HONDA ' * VF7sosmst 1' VF750CUSTDM VF750 'SD «983‘ VF750 ca 198 , ADDENDUM“;- _ sum MANllAl = - .f mm mm , wrnKsmn—Hnm a MANUAL II mum wmwmngmnd {m l ,. a :01: . . ‘ $.26:th .. .I. .‘21' ‘ 25.VF75OS°VF75DD ADDENDUM E, INTRODUCTION This addendum contains information for the VF750 SPORTS and CUSTOM. Refer to the base shop manual for service procedures and HONDA VF750$ VF750C CONTENTS 1. GENERAL INFORMATION ............ 25.2 SPECIFICATIONS ................ 25-2 TORQUE VALUES ................ 25-3 data not included in this addendum. CABLE & HARNESS ROUTING ....... 25-4 2. LUBRICATION .................... 25—8 3. MAINTENANCE .................... 25-9 4. FUEL SYSTEM .................... 25-11 5. CLUTCH .......................... 25-15 6. CYLINDER HEAD/VALVE ............ 25-23 7. CRANKSHAFT/PISTON .............. 25-23 8. TRANSMISSION ................... 25-23 ALL INFORMATION, ILLUSTRATIONS, DI- 9. FRONT WHEEL/SUSPENSION .......... 25-24 RECTIONS AND SPECIFICATIONS INCLUD- 10. REAR WHEEL/SUSPENSION/BRAKE ..... 2527 ED IN THIS PUBLICATION ARE BASED 11. SWITCHES ....................... 25-28 ON THE LATEST PRODUCT INFORMATION 12. WIRING DIAGRAMS ................ 25-29 AVAILABLE AT THE TIME OF APPROVAL 13. TECHNICAL FEATURES ............. 2531 FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER- MISSION. MODEL Engine No. Frame No. VF750 SPORTS RC07E—2103761~ RC070*DM103735~ VF750 CUSTOM RC09E—4120448~ R009—2100010~ VF750 SPORTS/CUSTOM ADDENDUM I. GENERAL INFORMATION SPECIFICATIIJNS Only new specifications for the 1983 VF750$ and VF750C are listed below. See pages 1-2 and 1-3 for all other specifications. SPECIFICATIONS < >:SA,U,ND ITEM VF750 SPORTS VF750 CUSTOM DIMENSIONS Overall lenth 2,295 mm (90.4 in) 2,270 mm (89.4 in) < 2,300 mm (90.6 in) > Overall width 830 mm (31.9 in) 815 mm (32.1 in) Overall height 1,195 mm (47.0 in) 1,195 mm (47.0 in) Wheelbase 1,575 mm (62.0 in) 1,540 mm (60.6 in) Seat height 780 mm [30.7 in) 740 mm (29.1 in) Foot peg height 320 mm (12.6 in) 385 mm (15.2 in) Ground clearance 135 mm I 5.3 in) 165 mm I 6.5 in) Dry weight 221 kg (486.4 lb) 219 kg (493 lb) Curb weight 241 kg (538 lb) -236 kg (520 lb) FRAME Caster angle 59°30’ 60° Trail 118 mm (4.6 in) 105 mm (4.1 in) Front fork oil capacity R: 375 cm3 (13.2 02), R: 420 cm3 (14.8 oz), L2390 cm3 (13.7 02) L: 442 cm3(15.6 oz) ENGINE Intake valve Opens 8° (BTDC) <—— Closes 40° (ABDC) , <— 0 at 1 mm Ilft Exhaust valve Opens 43 (BBDC) 4— Closes 7° (ATDC) 4—- CARBURETION Carburetor venturi dia 30 mm (1.26 in) <— ldentification number VD62E VD62C Pilot screw initial setting 2-1/2 turns out <—- Float level 7.5 mm (0.28 in) 7.2 mm (0.28 in) DRAIN TRAIN Clutch Wet, multi-plate 4— Transmission 5-5de with over drive 4— Primary reduction 1.736 4— Secondary reduction 1.187 <— Final reduction 3.181 4— Gear ratio | 2.294 ~4— Gear ratio H 1.619 <— Gear ratio lll 1.291 <——— Gear ratio IV 1.074 «1— Gear ratio V 0.896 +— Over drive 0.806 <—— Gear shift pattern Left foot operated return system, 1—N—2—3—4—5-OD <— Final drive oil capacity 170 cm3 (6.0 02) after disassembly <— 130 cm3 (4.5 02) after draining «~— 25—2 TORQUE VALUES 0 ENGiNE — VF750$ VF750 SPORTS/CUSTOM ADDENDUM Attachment Item O'ty Thread Dia. (mm) Torque N-m (kg-m, ft-Ib) Remarks Clutch center lock nut 1 24 45—55 (4.5—5.5, 33—40) 0 CHASSIS Item O’ty Thread Dia. (mm) Torque N-m (kg-m, ft-lb) Remarks Final driven flange bolt 5 10 50—60 (5.0—6.0, 36—43} Apply liquid sealant. 0 SPECIAL Description Part No. Remarks Ref. Sect. 07943—MBOOOO — 25 HONDA vr7sos vrzsoc VF750 SPORTS/CUSTOM ADDENDUM CABLE 8: HARNESS RflUTING 0 VF750 SPORTS CABLE 8: HARNESS ROUTING (2) CLAMPS (1) THROTTLE CABLES (4) CLUTCH HOSE (3) :Roggn BRAKE \ \(5) CHOKE CABLE (6) SPEEDOMETER WIRE (7) CLAMP (11) CLUTCH HOSE (12) BANDS (9) TURN SIGNAL CANCEL (10) MAIN RELAY UN'T 25-4 HONDA. vr7sos vr7soc VF750 SPORTS/CUSTOM ADDENDUM (1) BATTERY LEVEL SENSOR (2) REGULATOR/ (3) BANDS RECTIFIRE RELAY (5) RADIATOR RESERVE TANK OVER FLOW TUBE (10) MAIN FUSE I7) REAR BRAKE LIGHT I9) CLAMP I6) BATTERY (8) BATTERY DRAIN TUBE GROUND CABLE I12) BRAKE & TAIL LIGHT SENSOR (11) SPARK UNITS 25-5 HONDA VF750$ VF750 SPORTS/CUSTOM ADDENDUM VF750C 0 VF750 CUSTOM CABLE 81 HARNESS ROUTING K I. , A 7 i) f 4/ i ~~:~s;~‘:o an" 9" ‘I’f‘i‘ J / (1JPR0NT _’/, C__\~’?/ff '-L___/ BRAKE "\’ ' ’ 4 HOSE . P“ A» ()CHOKE CABLE (2) THROTTLE ‘ 4‘ l CABLES “ ' (5) CLUTCH HOSE {3) CLAMPS , 7 z ,7 <_ u (6] SPEEDOMETER "Le—Lg ' » .\ CABLE (7) THROTTLE CABLES 37. 2 If" (12) CLUTCH HOSE (13)BRAKEHOSE g .. CLAMP . '~ (17) WIRE BAND (14) SPEEDOMETER CABLE (10) PULSE GENERATOR (18) FUEL TUBE W'RE (15) FRONT (11) OIL PRESSURE BRAKE CABLE (19) VAngllEERNATOR SWITCH 25-6 VF750 SPORTS/CUSTOM ADDENDUM 25-7 H)BAND$ (2) BANDS :3‘ )\o ”X“ of (4} BATTERY (5) RESERVOIR BREATHER TUBE OVER-FLOW TUBE t7) BRA—kE & TAIL UGHTSENSOR (8) SPARK UNITS (6) WIRE BAND VF750 SPORTS/CUSTOM ADDENDUM HONDA VF750$ VF750C 2. LUBRICATIBN SPECIFICATIONS Engine oil Oil recommendation VOSCOSITY: SAE 1ow-4o Use Honda 4-Stroke Oil or equivalent. API Service Classification: SE or SF. Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. OIL VISCOSITIES SAE 20W 4|] 29W 50 SAE NEW 40 -SAF. luw 3U D 20 40 60 EU lm’F L I l J I l J ‘20 “ 1'] J 1'1 X! 3 MV'C ENGINE OIL LEVEL Run the engine and allow it to idle for 2—3 minutes. Stop the engine and support the motorcycle on the center stand. Check the oil level with the dipstick aftera few' minutes. Do not screw in the cap when making this check. If the level is below the lower level mark on the dip- stick, remove the filler cap and add the specified oil. Start the engine and check the warning light/ display. The light should go off when the engine starts. if it does not, check the oil pump function and/or oil circuit. (2) UPPER (3) LOWER (1) DIPSTICK ~« I) «0 (4) FILLER CAP 2 5L— 8 VF750 SPORTS/CUSTOM ADDENDUM HONDA VF7sos vr7soc 3. MAINTENANCE MAINTENANCE SCHEDULES-VETS!) SPORTS Perform the PR E-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE WHICHEVER ODOMETER READING (NOTE 3) FREQUENCY COMES _’ b D b .3 FIRST .5; 53 SS 55 5 $535 ‘ 698 3298:? S598 8§8§ .co $0. Q20. ‘Yw J39 Ro~ Yv‘ ~\ We SIS» 9C wx .90 .890 ITEM EVERY Refer to page * FUEL LINES I I I 35 * THROTTLE OPERATION I I I I 3-6 * CARBURETOR-CHOKE I I I 37 * AIR CLEANERS NOTE 1 c C C c C C 25-11 CRANKCASE BREATHER NOTE 2 C C C C C C 3-9 SPARK PLUGS R R R R R R 39 * VALVE CLEARANCE I I I I 3-11 ENIGNE OIL YEAR R R R R 257 ENGINE OIL FILTER YEAR R R R R 23 * CARBURETOR-SYNCHRONIZE | I I I 312 * CARBURETOR-IDLE SPEED I I I I I I I 3-13 RADIATOR COOLANT I I *R 3-13 * RADIATOR CORE I I I 314 * COOLING SYSTEM HOSES & I I I I 3.1 4 CONNECTIONS FINAL DRIVE OIL I I R 2-10 . FINAL DRIVEN FLANGE NOTE 4 , L L L 17-6,25-27 BATTERY MONTH I I I I I I I 3-15 BRAKE FLUID (FRONT) $921354; I I I I I I *R 3-15 BRAKE SHOE/PAD WEAR I I | I I I 3-15 BRAKE SYSTEM I I I I 3-16 * BRAKE LIGHT SWITCH I I I I 317 * HEADLIGHT AIM I I I I 317 CLUTCH FLUID $83133 JR I I I I I I *R 3-18 CLUTCH SYSTEM | I I I 313 SIDE STAND I I | 3-13 * SUSPENSION I I I I 319 * NUTS, BOLTS, FASTENERS I I I I 3-21 ** WHEELS I I I I 3-21 ** STEERING HEAD BEARINGS I I I I 321 * SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. MIN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER. NOTES: 1. SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS. 2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE. 3. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE. 4. LUBRICATE WITH LITHIUM-BASE MULTIPURPOSE GREASE NLGI No.2 (MOS; ADDITIVE) EVERY 8,000 MILES (12,800 KMI OR WHENEVER THE REAR WHEEL IS REMOVED. 25-9 HONDA VF750$ . VF750C VF750 SPORTS/CUSTOM ADDENDUM VF750 CUSTOM Perform the PR E-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE WHICHEVER ODOMETER READING (NOTE 3) FREQUENCY COMES FIRST I I ITEM EVERY \ 2’ * FUEL LINES I I I 3.5 * FUEL FILTER R 35 ' THROTTLE OPERATION I I I I 3-6 ’ CARBURETOR-CHOKE I I I 3—6 * AIR CLEANER NOTE 1 R R R 3.7 ORAN KCASE BREATHER NOTE 2 C C C C C C 3-9 SPARK PLUGS R R R R R R 3-9 * VALVE CLEARANCE I I I I 3-11 ENGINE OIL YEAR R R R R 2-3 ENGINE OIL FILTER YEAR R R R R 23 * CARBURETOR-SYNCHRONIZE I I I I 3-12 * CARBURETOR-IDLE SPEED I I I I I I I 3-13 RADIATOR COOLANT I I *R 343 * RADIATOR CORE I I I 344 * COOLING SYSTEM HOSES & | | I | 344 CONNECTIONS FINAL DRIVE OIL I I R 240 * FINAL DRIVEN FLANGE NOTE 4 L L L 17-6 BATTERY MONTH I I ' I I I I I 3-15 BRAKE FLUID (FRONT) geggsflR I I I I I I *R 345 BRAKE SHOE/PAD WEAR I I I I I I 3-16 BRAKE SYSTEM I I I I 3-16 * BRAKE LIGHT SWITCH I I I I 3-17 ' HEADLIGHT AIM I I I I 3-17 CLUTCH FLUID QASE‘ZES IL I I I I I I *R 3-18 CLUTCH SYSTEM I I I I 3-18 SIDE STAND I I I 3-18 * SUSPENSION I I I I 349 * NUTS, BOLTS, FASTENERS I I I I 321 “I WHEELS I I I I 3.21 ** STEERING HEAD BEARINGS I I I I 3.21 " SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. ” IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER. NOTES: 1. SERVCIE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS. 2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE. 3. FOR HIGHER 'ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE. 4. LUBRICATE WITH LITHIUM-BASE MULTIPURPOSE GREASE NLGI NO.2 (M032 ADDITIVE) EVERY 8,000 MILES {12,800 KM) OR WHENEVER THE REAR WHEEL IS REMOVED. 2 5 - 1 0 VF750 SPORTS/CUSTOM ADDENDUM AIR CLEANER (VF750 SPORTS) Remove the fuel tank. _ Remove the two air cleaner case cover mounting bolts and air cleaner case cover. Remove the element setting plate B and element. Wash the elements in non-flammable or high flash point solvent and let it dry. Soak the elements in gear oil {SAE #80—#90) and squeeze out the excess. Install the removed parts in the reverse order of disassembly. 4. FUEL SYSTEM SERVICE INFORMATION SPECIFICATIONS uiELeMENT Q)ELEMENTSETHNGPLATEB VF750 SPORTS VF750 CUSTOM Venturi dia. Primary 10.5 mm (0.41 in) Secondary 30 mm (1.18 in) IdmnwmafionNo. VD62E voezc Float level 7.5 mm (0.29 in) Main jet # 108 Idle speed 1,000 i 100 rpm Throttle grip free play 2—6 mm (0.08—0.24 in) Pilot screw initial opening 2-1/2 25-11 VF750 SPORTS/CUSTOM ADDENDUM VF750C (1) AIR CLEANER CASE CARBURETOR REMOVAL (VF7508) COVER Remove the air cleaner element (page 25-9). Remove the air cleaner case. Remove the air cleaner base cover screws and base cover. Remove the thermostat cover bolt and disconnect the ground cable. (1) GROUND CABLE 25-12 HONDA vr7sos VF750 SPORTS/CUSTOM ADDENDUM VF750C Remove the high tension cords and left electric parts bracket. ’ \3 l . I,‘ (1) LEFT ELECRRIC PARTS BRACKET Loosen the carburetor bands and remove the carburetors from the left side. ' j: (1) CARBURETOR BANDS (1) NEEDLE JET FLOAT CHAMBER I FLOAT AND JET Remove the needle jet holder and needle jet. NOTE: If the needle jet is difficult to remove, care- fully press the needle jet from the cylinder side with a soft material. (2) NEEDLE JET HOLDER 25-13 Ta] HONDA by.“ ,. vr7sos VF750 SPORTS/CUSTOM ADDENDUM \.:.-_-'=3/ vr7soc CARBURETOR SEPARATTION/ ASSEMBLY Remove and install fuel joints as shown. FUEL JOINT AIR CLEAN ER CASE/CHAMBER (VF7503) Check the air cleaner case for deterioration. CRAN KCASE VENTILATION SYSTEM Check that breather tube is not restricted. 25-14 HONDA vr7sos vr7soc VF750 SPORTS/CUSTOM ADDENDUM 5. CLUTCH SERVICE INFORMATION GENERAL 0 When reassembling the clutch slave cylinder on the 1983 VF750 SPORTS, use a new gasket between the body and the piston. See page 7-10 for assembly procedures. SPECIFICATIONS STANDARD . SERVICE LIMIT Clurch spring height i 3.9 mm (0.15 in) ' 3.6 mm (0.14 in) Clutch center 8 ID. 74.414—74.440 mm (29296—23307 in) 7450 mm (2.933 in) One way clutch inner O.D. 51755—51768 mm (22738—22743 in) 57.74 mm (2.273 in) SPECIFICATIONS TORQUE TORQUE VALUES Clutch center lock nut 45—55 N-m (4.5—5.5 kg-m, 33—40 ft-lb) TOOLS Special Mainshaft holder 07923-6890101 (7) WASHER (6) ONE WAY (16] WASHER (5] SLUTCH CLUTCH INNER (14) gnggHGUIDE (3) CLUTCH CENTER 8 (17) COLLAR PRESSURE PLATE (4) SPRING SETTING PLATE (2) SNAP RING (1) CLUTCH LIFTER \ PLATE Q \C, - ®.©® l (15) OIL PUMP DRIVEN SPROCKET 9'.' r-r % : s ! II I) WASHER\ I12) CLUTCH CENTER A W" (4.5—5.5 kg-m 33-4mm.” I18) CLUTCH LIFTER ROD 25-15 HONDA vr7sos vr7soc VF750 SPORTS/CUSTOM ADDENDUM DISASSEMBLY NOTE: Do not operate the clutch lever after removing the clutch or it will be difficult to reassemble. Remove the snap ring, clutch lifter plate, bearing, lifter guide and lifter rod. (4) BEARING _ (2) SPRING SET PLATE Place the transmission in 6th gear and apply the rear brake. NOTE: When the engine is not in the frame, shift the transmission into gear and use the shaft holder (07923—6890101) to hold the output shaft. Remove the lock nut and lock washer. Remove the clutch spring set plate, clutch spring and washer. a?" , (3) LOCK NUT WRENCl—l, 17 x 27 mm (1) DISCS AND PLATES ,, ' Remove the clutch pressure plate. Remove the clutch plates and discs. 25-16 HONDA vr7sos vr7soc VF750 SPORTS/CUSTOM ADDENDUM Remove clutch center B and the one way clutch as a unit. Remove clutch center A and the washer. INSPECTION CLUTCH SPRING Measure the clutch spring free height. Replace the spring if it is shorter than the service limit. SERVICE LIMIT: 3.6 mm (0.14 in) 25-17 ’ HONDA vr7sos vr7soc VF750 SPORTS/CUSTOM ADDENDUM ONE WAY CLUTCH Inspect the one way clutch for smooth operation. Check the rolIers for excessive wear. Measure the ID. of clutch center B. SERVICE LIMIT: 74.50 mm (2.933 in) Measure the 0.0. of one way clutch inner. SERVICE LIMIT: 57.74 mm (2.273 in) 25-18 VF750 SPORTS/CUSTOM ADDENDUM HONDA vr7sos vr7soc Remove the clutch outer and outer guide. CLUTCH OUTER INSPECTION Check the slots in the clutch outer for nicks, cuts or indenations made by the friction discs. Check the needle bearing for damage or excessive play. If the needle bearing is difficult to remove, use the following tools. Driver: 07749—0010000 Attachment, 37 x 46 mm: 07746—0010200 Pilot, 35 mm: 07746—0040800 CLUTCH ASSEMB LY Install the drive sprocket spacer. Install the clutch outer guide over the mainshaft. Install the needle brearing into the clutch outer. Align the holes in the clutch outer with the pins on the oil pump drive sprocket and install the clutch outer over the guide. (1) SLOT (2) NEEDLE BEARING (1) CLUTCH OUTER “ (2) PINS ‘ «o (3) CLUTCH OUTER (4) on. paws Dfiive GUIDE SPROCKET 25-19 HONDA vr7sos vr7soc VF750 SPORTS/CUSTOM ADDENDUM Install the clutch center A and washer. (1) CLUTCH CENTER B (Turns couter clockwise) .. ..... g V. Place the clutch inner onto the mainshaft with its grooves facing out. Place the one-way clutch over the inner with its markings facing out. Install clutch center 3, with its grooved side facing in, over the one-way clutch. Turn center B counter clockwise as you install it. CAUTION: Make sure the one way clutch assembly is installed correctly by turning clutch center B. It should turn counterclockwise freely and should not turn clockwise. .. (2) ONE WA CLUHTC (3) ONE WAY CLUTCHINNER Coat the discs and plates with clean engine oil and install them as shown. 25-20 HONDA. vr7sos VF750C VF750 SPORTS/CUSTOM ADDENDUM Install the clutch pressure plate. Install the clutch spring set plate, clutch spring and washer. NOTE: Install the clutch spring with dished face towards the inside. (2) CLUTCH SPRING (3) WASHER (1) LOCK WASHER '7‘ Install the lock washer with its dished face towards the inside. 25-21 VF750 SPORTS/CUSTOM ADDENDUM Place the transmission in 6th gear. Apply the rear brake and tighten the lock nut. NOTE: When servicing the clutch with the engine out of the frame, shift the transmission into gear and use the Shaft Holder (07923—6890101) to hold the output shaft. TORQUE: 45—55 N-m (4.5—5.5 kg-m, 33—40 ft-lb) Install the clutch lifter rod. Install the clutch lifter plate, lifter guide and bear- ing. (4) LIFTER PLATE Install the snap ring. 25-22 HONDA vr7sos VF750C VF750 SPORTS/CUSTOM ADDENDUM (1) VALVE GUIDE DRIVER 6. CYLINDER HEAD/ VALVE 07942—3290200 SERVICE INFORMATION TOO LS Special Attachment 07943—MBOOOO VALVE GUIDE REPLACEMENT 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. (2) ATTACHMENT 07943—M 300000 7. CRANKSHAFT/ PISTON SERVICE INFORMATION SPECIFICATIONS ITEM STANDARD SERVICE LIMIT PISTON Ring end gap top 0.15—0.30 mm (0006-0012 in) 0.50 mm (0.02 in) Ring end gap second 0.15—0.30 mrn (0006—0012 in) 0,50 mm (0.02 in) GEAR TOOTH CONTACT PATTERN CHECK COUNTERSHAFT/OUTPUT DRIVE GEAR ADJUSTMENT SHIMS A: 0.4 mm (0.016 in) B: 0.45 mm (0.018 in) C: 0.5 mm (0.020 in) D: 0.55 mm (0.022 in) E: 0.6 mm (0.024 in) COUNTE RSHAFT INSPECTION For 1983 models it is no longer necessary to select an output gear case gasket before selecting a countershaft spacer. After backlash inspection, if there is no other reason for selecting a new gear case gasket (see page 13-16), simply install the countershaft assembly on the lower crankcase with the existing gasket. Then select a spacer using the procedure described on page 13-18 if necessary. 25-23 HONDA VF750!) VF750 SPORTS/CUSTOM ADDENDUM VF750C 9. FRONT WHEEL/SUSPENSION SPECIFICATIONS STANDARD SERVICE LIMIT Fork spring free length 552.6 mm (21.75 in) 541.7 mm (21.3 in) Front fork fluid capacity VF750 CUSTOM Right 420 cm3(14.8 02}, Left 442 cm3(15.6 oz) — VF750 SPORTS Right 375 cm3II3.2 02), Left 390 cm3(13.7 ozI — Front fork air pressure VF750 SPORTS 0—40 kPa (0—0.4 kg/cm2 . 0—6 psi) _ VF750 CUSTOM 0-40 kPa (0—0.4 kg/cm7' , 0—6 psi) -— (VF750 SPORTS) H EADLI GHT Both the Sabre and Magna models a replaceable quart halogeh headlight bulb for 1983. For head- light, case and bracket removal procedures, refer to the base manual. NOTE: Do not leave fingerprints on the bulb, they may create hot spots. If possible, wear clean gloves when installing the halogen bulb. If you do touch the bulb with bare hands, clean it with an alcohol-moistened cloth before installing it in the case. BULB REPLACEMENT Remove the mounting screws from the headlight case, pull the lamp assembly from the case and remove the socket from the bulb. (VF750 CUSTOM) Reassemble in the reverse order. 25-24 VF750 SPO RTS/CUSTOM ADDENDUM INSTRUMENTS (VF750 SPORTS} Assemble and install the instruments in the reverse order of disassembly and removal. HONDA VF750$ VF750 SPORTS/CUSTOM ADDENDUM VF750C FRONT FORK {VF750 SPORTS) Remove the circlip and the orifice setting plate. Remove the pin on the inside of the case and pull out the orifice. Check the orifice for clogging by applying com- pressed air. Also check the orifice for damage and replace if necessary. Remove the check valve setting screw, valve spring and check ball. DISASSEMB LY/ASSEMB LY A sponge washer and a plastic seal washer have been added to the fork tube assemblies between the dust seal and the snap ring. The fork assembly service procedures are the same as for 1982. [3) VALVE (5) SETTING (2) CHECK BALL SPRING PLATE © . i //E\ (4) CIRCLIP (1) PIN (1) DUST COVER (2) SPONGE WASHER I3] PLASTIC SEAL'...» WASHER (4) SNAP RING/7% *7). Fl" (5) OIL SEAL (6) BACK-UP RING (7) SLIDER BUSHING VF750 SPORTS/CUSTOM ADDENDUM 10. REAR WHEEL/ SUSPENSION/ BRAKE (VF750 SPORTS) SERVICE INFORMATION TORQUE VALUES Final driven flange mount bolt 50—60 N-m (5—6 kg-m, 36—43 ft-Ib) REAR WHEEL ASSEMBLY Apply liquid sealant to the final driven flange mating surface and use a thread lock agent on the bolt threads. Tighten the bolts to the specified torque. TORQUE: 50—60 N-m (5—6 kg-m, 36—43 ft-lbl (1) FINAL DRIVEN FLANGE 50—60 N-m [5—6 kg-m, 35—43 ft-Ib) (2) MULTIPURPOSE NLGI No.2 GREASE (MoS2-additive) VF750 SPORTS/CUSTOM ADDENDUM i I. SWITCHES BRAKE AND TAIL SENSOR (VF750 SPORTS) 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/black (negative) wires. VOLTAGE: 5V If there is no voltage, replace the sensor unit. FUEL PILOT LAMP CHECK UNIT (VF750 CUSTOM) Turn the ignition switch ON and check the pilot light for operation. 0 If the pilot high come on and go off after 2—3 seconds with the ignition on, the check unit is good. I If the pilot light doesn't come on at all, check for the pilot light. If it is good, check for the unit. Make a circuit using pilot light (T7 3W), dry battery [12Vi and the unit as shown. The pilot lights should come on and go off after 2—3 second. If the unit is good, check the wire harness for a open circuit. 0 If the pilot light continue to light on with the ignition on, check for an amount of fuel in the tank or the stop and tail light. Fill the fuel tank or replace the stop and tail light if necessary and recheck. If the pilot light continue to light on yet, check the unit as shown above. If the unit is good, check for an short circuit in the wire harness. (2) G/Bl i2) TAIL & STOP LIGHT / i I3] FUEL REMAINING SENSOR (5) TAIL 84 STOP PILOT LIGHT (1) TAIL & T / STOP SENSOR (6) FUEL ‘ PILOT zj LIGHT :76 K (7) IGNITION ___ (4) FUEL SWITCH T— PILOT LIGHT -_~ CHECK UNIT C 9(1) LAMP 3w L1 (Tail/Stop) (2) LAMP 3w 322 y—@ (Fuel) 3 m u U L __ E (3) BATTERY 7 (12V) T \(4) CHECK UNIT HONDA vr7sos VF750 SPORTS/CUSTOM ADDENDUM vr7soc 13. TECHNICAL FEATURES ONE-WAY CLUTCH SYSTEM 25—31 OPTICAL-FIBER ANTITHEFT DEVICE 25—33 ONE-WAY CLUTCH SYSTEM First time on a production motorcycle, this system has been proven on the race circuits of Europe in Hondas Gran Prix road racers. Rear wheel lock up caused by rapid dOWnshifting and the resulting high engine compression braking force; is prevented by the slippage of the one-way clutch. (1} ONE-WAY CLUTCH (2) ONE-WAY .' CLUTCH OUTER l . x N I: g —— :__~ /\~~ ‘ fl ! /\ ‘ I ‘é§ L/EQ, , .Q;Q§ :1 ‘ \\‘ ‘4' , ‘\ ’P 1“ ”- mung (3) CLUTCH CENTER VI " i 0 Construction (4) CLUTCH OUTE R COMP The one-way clutch is installed with the clutch center inside the clutch outer. Half the clutch plates are controlled by the one-way clutch. The one-way clutch allows those plates to slip when backloading force during deceleration might normally cause the rear wheel to lock-up. Except for the one-way clutch, the primary driven gear/clutch assembly is a conventional design. We. HONDA ‘ 'f - («tug I vr7sos VF750 SPORTS/CUSTOM ADDENDUM \\"—:"/ VF750C 0 Operation (1) CLUTCH OUTER During acceleration, cruising and deceleration, power is transmitted through the clutch in the —-- normal manner: Clutch outer->friction disc->plate->one-way clutch K (3) ONE-WAY —’ mainshaft. CLUTCH OUTER (2) CLUTCH__.. CE L CENTER 5' I 4 (4) ONE-WAY ) = i > CLUTCH AT$\(5)8£\15-ngfiv — /l ‘ — INNER (6) MAINSHAFT When there is a backloading on the clutch caused by ' ' ~ the rear wheel nearing lockfup, the one-way clutch \ Fh—J (A) will slip just enough to prevent the wheel from locking: without losing the benefit of maximum engine compression braking. - (5) ON E-WAY CLUTCH INNER 0 POWER FLOW DIAGRAM (1 ) CLUTCH OUTE R ,__._._._._...._._ ._ J I I I (2) FRICTION DISC (5) FRICTION DISC. ‘ I I (3) CLUTCH PLATE (6) CLUTCH PLATE I -____.__.‘. (7) ONE WAY CLUTCH OUTER I (8) ONE WAY CLUTCH . I (4) CLUTCH CENTER (9) ONE WAY CLUTCH INNER ‘I I | |_ I __________ -IV (10) MAIN SHAFT (2) CLUTCH CENTER (1) CLUTCH OUTER hHI) ORDINARY POWER FLOW *——-(12) BACK LOAD 1 ;1\ HONDA gm J vr7sos VF750 SPORTS/CUSTOM ADDENDUM \{3/ vr7soc ———_._.——____—__*_ OPTIONAL FIBER ANTl-THEET DEVICE The divice consists of a built-in power source, buzzer, photo transistor light emitting diode (LED), and fiber scope locking wire. Function Braking the fiber scope causes the buzzer to sound due to interrupted transmission of light from the LED to the photo tran- sistor. A 9V dry battery is used to operate the system. The wire can be connected and disconnected with the ignition key and is stored in a compartment below the left side cover. (1) PHOTO TRANSISTOR I2) FIBER SCOPE ”E4 ere/é (3) LIGHT EMITTING DIODE