc. SERVICE LIMIT: FRONT: 4.0 mm (0.16 in) REAR: 6.0 mm (0.24 in) BRAKE DISC WARPAGE Measure brake disc for warpage. SERVICE LIMIT: 030 mm [0.012 in) HYDRAULIC BRAKE Date of Issue: January, 1983 ©HONDA MOTOR ('30., LTD. 16-7 HONDA HYDRAULIC BRAKE V45 INTERCEFTOR FRflNT MASTER CYLINDER DISASSEMBLY Drain brake fluid from the hydraulic system. Remove the brake Iever and rear view mirror from the master cylinder, Disconnect the brake hose. CAUYION Avoid milling brake fluid or: painted surfaces. Place a rag over the fire] tank whenever the brake system ix being serviced. NOTE When removing the fluid hose bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out. Disconnect the front brake switch wires. Remove the front brake master cylinder. Remove the piston boot and the snap ring from the master cylinder bodyv SNXP RING PLIERS or EQUIVALENT IN USA. 07914—3230001 Remove the secondary cup and piston. Then remove the primary cup and s rin . p g PISTON Remove the brake light switch from the master 3 cylinder body, rr necessary / <9 Clean the inside of the master cylinder and reservoir with brake fluid / \, 53 SECONDARY CUP PHIMAR'V CUP Date of Issue: January, 1983 16-8 ©HONDA MOTOR C0,, LTD. HONDA v45 INTERCEPTOR INSPECTION Measure the master cylinder I.D‘ Check the master cylinder for scores, scratches or nicks. SERVICE LIMIT: 15.925 mm (0.6270 in) Measure the master piston O.D. SERVICE LIMIT: 15.815 mm (015226 in) Check the primary and secondary cups for damage before assembly, ASSEMBLY CAUTION Keep the master cylinder piston, cylinder and spring as a set; dun? substitute individual parts, Assemble the master cylinder. Coat all parts with clean brake fluid before assembly‘ Install the spring and primary cup together. Dip the piston cup in brake fluid before assembly. cwnou When installing the cups, do no! aIIow the lips to turn imide out and be certain the map ring HYDRAULIC BRAKE is firmly seated in the groove Install the piston and snap ring, Install the boot. PISTON BRAKE FLUID DOT»4 LIGHT SWITCH Date of Issue: October, 1983 © HONDA MOTOR CO.l LTD. 16-9 HYDRAULIC BRAKE Place the front master cylinder on the handlebar and install its clamp and two mounting bolts. Align the index mark on the Clamp with the punch mark on the handlebar, Tighten the upper bolt first, then tighten the lower bolt. Install the fluid hose with the bolt and two sealing washers. Install the brake lever, Install the rear view mirror. Connect the front brake switch wires. Fill the reservoir to the upper level and bleed me brake system according to page 16-4. BRAKE CALIPERS FRONT BRAKE CALIPER REMOVAL Place a clean container under the caliper and dis- connect the brake hose from the caliper. CAUYION Av d Sp ted xurfacex g brake flu on p Right caliper: Remove the caliper pivot bolt and caliper bolt] and remove the caliper. Left caliper: Remove the caliper pivot bolt and antidive link bolt, and remove the caliper. REAR BRAKE CALIPER REMOVAL Place a clean container under the caliper and dis- connect the brake hose from the caliper. CAUTION Avoid spilling brake fluid on the painted surfaces to prawn! paint damage. Remove the caliper pivot bolt and caliper bolt, and remove the rear brake caliper. RIGHT CALlPER HONDA V45 INTERCEP‘I'OR LEFT CALIPER 16-10 Date of Issue: October, 1983 © HONDA MOTOR C0., LTD. HONDA v45 INTERCEP‘I’OR DISASSEMBLY Remove the brake pads (page 16-5). Remove the pad spring. Remove the caliper pivot collar and boots. 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 air in short spurts. 00 not bring the 110221: too close to the tale! Examine the pistons and cylinders for scoring, scratches or other damage and replace if necessary. Push the piston seals in and lift them out, then discard them. Clean the piston seal grooves with brake fluid. CAUTION Be care/i4! not Ia damage Ihe pisran sliding mrfacex. HYDRAULIC BRAKE BOOTS PAD SPRING PIVOT COLLAR Date of Issue: January, 1983 © HONDA MOTOR 00., LTD. HYDRAULIC BRAKE PISTON INSPECTION Check the pistons for scoring, scratches or other damage. Measure the piston diameter with a micro- meter. SERVICE LIMIT: FRONT: 31.940 mm (1.2575 inl REAR: 26.910 mm (1.0594 in) CYLINDER INSPECTION Check the caliper cylinder for scoring, scratches or other damage. Measure the caliper cylinder bore. SERVICE LIMIT: FRONT: 32.090 mm (1.2634in) REAR: 27.060 mm (1.0654 in) ASSEMBLY If the collar boots are hardened or deteriorated, replace them with new ones. The piston seals must be replaced with new ones whenever they are removed. Coat the seals with silicone grease or brake fluid before assembly. Install the pistons with the dished ends toward the pads. Apply midium grade of Hi-Temperature silicon grease to the collar and inside of the collar grease Install the collar boots and collar making sure that the boots are seated in the collar and caliper grooves properly. Install the pad spring. Install the pads (page 16-5). COLLAR BOOTS HONDA V45 INTERCEPTOR PISTON SEALS V 0\ ~ \ PAD SPRING PISTONS 16-12 Date of Issue: October, 1983 © HONDA MOTOR (20., LTD. HONDA v45 INTERCEPTOR HYDRAULIC BRAKE CALIPER 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 mllper pivot bolt. RETAINER CLIP FIIGHTCALIPER LEFTCALIPER Install the caliper assembly over the brake disc so that the disc is positioned between the pads. CAUTION Be careful not [0 damage the pad Right caliper: Install the caliper pivot bolt and caliper bolt, and tighten them securely‘ Left caliper: Install the caliper pivot bolt and anti- dive link bolt, and tighten them securely. Connect the brake hose to the caliper with the bolt and two sealing washers. Fill the brake Iluid reservoir and bleed the brake system (page 16-4). CALIPER PIVOT BOOT REAR BRAKE CALIPER INSTALLATION Make sure that the retainer clip is in position on the caliper bracket‘ Inspect the condition of the caliper pivot boot. Apply silicone grease to the caliper pivot bolt. RETAINER CLIP Date of Issue: January, 1983 ©HONDA MOTOR CO., LTD. 16-13 HONDA. V45 INTERCEPTOR J HYDRAULIC BRAKE BRAKE H Install the caliper assemblv over the brake disc so i 05E that the disc is positioned between the pads, being v \ ' V careful not to damage the pads. Install the caliper pivot bolt and caliper bolt and tighten them securely. Connect the brake hose to the caliper with the bolt and two sealing washers. Fill the rear brake fluid reservoir and bleed the rear brake system (page 164). SEALING WASHERS REAR MASTER CYLINDER BRAKE HOSE BOLT REMOVAL Drain the rear brake hydraulic systm'n (D396 1673), Remove the brake hose bolt and disconnect the brake hose. In ll - It" I!“ x . 0‘. 02 O . RIGHT FOOTPEG BRACKET Loosen the rear master CVIlnder mount balm. Remove the right footpeg bracket, Unhook the rear brake switch spring from the rear brake actuating arm. MASTER CYLINDER MOUNT BOLTS 16' 14 Date of Issue: January, 1983 © HONDA MOTOR CO, LTD. \ HONDA v45 INTERCEP'I'OR Remove the hose connector screw and disconnect the master cylinder hose Unhook the rear brake pedal return sprmg. Remove the rear brake actuating arm bolt and the middle arm. Remove the cotter Din, washer and joint pin, and discunnect the brake actuating arm from the master cylinder push rodt Remuve me reav master cyIindey from the footpeg bracket. HYDRAULIC BRAKE MASTER CYLINDER HOSE x t. HOSE CONN ECTO R ACTUATING ARM BO LT RETURN SPRING JOINT PIN WASHER CYLINDER Date of Issue: January, 1983 © HONDA MOTOR CO., LTD. 16-15 HYDRAULIC BRAKE DISASSEMBLY Remove the rubber hoot. Remove the snap ring and push rod from the master cylinder bodv. Remove the master piston, primary cup and spring. It may be necessary to apply a small amount of air pressure to the fluid outlet to remove the master piston and primary cup. Clean all parts with brake fluid. CYLINDER LD. INSPECTION Measure the inside diameter of the master cylinder hare. SERVICE LIMIT: 14.055 mm (0.5533 in) Check for sCmes, scratches or nicks. PISTON OD. INSPECTION Measure the master piston O.D. SERVICE LIMIT: 13.945 mm (0.5490 in) Check the primary cup and piston cup for damage. HONDA V45 INTERCEI’TOR SNAP RING SNAP RING PLIERS or EQUIVALENT IN USA. 0791473230001 16-16 Dateof Issue: January, 1983 © HONDA MOTOR (20., LTD. HONDA V45 INTERCEPTOR ASS E M B L Y CAUTION HYDRAULIC BRAKE Keep the master cylinder piston, cylinder and spring as a set; d0 nut substitute indivi- dual parts Assemble the master cylinder. Coat all parts with clean brake fluid. Dip the piston cup in brake fluid before assembly. CAUTION When installing the cups. do not allow the lips in turn inside out and be certain the snap ring is seated firmly in the groove Install the primary cup and piston. Install the push rod and snap ring. Install the rubber covert INSTALLATION Install the master cylinder to the right footpeg bracket. Connect the rear brake actuating arm to the master cylinder push rod with the joint pin, and secure the joint pin with the washer and a new cotter pin. Install the actuating arm onto the rear brake pedal shaft, aligning the punch marks on the arm and shaft. Hook the rear brake pedal return spring to the actuating armt Tighten the actuating arm bolt, TORQUE: 10—15 N-m (1.0—1.5 kg-m. 7—11ft-lbI L‘ , MASTER CYLINDER PUNCH MARKS RETURN SPRING JOINT PIN Date of Issue: January, 1983 © HONDA MOTOR CO” LTD. 16-17 HONDA V45 INTERCEPTOR HYDRAULIC BRAKE MASTER CYLINDER HOSE Q‘EAR BRAKE SWITCH SPRING l : ' x. _ , Connect the master cylinder hose to the master cylinder with a new O-ring and screws Hook the rear brake switch spring to the actuating arm. ACTUATING ARM RIGHT FOOTPEG BRACKET Install the right Iootpeg bracket. Tighten the bracket bolt. Tighten the rear brake master cylinder mount bolts. FLUID BOLT Connect the rear brake hose with the fluid bolt and two sealing washers. Fill and bleed the rear brake system (page 16-4). Date of Issue: January, 1983 16- 18 © HONDA MOTOR CO‘, LTD, HONDA v45 INTERCEPTOR HYDRAULw BRAKE MEMO Date of Issue: January, 1983 - ©HONDA MOTOR 00., LTD. 16 19 HON DA V45 INTERCEPTOR BATTERY/CHARGING SYSTEM IGNITION SWITCH BATTERY ~g.“ Wumlmmaw ALTERNATOR REGULATOR/RECTIFIER BATTERY/CHARGING SYSTEM RED/WHITE —j—— RED FUSE 30A IGNITION (SWITCH BLACK Date of Issue: January, 1983 1 7-0 ©HONDA MOTOR CO,' LTD. BATTERY YELLOW VOLTAGE SENSOR ll} REGULATOR/RECTIFIER ALTERNATO R wees: ll. BATTERY/CHARGINGSYSTEM SERVICE INFORMATION 17—1 TROUBLESHOOTING 17—2 BATTERY 17—3 CHARGING SYSTEM 17—4 SERVICE lllFflllMATlflN GENERAL Battery fluid level should be checked regularly Fill with distilled water when necessary. Quick—charge a battery only in an emergency; slowcharging Is preferred. 0 Remove the battery from the motorcycle for charging. It the battery must be charged on the motorcycle. disconnect the battery cables. Do not smoke or allow flames near a charging battery, The gas produced by a battery will explode if flames or sparks fare brought near. All charglng system components can be tested on the motorcycle, Alternator removal is In Section 9, SPECIFICATIONS Capacity __ 12v 14AH Battery Specific gravity two/20°C (68°F) Charging rate 14 amperes rnaximum Image regulator Type Translstorized non-adjustable regulator , Regulated voltage. ”-6 V—l5.0 v Reytsed January, 1986 e Amer-can Honda Motor 00,, lnc 7A" Rtgnts Reserved 1 7 MSV 9675 (8601 l _ ‘83-‘85 VF700F/VF750F 1 Mini BATTERY/CHARGING SYSTEM TRlllJBLESHflllTINE No power — key turned on: 1. Dead battery 7 Low fluid level — Low specific 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 7 Low fluid level — Low specificgravity — Charging system failure 2. Loose battery connection Low power — engine running: 1. Battery undercharged 7 Low fluid level 7 One or more dead cells 2. Chargingsystem failure é HONDA v45 INTERCEP‘I'OR 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 Loose connection or short circuit in lighting system .0" charging system failure; 1. Loose, broken or shorted wire or connection 2. Faulty voltage regulator/rectifier 3. Faulty alternator 17-2 Date of Issue: January, 1983 ©HONDA MOTOR 60., LTD. é HONDA V45 INTERCEP'I’OR BATTERY REMOVAL Remove the battery holder bdlt, 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. Remove the battery. TESTING SPECIFIC GRAVITY Test each cell with a hydrometer, SPECIFIC GRAVITV: 1270—1290 (20°C, 68° Fl 1.270—1 290 Fully charged Below 1,260 Undercharged NOTES - The battery must be recharged if the spe- l cific gravity is below 1 ,230. ~ The specific gravity varies with the tempe- tature as shown in the accompanying table. - Replace the battery it sulfatton is evident or if the space below the cell plates is filled L with sediment. The battery contains sulfuric acid, Avoid contacl will! skin, eyes, 0r clothing. Antidote: Flush with water and get prumpt medical attention, CHARGING Remove the battery cell caps. Fill the battery cells with distilled water to the upper level line, if necessary. Connect the charger positive (+l cable to the battery positive (+) terminal. Connect the charger negative (—l cable to the battery negative (-) terminal. Charging current: 1.4 amperes max. Charge the battery until specific gravity is 12707 1.290 at 20°C (68°F). Before charging a battery, remove [he cap from each cell. Keep flames and sparks away from a charge ing battery Turn power DN/DFF al the charger, not at /he battery terminals to prevea/ sparks. Discon/i‘nue charging if (he elecrmlyle Iemperarure exceeds 45 °C ( I I} °F). BATTERY/CHARGING SYSTEM POSITIVE CABLE GROUND CABLE BATTERY HOLDER ‘ 3r aarrznv rEMPeRAruRE vs sPEcrnc damn I 304 spzcmc GRAVH’Y \ 255 5 l5 711' 25 3073 s 32 at 50‘ 55‘ ee- 77 ea 55 yea ELECYROLWE YEMPERAYURE Revrsea January 1986 ’9 American Honda Molor Co, Inc —4 All Rights Reserved MSV 9575 (3601; 7 '837'85 VF700F/VF750F 17-3 M] N N (w BATTERY/CHARGING SYSTEM CAUTION - Quick-charging shouki only be done in an emergency; slow—charging is prefened, - Route the breather tube as shown on the battery caution label. After installing the battery, coat the terminals with clean grease. CHARGING SYSTEM CURRENT TEST NOTE Make sure the battery IS lullv charged before perlormtng thts te Start the engine and warm tt up to operallng temperature Remove the frame nght stde cover and seat. Connect the voltmeter between the battery terminals as shown Start the engme and allow It to idle. Check the voltage by ralslng the engme speed gradually The voltage should be maintained wuthln the regulated voltage REGULATED VOLTAGE: 14‘0—15.0 V llvoltageexceeds 15then ratstng the engme speed, the llkellhood Is‘ - Open or short circutt (black wlre ol the regulator/ rectther). - Loose or poorly connected regulator/rechher coupler - Faulty regulator/rectlller, ll voltage does not Increase when ratsmg the engtne speed, the Ilkellhood IS' 0 Open or short ctreutt between the alternator and regulator/rectther. - Loose or poorly connected alternator or regulator/ rectifier couplers . Open crreutt In wire harness (red/whtte or green wtres). . Faulty alternator or regulator/rectmer, é HONDA V45 INTERCEF‘I‘OR r' it'll? l o N" W Pll'lufi AS SNOW ”WW e l BATTERY “an Hlfli “All? « ! “Wilt “MW” lllflr (WISH?! THC BATH“ HUN” TUBE SECVUHLV ) VOLTMETER BATTE RY 17-4 Revused Januarv, 1986 @ American Honda Motor Co , Inc — All nghls Reserved MSV 9675(3601l— '83-'85 VF7CIOF/VF750F NHN HONDA v45 INTERCEP‘I‘OR BATTERY/CHARGING SYSTEM STATOR CONTINUITY TEST Remove the left side cover, Disconnect the alternator and regulator/rectifier coupIer. Check for continuity between the leads, and be tween the leads and ground. Replace the stator if there is no continuity between the leads, or if there is continuity between the leads and ground. VOLTAGE REGULATOR/RECTIFIER TEST Remove the left side cover. Disconnect the regulator/rectifier couplers. Check for continuity between the leads With an ohmmeter. NOTE The test results shown are for a positive ground ohmmeter and the opposite results I will be obtained when a negative ground ohm- meter is used. NORMAL DIRECTION: CONTINUITY G) probe G) probe | YELLOW GREEN || RED/WHITE YELLOW REVERSE DIRECTION: NO CONTINUITY ALTERNATOR COUPLER @ probe (3 probe I GREEN YELLOW II \ VELLOW RED/WHITE NORMAL DIRECTION YELLOW RED/WHITE REVERSE DIRECTION Date of Issue: October, 1933 © HONDA MOTOR CO” LTD. 17-5 HONDA V45 INTERCEPTOR BATTERY/CHARGING SYSTEM 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 ~ 15.0 V. Date of Issue: January, 1983 1 7-6 ©HONDA MOTOR C0., LTD. HON DA V45 INTERCEPTOR MEMO Date of Issue: Januarv, 1983 _ .HONDA MOTOR CO, LTD. 1 7 7 HONDA V45 INTERCEP‘I‘OR IGNITION SYSTEM IGNITION SWITCH ENGINE STOP SWITCH SPARK UNITS SPARK PLUGS PULSE GENERATORS BATTERY IGNITION SYSTEM DIAGRAM WHITE COUPLER IGNITION COIL SPARK PLUG 1.3 CYLINDER SPARK UNIT I| IGNITION SWITCH II ENGINE STOP SWITCH i .,. I : BATTERY @E J PULSE GENERATORS I RED COUPLER :— 2.4 CYLINDER SPARK UNIT Date of Issue: January, 1983 18'0 HONDA MOTOR co., LTD. HONDA VF700/750 INTERCEPTOR 18. IGNITIIIN SYSTEM SERVICE INFORMATION 18—1 TROUBLESHOOTING 18—2 IGNITION COIL 18—3 TRANSISTORIZED IGNITION SYSTEM 18—4 IGNITION TIMING 18—5 SERVICE IIIFIIIIMATIIIII GENERAL 0 A TRANSISTORIZED IGNITION SYSTEM IS used and no adjustments can be made, SPECIFICATIONS 7 1” I 7777i_ I ND NGK Snark plug 1—Slzndard i XZAEPRvUQ DPRBEAQ I. :or cold clwmale BeIow 5°C (IIIUFI IKZQEPFHJQ DPR7EA-9 For extended mgh speed drlving X27EPR-U9 DPRQEA~9 83m} pIug gap 0.8—0.9 mm “1031—0035 in) Ignitlon llmmg At we , VF750F: 10°, VF7OOF: 15“ BTDC Fu'yl advance 37°BTDC/3,300 rpm PuIse generamr air gap 0,370.9 mm [0,012—0.035inI TOO L Sgecial Tlmmg Inspecnon cover 07998—M800000 Date of Issue: June, 1984 ©Amorican Honda Mmor Co.,|nc,1984 - AII Rights Reserved 18-1 IGNITION SYSTEM TRUUBLESHUDTINE The lgnrtron system has two subsystems; one for the No 1 and No 3cy|lnders and one tor the Nov 2 and No. 4 cylmders. Determlne wnrch subsystem ls iaulty, then proceed to the detarled tests belowv Engine cranks but will not start 7 Engrne stop switch OFF 7 No spark a! plugs — Faulty transrstonzed spark unrt 7 Faulty pulse generator Np spark at plug 7 Engrne stop switch OFF 7 Poorly connected, broken or shorted wrres Between rgnrtron swrtch and engrne stop swrtch Between spark um and engine stop swltch Between spark um! and ‘rgnrtron coll Between rgnrtron coil and plug Between spark unrt and pulse generator — Faulty lgnltlon cor! 7 Faulty rgmtron swrtch 7 Faulty spark unlt 7 Fautty pulse generator Engine starts bul vuns pomly 7 lgnltlon primary clrcult Faulty rgnrtion corl Loose or have wrre Intermrttent short crrcurt 7 Secondary crrcurt Faulty plug Faulty high tensron wlre Timing advanca incur-act — Faulty pulse generator 7 Faulty spark unrt é HONDA V45 INTERCEP'I'OR 18-2 Date of Issue: January, 1983 © HONDA MOTOR (20., LTD. HONDA v45 muncmon IGNITION SYSTEM IENITlflN BfllL nemmow COILS Remove the Seal and fuel tank. CONTINUITV TEST Disconnect Xhe coils primary leads. Measure the prlmar‘l ccil reslslance. RESISTANCE: 2‘3 9 Measure the secondary coir resistance with the spark plug caps in place. RESISTANCE: 21—28 k H Dare oI Issue: October, 1983 © HONDA MOTOR 00., LTD. 18'3 IGNITION SYSTEM Remove the spark plug cap resistors and measure the secondary coil resistance (page 18—3). RESISTANCE 13.6—15.5 kn TRANSISTURIZED IENlTlllN SYSTEM PULSE GENERATOR TEST Remove the right side cover. Disconnect the pulse generator coupler and measure the coil resistance. RESISTANCE: Appraximawly 480 (Z Between white/yellow and yellow leads (1,3 cvr Iindersl Between white/blue and blue leads (2,4 cy- lindersl PULSE GENERATOR REPLACEMENT Remove the clutch cover (page 7-10). Remove the pulse generator mounting bolts, and pulse generators. Install new pulse generators. Measure the air gap between the pulse generator and rotor. AIR GAP: 0.3—0.9 mm (0012-0335 in) Install the clutch cover (page 7-22). Recheck the ignition timing (page 18-5), HONDA v45 INTERCEPTOR RESISTOR 2»4 CYLINDER PULSE GENERATOR 173 CYLINDER PULSE GENERATOR FEELEH GAUGE 18-4 Date of Issue: January, 1983 © HONDA MOTOR (20., LTD. HONDA V45 muncmon IGNITION SYSTEM SPARK UNIT If the pulse generators, ignition coils and wiring are good. and the ignition timing is not within specifica- tion; replace the spark units with new ones and recheck the ignition timing. llilllllflll TIMING Warm up the engine and remove the alternator cover. Align the F mark on the flywheel with the rear crankcase mating surface. Use a felt pen to mark a dark line and "18F" in line With the F mark on the end surface of the flywheel. Install the timing inspection cover. Connect the timing light to the high tension wire of the No.1or No. 3 cylinder. Start the engine and check the ignition timing. ATIDLE SPEED: The dark line l’l-3F) should align with the index mark on the timing covert 1,300—1,750 rpm: The advance startss 3,100—35001pm: The advance end: and the index mark should be between the full advance marks. Connect the timing light to the high tension wire of the No. 2 or No. 4 cylinder and check the ignir tion timing for No, 2 and No. 4 cylinders. NOTE The ignito system is trans cannot be adjusted. If the ignition timing is incorrect, check the spark units and pulse generators. Replace parts as required. 1,3CYLINDER 2,4CVLINDER SPARKVUNIT , SPARK UNIT FULL ADVANCE MARK After timing inspection, Check the engine Oll level and add if necessary. TIMING INSPECTION COVER 07998—MBOODUO AT IDLE SPEED @\ ”FHMARK INDEX MARK AT 3,100~3,500 rpm FULL ADVANCE MARKS Date of Issue: January, 1983 © HONDA MOTOR (30., LTD. 18-5 HON DA V45 INTERCEPTOR ELECTRIC STARTER C LUTCH SWITCH ' P i STARTER STARTER BUTTON RELAv SWITCH STARTER BATTERV MOTOR NEUTRAL SW|TCH STARTER STARTER MOTOR REL/W SW‘TCH © GREEN/RED FUSE DIODE I 30A ,9 STARTER g BUTTON m RELAY COIL 2' CLUTCH ‘ IGNITION SWITCH E SW'TCH I) N Z 9 @ NEUTRAL INDICATOR GREEN GREEN - ' BATTERY ' ' Date of Issue: January, 1983 19'0 © HONDA MOTOR 00., LTD. HONDA v45 muncmon Ill. ELECTRIC STARTER SERVICE INFORMATION TROUBLESHOOTING STARTER MOTOR STARTER RELAY SWITCH CLUTCH DIODE 19—1 19—1 19—2 19—5 19—5 SERVICE llIFlIRMIITIlIN GENERAL 0 The starter motor can be removed Wltl’l the engine in the frame, SPECIFICATIONS STANDARD SERVICE LIMIT Starter motor Brush spring tension 680v920 9 (24.0—32.5 01) 545 9119.2 ozl Brush length 12.0—13.0 mm (0.474051 'lnl 6.5 mm (0.26 ml TllllllBlESHllllTlllG Starter motor will not turn: . Battery discharged. . Faulty ignition switch. , Faulty starter switch. . Faulty neutral switch. ’ , . Faultv starter relay switch. ’ . Loose or disconnected wire or cable. . Clutch diode open. f \lmO‘lbLJN—t Starter motor turns engine slowly 1. Low specific gravity ln battery. 2. Excessive resistance in circuit. 3. Binding in starter motor. Starter motor turns, but engine does not turn: 1. Faulty starter clutch. 2. Faulty starter motor gears. 3. Faulty starter motor or idle gear. Starter motor and engine turns, but engine does not start 1. Faulty ignition system. 2. Englne problems. ‘ Low compression. — Fouled spark plugs. Date of Issue: January, 1983 © HONDA MOTOR 60., LTD. 19-1 HONDA V45 INTERCEP'I'OR ELECTRIC STARTER STARTER MflTllR STARTER CABLE REMOVAL Will! the rgmnnn swr/ch OFF, remove the ”egg/I've cable a! the battery before servicing the starter molar. Remove the lower radiator (page 6-7), Drsconnect the starter motor cabte at the motor, Remove the starter motor mounting bolts, and starter motor, STARTER MOTOR BéLTS CASE AND FIELD COIL O’RING ARMATUHE BRUSH HOLDER BFIUSH SPRING REAR COVER SHIMS CABLE TERMINAL AND BRUSHES FRONT COVER 2 Date of Issue: October, 1983 © HONDA MOTOR (30., LTD. 19 HONDA v45 INTERCEPTOR BRUSH INSPECTION Remove the starter motor case screws, Inspect the brushes and measure the brush length. Measure brush spring tension with a spring scale. SERVICE LIMITS: Brush Iength: Brush spring tension: 6.5 mm (0.26 in) 545! (19.2 oz) COMMUTATOR INSPECTION Remove the starter motor case. NQTE Record the location and number of shims. Inspect the commutator bars for discoloration. Bars discolored in pairs indicate grounded armature coils. NOTE Do not use emery or sand paper on the com- mutator. Check for continuity between pairs of commutator bars. There should be continuity. Also, make a continuity check between individual commutator bars and the armature shaft, There should be no continuity. Date of Issue: January, 1983 © HONDAMOTOR 00,, LTD. ELECTRIC STARTER BRUSH SPRING BRUSH LENGTH COMMUTATOR CONTINUITV BETWEEN COMMUTATOR BAR PAIRS: NORMAL n . _ ~ NO CONTINUITY BETWEEN COMMUTATOR BARS AND ARMATURE SHAFT: NORMAL 19-3 HONDA v45 INTERCEP'I'OR ELECTRIC STARTER NO CONTINUITY BETWEEN FIELD COIL INSPECTION 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 field coil does not have continuity or if it is shorted to the motor case. CONTINUITY BETWEEN CABLE TERMINAL AND BRUSH WIRE (INSULATED): NORMAL BRUSH HOLDER NOTCH PIN ASSEMBLY/INSTALLATION I. ‘ Assemble the starter motor. Align the case notch with the brush holder pin. Install the rear cover aligning its slot With the brush holder pin. Install the starter motor in the reverse order of removal BRUSH HOLDER REAR BRACKET _ Date of issue: October, 1983 19 4 ©HONDA MOTOR co., LTD. HONDA v45 Immcmon ELECTRIC STARTER STARTER RELAY SWITCH STARTER RELAY SWITCHV |NSPECT|ON Depress the starter switch button with the Ignmon ON The coil is normal it the starter re‘av switch clicks. Connect an ohmmeter to the starter relay sthch terminals. Connect a 12 V battery (0 the switch cable termi- hats, The switch is normal if (here is continuity. CLUTCH IJIIJDE CLUTCH DIODE REMOVAL Remove the fuel tank. Remove the clutch diode from the ere harness. Date of Issue: January, 1983 © HONDA MOTOR (20., LTD. 1 9‘5 HONDA V45 INTERCEP'I‘OR _ . - NORMAL DIRECTION: CONT|NUITY REVERSE DIRECTION: N0 CONTINUITY ELECTRIC STARTER INSPECTION Check for continuity with an ohmmeter. Date of Issue: October, 1983 19‘6 ©HONDA MOTOR 00., LTD. HONDA V45 INTERCEPTOR 20_ SWITCHES SERVICE INFORMATION 20—1 FUEL PUMP RELAY 20—6 OIL PRESSURE SWITCH 20—2 FUEL LEVEL SENSOR 20—7 BRAKE LIGHT SWITCH 20—2 THERMOSTATIC SWITCH 20—8 NEUTRALSWWCH 20—3 FAN MOTOR RELAY 20—8 CLUTCH SWITCH 20—3 TEMPERATURE SENSOR 20—9 HANDLEBAR SWITCHES 20—4 TEMPERATURE GAUGE 20—10 IGNITION SWITCH 20—5 TACHOMETER 20—10 FUEL PUMP 20—6 BRAKE AND TAIL LIGHT SENSOR 20—10 SERVICE INFORMATIIIII GENERAL Some wires have different colored bands around them near the connector. These are connected to other wires which cor- respond with the band color. All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. The following color codes used are indicated throughout this seetion and on the wiring diagram. Bu = Blue G = Green L6 = Light Graen R = Rod Bl = Black Gr = Grey 0 Orange W White Br = Brown LB = Light Blue P = Pink V = Vellow 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 terminals or connections. A continuity tester is useful when checking to find out whether or not there is an electrical connection between the two points. An ohmmeter l5 needed to measure the resistance of a circuit, such as when there is a specific coil resistance involv- ed, or when checking for hlgh resistance caused by corroded connections. Date of Issue: January, 1933 HONDA MOTOR CO.l LTD. 20- 1 HONDA swircues V45 INTERCEP‘I'OR IJIL PRESSURE SWITCH Disconnect the oil pressure switch lead and remove the switch. Check for continuity while applying pressure to the switch. Cont uity: Below 20 kPa (0,2 Ito/cm2 , 2.8 psi) No continuity: Above 20—40 kPa (0.2—0.4 kglcmi, 2.8—5.7 psi) Replace the switch it necessary. Apply a liquid sealant to the switch threads before installing the switch. Screw the switch into the crankcase but stop two threads from the bottom. Then tighten it to the specified torque, TORQUE: 15—20 N-m (1.5—2.0 kg-m,11—14 ft-Ibl NOTE To prevent crankcase damage, do not over» tighten the switch, BRAKE LIGHT SWITCH Check the rear brake light switch for continuity with the rear brake applied. FRONT BRAKE LIGHT SWITCH Check the front brake light switch for continuity * ; .~ with the front brake applied. ‘ G i‘ Replace the switches if necessary. Date of Issue: January, 1983 20-2 © HONDA MOTOR CO” LTD, HONDA v45 INTERCEPTOR NEUTRAL SWITCH Remave the left side cover and disconnect the neutral switch connector. Check the switch for continuity between the switch connector terminal and ground. There should be continuity with the transmission in neutral and no Continuity with the transmission in any gear. R E MOVA L Remove the neutral switch cover. Remove the neUtral switch attaching screws and the switch. INSTALLATION Install the neutral switch in the reverse order of removal. Tighten the switch mounting screws. TORQUE: 7—11 N-m (0.7—1.1 kg-m, 5—8 it-lb) Install the neutral switch cover. CLUTCH SWITCH Check continuity ol the clutch lever (safety) switch with the clutch released and applied. Replace it necessary, SWITCHES NEUTRAL SWITCH CONNECTOR SCREWS NEUTRAL SWI/ COVER CLUTCH APPLIED: CONTINUITV CLUTCH RELEASED: NO CONTlNUlTY Date of Issue: October, 1983 © HONDA MOTOR (10., LTD. 20-3 SWITCHES HONDA V45 INTERCEPTOR IIANIJIEBIIR SWITCHES The handIzbar cluster switches (lights, turn signals] horn, etc.) musl be replaced as assemblies. Remove the fairing, headlighl, and headlight bracket. Continuny tests for the componenls of the handle- bar cluster switches follow; Continuity should exist between \he color coded wires in each charl, HEADLIGHT Hl—LOW SWITCH HI: BIA/W to Bu MIDDLE (N): BMW ttho Bu LO: Bu/W (0W TURN SIGNAL SWITCH LEFT: Gr to O, Br/W to LB/W OFF: Br/W to LB/W and OM RIGHT: Gr to LB, Br/W to CM HORN BUTTON L6 to W/G with button dopvessed No continuity with button released HO RN BUTTON Headlight Hi—Low Switch HEADLIGHT Hl—LO SWITCH « TURN SIGNAL SWITCH HL2 Hi Lo iHi O——O ,— (N) 0 Lo 0L 0 Colorcode Bu/W ( Iii: W Turn Signal Switch IT W L R Pl PR PL LEFT O——O O;~O oFF Oa—O—AO —RIGHT O O 7 7 I O iColgrioode Er I 0 Ta “Br/W LB/W o/w Horn Button Ho BATS ‘ I I Q— Colorcode LG I W/G 20-4 Date of Issue: January, 1983 © HONDA MOTOR CO” LTD. HON DA V45 INTERCEP‘I‘OR STARTER BUTTON Bi to VII! with button pushed in. aim to Bu/W with button out. Star“! Button I I IG I ST E1 HL2 our 1 START I 0‘47) Colorcoda LEI le BI/R Bu/w ENGINE STOP SWITCH RUN: BI to Bl/W OFF: No continuity Engine Stop Switch | BAT2 IG OFF ‘ RUN Q——O Culor coda Bl/W BI IGNITIIIII SWITCH Remove the fairing and headlight. Disconnect the ignition switch coupler. Check continuity of terminals on the ignition switch coupler in each switch position. SWITCH POSITION LOCK: Nu continuity OFF: No continuity 0N: R to Bl, firm to B! — continuity PARK: Er to R — continuity Tlrminal ' I P K PA ‘BAT1 IG TL. TL2 i as ion . 7,. d 7W4. ._ I P O—t—O ‘ i 7 i ON . O O O —‘f¥ ,, , ‘ OFF I fl 7 I ‘7‘ LOCK l Coior code Er R Bl Br/W Br ‘. ._5V£T°”ES ENGINE STOP SWITCH STARTER BUTTON IGNITION SWITCH Date of Issue: January, 1983 ©HONDA MOTOR 00., LTD. 20-5 NEW SWITCHES IGNITION SWITCH DISASSEMBLY Insert the key and turn it so it is part way between the "ON” and ”OFF” detent positions. Pry open the wire retainer. Push in the lugs that are locked In the slots, then pull the contact base lrom the swnch Assemble in the reverse order of removal. FUEL PUMP Turn the fuel valve and ignltlon switch ofl. Remove the lrame side covers, seat and fuel tank. Disconnect the luel pump relay coupler and short the white and black ere terminals with a jumper wire. Disconnect the fuel line at the fuel line joint and hold a graduated beaker under the outlet tube. Reinstall the fuel tank. WWARNING ~ [)0 not allow flame: or sparks near gasoline. ~ Wipe up spilled gasoline at once. Turn the ignition switch on and let fuel flow into the beaker lor 5 seconds, then turn the ignition switch off. Multiply the amount in the beaker by 12 to determine the fuel pump flow capacity per minute‘ FUEL PUMP FLOW CAPACITY: 6606c (22 US 01,18,6lmp 01lt10%/minute NOTE - Uses fully charged batiEry or false readings may result. Itage should be above 12.5 v. - Battery vo II the fuel pump llow capacity is below the specifi- cation, measure the voltage at the fuel pump coupler. Replace the fuel pump il battery voltage is present, FUEL PUMP RELAY Check for a burnt sub~fuse. Check the relay coupler for improper contact and looseness. Measure the voltage between the relay black wire and a body ground. The battery voltage should register with the ignition switch ON. Make sure that the fuel pump operates while the relay coupler black and white wires are shorted and the ignition switch is ON. If the pump does not operate, check the Iuel pump coupler for improper contact and the luel pump. Check lor continuity between the ignition control unit blue wire and the fuel pump relay coupler blue Wire. If there is continuity, replace the fuel pump relay. If there is no continuity, replace the wire har- ”2554 % HONDA V45 INTERCEPTOR FUEL PUMP RELAY JUMPER WIRE M; N VOLTMETER MEN 20-6 Revised. January, 1936 © American Honda Motor Co Inc ‘All Rignts Reserved MSV 9675l8601ii 3485 VF700F/VF750F \_,, HONDA v45 muncmon SWITCHES FUEL [EVEL SENSHR FUEL LEVEL SENSOR REMOVAL L ‘ ‘ Remove the fuel tank and drain the fuel. Remove the fuel level sensor attaching nuts and fuel level sensor. INSPECTION Measure the resistance of the fuel level sensor in the full and empty float positions. RESISTANCE: FULL 3.5—9.5 fl EMPTV 90—100 Q EMPTY Turn the ignition switch 0N. Connect the fuel level sensor coupler to the wire harness. Move the float to full and empty and check FULL the fuel gauge needle in both positions. If the fuel gauge does not indicate the proper level, replace it with a new one. FUEL GAUGE Date of Issue: January, 1933 .HONDA MOTOR co.‘ LTD. 20'7 é HONDA SWITCHES VF700/750 INTERCEPTOR THERMOSTAT SWITCH THERMOSTATlC SWITCH LEADS , gl‘jfiR‘lsfll-OSTATIC The cooling fan motor is actuated by the thermo- static switch located in the lower radiator. If the fan motor does not start, disconnect the black and green leads from the thermostatic switch and short them together with a jumper wire as shown, Turn the ignition switch on_ The cooling fan motor should start running, If it does not start, check for batterv voltage from the black lead (positive) to black/blue (nagative) of the fan motor coupler If there is no voltage, check for a blown or tautty fuse, loose terminals or connectors, or an open circuit If it starts, inspect the fan thermostatic switch as / follows' JUMPER WIRE Suspend the switch In a pan of coolant [50750 mixture) and check the temperature at which the SWllCh opens and closes Make sure that there is no swttch continuity with room temperature and gradually raise the coolanttemperature The switch should be continuity (close) at 98—102°C (208—21 5°F) TEMPERATURE SENSOR NOTE ‘ Maintain the high teperature for 3 minr utes before testing continuity. A sudden change in temperature will cause an error in the reading. Do not let the themometer or switch touch the pan as it will give a false reading, Soak the switch in coolant up to Its threads, FAN MOTOR HELAY('83 VF750F) NOTE THERMOMETER FAN MOTOR RELAY \ The VF700F/VF750F aher '83 do not have the lan motor relay. The ’83 wiring diagram calls this part a Main Relay. Remove the left side cover and disconnect the fan motor relay coupler. Date ol Issue October, 1934 20-8 ©Ametican Honda Motor Co , Inc 1934 , All Rights Reserved HONDA V45 INTERCEP'I'OR SWITCHES Connect a fulw charged 12 V battery and an ohm~ meter to the relay terminals as shown. The re‘ay is normal if there is continuity when 12V BATTERY voltage is applied 7? en T u Jr :2 was K_ OHMMETER TEMPERATURE SENSflR Disconnect the green/blue wire from the tempera» ture sensor‘ Drain the coolant and remove the temperature sensor from the thermostat case. TEMPERATURE SENSOR Suspend the unit in oil over a burner and measure the resistance through the unit as the oil heats up. 60°C BSDC 110°C 120°C TEMPERATURE SENSOR 140°»: 135°F 230°F 248°F Resistance 104.09 43.99 20.39 16.19 Temperature Wear gloves and eye’pmrecriont NOTE ~ Oil must be used as the heated liquid to check operation above 100°C (212°F)‘ ‘ - You'll get false readings if either the thermometer or temperature sensor touches the pane THERMOMETER Date of Issue: October, 1933 © HONDA MOTOR COt, LTD. 20-9 SWITCHES HONDA v45 INTERCEP'I'OR TEMPERATURE GAUGE 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 Iampemmre sensor wire grounded for longer than a few seconds or [he temperature gauge will be damaged TACHITMETER If the tachometer does not work properly, replace the 1—3 spark unit with a new one and recheck the operatlon. If the problem still appears, replace the spark unit with the original one and tachometer with a new ODE. BRAKE AND TAIL lIRHT SENSIJR Turn the ignition switch on. Check the source voltage at the black/brown lead. if there is no voltage, check and repair the source circuit, If there is voltage, measure the voltage at the white/yellow (positive) and green/yellow (negative) wrresv VOLTAGE: 5V If there is no voltage, replace the sensor unit. . I TEMPERATUR/E/SENsoR/ \' v TACHOMETEH xmnurvm SPARK UNIT ' PULSE GENERATOR BRAKE AND TAIL LIGHT SENSOR \r \—v 'V 20-10 Date of Issue: January, 1983 © HONDA MOTOR (20., LTDr é HON DA VF700/750 INTERCEPTOR '83 V45 INTERCEPTOR [VF750FW mum um cumin w... wuuvu‘ 7 . ".1 SM una- m u. mulm ‘ / km w ww- mum 5mm x m sum mum- \ w:- m- u m roam um m, m am. my uwfi mum. . c " loch-m. . mmgwtwumlul 9..“ 9‘ 041$ «- "1a;- mmn :- u va'unbds-rz. 5, _ I \ mmswuuummwlbum - ‘- m I 1 qua. a»: 21 eunu- mu Mi mum-nan sum. :1 4mm: in, mm mu mum mm” m m. m m. m M. m m. .— m nu a m n: u “cm ‘1 E" “" 4“ 7 m1 _ W m‘ * K601. H Dale of Issue: October, 1984 © American Honda Molar Ca, Inc. 1984 - AI| Rights Reserved 21. WIRING DIAGRAMS V45 INTERCEPTOR (VF750F) u» m- w- mm: mm m. e 211:: 6m 6% cm Wt luv T 7 .. Mm my .0. me m, up mm vtmuw -._ 3—.» W mm. f) mwvu. Imlmv mm u-Cn-u Immmx , ,_ mm: .m- w m. mm.- m w u. M G DWOEOW- \mawwvn mum cm: 2" ule 2‘ 1‘3 ‘73 2. lvwn mm mm mm m mm "Hm mm.” . m . m- ...» m. a m, . m. u an .k , ‘A ‘ .,, . u u “mu —— a 0:51 .. m m 2030‘ "i, . . Kn . .. .. A on-o . mm a m 00302—M32 — 6700 21-1 HONDA VF700/750 INTERCEPTOR ‘ INTERCEPTOR (VF760F) . u. mu m WW “cm.“ [—5 mm JDG%HJ:D E a 1282]” raj) a u WWW um/su‘m-r “$6" a . . . . | (-7 mu. m. —c "Do—n x m- mm m .zmuw mmmm 932% “fig; g; 003OZ—M3279000 Dale 0' Issue: Oc‘ober, 1984 © American Honda Mmor Coy, Inc. 1984 - All Rights Reserved WIRING DIAGRAMS AFTER '83 V45 INTERCEPTOR [VF75OF) mm a main um .. .mmmw m «M W. .m m... ‘ V WWW w a. mm. , ‘ mm mm.» ‘ .P f , , ‘ ‘ V ‘ V my. .9. mum 2 mm. mm, ) ms! vn ”mum 5"! lm mm m- W m s-m u \ /- - mu llama-Ax n'wvmm Lagan— a. . mu mmummm. n . mum-(MI) | w‘_' @fi1———- lJ mum My m- nuns fl - ' mum.“ m» 3mm mum-I sen-mum: mm mm man-m1 , i mu sum warm "no. mu m» sum n»: a.“ mu v m. m. w m“ m m numb-ll» m m M‘s m nu . . _ . n a .u n w an w__- V ‘ moo . m . .QLQ IOJ—LQ “070‘ m: 7 100mm; W W I“0+0 - O‘O‘O O‘OfQ Moro i ii a 3: 21-2 % HONDA V45 INTERCEP'I'OR V-4 ENGINE FEATURES ONE-WAY CLUTCH SYSTEM V-4 ENGINE FEATURES The engine design is a DOHC, 16avalve, water cooled V4. The cylinders are arranged in two banks of two cylinders, 90 degrees apart The pent-roof combustion chamber has four valves per cylinder (two intake and two exhaust valves) ensure highly-efficient intake and exhaust flow. 22. TECHNICAL FEATURES 22—1 22—2 o Self-adiustine hydrlulic clutch o Onemav clumh Prevents rear wheel lockup during rapid deceleration caused by down shlfiing of the Transmission ar high engine speeds Hydraulically assisred, rhe clinch requires a lighter lever pull compared lo caoie operaled mororcyele clinches, This system also providesa censisremiv smocrh leeling when rhe clurch lever is pulled in and released, The hydraulic sysrem aulomancally compensales for wear and (he only maime- nance check required is lhe hydraulic fluid reservoir level, . Flack-13ml: Wilh the rocker arms under lhe eemshalrs, overall weighr is reduced and valve flow at high rpm is virtually eiiminered. o Carin-mars wilh hvslamr valve The carburetors deliver rhe proper amoum of air/fuel mixlure inlo rhe cylinder under all operaling conditions The bvstaner valve in eech carburaior provides suHicienl fuel (low during cranking, making me engine easier re sran in cold weather. The byr slaner is eonrrolleo by rhe choke lever on rhe handlebar, e Au‘amatic cam chain adjuflcr The cam chain rensioner eurcmaneallv com- pensares Ior cam chain wear, eliminaling periodic adlustment and maimenanee. Dare of Issue: January, 1983 © HONDA MOTOR CO., LTD. 22-1 é HONDA TECHNICAL FEATURES V45 INTERCEPTOR ENE-WAY CLUTCH SYSTEM Purpose: On rapid downshifting from high RPM, the compression braking forces created by the engine can exceed the rear wheel’s traction; the engine becomes a rear wheel brake. This can cause momentary lockup of the rear wheel — until the compression braking force drops below the level necessary to make the rear tire break traction. if multiple downshifts are made. the result will be a much longer loss of traction. The one-way clutch system has been specifically designed to prevent this loss of traction. C LUTCH INN E R (has splines) ONEVWAY CLUTCH ONEVWAY SPRAG CLUTCH (Splined to mainshaftl INNER PORTION CLUTCH INNER lno splines but receives power via the one~way sprag clutch] OUTER PORTION Design: The maior difference between this system and a conventional clutch is a two-piece clutch inner. In addition, the outer portion of the clutch inner. that which controls the maiority of the clutch plates and discs, is driven by a special one-way sprag Clutch. 0 The inner portion of the clutch inner is splined to the transmission's mainshaft as is normal, But it only controls about two-fifthes ol the clutch plates and discs. This portion of the clutch transmits power and deceleration forces in the usual manner, 0 The outer portion of the clutch inner is not splined to the transmission’s mainshaft, It controls about three~fifthes of the clutch plates and discs. This portion transmits power when the sprag clutch is locked up, such as during normal acceleration, cruising, and deceleration. Operation: When the transmission is downshifted from high RPM, it causes a backloading at the clutch because of the forces generated by the engine’s compression braking effect. If these forces approach that which will cause the rear wheel to lock up, the onerway clutch Will disengage the outer portion and allow the inner portion to slip. It will do this to a degree that allows the rear wheel to maintain traction while maintaining the highest effect of engine braking. So rather than being a harsh ON or OFF mechanism, the one-way clutch determines the correct amount of slip for each situation, all the while maintaining maximum possible engine braking effect Date of Issue: January, 1983 22-2 (9 HONDA MOTOR 00., LTD. HONDA v45 INTERCEP‘I'OR TECHNICAL FEATURES u Operation CLUTCH OUTER Durlng acceleration, cruismq and deceleration, power is transmined Ihrough the cluxch in the normaI manner: Clutch Outer4 friction discaplate+onesway clutch ONE-WAY —. malnshah CLUTCH OUTER CLUTCH CENTER ONEWAV CLUTCH ONEAWAV CLUTCH ,7 INNER When there IS a backloading on the clutch caused by the rear wheel nearing lockup, the one-way clutch (A) will slip Just enough Io prevent the wheel from Iucklng. WIIhOuI losing me benem ol maximum engme Compression braking, v ONEVWAV CLUTCH INNER CLUTCH CENTER CLUTCH . POWER FLOW DIAGRAM OUTER CLUTCH OUTER , _________ ONE»WAY CLUTCH L, _ ,i l FRICTION DISC I [’CLUTCH PLATE _I, ON EVWAV CLUTCH FRICTION DISC CLUTCH PLATE ONE WAY CLUTCH OUTER . . I ; ONE WAY CLUTCH ONE WAY CLUTCH INNER TCLuTCH CENTER MAIN SHAFT b— ORDINARY POWER FLOW -L,A BACK LOAD Date of Issue: January, 1933 © HONDA MOTOR 00., LTD. 22'3 TECHNICAL FEATURES MEMO Date of Issue: January, 1933 22-4 © HONDA MOTOR co., LTDV é HONDA v45 INTERCEP‘I’OR 23. TRflUBLESHflflTING ENGINE DOES NOT START OR IS HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEEDS POOR PERFORMANCE AT HIGH SPEED POOR HANDLING ENGINE DUES IIIJT START [JR IS HARD Tl] START 1. check Iuel Ilowm carburemr REACHING CAHBUR ETOR z, Periorm a 3-pomr spark lesr GOOD SPAFI K 3. Test cylmder compression COMPRESSION NORMAL 4, Srarr by lollowlng normal procedure ENGINE DOES NOT FIRE 5. Remove and lnspeor spark plug NOT REACHING cARBUHETOR—> (1) I2) (3) [4) (S) 16) WEAK OR NO SPARK—DH) I?! 13] (4] (5) I6) 17) (8) LOW COMPRESSION—>11) (2] I3) (4] IS) 16) I7) ENGINE STARTS BUT STOPS~>III IEI I3) (4) I5) WET PLUG —>l1l (2) (SI [4) POSSIBLE CAUSE Fuel rank emDIV Clogged luel llne or luel lllrer Srleklng lloar valve Faulty Iuel pump Faulry fuel pump relay Plnched luel rank vent hose Faulry spark plugs Fouled spark plugs Faulrv spark unlr Broken or shorreo hlgh lenslon wlres Faulw spark unll Broken or shorred lgnrrron cOlI Faulty lgnmon swllch Faolrv pulse generaror Lovv barrery charge Improper valve clearance [too small) Valve stuck open Worn cvllnder and pis‘nn rings Damaged cylinder head gasker Se‘lled valve Improper valve limlng Improper choke operarlor. Carburetor lneorrecrlv adjusted lmake pipe leaking Improper Ignlllon llming (Spark unlr or pulse generalorl Fuel eonramlnareo Carburetor Hooded Carburetor choke excessively closed. Cvlmoer flooded Alr cleaner dlrly Date of Issue: January, 1983 © HONDA MOTOR 60., LTDV TROUBLESHOOTING ENGINE [ASKS PIIWER é HONDA I. Raise wheels elf ground and spin by hand WHEELS DO NOT SPIN FREELv——>ll) WHEELsPle FREELV 2. Check tire pressure PRESSURE NORMAL :l. Accelerate rapidly lrom low to second ENGINE SPEED LOWERED WHEN CLUTCH IS RELEASED 4. Accelraie lightly EN IGNE SPEED INCREASES 5, Check ignition timing CORRECT 6. Cneck valve clearanoe CORRECT 7‘ Test CVIinder compression NORMAL 3. Check oarouretor lor Clogging NOT CLOGGED 9. Remove spark plug NOT FOULED OR DISCOLORED 10. Check oil level and condition CORRECT 11. Remove cylinder head Cover and inspect lubriarion VALVE TRAIN LUBR ICATED PROPERLY 12. cneck lor engine overheating NOT OVERHEATING 13, Accelerate or run at high speed ENGINE DoEs NOT KNOCK (2) (3) [4) [5) PR ESSURE LOW —‘——' (II (2) ENGINE SPEED CHANGED ——>l1l WHEN CLUTCH Is RELEASED 12) (3) ENGINE SPEED DOES NOT INCREASE —>(|I (2) (3) (4) [5| INCORRECT—>(1I 12) INCoRRECT——>(l) [2] TOO LOW——>(1I (2) [3) (4) CLOGGED ———>l1) FOULED OR DISCOLORED—>(l) (2) INCORRECT _>ll) (2) (3) VALVE TRAIN NOT LuaRlCATED-_>l1) PROPERLV i2) _>(1) l2) OVERHEATING— ‘3’ <4) (5) Is) ENIGNE KNOCKS ——>l1l l2) l3) (4) V45 INTERCEI’I’OR POSSIBLE CAUSE Brake dragging Worn or damaged wheel bearings wheel bearing needs lubrication Drive cnain too tight Rear axle nut excessively right Punctured rile Faulty tire valve Clutch slipping Worn elutcn disc/plate warped dutch disc/plate Carburetor choke Closed Clogged air Cleaner Restricreo fuel flow Clogged mulller Clogged fuel tank vent nole FaulW spark unit Faulty puls! generator Improper valve adjustment Worn valve seat Valve stuck open Worn cylinder and piston rings Leaking tread gasket Improper valve Timing Carburetor not serviced Irequentlv enough Plugs nor serviced lrequentiv enougn Spark plug with incorrect near range Oil level too high Oil level (DO low Conlaminared oil Clogged oil passage Clogged orl control oriliee Coolant level low Fan motor not working llan motor relav laulwI Thermosrar sluck Closed Excessive carbon buildup In compusnon chamber Use or poor quality fuel Clutcn slipping Worn piston and cylinder Wrong tvpe ol luei Excessive carbon buildmp in combustion chamber ignition timing too advanced (Faulw spark unit) 23-2 Date of Issue: January, 1983 © HONDA MOTOR (30., LTDV é HONDA V45 INTERCEPTOR TROUBLESHOOTING PflflR PERFIIRMANBE AT LllW AND IDLE SPEEDS POSSIB LE CAUSE 1. Check ignition timing and valve clearance INCORRECT_H) lmpvoper valve clearance l2) Improper ignition tuning CORRECT (Faulty Spark uniil 2. cneck carburetor pilot screw adjustment INCORRECT —> See Fuel Syslem Secrion CORRECT 3. Check l0! leaking Intake plpe LEAKING——>l1) Deteviorared insulator O-rirlg (2) Loose carburetor NO LEAK 4. Perform spark lest WEAK OR INTERMITTENT SPARK —>(l) Faullv, carbon or we! louled spark Dlug GOOD SPARK l2) Faulty snark uml (a) Faulty Ignition coil PflllR PERFflRMANCE AT HIGH SPEED NOTE: Ignition to the No, 2 and No. 4 cylinders is cut-off at 11,300—1 1,800 rpm to prevent engine damage. 1. cneelt ignition timing and valve clearance lNCORRECT—> ll) lrnproper valve clearance l2) Faulty spark unit CORRECT l3) Faulty pulse generator 2. Disconnect Iuel line at carburetor FUEL FLow RESTRICTED—DH) Fuel tenlt empty (2) Clogged luel line FUEL FLows FREELV [3) Clogged luel Iank breetner hole [4) clogged Iuel velve l5l Faulty luel pump 3. Remove carburetors and check lor CLOGGED——> Clean clogged lets NO CLOGGED JETS 4. Check valve timing INCORRECT—>Cam sprocket not installed preperlv CORRECT 5. Check valve spring tension WEAK——> Faulty spring NOT WEAKENED Pflllll HANDLINE _* Check tire and suspensions pressures 1. ll steering is heavy (I) Steering stem adiuster nut too tight (2) Damaged steering head beatings 2‘ It either wheel is wohhling lIl Excessive wheel bearing play 12) SAM rim 13) Improperly installed wheel (4) SNingarm pivot bearing Excessively worn (5) Bent Irame 3‘ ll the motorcycle pulls to one side —> (1) Bent lrame (2] Front and rear wheels not aligned (3) Ban! lion! lurk (4) Barn swingarm Date of Issue: January, 1983 © HONDA MOTOR (20., LTDV 23-3 HONDA v45 muncmon MEMO Daxe of Issue. January, 1983 © HONDA MOTOR CO., LTD.