oe HON DA SHOP MANUAL V65 MAGNA-VF1100CIMPORTANT SAFETY NOTICE Iie aon pally face paved oie of fof taragoaot wt foeet CAUTION: snes «pus of pemonal wry cr celomen demage srr ot find. NOTE; Giveshetpu information, Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is ‘important to not that this manual contains some warings and cautions against some specific service methods which ould cause PERSONAL INJURY to service personnel or coukl damage a vehicle or render it unsafe, Please understand ‘Mat those warnings could not cover all concehable ways in whieh serves, whether or not recormmended by Honda might bbe done or of the possibly hazardous commaqsences of each concevable way, nor could Hende invstgats all such ways. Anyone using service procedures oF to0's. whether oF nat reeommended by Honda must satisfy himself thoroughly that ‘neither personal safety nor vehicle safery willbe jeopardized by the sevice methods or tools selected. Pan RT RTO biveon joo Le SHOP MANU VFLJDOC 839028331 serene | a aoare? | Togavsoiwly | O-D ee aa Pie sae P $ r\— HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emission Eaves are within the standards st by the US, Environmental Protection Agency. Perform: ing the first scheduled maintenance is very im- portant. It compensates for the initial wear ‘that occurs during the breakin period, Sections 1 through 3 apply to the whole ‘motoreycle, while sections 4 through 21 describe parts of the motorcycle, grouped according to location Find the section you want on this page, then turn to the table of contents on page 1 of that section. Nost sections start with an assembly or system illustration, service information and troubleshooting for the section. The sub: sequont pages give detailed procedures. If you are not familiar with this motorevele, fead the TECHNICAL FEATURES in section 2. If you don't know the source of the trouble, ge to section 24, TROUBLESHOOTING. | ALL INFORMATION, ILLUSTRATIONS, RECTIONS AND SreciFicaTions IweLUD- Ep IN THIS PURLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO. tro, necenves The niottT To MAKE | chances at any rime wirnouT no. TICE AND. WITHOUT. INCURRING ANY OBLIGATION WHATEVER. INO PART OF THIS PUBLICATION MAY aE REPRODUCED WITHOUT WRITTEN PER: imiscion C > HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OF FICE ENGINE GENERAL LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION __ COOLING SYSTEM CLUTCH SYSTEM GEARSHIFT LINKAGE ALTERNATOR: Le [_OYLINDER HEAD/VALVE CRANKCASE PISTON/CRANKSHAFT ‘TRANSMISSION DRIVE TRAIN HYDRAULIC BRAKES evectatcat || cassis BATTERY /CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER Ea SWITCHES WIRING DIAGRAM [Techical FEATURES En | TROUBLESHOOTING Ew Dae of tue Ove, 1008 |GHONDA MOTOR CO, LTD.NERS 1, GENERAL INFORMATION GENERAL SAFETY SERVICE RULES mW MODEL IDENTIFICATION 12 ‘SPECIFICATIONS 1 | TORQUE VALUES 1s TOOLS WW CABLE & HARNESS ROUTING 19 EMISSION CONTROL SYSTEM 4 EMISSION CONTROL INFORMATION LABEL 1M GENERAL SAFETY oom Uf the engine must be running t0 do some work, make sure ‘he area is welbventilced. Never run the engine ina closed ee, The exhaust contains posonous carbon monoxide we Gasne ts exrenty fomnabe end ts exloe ender 5 plidesin epee an noel Teo soa SERVICE RULES damage the motoreyeie, 2, Use the special tools designed for this product 3 CI The battery electroie contains sulfur acd. Protect your ‘ves, skin and clothing. Incase of contact, flush thoroughly with warer and call @ doctor ifeleerolyte gets in your eves. oI The battery generates hydrogen gas whick can be highiy explosive. Do not umoke or allow flames or sparks meer the ‘artery, especially whe charging It NDA or HONDA.racommanded parts and lubtieants oF their equivalent, Parts that do not matt HONDA'S ‘Use onty metric tools when servicing this motorcycle, Metre belts, nus, andl screws are not interchangeable with English festeners. The we of incorrect tots and fasteners may damage the motoreye. 4 Inet cular sequence is Specfed 7. Attar ressombi HONDA MOTOR CO.,LTD, sing vohent upon eisassembly. Lubricat ‘check al ports for proper installation ad operation. ‘new gaskets, Ovings, cotter pine, ack later, et, when reassembling. tening bolts oF nuts, begin with largerdlameter or inner belts fist, ard tighten to the specified toraue diagonally, ny siding surtaces bafore reasebly 1-1GENERAL INFORMATION MODEL IDENTIFICATION > BEGINNING FNO, Sc120+DMo00029 ENO. S¢12¢ 2000029 The frame serial number stamped on the steering head righ sae, Tie color label Wr attached to the Fame behind ie bt ide “The vehicle dertifieation number (VIN) fz an the steering ‘Tha euburetor Wortication number fron the exbuntar bed ots. ‘Dave of tues Ose, 1082 GHONDA NOTORCO,, LTDHONDA V65MAGNA SS GENERAL INFORMATION \\ SPECIFICATIONS ire SPECIFICATIONS DIMENSIONS | Owl nah 2.200 (9.8) ovr wan tom (31950) € Oven age 1210mmn (48 in) Werte Vino (ozo) Seaton 00 mm (1.8m) Foot ea hit deo mm (138m) Grove wane "86mm (ti Dry welt as (40 & conecant 2g (041 FRAME oe Dowblcrat Fron pein, Tedesco rk, 160mm (63) ae Swage/ Shs sb 112 in ‘Seomce ton rg reereonty Vaslocony ood Toots ove feetreace ve0700 1 Toes few te soe wiao/0 1 Tass Toe tile Fon 2 pi 26K, 226 len?) Cotsire | (2001 tod fe 22 thn 278 nen?) pressures i Upto whiele Front 32 pui (225 kPo, 2.26 kg/cm?) tact tnd Re ‘opi tno 23" ten?| e ng oet a Dose, 604 an? (40 pa) ina et a Sin, B\8em? (bo Ful capac {ites (8 US a0 39 tro ou) Flere cacy ‘tes 0.8 US, 07 Iw su Caster angle 59°40" tat 105 mm 61 Frente F808 cette oh L380 (108 ce) maw ae Wat ote 4troke, DOHC ese Or soya eneccee: a5xe03mm(a101 218 W) Diasnanent non? (6? ein) Comresion rao woes Vale tan Sit, nt ik chai ive wd DOHC wi recer as € Minow teiowar 113 BHP B00 pm Neti tre 7 kp (701 t/7 2000 Ot etpcy as wa (27 Use 8 tmp ater suenbly 30 ten (92 U8 20 tp arden retin soy Sas we (288 Us 2.04 np Linacre Tall pontoon niooe Airtitreion na ee PM CVlinder compression | 1342 kg/em? (186 +28 psi) , Intake valve Opens 8°(BTOC) Com 718800) | os Exhaust valve Opens: 4x ene) [i elit Soom PaToC) Valvecarance (Col) v7. 013 mm (0.0085) KR Eis eit 07 (21321) (de end 1000 100 om issue Oee, HONDA NOTOR C0. LTO, 1-3GENERAL INFORMATION ONSmon VO6SMAGNA TEM SPECIFICATIONS CARBURETION | Carburetor type/Throtti bore ‘CV/36 mm (1.420) Identification number vO70A Pilot srew initial wetting See page 4-16, Float level {8.0 mm (0.24 in) DRIVETRAIN | Clutch Wer, muttiplaw Tranmsion S-speed with ore dive Primary reduction 1707 ‘Secondary redieton 1068 Final reduction 3.182 Gear ratio | 2204 Gear ratio It 1818 Gear ratio It 11202 Geer ratio IV 1974 Geer ratio V 0.807 Over drive 0.760 Gear shit patzern Left foot operated evtum system, |-N—2-3-4-B-OD Fina dive gear oll eanacty 170 (5,7 02) after dassembly 130 ce (6/402) after draining ELECTRIGAL | lonition Full transistor ignition Ignition timing 30" aTOC at ide Ful advance 37° BTOC at 3800 rpm Starting system Starting motor Alternator 30010/2,000 rpm Datcery capacity 1V-18AH Spark plug Nox I NO) Standard DPR BEAR K24EPR-UB For cold gimaty rene DPR TEAS X22EPR-UB Forextended ei sote DPR SEAS XQ7EPR-UD Spark plug 9a 018-0.8 mm (0.081-0.058 me) Firing order 12-34 Fuse/Main fuse 10d. 15/304 LIGHTS esate sigh /iow bear) e0s6w Tailstopight BAW 1926p SAE NO, 1157 Front wen in 2 Sep SAENO. 1034 Rese turn sana! ZW Sep SAENO. 1073 Instrument tights 34W ep Neutra indicator aw Tum signa indicator aw Hun beam incieator aw 1-4 ‘Date of fave Ove, 1982 HONDA MOTOR CO, LTD.GENERAL INFORMATION nent inronmarion \— TORQUE VALUES « enaine ie Cw [Tewou wei | Toon lin ben Oe] a « eee 3 5 $12 [08-12,58-00 rin 6 @ | sete (ho-aal sso) 2 8 | eras ats wn | | aeae emvareren ee 1 {ia | eoo ma-motacra © | Se. 1 |tioar | sow eo-angecin pe w |. t | asar moana | uss 3 @ | ara @oes we) 1" | sccm (naa an Rect ar th 8) 2 | asso fesco.ar an) |pAppy Locnre® Gan roc 3 7 — | ve-20 rez ta) Serer ach : 8 | ae aaa ian Shi freer 1 7 | te-z0 te-zo, Carat chtn ple 1 | | 20a @oas non omer +] 020 | tego meget Cua 2 8 | 228 eras | soem @ | verre ns 7 | ava eres |ramweten nin bolt 1 2 38-40 (95-60,25-2) [ead and setng Connecting rod nuts: a 8 30-34 (3.0-3.4, 22-25) ut rs er sak i ‘ 2-12 (08-12, 66-00) heel dtp 1 2 | eoctontao-t00.se-201 | Oil pressure switch 1 - 10-14 (1.0-1.4, 7-10) Lee we @ CHASSIS ma iy, [Tad batead | _Taaeben ba fas] inane | a | Oe Wiesencan € tower) | 2 10 35-85 (5-45, 25-33) | ica ab os (Upper) 2 8 40-50 (4.0-5.0, 28-38) | tees | Fol Sas omen seston i=) — +] Aas otanes oy fas sects : 8 | an88 ewes oom perio i a | soos ogee soe i [seas Beane Soot ' | zoo (zeae, wan : w__ | ses ao-anae a Date of teas: Owe 1987 " _ SWONDA MOTOR C0. LTO. 1-5GENERAL INFORMATION ‘Brake hose bolts Caliper sirbleed bolt ‘Axi pinch bolt Front fork stabilizer ‘clutch matt Free eater Final par ease nut ‘Stenring stem aut Front sxe Front ale pinch bolt Goarehitt pedal pivot Fn esecve sensor Brake master cylinder holder (Clutch master evlinder holder Brake matter cylinder cap evlinder 3p Flea! zar ol filer cap Fae brake torque rod Swingarm lett pivot holt Swingarm right pivot bolt Swingarm pivot lock nut Front fork tap pinch boits Front fork bottom pinch bolts Steering stom pinch bolt ty_| Thread Dia. (mm) 10 “Torque N-m(ka-m, 3b) Remake 25-35 (2.5-9.5, 18-25) 4-7 (04-07,29-5.1) 10-14 (1,0-1.4, 7-10) 10-14 (1.0-1.4, 7-10) 20-30 (2.0-3.0, 16-22) 18-28 (18-28, 13-20) 2-35 (02-0:3, 14-28) 2-38 (02-05, 14-2.) 10-14 (1.0-1.4, 7-10) 30-45 (20-4,5, 22-23) 18-25 (18-28, 13-18) 90-120 (9.0-120, 65-871 16-20 (1,6-2.0 12-14) 100-130 (10.0-13.0, 72-94) 45-70 (4.5-7.0, 33-51) ‘90-120 (8.0-120. 65-87) 9-13 (09-13,7-9) 45-55 (45-85, 33-40) 18-30 (1.8-30, 13-22) 55-65 (55-65, 40-47) 18-30 (18-30, 13-22) 5-105 (85-105, 61-76) 18-25 (1.825, 13-18) 27-38 (27-35, 20-28) below. ‘© STANDARD TORQUE VALUES “Torque specifications lated above are for important fasteners. Others should be tightened to standard torque values listed |Bmm bot and nut 0mm halt and nut 12mm balt and nut 18-25 (18-25, 13-18) 30-40 (3.04.0, 22~70), 50-60 (6.0-6.0, 36-43), ‘Brin tange bolt and mst im flange bolt and nut 10mm flange belt and nut ‘mm SH Mange bolt Toraue Val en Torave Valu i) Nem tkgm, fb) Nem (kg, Mb) Smm bolt ndnut | 4-6 (0.408, 3-4) ‘Smm screw 3-5 103-05, 2-4) mm bolt ndnut | 8-12 (08-1.2.6-9) ‘8mm screw 7-11 (07-1.1,5-8) 10-14 (1.0-1.4, 7-10) 29-0 2.0-3.0, 14-22) 20-40 (3.0-4.0, 22-29) 75-1085 (0.75-1.06,5.4-7.8) 1-6 Tawar ee, 1082 HONDA MOTOA CO., LTO.NSO GENERAL INFORMATION TOOLS o SPeSIAL si a ange ii aR eee | ee ee came ee ee nee : tte. | Seaen F Soviet | ceases i eee ee enn een See eae J Covsitatie in US. HOKK Mi ae : Gt | ny om ; omroee (iocrabe : Soares || eee : Scoweceees | Secamer ; Sc vont — | saeamrae. | cece mite | * ao cae ee | econ tae Soin acon | seo pleted ; etiam: | Soran > orton orer-seman |Site cemay i = a 3 Final pinion holder ‘o7924-NeD0000 lw Shaft pub (7921-40000 | Pinion puter nt ‘7e06-sacoom | 4 [tease ontam| freemen | Seta soniateceeties: | canes P Sar 2 : Soe Sersnise [owen — | smear: | <5 aos 3 Soa | eee Q oe oe : eooried a = oon . —— ene d sett 17m corasorzoson [Eilon woo community 8 osm nied : mearietone oo : poe 4 : Eee, | Soe : sna oe : Si | See = one Rsrail ee ‘ oor os ; Date of sue: Dae, 1082 ‘HONDA MOTOR CO.,LTD.GENERAL INFORMATION Sk) VO5MAGNA common DESCRIPTION | nuween “ALTERNATIVE. ‘NUMBER REF, SECT. Flost level gouge T” 07401-9019000 1 gunn | rence } =O cmesmes {Jraeonm usa H coos cree camen: | sisal pees | noua | arms-sonon | nora coaamem | 2 enor S3ine seems te jevdees atest omen pe poeeceeaian orneannoe oe “Attachment, 52% 53 mm 07746~-0010400, | atte | socatwn Gees Pitot. 20 rm (0746.-0040600 |e Pilot, 30 mm 07746-0040700 | oaste ae one snas | a oe | srmectoco | ove croe-avoen | ped poor aw “Attachment, 23mm ‘o7782-o030200 SO" ae | 1“ eee nae . Bewing remover shaft (07746-0060109 | te r6 ‘Bearing remover heed, 15 ren (07746 -0050400 |e Noovomocaasins | eos \is pecoutenioy ore sro ' omc a Few shock auerberconprsior, 1-8 Dita of sue: Ove, 1962 SHONDA WOTOR CO., LTD,GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses, ‘A loose wir, harress or cabl can be safety hazard ‘Atter camping, creck each wire 10 be sure itis 1 Do not squeeze wires against the weld of end of Its clamp when a weld-an clamp Is usd, 1 Stoure wires end wite harnesses ta the frame With ther respective wire bands atthe desionated locations. Tighten the bands so that only the insulate surfaces contact. the wires or wie nasa, ‘© Rout harnesses so they are not pulleé that or have oxonssive sack. ‘© Protect wires and harnesses with electrical ‘or tube if they aro contact a sharp ede or comer. Clean the attaching surface thorovohiy before applying tape, © Do not ust Wires oF heres with © broken insulator. Repair by wrapping them with + pro ‘tetive tape or replace them, ‘© Roum wire hamesses to avold sharp edges or © Also avoid the projected ands: of ‘bolts and 1 Koop wire harnesses away from the exhaust pipes ‘nd other hot parte ymmets axe seated in their grooves ‘After clamping, check wach harndis to ba eertin that it & rot interferring with any moving oF siding pats. '¢ Attar routing, hack that the wire harnesses are rat twisted ar kinked © Wire harnesses routed along the handebars should not be pulled taut, have excesive sack, bbe pinched, or interler with adjacent or sur rounding pats nal staering positions, O x Dateot ium: Dec 1082 HONDA MOTOR CO. LTD, 1-9Naren GENERAL INFORMATION V6S5MAGNA R.TURNSIGNAL WIRE SPEEDOMETER WIRE \ ‘THROTTLE CABLES WIRE BANDS FRONT BRAKE HOSE CLUTCH Hose A V\ EQUALIZER PIPE | | HORN WIRE 1-10 . SHowoA MOTOR CO, LTD.SEA VESRAGNA ener inFor Aion c | radeon sie ALTERNATOR WIRE BATTERY GROUND CABLE BATTERY BREATHER TUBE { A STARTER MOTOR FEAR BRAKESWITCH wae Dateot taus: Gee, 1982 13 HONDA MOTOR CO. LTD, 1-11HONDA GENERAL INFORMATION V6S5MAGNA THROTTLE CABLES MAIN WARNES ‘COOLANT RESERVE TANK ‘OVERFLOW TUBE. COOLING FAN MOTOR WIRE. J) \ {CyRADIATOR OVERFLOW TURE 0 af: FUEL HOSE aa THERMOSTATIC SWITCH FUEL RESERVE SENSOR FUEL FILTER FUEL FUNP 1-12 = SHiooa NOTOR co. LTD,@) HONDA \Si/ V65MAGNA GENERAL INFORMATION EMISSION CONTROL SYSTEM The VE5 engine is equipped with a erarkease emission contiol system which routes crankease emissions through the sit leaner and into the comburtion chamber, Condensed crankcase vapors are accumulated in & storage tank which must be tmptied periodically. See the Maintenance Schedule in Section 3. AIR CLEANER © <1 ‘FRESH AIR <— :sLowey cas BREATHER SEPARATOR DRAIN TUBE DRAIN PLUG. EMISSION CONTROL INFORMATION LABEL ‘An Emission Control Information Label i located ‘on the frame ax shown. It gves basic tune-up specications. EMISSION CONTROL INFORMATION LABEL Dareot taon 7 GHONDA NOTOR CO.,LTD. 1-13LUBRICATION fe) on onirice COUNTERSHAFT OILFILTER OILSTAAINER ‘Date of tes Dac; 1082 (HONDA MOTOR CO., LTD.) HONDA (i (WL) VOSMAGNA 2. LUBRICATION SERVICE INFORMATION ‘TROUBLESHOOTING ENGINE OIL LEVEL ENGINE OIL & FILTER CHANGE OIL STRAINER CLEANING 2-1 OIL PRESSURE CHECK 24 2-2 OlL PUMP 25 2-3 FINAL DRIVE O1L 210 2-3 CONTROL CABLE LUBRICATION 2~10 2-4 LUBRICATION POINTS 20 SERVICE INFORMATION GENERAL “To service the ol pump, It is necessary to remove therght side cover and water pump esiembly, Sev section 6 for water pum removal and ination, SPECIFICATIONS Engine oil | Oiteapciny 30 ier (92 US ai, 26 inp gH afer an iat (3.7 US gt 3.1 imp at) aftr di Ditrecommendatian | Oil rewure lat oi presiure switch) ‘Ol VisCOSTTIES Use HONDA 4STROKE OIL. or equivalent. ‘APLSERVICE CLASSIFICATION: SE or SF Viscosity SAE 10W-—40 Other viscosities shown inthe chart may be ‘sad when the average temperature in your riding area is within the indicated range 5.42 0.7 kolem? (77 + 10 ps) at 5,000 rpm (80°C!178°F) pump celery 28.8 ter (30.5 US qHmin, at 500 rpm Oi pump service data ‘STANDARD SERVICE LINIT 1.15 mm (0.006 in) (020 mm (0.008 in) Pump body clearance (0.15-0.22 mm (0:006-0.009 in) (0.35 min (0.014 in) [Pore ed tearance (0.02-0.07 wm (0:001=0.003) {0.10 mm (0.004 in) Final drive gear Oi capaciey 170 ee (67 oa) wer disassembly 130.ce (44 62) after draining Recommended oil Hypoid gear cil Abowe &°CIAi°F SAE HO I Below S°CI81°F SAE #80 ‘Date of hour: Dec, 1962 7 HONDA MOTOR CO.,LTD. 2-1& ()\HONDA LUBRICATION SS/ VOSMAGNA TORQUE VALUES Engine oll drain plus 35-40. Nn 5-40 ke, 25-29 feb) Engine of fier 15-20 Nem (15-20 kem, 11-14 ftib) — Apply Loctite to erankease bolt threads, 1 preesure sito 1014 Nim (1.01.4 kp, 71018) — Apply 3.BOND® or its equivalent to the ott threads, TOOLS ‘Specil i pressure 07506~-2000000. valable equivalent. (Oi pressure 0751042201001 oF mmr TROUBLESHOOTING Oit evel too low 4, External ol oaks 2. Worn piston rings 3. Worn vale guide or seal il contamination 1, Oi'or filter rot changed often enough 2, Head gas faulty 3, Worn piston rings 2. Pressure slit vaive stuck open 23. Plugged oil pick-up sreen 4 Ol Kump worn 5, External oi leaks High of presware 1. Prosar relia valve tuck open 2. Plupoed ol fier galery, or metering orifice 13 Incorrect ll being used ‘No ol prssere 1, Of lve low . ‘Dit of nue: Ove, 1002 2-2 @HONDA MOTOR CO. LTD.(>) HONDA is) V65MAGNA LUBRICATION ENGINE OIL LEVEL Pur the motereysie on its center stand on level ground, Start the enpine and let it dle for 2-3 ‘minatey Turn off the engine, Remove the dipstick, Remove the dipstick end chock the oi evel 1H the level is Below the lower level mark, remove the fi 10 the Upper level mark. Check the oll pressure with the warning indicator switch after the engine starts, The indicator should {0 off alter one oF two seconds, ‘ump function andor oil ereuit FILLER CAP ENGINE OIL & FILTER CHANGE NOTE: 9 engine oil with the Engine warm and the motorcycle on its center sind to nd rape deaning, Stop the engine Remove the oi filer cap, eylindor head oll drain ‘lug, engine bottom cll drain plug and drain the ol Remove the oll iter witha fater wrench ard let the ramsining ol drain out. Discard the oi it Make sure that the sealing washers on the drain ‘lug: ae in good eanektion and instal the plugs ‘After completely draining the oll repiace the oll filter with aaow one. Check that the ol filter O-ring Is in good conditon, and coat it with all bifor OIL FILTER 16-29Nm Installing it Coat the oi filter sal with ol. ill the (15-2.0kom, 11-14 feb) cankcow with 3.0 ners (32 US gt, 2.6 Imp at) Ra WRRERS fof the recommended al (page 2-1, ~ Start tho engine and lat it idle for 2-3 minutes, then stoo the engine. Make sure that the oll level fs at the upper level Make sure that shete are 1 ol teks, DRAIN PLUG 35-a0Nm CYLINDER HEAD OIL DRAIN PLUG. 4 Nim (1.0-1.4 kgm, 7—10 feb) 2-3 Dateot ta Bec, 1980 HONDA MOTOR Co., LTD,HONDA V6SMAGNA LUBRICATION OIL STRAINER CLEANING NOTE: The of wralner ean bi fangine mounted inthe frame Remove the front exhaust pipet Drain ah ane oil (poe 2-3), Remove the cil pan bolts ard ol pan OWL PAN RELIEF VALVE RELIEF VALVE ORING Remove and clean the osraner Check. the operation of the pressure relief valve ‘Make sure the Oring is in good condition when the elit vale ir removed, all the il trainer and ail pan Install the exhaust pipes Fl the crankcase withthe recommended ot (p29e 24) OIL PRESSURE CHECK Warm the engine up to normal operating temper: ature (approximately 80°C/176"F). Stop the engine afd disconnect the of pressure Remove the oll pretsure switch and connect an ‘ll prosure gauge to the pressure switch tole (page 25), (Creek theo evel ‘GIL PRESSURE EVITCH e aie of hase Dee, 1982 2-4 SHONGA OTOR CO.,LTD.))) HONDA (yt) ‘is / VO5MAGNA LUBRICATION OL PRESSURE GAUGE 1078962000000 [Not available in USA.) OL PRESSURE: 0.7 kefem™ (77 = (ao°e/176"F) Stop the engine Apply JOND© sealant or equiva Breese switch threacean itll TORQUE: 10-14 Nim (1.01.4 kg, 7-10 Fb) Comect the oll pressure svitsh wire Start the engi Operate the warning indicator switch. Chock that the oF pressure warning indicator goes ‘out after one or two seconds if the il premure warning Indicator the angine mmediately and determine the cause (OIL PRESSURE GAUGE ATTACHMENT 075104220100 OIL PUMP REMOVAL Nore: “The oll bump can be removed with the engine ‘mounted inthe rue. Drain the engine oil. Remove the exhaust system, Remove the right side coer Remove the 0} pump driven sprocket by removing {he bolt and wesher Remove the water pump asambly (page 6-12) ‘OIL PUMP DRIVEN SPROCKET OIL Pass PIPE Remove the oi strainer (page 24) and the oil pass pie, Make sure the O-ringsare in good condition O-RINGS, SHONDA WOTOR C0..L70. s 2-5()) HONDA LUBRICATION \Mis / VOSMAGNA MOUNTING 807 Remove the oil pump by removing the mounting bots, OL FUMP, STRAINER STAY O-RING Strighten and remove the pin holing the oi! strainer say Femove the ol svainer 0 Make sure the O-ringsare in good conditions rN DOWEL PIN DISASSEMBLY Remove the oll pump body cover and remove the f owe pi Rerrove the dive pin from the rotor shit. O11 PUMP BODY covER EELS 2-6 i SwonDA MoTGR e0. LTD(DP) HONDA (WL) V65MAGNA LUBRICATION ‘Measure the rotor tip clearance ‘STANDARD: 0.15 mn (0.005 in) ‘SERVICE LIMIT: 0.20 mm (0.008 in) Meature the pump body dearance, ‘STANDARD: 0.15022 mm (0,060,009 in| 10.35 mm (0.014 ia) Remove the rotor shaft and measure the pump end slew ‘STANDARD: 0.02-097 mm (0.001-0,008 in| ‘SERVICE LIMIT: 0.10 mm (0.008 i ‘Date of im Ose, 1082 (HONDA MOTOR CO.,LTD, 2-7LUBRICATION V65MAGNA ASSEMBLY tL PUMP Roby oureR ROTOR Isa the outer rotor into the Body and insert she rotor shah Insert the drive pin into the rotor shaft Pie rotor SuarT RIVE iN Align the slow inthe inner rotor with the ive sin, er DRIVE PIN wer ROTOR DOWEL PIN Insta! we dowel pin and ol pump body cover = Dae ot ise, Dae 198 2-8 S HONDA MOTOR CO. LD))) HONDA (WL) Vo5MAGNA INSTALLATION Insta the dowel pins and Oring and install the Install the strainer stay with a new ple and install the oil pipe. “ings are installed on the stay and ol pipe Install the of strainer and ail pan Place the oll pump dhven sprocket into the drive hain, a ‘mark on the driven sprocket should aca the rankcave, Insta the washer and tighten the bol. Insta the dowel pins en « new gasket. Ital the eight side cover, Insta the water pump assy (page 6-11), Isat the exhaust pipe Fill the engine with the recommended il ooge 20). True Dre, 1082 HONDA MOTOR Co., LTD. onIvEN SpROcKET O-RING. OweL Pins DRIVE CHAIN@) _oNn LUBRICATION is) VO5MAGNA FINAL DRIVE OIL OILFILLER CAP. CHECK Place the motorcycle of its cantar stand on level grou Remove the ol filereap, [Check that me oi level reaches tne lower edge of the il filler cap hole. CCheck for Ioaks, ifthe lewl is tow. Pour fresh oft through the ol filer hole until it reaches the loner ae CHANGE Remove the ol ile C39 and ¢rain bolt wo dein all OWL DRAIN BOLT fll fram the tinal gear cae, Install the drain bol sscurey. Fill the gear case withthe recommerded ol! up to the corres lev! (above). OIL CAPACITY: 190 ¢¢ (4.4 02) RECOMMENDED OIL: HYPOID GEAR OIL API, GL-5 SAE #90 (Above 5'C/a1°F) SAE #90 (Below 5°C/41°F) ‘OIL LEVEL, CONTROL CABLE LUBRICATION Periodically, disconnect the throtle cables st their upper ends, Thoroughly lubricate the cables. snd their pivet points with @ commercially avilable cable ibeeant or lght weight al 2-10 "= SNONDA NOTOR GO. LTD(HONDA s/ V65MAGNA LUBRICATION POINTS A ) or [GABLE LUBRICANT) a a THROTTLE AND THROTTLEGRIE = SWING ARM. CHOKE CABLES. wb PivoT FTOH AND BRAKE tevenrivors BRAKE DAIVEN FLANGE ) HONDA \Wis) V65MAGNA 3, MAINTENANCE SERVICE INFORMATION 341 COOLING SYSTEM Hoses MAINTENANCE SCHEDULES 3-3 & CONNECTIONS a ENGINES CYLINDER COMPRESSION 22 FUEL LINES 24 FUEL FILTER 2-4 BATTERY THROTTLE OPERATION 36 BRAKE FLUID CARBURETOR CHOKE 3-6 BRAKE PAD WEAR AIR CLEANER 3-6 BRAKE SVSTEM CRANKCASE BREATHER 3-7 BRAKE LIGHT swiTcH 216 SPARK PLUGS 3-7 HEADLIGHT AIM 315 IGNITION sysTEM 38 cLuTcH 318 VALVE CLEARANCE 3-8 SIDE STAND 316 CARBURETOR SYNCHRONIZATION 3-10 SUSPENSION 16 CARBURETOR IDLE SPEED a WHEELS 37 RADIATOR COOLANT 2-11 STEERING HEAD BEARINGS 218 RADIATOR CORE 3-12 NUTS, BOLTS, FASTENERS SERVICE INFORMATION GENERAL sin ot see ome 23 Sere ree Sx por 23 Pia ee pear ob are 210 SPECIFICATIONS Seat oie Swnand | Foren ainae meow PG, 4771 | Foreman nanone Wrw Tax 7 NGK NO NGK NO. DPRGEAS | vasepmuB | DeRVEAS | —x@EPR-US | bPReEAS | KATEPRTD Spark plug gap: 082.8 mm (0031-0035 in) Of isu Dee, 1962 HONDA NOTOR CO. LTD. 3-1gerry MAINTENANCE VO65MAGNA Agen en fees to'eroc ‘Advance sas 19'STDC a 1.500 rom Pall atvence BP RTOC st 3,800 mm Valve ctwrance Cold (Below 35°C, 95°F): lei speee Carburetor synchronization Gylinear compres ‘Throttle grip free play: Tntake/Exhaust: 12 mm (0.005 jn) 4,000 * 100 rom All earburetors within 60 mm (2.4 in) Ha 434 2kglem* (184 £ 28 ps) 28 mm (1/8-14 i) Tie Fete oe _ a wi10780-78 aTA0790-76 Up fo 0ka 0) 2 026,226) 22,028,226 Cold tire pressure, psi (kPa, kg/em?) — ‘ike 200 ie bat 32 (228. 2.25) | +40 (280. 2.80) a Ta ass - | Buntep Fu ~ 627 Front fork air pressure: O—6 psi (0-40 kPa, 0-04 kg/em*) TOOLS Sovcia aes C74o4-oco0000 oc WE8PE081-O (SA ont) TEE cen Snot ono Your gopreconne® osot-atoazeo Tree caeee eek oro8-azaca04 Scenes ovsto-Ma00r01 Sarena con Oreos MaoorO0 Pecioes ore0e-Maoanon pobadog seh (4) O08 003000 7 Sandie ba 3-2 ©HONDA MOOR CO. LTO.@ HONDA We) V65MAGNA MAINTENANCE MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION in the Owner's Marual at each scheiled msintenance period, |: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY. ©: CLEAN, Ri: REPLACE, A: ADJUST, L: LUBRICATE = Twmoneven ODOMETER READING (NOTE 3) FREQUENCY | Comes a) ol | i 3 est Free /. 9 odode edad) —~_ e wre every | OFFS SG 8S) BE te ve = [Fuel Lines 1 i [a4 = FUEL FILTER af aa * | THROTTLE OPERATION i cl tr [35 g|[* | canuneror.cHoKe co [| aircceanen NOTET a | —[r{ {ry} 36 E [[CGRANKCASE BREATHER NOTE? tte fete ete] sr £ [yseank tues aa RTARTA | 37 [ETvalve cLesnance i 1 i [38 = TENGINE OIL. Yean | ® RL [R | 23 = [| eneine oit FILTER vean [Tw] Tat tate |e @ |_| cansuneTon syncinonizati 1 1 et 1 10 9 | [ennaunrroniour seo oc A RADIATOR GOOLANT Li Lope oa = [RADIATOR cone i 1 1 [oar +] GOoLING svsTEM HOSES & ; ; ; | Si CONNECTIONS | = FINAL DRIVE O1L rz BATTERY = Ti 2 BRAKE FLUID st ET anaie PAB WEAR Tf] ai & [1 anake sveren i ts & [= nate uicur swiren 1 Ta @ [FT neapvichT am i i) 316 3) | cwrevrivio ila [eal ots 8 Teuton svsrew Toa] 318 5 [sive srano Temi — 316 5 =| SUSPENSION ene 316 = NUTS, BOLTS, FASTENERS J 38 =| wieeus T[3i7 =e] “STEERING HEAD BEARINGS ria per ai8 * SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND ‘SERVICE DATA AND ISMECHANICALLY QUALIFIED. iN THE INTEREST OF SAFETY, WE RECOMMENDED THAT THESE ITENS BE SERVICED ONLY BY AN AUTHOR: ED HONDA DEALER, NOTES: 1. SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS. 2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE (USA. ONLY). 3. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE, Darna eae Dee 1007 = HONDA MOTOR 0. LTO. 3-3MAINTENANCE >) HONDA ) V65MAGNA FUEL LINES Remove the left and sight side covers, and sat Make sure the fuel tank slss than all fll, Drain it st more man hal ful Remove the tank mounting bolts lift the fuel tank Lup and hold it in place with the tank siopert rod ‘Check the fuel lines and replace any parts which show detecioration, damage oF leakage, DDisengoge the tank support ra by lifting the tank Mighty. Let the fuel tank down into. place and insall the mourting belts. Be careful net te pinch ‘or kink the vent an fue ines FUEL FILTER Remove the seat. ‘Remove the fue iter from the holder Unelip the fue ine. Disconnect the fel lines from the filter Replace the fuel filter with anew ane when indict fd by the maintenance schedule. (See page 33) Trae the fuel fer certin conditions, Do not smoke ot allow Gasoline is flammable and is explosive under Flames or sparks in your working area Attar inetaling, check that shore ara not fuel lak TANK MOUNTING 8OLT SUPPORT ROD, FUEL FILTER FUELLING 3-4 Das of Prue, Dee, 1982 © HONDA MOTOR CO, LTD.HONDA V6SMAGNA MAINTENANCE THROTTLE OPERATION Cheek for smeoth throttle grip ful opening and automatic full closing in ail steering positions Check the tortie cables and replace them if they te deteriorated, kinked or damaged, Lubricate the throttle cables (pape 211), if throttle Operation is not smooth Measure thvotdle gip tree plyy ot the throttle grip flange FREE PLAY: 2-6 mm (1/8-1/ ‘Adjustment cen be made at either end of the throttle cable, Minor adjustments are made withthe per echvster and major edlstments are marie with ‘the lower adjuster after iting the fuel tank up. ‘Adjust by loosening the lock nut and tuming the adjuster ‘Tighten the lock nut and rectuck throtte operation LLowor tual tark into place and check throttle fee slay once more Lock NUT UPPER ApuusTER, LOWER ADJUSTER, Datoot iaue: Ovo, 1052 (HONDA MOTOR CO. LTD, 3-5\ HONDA V65MAGNA LUBRICATION CARBURETOR CHOKE cHOKE LevER “The VOE choke system uses a fuel enrichening itcuit controlled by a bysurter valve. The by: Sartor valve opens the enechening ckeuit vin cable when the choke lever on the handlsba Ir pushed up Check for emoath upper choke lever ops Lubricate the choke eable, ifthe aperation is not smooth, Push the choke lever en the handlebar all te way up te fully psn. Make sure the choke valve ie fren by trying to meve the choke lever on the carburetor, ate lifting the fue tank up. ‘There should be no free play. Aslust it necesary, BY loosening the choke cable flemp on the carburetor and moving the choke table cating #9 the choke lever ie flly one, Tighten the carr, CABLE CLAMP. Pull the choke lover all the way to fully cloed Make wire the chOK® valve ls fly closes By check ‘fer fos play in the cable betwoon the Iver on the carburetor and cable exina Reinstall the removed pars inthe reverse order of assembly, AIR CLEANER Make sure the fuel tank i ess than half-full, Drain Ff ft fs more than hall, Remove the tank rourting bat and lft the fuel tare up and hold iti place with the tank support rod, Remove the sir clearar cover sews, AIR CLEANER COVER 3-6 “ SHONOR MOTOR C0, LTO.) HONDA sk) V65MAGNA MAINTENANCE Remove the air cleaner element and discard it in sccordance with the maintenance schedule Alto, replace the dirty oF damaged emant any time it is excestvely Instat «new element and install the cover Disengoge tho tank support rod by fing up sity. Let the fuel tank down into place ard incall the {uel tark mounting bots. Be careful not to pch or kink the vent and fuel ines CRANKCASE BREATHER Remove the plug from the dain tube to empty any deposits NOTE: ‘Service more frequently when tdirg ia rain (F at ful throtte, ori the deposit level can be sean in the tranuparentection of the drain tube. ‘SPARK PLUGS RECOMMENDED SPARK PLUGS x wo) Standed DPRIEAS | X2AEPRUD For cold climiate a (Beiow 8c, a1") For extended DPRIEAG | x22EPRUG DPRIEAS | x27EPRUD Disconnect the spark lug caps ‘Clean any cit trom arourd the spark plug bases, Remove and discard the spark pugs Meature the new spark Bla gars using wiretyee feeler gauge [SPARK PLUG GAP: 0.8-0.9 mm (0.031-0.035 in} Adjust by bending the side eloctode carefully, With the plug washer attached, thread each spatk plugin by hand ta prevent eroeetresding Tighten the spark plugs another 1/2 turn with a spark plug wrench to compress the plug washer, Connect the sparkplug cap. AIR CLEANER ELEMENT DRAIN PLUG SIDE ELECTRODE Lai { (0.031-0,098 in) Duteot ane. bee, one ‘HONDA MOTOR CO.,LTD, 3-7MAINTENANCE IGNITION SYSTEM Nore The jgnition system i not be adjusted. Ifthe igi Remove the altersatr ard eft crankeate covers Inala flywheel cover (07898800000) Wipe off the cil from the flywheel Connect the timing light to the high tersion wire of tye No. cylinder, Start the engire an lot it ile IDLE SPEED: 1,000 100 mm The timing is correct if the ‘hel aligns withthe crankease rear mating surfaces, VALVE CLEARANCE 2 NEAR CRANKCASE MATING SURFACES Nore: | Inspect ond adlust valve clearance while the ingine b cod, [Below 35°C, 95°F) Remove the heat quer, radiator cap ard drain bolt Drain coolant from engi and tram (gage 63) Nore: Drain the coolant inta a clean container for euse, Scheduled coolantreptacement i every 2 years oF 24,000 mites (98,600 Kr Remove the sight and left frame side covers and remove the sat LUftup the fuel tank by removing tne front mount ing bolts. Be sure the tank less than hal fll rat, drain the tne Remove the spark plug caps and the spark lugs SIDE COVER = Daw of ue Dec, 108? 3-8 @ HONDA MOTOR CO. LTO) HONDA ) ) VO5MAGNA MAINTENANCE JGnITioW conLs CYLINDER HEAD COVER Remove the ignition coils with their bracket and Remove the radiator (See pape 66) Remove the front and rex oyliarhasd cover bolts ‘nd both cylinder head cover. Remove the alternator and ie crankcase covers, INSPECTION Mesure anc adjust the intake and exhaust valve slearances as dexcibed below. Route the crankshat clockwise to align the TL3 mer with the erankcase mating sutton, ke tute the No, 1 plitan is at TOC (Top Dad INSULATOR COVER Center} onthe compression stroke Chock the valve clearances or the No. 1 cylinder sing two feel giuges for each par of valves: one for each valve that shares & common rocker arm. VALVE CLEARANCE (IN, EX): ‘072mm (0.006 in) 713 MARK If adjustment i needed, loosen the eck nuts and ‘urn the adjusting serews until were ie a sight dea fon both feeler gauges. Both feeler gouges should ramaininsertee during adustrent. Hold the adjusting cere ae tight th TORQUE: 21-25 Nom (2.1-2.6 kgm, 15-10 ft16) CAUTION: - The lock nuts wil come loose if not tightened to the cere torave value Recheck the valve claeranoe look nuts REAR CRANKCASE MATING SURFACE VALVE ADJUSTING WRENCH FEELERGAUGE | 07008-MBOcI01 Rotate the crankshaft 270° clockwise to align the T2A4 rmatk with the crankcase mating surtaces and check the valve clearances forthe No, 2 cylinder [Adjust using the procedures for he No, 1 cylinder. Rotate the crankshaft 60° clockwise to align the 71.3 mark with the crankcase mating surlaces and check the valve coarances forthe No, Selinger. Adjust using the procedures for the No.1 cylinder. Rotate the erankshatt 270° clociwiee to lips the 72.4 mark with the crankcase mating surfaces and check the valve clearances forthe No. 4 cylinder Adjust using the same procedures as forthe Mo. 1 evinder Date of lace: Dee, 108 7 HONDA MOTOR CO.,LTD, 3-9MAINTENANCE. HONDA (QLD V65MAGNA Install the removed parts, excuot the radiator cap, in the revere order of duatsemby, Be sure the east mark inside th roar cylinder has ‘over faces the front and the tabs ofthe front evi ‘er ead cover face the rea ‘check the engine olt ave Fill the radiator with clean coolant to the specified ‘eva Nore: ‘After filing the radiator, start the engine and ‘rev tat least tree times to remore any ait bubbles trem she cooling sytem. Add more ‘olin mixture as necessary Inetall the radiator coo, CARBURETOR SYNCHRONIZATION Nore ‘Synehrenize the carburetors with the engine {at poral operating temperature, transmission in neutral and motorcyele onthe centr stand, Remove the plug from the No.1, 2,3 and devlin: der head ports and install the vacwum gauge adap- CConmect the vacuum gouses, ADJUSTMENT Nore “The No. 1 serburetorcarnot be ajated; Ile the ace eatourator ‘Start the engine and adjust the idle specs, IDLE SPEED: 1,000 + 100 mm Install the vecuun gauge adapter and connect the vacuum gauge Check that all carburetors are within 60 mm (2.4 in) Hs, CAST MARK No. 1 CYLINDER HEAD PORT PLUG. NO. 2 CYLINDER HEAD PORT PLUG ‘VACUUM GAUGE 074040020000 (or W9378-021-XXKXX (USA only) ‘ADAPTERS, 3-10 Date of tue Dec 1089 HONDA MOTOR CO,, LTO.; \HONDA ‘SL V65MAGNA Synehranize to specification by turning the aclust Ing serows with the special too, Recheck the idle speed and synchronization, ‘Remave the gauge adapter and instal the pugs CARBURETOR IDLE SPEED Nore [ inspect and adiust idle speed afterall other engine adjustments are within specications, ‘The engine must be warm for accurate adj ment. Ten minutes of stopandgo riding ts sificent Worm up the engine, shift to NEUTRAL, and place ‘the motoreycie on its center sane, ‘Turn the thiotte op setew as required to obtain the specified idle spoed, IDLE SPEED: 1,000 + 100 rpm RADIATOR COOLANT Remove the frame right side cove. ‘Check the coolant level of the rsorve tank with the ergine runing at normal operating temperature. ‘The level should be between the “FULL” and LOW" level LE recnsery, remove the rvsare tank expand fill to the "FULL® eval tine with @ 50/60 mist litiled water and antitretze, Reinstall the cap and frame side cover, MAINTENANCE ‘CARBURETOR ADJUSTING WRENCH 07902.4220201 i DECREASE oma Sere] SPEED Sail ISPEED RESERVE TANK CAP "FULL MARK Dato ot tae Boe, 1982 @HONDA NOTOR CO,, LTO.MAINTENANCE )))/ HONDA SL.) V65MAGNA RADIATOR CORE Chick the air passages for clogging or daerage Straighten ant fins and collapsed core. tubes, Flemove insets, mud or ary ebstructon with com [Bret eit or low wrtar recut Replaca the radivtor ifthe ar flow is restricted over ‘mote than 20% of the radiating surface COOLING SYSTEM HOSES Ingpect the hoses for eracks or deterioration, and replace if necessary. ‘Check the tightness of a hove clamps CYLINDER COMPRESSION Warm up he engine the engine, than disconnect the spare phig ‘cane and remove the sour lust. Insert the compression gauge, (Ogen the thratl all the way and crank the engine Note: Crank the engine until te osu reading | stops rising, The maximum reading is usually ached within 47 seconds, ah COMPRESSION PRESSURE: Y3+ 2kglem? (184 + 28 ps) Hf compression islow, check for the fllowing = Ley valor = Leaking eylinder ead gasket = Worn pston/inglevinder 1 compression is high, it indicates that carbon posts have accumulated on the combustion 0751 ‘800101 3-12 ‘Dureof leur: Dec, 1982 GQHONDA NOTOR CO., LTD,HONDA V65MAGNA MAINTENANCE BATTERY Remove the right frame side covet and inspect the battery ud ov ‘When the fuid level nears the lower level, remove ‘and add lstlied water to the upper olowe: Remove the battery holder bolt and pull out the battery Disconnect the nagatve cob a the bettery twrminal, then disconnect the positive cable Remove’ te filer caps and ada distiled water to ‘the upper level line. Reinstall the Bator Note: ‘Add only disilled water, Tap water wil shorten the service life ofthe battery, The battery elecrolyie contains sulphuric cid. Protect your eyes, thin, and clothing. If electrolyte rs in your epee, flash them thoroughly with water and. tet prompt ‘medical attention. BRAKE FLUID Check the beak tid ceservo lve 1 the level noats the lower lel mark, the ve: sarvoir with DOT BRAKE FLUID to the upper level mark, ‘Guede tne entire system for leaks, tthe CAUTION: * Do not remcne the cover nfl the handle] ‘bar has been tumed so thatthe reservoirs level, + Avoid operating the brake lever with the ‘cap removed. Brake fluid wil squirt out if the lever is pulled. + Do not mtx different rypeso fll, as they arene compatible, Teter to section 17 for brake bleeding procedures, HOLDER Bout UPPER LEVEL LINE TOWER LEVEL LINE UPPER LEVEL MARK LOWER LEVEL MARK UPPER LEVEL MARK LOWER LEVEL MARK Date of eum Bee, 1089 HONDA MOTOR CO.,LTD. be 3-13HONDA MAINTENANCE \\G) V65MAGNA BRAKE PAD WEAR BRAKE PADS ooking throush the slot indicated by the arrow cast on th caliper sembly, Replace the brake pads if the wear line on the pase reaches the ede ofthe brake die: (page 175) CAUTION: “Always replace the brake padi in pairs to ‘assure even dise pressure BRAKE DISC ARROW BRAKE DISC BRAKE PADS | BRAKE SYSTEM Inspect the brake hoses and fittings for detero ration, oratks nd agne of leakage, Tighten any Ioose Fitnes Repiace hoses and fittings as requited. BRAKE PEDAL HEIGHT ‘Aajuet brake ca height tothe pedal i 7 min (1/4 in) below the top of the foot pea, CAUTION: | trcomect brake polal height can cause brake dog. To Adj Looten the stopper bolt fock nut and turn the oper bolt Fetiohten the lack nut Nore: ‘STOPPER BOLT [After adjusting the brake pedal height, check _ | ‘the tear broke light awiten and brake pedal free play and aust i necessary, 3-14 = SHONDA MOTOR 0. LTD.()) HONDA ‘ss ) V65MAGNA MAINTENANCE BRAKE LIGHT SWITCH BRAKE LIGHT SWITCH NOTE: Perform brake light sites adjusiment afte adjusting the brake pedal play and height, ‘Adjust the brake light site 29 that the biake light wil come on when the brake. engagement bain Adjust by holding the switeh body and turning ‘he adjusting nut, Da not turn the switch body, Nore font bnke ight wkd doesnot emus] adustnent ‘ADJUSTING NUT CASE MOUNTING BOLT HEADLIGHT AIM Adjust horizomally by loosening both headlight bracket mounting bots Adjust vertically by loosening beth headlicht case ‘mounting bois Te. ‘Adjust the heodlight bear a specified by local lews and regulations | An improperiy adjusted headtight may Blind ‘oncoming drivers, or Ut may fil to light the | road fora safe distance BRACKET MOUNTING BOLT UPPER LEVEL MARK CLUTCH (Check the clutch fluid reservoir level It the teva! nears the lower tovel mar, fil the feseroir with DOT BRAKE FLUID to the upper Check the entteevstom for leaks. f the lve slow. ‘CAUTION [+ Bo nor remove the cover until the han lebar hes been tured 10 that the reersowr fs level + Avoid operating the clutch lever with the ap removed. Fld will squirt out ifthe lever pulled + Do not mix different wpes of fuid, as ‘they are not compatible. LOWER LEVEL MARK, Dae ot ae Be 3 StoNoR MOTOR ES. LTO. 3-15MAINTENANCE SIDE STAND (Check the rubber pad for deterioration oF wear Replace if any tends t0 wear line 95 shown. Check the side sand spring for damage and lox of tension, and the side stard assembly for freedom fof movement. Make sure the side stand ik not bent. € * When replacing, use a rubber pad wi ‘ark “Over 200 Ibs ONLY”, + Spring tarsion ie correct the meauare ments fall within 2-3 ko (448.6 Ib), when pling the side stand lower end with [_ssering scale the ‘SUSPENSION ‘Do not ride a vehicle with faulty suspension, | Loose, worn or damaged suspension parts “pat vehicle stabi au control Replace damaged components. which cannot be Tighten all pute snd bos. (Check the front fork air pressure when the forks Pisce the vehicle on its center and. Renore the alt valve cap and measure the air pressure AIR PRESSURE: (0-6 pal (0-40 kPa, 0-04 hg/em*) ))/HONDA S V65MAGNA 000 No ooo Pp wear ,, & ee O x ’AIR VALVE CAP 3-16 Dateof leas: Dee. 1082 SHONDA MOTOR CO,, LTD,\ HONDA ) VOSMAGNA MAINTENANCE ANTLDIVE SYSTEM INSPECTION Select a saje place away fiom traffic to perform this inspection. Position ‘Antidive damper force | 1 LIGHT ANTLDIVE @| : MEDIUM aM HARD. Low MAXIMUM ANTL-DIVE Inspect and it necessary, repair the system (Rater 1osection 18) REAR Place the motorcycl on its canter stand. Move the tear whos! sideways with foree to see it ths swingarm bearings ae worn Replace the bearings if thee i any looseness (page 16181 ‘Check the shock absorbers fr rake or damage, Tiaheen al ear wspanaion nut ae bolts WHEELS Nove: Tite pressive should be checked when tirer Li Check the tires for cuts, imbedded nails, orher (C Recommenneo RES aND PRESSURES: COLD. ton (a6 2261 fst | ay o [e882 | aera an | iad |e | { | ——— ~~ Teo, [Eton | a 508 puncor | en cen ‘Dace of tous Bee 1002 @HONDA MOTOR CO, LTD, 3-17)) HONDA sk) VOSMAGNA MAINTENANCE (Check the front and rear wheels for trusness (See tien 15 ard 16), Measure the td depth st the center of the thes, Replace the tie f the te folowing tim: [Minimum texd depth: Front: 15 mm (1/16 b) Rear: 20 mm (3/32 in} STEERING HEAD BEARINGS Nore: ae ‘that the control cables de not inter {ere wth handlebar rotation. Fite the front wheal off the ground and check ‘thatthe Panclebar rotates freely If the handlebar moves uneven, binds, oF has vertical movement, adjust the steering head bearing Dy turning the sterring head adiusting nut (page 15:38) NUTS, BOLTS, FASTENERS Chock tat all chasis nuts and bolts are tightened to their correct torque values (Secton 1) ot the Iervals shown in the Maintenance Schedule (eage 33), Chock all cotter gins, safety clips, hose clamps and cable stays 7 ‘Dn of onan Ove, oR 3-18 GHONCA NOTOR CO., LTO.FUEL SYSTEM a a LTT ae 4-0 HONDA MOTOR CO.,LTD.@) HONDA ‘SL V65MAGNA 4. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING CARBURETOR REMOVAL VACUUM CHAMBER FLOAT CHAMBER PILOT SCREW CARBURETOR SEPARATION CARBURETOR ASSEMBLY 4-10 412 CARBURETOR INSTALLATION PILOT SCREW ADJUSTMENT FUEL TANK AUXILIARY FUEL TANK AIR CLEANER FUEL PUMP HIGH ALTITUDE ADJUSTMENT {USA only) 416 416 a7 a7 418 18 419 SERVICE INFORMATION GENERAL Gasoline is extremely Mlammable and is explosive under certain conditions. Work i a well ventilated area. Do not smoke ‘or allow flanes or sparks i the work ares ‘©The front evlindors use down dratt carburetors ‘© When disassembling fuel system parts, note the loctions of the Orrngs. Replace them with new ones on reassembly ‘pump inspection i in section 21 Do not interchange these par’ TooLs Special Valve guide driver, 7 mm “The float bowls have drain screws that can be loosened to drain residual gasline. (07942—€230000 (U.S.A. only) “The No, 1 and No. 3 carburetors use different jet neous (thinner) andl shorter spring than the No. 2nd No, A earburators Common Float gauge (07401—0010000 SPECIFICATIONS T Primary 12.3 mm (O48 in) Venturi a Secondary 33,2 (1.31 in} {dentification No. _VO708, a ‘80 mm (0.24 in) Main jet Front # 140, Rear #140, Tale 900d — 11000 + 100 rom “Tarottle grip Wes psy 2-6 myn (0.08-0.24 in) Pot screw iit [ See page $16 Date issue: Dec. 1982 HONDA MOTOR CO., LTD, 44FUEL SYSTEM Va HONDA V65MAGNA “e TROUBLESHOOTING Engine cranks but won't start ‘No fuel in tank "No fue! tocarourstor Engine Hoades with fas "No spark at pla iaition system faulty) Air leaner clogged Intake ai leak Improper cote operation Improper thrttleoperstion i sartng o talling aftr starting Improper choke eperation| Igetion malfunction : Carsurator Faulty Fuel contaminated Intake air eak Idle sped incorrect Rough ile 1. Ignition system faulty 2. Idle speed incorrect 3, Incorrect carburetor synchronization 4. Carburetor faulty 5. Fu contaminated Misiing during scedteration 1. Ignition system faurty, Backfring 1. Ignition system tauty 2 Carburetor faulty Poor parformancs (driveability) and poor fuel eccnomy 1. Fuel system clogged 2 lanition system faulty ‘Lean mixture Cloged fue jets Vacuum piston stuck closed Feulty fost valve Float level lowe Fuel cap vert blocked Fuel strainer seen clogged Restricted fuel ine Air vent tubo clogged Intake at lak Restricted or faulty fuel pump ich mixture 1, lopped ar jes 2. Faulty fost valve 3. Float level t00 high 4. Choke stuck or clogged 5. Dirtyairclosner ‘Date of tue: Dex, 1082 HONDA MOTOR CO, LTD.Wk)” V65MAGNA Fue syerem CARBURETOR REMOVAL LAIR. CHANGER COVER. Cee TE oa ce peace t See a Teo haat ae wut Femove the right and lft ar chamber coves, ® Remove the bolt attaching the thermottat housing to the air chamber andthe ground cable, € Remove the six serews and the air chamber top Disconnect the breather tubs U V Date of Tous: Den toe] — ~ HONDA MOTOR CO. LTD. 4-3FUEL SYSTEM (.) HONDA V65MAGNA Remove the carburetor choke cama and disconnect thechoke and throttle cable Loosen the carburetor bands and remove the ca. bburetor asembly from the left side nore: ibber mounts to provide coarance for cat Tt may be necessary to loosen the engine ‘mount bolts and move the engine on Its VACUUM CHAMBER REMOVAL Remove the four vacuum chamber cover srews and CAUTION ‘Do not interchange vacuum chamber covers, Disions or jet needles between car. bureore 4-4 THROTTLE CABLES ‘CHOKE CABLE ‘CLAMP Date of lees Dee S HONDA MOTGR CO. LTD.Se € ) HONDA WL) VO5MAGNA FUEL SYSTEM Femove the compresion sorig, diaphragm and scum piston. Inspect the yocsum piston for wear, nhs, seratches or ther damane Nake sure the piston moves up and down freely in the chamber, Note that the No. 1 ard No, 3 carburetors use ‘inner Jet needles and short springs than the No. 2 and No 4 carburetors Push the needie holder in and turn it 60 degrees ‘with an 8 mm socket, Then remove the needle holder, spring and noodle trom the ptton Inspect the needle for excessive wear atthe tip ara for bending, or other damage ‘Check the diaphragm for deterioration and teas COMPRESSION SPRING DIAPHRAGM NEEDLE HOLDER 'VACUUN PISTON DIAPHRAGM \ bd NecbLe SPRING i | NEEDLE HOLDER Dateot nu Dec 1082 HONDA MOTOR CO., LTD, 4-5FUEL SYSTEM (>) HONDA (yb) Ve5MAGNA INSTALLATION Inatallation i estanially the revere of removal Install the chamber cover 10 that its cavity allens with the hole in the diaphragm, Be sure the thinner jet needles and shorter springs sre instatod i the No, 1 and No, earburetor, FLOAT CHAMBER REMOVAL Remove the four float chamber servi and the leat chamber FLOAT LEVEL Megsure the float level with the carburetor inclined 15-45" from vertical and the flost tang just contacting the flat valve, SPECIFICATION: 6.0 mm (0.24 in| nore: Adjust tho float lavel by carefully bending the float ran cavity HOLE FLOAT CHAMBER FLOAT LEVEL GAUGE ‘074012010000 Dats of fee: Dec 1082 ‘HONDA MOTOR CO.,LTD,a /)\ HONDA iL) V65MAGNA FUEL SYSTEM FLOAT AND JETS FLOAT PIN Remove the float pn, Hoet and float va, Inspect the float valve for grooves and nicks, Inspect ihe operation of te float valve € FLOAT VALVE FLOAT VALVE SEAT MAINJET jt, main jet and stow jer. Aerrove the float valve vext and fe STARTER JET SLOWJET Daeot a ©HONDA MOTOR CO.,LTD, 4-7FUEL SYSTEM FILTER VALVE sear Inspect the flat valve seat and filter for grooves, hicks or deposits. ASSEMBLY ‘Assemble the fost chamber components in the reverse order of cisasembly PILOT SCREW REMOVAL NoTE: * The pilot serews are factory prewt ond should not be removed Unless the carbure- ~ ovechauled it serew plugs are factory installed to pravant pilot screw misadjustment. Do not remove the plugs uniss the pilot screws are being removed Coverall epering with tape to Keep metal particles out when the plugs are dried. + Genter punch the pilot screw plug to canter the il pein. Drill through the plug with a & mm (5/92 in) dil bit, being careful not te drill sto the pilot serew. CAUTION: ate ‘Be careful noi 10 dr to the plot screw. AUI pilot serews must be replaced exen if onl ‘one requires it for proper pilot screw adjust- ment (page 416), 4-8 = ‘Dave of faves Da 1982 - © HONDA MOTOR CO,, LTD,(>) HONDA (yL)) V65MAGNA FUEL SYSTEM Force a selt-tapping 4 mm screw (H/C 069309, PIN 93803-35410) into the driled pug ard continue turning the strewdrver unt the plug ‘otatos with the sere, Pull on the serew head with pliors to remove the plug Use compresed alr to clean the pilot srew ares arc ramove metal shevings. CAUTION, ‘Dumage t0 the pilot screw seat will occur if ‘the pilot screw i tightened agains the set. Remove the pilot terews and ingpact them, Re ‘them if they are woen or damaged. Puorscrew INSTALLATION Install the pilot seews and return them to ‘rina position as noted during removal. Perform pilot sorew adjustment if new pilot screws ‘ar installed (page 4-16), nore * De rot inetall new plugs on naw pilot screw holes until after adlustment hasbeen made, * If you replace the pilot screw in one ca bburetor, you must replace the pilot serews in the otrer exburetors for proper pilot screw adjustment Dare of was oc 1007 7 GHonoa woTOR co. Lro, 4-9FUEL SYSTEM CARBURETOR SEPARATION Remove the screws attaching the aie chamber to the carburetors ard seperate the chamber and. carbu Remove the nuts, and remove the choke levers and rods Remove the choke ro, ‘cotter pins and washers, and remove Carefully separate the No, 3 carburetor rom the “sembly. Then separate the No, 4 carburete. CAUTION ipanite the earuretor horizontally to pre rent damage 1 the join pioes. 4-10 (>\HONDA (9k) VOSMAGNA AIR CHAMBER (CHOKE ROO Fuee ‘No. 1 CARBURETOR JOINTPIPE AIR JOINT PIPE No, 2GARBURETOR, ‘No, 4 CARBURETOR SYNCHRONIZATION THRUST No.3 CARBURETOR senINGS SPRINGS = Dateat ue: Dec, 1982 | HONDA MOTOR CO,, LTD.tre te FUEL SYSTEM Disconnect the throtle link from the No, 1 and 2 carburetors by removing te eater pins. THROTTLE LINK ae gra No.2 CARBURETOR Carefully separate the No. 1 and No.2 carburetors CHOKE ARM © SPRING COLLAR FRerave the choke arm collar and remove the choke * fm and spring. Femave the choke valve rut, spring an vate, Dateot aso: Dec, 1090 ‘HONDA MOTOR CO.,LTD.FUEL SYSTEM (> HONDA WL) V65MAGNA Check the choke valve and spring for nicks, grooves, or other damage. CARBURETOR ASSEMBLY Install the choke valve, valve soring and nut and tighten the out. Install the choke arm and spring while haoking the tm to the groove in the choke vale. Inatll the thal arm collar. Coat the new Oring: with oll and install them on the fuel joint plpe for No, 1 and No, 2 carburetors. Install the fuel joint pipe to the No, 1 and No. 2 carburetors CHOKE VALVE SPRING ARM VALVE SPRING COLLAR FUEL JOINT PIPE oRINGs 4-12 ‘Dawn of reas Doe 1082 |B HONDA MOTOR CO.,LTD.@) HONDA _) V65MAGNA FUEL SYSTEM THROTTLE LINK Reconnect the throttie linkage between the Ho. 1 and No.2 earbutetors, using new cater pin, No. 2GARBURETOR COTTER PINS No. 1 CARBURETOR FUEL JOINT PIPE Coat new O-rings with ol and install them on the ‘uel and air aint pipes Put the No. 3 and No, 4 carburetors together with the joint pipes. AIR JOINT PIPES Loosen the syachronization adjusting terows unti {here tno tense, Install the syneanieation spring Install the thrust springs between tha throttle vale shat No.3 SYNCHRONIZATION SPRING. Dareot tun: Oo am SHioNoAWoTOR eo, LTD 4-13(>) HONDA FUEL SYSTEM (SL V65MAGNA No.2 CARBURETOR THRUST SPRING _ No.4 CARBURETOR M the fuel joint and air joint pipes are - securely insted No.2SYNCHRONIZATION. No.§ SYNCHRONIZATION. SPRING SPRING CHOKE RODS AND LEVERS Install the choke rods and lvers, using the nuts and ew cotter ins ‘CHOKE ROD FUNNEL GROMMETS Make sure the aie chamber funnes, grommets and ‘dowel pins are in place. DOWEL PINS @ Tse: Dee, 1087 4-14 HONDA WOTORO, LTD.(>) HONDA WL.) Vo5MAGNA FUEL SYSTEM Place the air chamber over the carburetors allning ‘the dowe! pinewith the carburetor Poe, [Attach the ar chamber to the carburetors with the fight screws Turn the throttle stop screw t0 align the to, 1 ‘hotel valve withthe age ofthe by-pes noe, © No.1 CARBURETOR THROTTLE STOP SCREW No.9 ADJUSTING SCREW * Align ach throttle valve with the by-psts hole edge by turning the synchronizaticn adjusting eer Inspect throttle operation as deseribed below: * Open the throttle sighey by presing the tote linkage. Then release the throte ‘Make sure that & returns smoothly, + Make sure that there i 0 dreg wen opening ‘and closing the thot, Make sure that choke valve operation is smooth by roving the choke linkage Close the choke valve by turing the choke lirkaoe. Release the choke linkage and make sure that i returns smooth. No.2ADJUSTING SCREW No ADJUSTING SCREW Bare ot soe Oe v0.02 o GHONDA MOTOR Co., LTO. 4-15( 3 | HONDA FUEL SYSTEM \,) V65MAGNA CARBURETOR INSTALLATION Inetallation i eeantaly the reverse of emovsl Nore Route the throttle and choke cables properly (poye 1-9 t0 1-12). Pertorm the fllewirg inapctions end adjustments “Throttle aperetion (pepe 2-5) + Carburetor choke (page 36) + Carburetor idle speed (page 3-11) + Carouretor synchronization (page 3-10, PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE (USA. ONLY) NoTE + The pilot screws ae factory preset and ne adjustment is necessary urless the pilot screws af replaced (pape 4-8) + Uce 8 tachomster with graduations of 60 ‘om or smaller tht wil accurately indicate 1150 rpm chang, 1, Turm each pilot serew clockwise until sats lighty_and back it cut to the specification iven, Ths an intial setting priae tothe final pilot screw adjustment INITIAL OPENING: 3 tums out CAUTION: ‘Darage 1 the plot screw seat wil occur If the pilot sere is tightened against the 2. Warm up the engine to operating temperature ‘Stop and go driving for 10 minutes i suficent ‘3 Attach a tachometer according to Its manutae- 4 Adjust the idle spsed with the throtte stop IDLE SPEED: 1,000+ 100 1pm 5. Tum each pilot sevww 1/2 turn out fram the initia! setting. 6. If the engine speed increases by 50 rpm or more, turn och pilot sctew oWt by svectsive ? 172 turns until engine speed rope by BO rpm or THROTTLE STOP SCREW les. 4-16 Dare leas: Doe, 1982 GHONDA MOTOR CO., LTD.HONDA FUEL SYSTEM LU V65MAGNA 1, alt the ie ste wth the ote sop 8. Jurm the No.1 erburtor plot sw in nt the naine speed drops 50 rpm. 9, Turn the Na, 1 carburetor pilot screw 1 turn cut from the position obtained instep &. 10, Adjust the ile speed with the throtle sop 11, Perform steps B, 8 ard 10 for the No.2, Sand 4 carbureter plot srews, 12, Drive new pilot serew plugs into the pil srew bores with » 7 mm valve uide drver(®/N 07042 8230000), When fly seated the plug surfaces ‘willbe recessed t mm into the plot srew bore. FUEL TANK = ‘Do not allow flames or sparks near gasoline Wipe up spied gasoline at once. Check the vent hole of the filler cap for Blackage ‘Check that full is flowing out of the fuel valve Freely, If fuel Tlow is restricted, clean the fuel Make sun that there aren fat lek, AUXILIARY FUEL TANK Drain Yel trom the main and ausiiary tank, Remove the seat, ain fel tank ad side covers Remove the regulator tect Disconnect the battery negative cable, then postive cable and remove the battery. Remove the rear wheel (pape 16-2), we rear fenders And 8, Detach the ausilary fuel tark hose from the fuel ump. Disconnect the fuel level sensor wire termin Remove the auxiliary fuel tank mounting bolt and Inetall the auilary fue tank i the rovers order of removal | PLOT SCREW PLUG AUXILIARY FUEL TANK MOUNTING ALT LEVEL SENSOR REGULATOR/RECTIFIER Dateof aus: Dec, 1082 {CHONDA MOTOR CO., LTO, * 4-17) HONDA FUEL system cy ) V65MAGNA AIR CLEANER CASE/CHAMBER (Chock the air cleaner eat forcatorioration CRANKCASE VENTILATION SYSTEM Chek thatthe breather tube fe nt rrtrited FUEL PUMP Diconnset the fel pure coupler. Remove the fuel ump mounting bolts Disconnect’ the fuel tines from the pump and amove the pump. NOTE: [Before discomecting the ines, turn the fuel valve off and clamp the fusl ines to. | prevent the fuel from flowing out MOUNTING BOLT 4-18 = Birowoa MOTOR CO. LTO.(>) HONDA AL) VosMAGNA FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT (USA only) When the vehicle is to be operated continuous sbove 2,000 m (6,500 feet} the carburetor must be Feadjusied as follows to improve drivetiity and € ecoaes exhaust emision. Warm up the engine to operating tomperatre. Step land go driving for 10 minutos is weir Remove each pilot screw plug (page 48). ‘Tum aach pile screw clockwise 1 tur. Adjust the idle speed to 1,000 ¢ 100 ‘pm with the cae Bee sat sete Sons a sore [ie ciarant oon a HA [i Seana oa ‘Attach «Vehicle Emision Control Information Update label onto the frame as shown. Refer to Service Bulletin 431.132 for information on ebtain ing the abel. Mores __—_ eee Do not atch the label to any part be easily removed from the vehicle. © im iperaton at an ctiude Tower than 1500 m | {8,000 fee) with the carburetor adjusted for Sigh atitudes may cause the engine 10 idle ‘oushly anda When the vebicle is 10 be operated cout ‘ously Detow 1,500 m (5,000 fet), rum exch | lot sere: counterlockwhe I turn 40 tts VERIGLE EMISSION CONTROL ‘riginal position after removing each pilot INFORMATION UPDATE LABEL, Serew plug and adust the idle speed 101,000 £100 rpm Drive new pilot screw plugs into te pilot screw bores (page 4-17). Be tre to + | dete achsments tlw abide SHONDAMcTOR eo, LTO. ° 4-19HONDA ENGINE REMOVAL/INSTALLATION V6SMAGNA 35—45Nn (5-45 kom, 25-33 10) 35-45 Nm (35-45 kom, “v 38-48 Nm (35-45kam, 25-34 trib) 20-30 Nim = (20-0 gn, —> 14-22 rein) 85-106 Ni {85-105kgm, 81-76 feb) 3-70 (457 dtp, Seta) 5-48 hin B54 tom, mane Ae _tzann pane ato lem, Saat, 120K eaon) sum fonstana Sone EN 08-12kom, 5-0 “ Baek ge uoENGINE REMOVAL/ )NSioe 3. INSTALLATION SERVICE INFORMATION 5-1 ENGINE REMOVAL 52 | € ENGINE INSTALLATION 65 SERVICE INFORMATION GENERAL i gsm sta tara tome vats 5 Sincibnene are os computa mr moe tuner gee mae tas + Gites + Alternator + Gearshift linkage + Starter metor + Gylinder heads + Carburetors SPECIFICATIONS Engine dry weight 96.7 kg (213.210) Olt capacity 3.5 tes (37 US.at) TORQUE VALUES Engine hanger bolt ‘8mm bolt 20-30 Nim (2.03.0 kom, 14-22 feb) 10 mm bott 35-45 Nom (354.5 kam, 25-33 feb) ‘Sub-rame bolts Upper 60-70 Nn (6.0-7.0 by, 43-81 fb) Lower 5-15 Nm (35-45 kgm, 25-23 1b) Fear axle rut 5105 Nm (6.5105 kom. 61 Fear axle pinch bot 20-30 Nm (20-3.0 kgm, 1 Final ger cao nut 4570 Nem (457.0 kgm, 33-81 feb) Date af enn Dae, 10RD = HONDA MOTOR CO.,LTD, 5-1ENGINE REMOVAL/INSTALLATION. ENGINE REMOVAL Place the motorcycle on its center stand, Remove the seat and rise the fuel tank, Remove the left and right frame side covers, Drain the engine oil (paye 2-2) and the coolant (age 6.3). Remove the rer whe! (08@ 163), Remove the radiator (poe 8) Remove the carburetor (pee 43), Remove te exaust chamber moun: bet. Aerrove the exhaust muller mount belts and joint Ucn te exhaut por cen bts nd moe Disconrect the wire couples forthe alternator, oi pressure switch and pulte gererator. Remove the wire bande Disconnect the spark plug wires. Remove the bolt attaching the ground cable to the ‘rankcave and disconnect the ground cable. 7 CLAMP CHAMBER JOINT NUTS BOLT MOUNT BOLT OL PRESSURE SWITCH AND. PULSE GENERATOR WIRE COUPLER ALTERNATOR WIREBANDS SPARK PLUG WIRE WIRE COUPLER GOUNDCABLE BOLT 5-2 7 Dave of fess Dee, 1002 © HONDA MOTOR CO., LD,(p) HONDA p/ V6SMAGNA ENGINE REMOVAL/INSTALLATION & STARTER MOTOR CABLE Disconnect the starter motor cable c € STARTER MOTOR, CRANKCASE REAR COVER. Remove the crankease rear cover : € Remove the crankcase rear cover front bracket \— remove the cliteh slave eyinder Nore: Do not operate the clutch lever after removing the clutch save cylinder, To do so will cause |_sitteutty in rnstating the slave ov ‘CRANKCASE REAR COVER FRONT BRACKET Daw of trae: Don 1002 © HONDA MOTOR CO. LTD,) HONDA ENGINE REMOVAL/INSTALLATION / VO5MAGNA Remove the rarshit arm from the shit spindle Loosen tne water pump nose bend, GEARSHIFT ARM GEARSHAFT INDICATOR WITCH WIRE COUPLER. Ditcornect the gearshitt Indicator switeh coupler and eamowe the wire bard, WIRE BAND, BREATHER TUBE Disconnect the crankcase breather tube, Place 8 floor jack or other adlurtable sipportuncer the engine Nore Ne &. The jack height must be continuously adjust- dso that mounting bolts can be removed, nd so stress talleved from other Dots um they are removed 10 the engine routing bolts We the lef subframe Bolts and the eub- ame ove the engine from the left side, LEFT SUB FRAME = ‘Dro haoe Boe, 100 5-4 SHoNoA WOTOR CO, LTO@ )) HONDA V6SMAGNA ENGINE INSTALLATION Check the engine maunt rubbers for damage or wear land replace if necesary Iratall the engine mount rubbers Engine installation is essemally the revere of moral Use floor Jack or other adjustable support to carefully manuever the engine into pce CAUTION: Garefully elign mounting points with the ack] 10 pravent damage to mounting bolt vhesds land wire harness an ea * Route the wires and cables propely (Page 19) + Fill the erankease te the proper lavel with the recommerded ol (Page 2-1). + Fill the cooling sytem (Page 6:2), * Perform the following inspection and ac justnene Throttia operation (Page 2.6). Clutch (Page 3-18), ENGINE REMOVAL/INSTALLATION Dateot aus: One, 1987 HONDA MOTOR CO.,LTD,HONDA V65MAGNA ENGINE REMOVAL/INSTALLATION Install the exhaust system: Install new exhaust pipe joint gakers, ble the lft an ight exhadst pipe, sn the exhaust pipe band loosely and install haus ies. tighten all bolts and nuts, then torque them in the order given below: 1. Tighten the exhaust pine joint nite. TOROUE: 8-14 thm (0.814 kom, 6-10 fib) 2, Tighten the exhaust chamber mounting belt. TORQUE: (08-12 hom, 6-9 felt) 2, Tighten the row muffler hanger sting bolts, ‘TORQUE: 18-26 N: (18-28 gen, 13-20 fb) 44 Tighten the! aust pipe joint band bot, 18-28 Nem (18-28 kgm, 13-20 tb) 5-6 7 Dewar Ton HONDA MOTOR CO. LID,COOLING SYSTEM eS ©@rxener 6. COOLING SYSTEM SERVICE INFORMATION 6-1 THERMOSTAT 64 ‘TROUBLESHOOTING 61 RADIATOR/COOLING FAN 6-6 SYSTEM TESTING 6-2 WATER PUMP 6-10 COOLANT REPLACEMENT 63 SERVICE INFORMATION GENERAL, aaa ‘Do not remove the radiator cap when the engine is hot, The coolant és under pressure and severe scalding could real. ‘The engine must be coo! before servicing the cooling system. © Use only disiied water and ethylene alycot in the cooling sytem, A 50-50 mixture ls recommended for maximums cerro sion protection. Do not use aloohol sed antifreeze ‘© Acd coolant at the reserve tank, Do not remove the radiator cap except to reil or drain the system, Alt cooling system sevice can be made with the engine the fare, '© Avoid siling coolant on painted surfaces ‘© ‘Attar servicing the system, check for leaks with 3 cooling system teste. '® Refer to Section 21 for fan motor thermostatic itch and temperature sent inepections. SPECIFICATIONS Radiator cap reli prestur ‘075106 Kglom? (10,7149 pai) inylene giveok: ~32°C (25°F) 450% ethylene glyeot: ~37°C (34°F) 48% Distilled water + 5B eviylene glycol: —48.5°C (80°F) 20 itor (2.2 US ot Reserve tank 0.45 iets (0.5 US at) Total system 345 lites (3.7 US at | wines Begins to open: 80" to 84°C (178° 1 183° Ff Vale it: Minmmum ef Brmm at 98°C (0.396 in. at 203°F) Unpresuried: 107-7°C (226°F) Capon, pressurized: 1255°C (258"F) Boiling point (with 80~50 mixture) TOOLS Special Cooling system Tester ‘TROUBLESHOOTING Engine temperature too high 1. Faulty temperature gauge or gauge sensor 1. Faulty temperature gauge or gaune sensor 2. Thermostat stuck cloree 2) Thermestat stuck open 23. Faulty aciator exp 4, Inaifiient coolant Coolant lke 5, Passages blocked In radiator, hess, or water jacket 1. Faulty pump mechanical seal 8. Fan bade: bent 2, Deteriorated Orings 7. Faulty fan motor ‘ate of som Ove, 108 7 GHONDA MOTOR C0, LTD. 6-1HONDA } cooLine system i.) V65MAGNA SYSTEM TESTING ANTIFREEZE TESTER COOLANT ‘Test the coolant mieture with an antifreeze reser. For maximum corrosion protection, 2 B0~£0% solution of ethylene glycol and listited water is RESERVE TANK, RADIATOR CAP INSPECTION Pressure wot the radiator cap. Replace the adistor cea if t does not hold oreeure ot felt pressure COOLING SYSTEM TESTER is too high ot too low, It must hols speciied CONMERCIALLY AVAILABLE ‘ressure fora least six second, Nore RADIATOR CAP RELIEF PRESSURE: 0.92 0.15 kgiom’ (1 21 Fai) RADIATOR CAP Pressurize the radiator, engine and hoses and check. tor looks. CAUTION: Excessive presure cin darnage the radiator. Domot exceed 1.05 kg/on' (14.9 Psi) Repair oF replace componants ifthe system will not hold spaced promure for at last se second, 6-2 7 ‘Date of fears Dee, 1082 i. HONDA NOTOR CO, LTD,€ (>) HONDA (WO) VesMAGNA COOLANT REPLACEMENT CAUTION: The engine rust be cool before service the cooling system, or severe scalding may result Remove the raclater cap. Drain the coolant frm the radiator by ‘rain pg located et the lower left ub Drain the coolent from the engine by removing the dain bolts at tha water pump cover and cylinder heads Replace the drain plug and bolts, Fil the system with + 50-60 mixture of distileg ‘and run until there are no air 0 coolant, and the level sablizes, engine anc ad ceotant wp t0 the proper COOLING SYSTEM RADIATOR CAP DRAIN PLUG WATER PUMP COVER DRAIN BOLT DRAIN BOLTS Date of tue One, 1982 HONDA MOTOR CO,, LT, 2 6-3(>) HONDA V65MAGNA COOLING SYSTEM THERMOSTAT RIGHT AR CHAMBER COVER: REMOVAL Remove the coolant drain plug and drain the octane (page 6 3). Feemove the right air chamber cover attaching scr nd the cove. ‘SCREW AIR CHANGER BOLT TEMPERATURE SENSOR Discomect the wiee from the temperature sensor. Remow the bolt that attacnes the trermostat housing tothe air ehambue Loosen the hore bands Feemove the thermostat housing Flemove the thermostat housing cover » Date of tue Ose 1982 6-4 GHONDA WoTOR CO, LTO@) HONDA (Wh) V65MAGNA COOLING SysTEM ~ Remove the thermestat fem the housing, € & INSPECTION Inspect the thermostat visually for damave, Suspend the thermostat in heated water to check its ‘operation, Do rot let the thermostat or thermometer touch the pan or fale readings wil est Feplice thermosta if valve staves open st room ‘temperature, or if it responds at temperatures other than thowe species, Trchnieal Data Start 0 open | 00" wo #61178" 183° F) ‘mm minima (0.3 in) when heated to 95°C (203°F) fer five minutos, + INSTALLATION Insert the thermortat into the housing Install a new Ovrng on the thermostat housing Inetall the thermostat housing covar and tighten the bolts, THERMOSTAT HOUSING THERMOSTAT THERMOSTAT wousinG nine cover Datwof lau Dac, 1989 HONDA MOTOR CO,, LTD,COOLING SYSTEM )))HONDA iL) V65MAGNA Connect the housing to the hover aed tighten the how bend, Seaute the thermostat housing to the air chamber with the bolt attaching the ground wire terminal at the sare time, Connect the temperature sensor wire to the sensor Install the right sir charter cover, Fi the cooling system (page 63), RADIATOR/ COOLING FAN REMOVAL Remove the wat and raise the fuel tank after rake Ing sure thatthe tank sess than halt fl Remove the drain plug and drain the coclant (page 63). LLooten' the riditor ide ‘over stacking batt end ‘nuts and remove the side covers and gil Remove the let steering head cover attaching nut and cover. Dissonnect the fan motor coupler. AIR CHAMBER GROUND WIRE THERMOSTAT HOUSING. TEMPERATURE SENSOR wiae BOLT RADIATOR GRILLE RADIATOR SIDE COVER LEFT STEERING HEAD covER 4 i; NUT FAN MOTOR COUPLER 6-6 a Toa WONDA MOTOR CO. LTD.@) HONDA ‘Si / V65MAGNA COOLING SYSTEM ovenrLow suet Disconnect the overtow tube atthe radiator filer ck Diseanneet the thermortatc switch wires ‘rom the switch Loosen te ower distor how bind ‘LOWER THERMOSTATIC, RADIATORHOSE SWITCH WIRES UPPER RADIATOR HOSE BAND. Locsin the upper raditor how band, Femove the radiator mounting bolt Remove the radiator while pulling the ueper and lower hoses off, RADIATOR MOUNTING BOLTS: + DISASSEMBLY FAN SHROUD (Co Remove the four nuts atsching the fan shroud to the radiator and ramove the shroud. RACIATOR Date ot tess: Ove, 1982 « 6-7 {© HONDA MOTOR CO., LTD.COOLING SYSTEM (PB) HONDA ‘Wis / V65MAGNA Remove the fan attaching rut and pull the fan off ‘he fan mot Remove the strews attaching the fen motor to the tan shroud. RADIATOR INSPECTION Insect the radiator soldered joints ard seams for leaks, Blow dirt out from between core fine with com: resid er. If insect, ee, are cogging the radiate, Seach them off with low prvesire water COOLING FAK. ut FAN MoroR Fan sHROUD screws RADIATOR ‘Dae ol fen Dee 108 HONDA MOTOR CO,, LTD.) HONDA ‘) V65MAGNA COOLING system \ ASSEMBLY COOLING FAN Nur Install the fin motor onto the fan shroud and tighten the thee srews lost the fan ove the mater shat. Aooly« tockig ower to the. la rotor daft Cerreats.ietat ane tonne the pin wens, eck vwaher and nt FAN SHROUD Install the fan shroud onto the radiator and tighten € INSTALLATION ¥ Install the upper and lower hoses onto the radiator. Install the radiator onto the trame and tighten the mounting bot, Connect the uoper and lower hoses and tighten the hose bands, \C onmece the wees to the thermostatic switch Comect the overflow tube tothe filer neck Install the radiator gre and side covers Connect the fan motor counter and install the left steering heed cover. Fille coating sytem (page 63), RADIATOR MOUNTING BOLTS if sue: Dee. 1082 HONDA MOTOR CO., LT0,COOLING SySTEM ()) HONDA. w _) V65MAGNA WATER PUMP MECHANICAL SEAL INSPECTION for tone of mechanical ‘tal coolant leakage. Replace the water pump a: an assembly it the ‘recraniea ea leaking, REMOVAL Remove the dain plug trom the lower let frame and drain the coolent FRemave the drain bolt at thewater pump and dra, the coolant from the cylinders, Femove the geushift arm and left footseg bracket ‘Disconnect the wet. hose from the: water sump, Remove the water pump cover bolts and cover WATER PUMP. TELLTALE HOLE DRAIN BOLT LEFT FOOTPEG BRACKET WATER HOSE GEARSHIFT ARM COVER BOLTS WATER PUMP COVER DRAIN BOLT 6-10 a6 Date of fe: Dae, 1982 ‘HONDA MOTO(>) HONDA @ ) VO65MAGNA Loosen the water hose bands Remove the water pur from the erankease, WATER PUMP INSPECTION O-RING WATER PUMP ASSEMBLY O-RING ‘Check the water pump for machanical sat leakage and bearing deterioraticn Replace the water pump as an assembly if necessary. INSTALLATION Anoly & coat of elran engine ol t0 a raw O:ting ‘and instal it in the water pomp groove ‘Align the waver pump shaft groove with the oil pump shaft and Insert the water pump lato the crankease Data ot rem Dee SHowDA MOTOR CO, LTOCOOLING SYSTEM Connect the water hose to the water pipe and the water pump and tghton tne hose bance Insert the dowel pins into the water pump, and Install a new O-ring Inthe groore of tha water pump Ista the water pump cover and torque the bots O-RING WATER PUMP COVER PUNCH MARKS {neal the let toot peg bracket ‘Algn the punch marks on the gearshift wim and the spindle, an incall the gearihite arm, Insta the crank rear cover. Tighter the dain plug at the let sub-rame, FF the system with # 80-50 mixture of distited tar and ethylene glycol (page 63) LEFT FOOT PEG HOSE BAND GEARSHIFT ARM BRACKET 7 oT sr Dee 1082 6-12 HONDA HOTOR CO, LTO.>) HONDA V65MAGNA CLUTCH 2.25Nm (0.2-0.36 kam, 1.5-25 feib) 10-14 Nem ya 1.01.8 ke, 7-10 fl) aN (04-07 kom, 3-5 feb) (25-35 koe, 18-25 fb) 7-0 = Dae ot tae: Doe_ 10m HONDA MOTORCO, LTD.=a 7. CLUTCH ( ~ | SERVICE INFORMATION 7-2 CLUTCH COVER REMOVAL mH ‘TROUBLESHOOTING 7-3 STARTER, CLUTCH DISASSEMBLY 7-11 CLUTCH FLUID REPLACEMENT/ CLUTCH DISASSEMBLY 713 AIR BLEEDING 7-4 cLurcH AssemeLy 718 | CLUTCH MASTER CYLINDER 7-8 STARTER CLUTCH ASSEMBLY 7-21 | See AVE evLinoeRe 7-8 CLUTCH COVER INSTALLATION 7-23 & c0-s0¥ (6.0-80 kom, 36-49 feb) {80-100 Nim (80-100 kgm, € 58-72 feb) ( & U on 26-20 Nm (26-20k9, 16-22 tub) of Xe So Date of tan Ove, 198 m HONDA MOTOR CO,, LTD. 7-1CLUTCH SERVICE INFORMATION GENERAL “This section covers emova anc inatalaton ol the clutch hydraulic system, clutch are st 1 DOTA brake flud i used for the hydraulic oluteh and ie Yefered to at clutch Mid in the setion. Do not use other types Of fluid as they ave not compatbie, © Clutch maintenance can be done with the engine SPECIFICATIONS. inthe trae | Clutch master eyiinder | Cylinder 1.0. ‘STANDARD SERVICE LIMIT 16.870—16.913 mm (0.5248-0.6265 in) 15.93 mn (0.677 in) Piston OD. 15.827— 16.854 mm (0.6281-0.6242in) 15.80 mm (0.622 i) (Clute save cylinder '38:100-B8.162 mm (1 5000—1.6024 in} £38.18 mm (1.603 in) (38 035-—38.075 mm (1-4975—1 4900 in} "3R.02 ym (1.487 in) ‘Cluteh Outer guide 10, 28,905-30,012 mm (1.1800-1.1816 in) | 30.08 mm (1.184 in) Spring roe height 4.6 mm (0.18 in) 3.8 mm (0.14 in) Ser jdiiennth | 115135 ka/2 my 54258 70.08 in) == ise thiokress| ‘3728.88 rm (0.147-0.189 i) Samm (0.2m) Fiate warp = ‘30 mm (0.012 ‘Sorta cuter [Driven gear O.D, '54.170-54.200 mm (2.1827-2.1338in) | _ $4.18 mm (2.132 nh TORQUE VALUES Clutch nove il boits Clutch fluid reservoir cover Starter eluteh bot {Clutch center fork rut ‘Strtreluten cover Mester cylinder holder bolt TOOLS Speci ‘Snap ring pies ‘07814~3230001 Lock rut wrench ‘07168220000 Common Universal holder (07728-0030000, Driver 9749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 35 mm 1077460040800 7-2 7 Date of tae Dec 1082 - ‘|OHONDA MOTOR CO., LTO. 25-96 Nim (2.5-3.6 kgm, 18-25 Fe) 2-35 Nem (02-0.35 kom, 15-25 fb) 80-100 Nem (8.0—~10.0 kgm, $872 fb) 50-60Nom (5.0-6.0 kgm, 36-43 ftib) 26-30 Nom (2.6-3.0 kgm, 19-22 f-) 10-14 Nom (1,0-1.4 kg, 710 fel)() NSnnene CLUTCH TROUBLESHOOTING (Cuteh lever soft or spongy 4, Air bubbles in hydraulic system 2. Low fuld ive 83. Hydraulic system leaking (Clutch lever too hard 1. Sticking piston(s) 2. Clogged hydroutic system ‘chute i 1. Hydraulic system sticking 2. Dies worn 3. Springs weak Clutch will not disengage 1. Al bubbles in hydraulic system 2. Low Pid eve 3. Hydraulic system leskirg 5 irate system sticking lee warped Motocyels creeps with euteh disse gaged 1. Air bubbles in hydraulic system 2. Low fluid ivel 3. Hydraulic ystem leaking 4 Hydronic syste atid 5. Plnae warsed Excesive lever peessure 1. Hycraulie system sticking 2. Lifter mechanism damaoed (Clutch operation fees rough 1. Outer drum slots rough 2. Sticking paton(s) Date of tue: ee, 1082 ‘SHONDA MOTOR CO,, LTD. 7-3CLUTCH ) HONDA / V65MAGNA CLUTCH FLUID REPLACEMENT / AIR BLEEDING ‘Check the fluid evel with the Mid reservoir parallel ‘CAUTION * Install the diaphragm on the reservoir when operating the clvzh lever. Failure wo do 20 mil allow clutch fluid to aqurt out of he + Avoid soiling fluid on painted surfaces, Place a ray over the fuel tank whenever ‘he syste i sevice, CLUTCH FLUID DRAINING Connect abled hore ta the bleed al, Loosen the slave evinder Bleed vlave and oun the clutch lever ‘Stop operating the fver when no fluid flows out of the bleed vale, CLUTCH FLUID FILLING NOTE: Do not mix diferent types of fuid ance hey may not be compatite, Close the blosd va the diephrage, ‘To prevent plston overtravel snl clutch td se: page, keep © 20 mm (3/4 in) spacer between the handlebar arp and lever whan bleeding the clutch system. Pump up the system pressre withthe lever luni! tere are no air bubbles in the fluid fowing (U1 of the reservoir small hole ant lever revistance it felt, Then bleed the system AN the reserveir, and install BLEED Hose LOWER LEVEL BLEED VALVE 7-4 ‘Date ot tae Bec, 1087 ‘HONDA NOTOR CO, LTD() HONDA WL) VOSMAGNA CLUTCH AIR BLEEDING note: Check the Fuld level often while bleeding the clutch to prevent air from being Dumped tothe system | + Giri 007 brake tue trom ovat Do not mix beake fluid types and never the fluid which hat bean pumped aut during bleeding. or the etficency of clutch system will be impaired. 1) Squeeze the clutch lever, open the bleed valve 12 turn hen clowe ine valve, NoTe Do not relosse the clutch leer unt the bleed ralve has been cloted again, 0 bie. ctr Sa Repeat the sbove steps until bubbles cease to appear in the fluid coring our ofthe bleed valve, + Fill the tuk reservoir to 8 point somewhere bet ‘ween the upper and the lowe lev & BLEEDHOSE BLEED VALVE UPPER LEVEL. LOWER LEVEL Die of haus: Deo, 1982 OHONDA NOTOR CO,, LTD, 7-5CLUTCH fe p) HONDA Q V65MAGNA CLUTCH MASTER CYLINDER DISASSEMBLY Drain clutch fluid from the hydraulic system, Remove the left eae view miror and elute lever Dissonneet the sluteh switch wires and remove thecluteh ho, CAUTION: ‘Avoid sping clutch ud on panel surfaces. ‘Place a rag over ihe fuel tank whenever the lurch system i serviced. Nore: When removing the oll bolt, cover the and of the hots to prevent contamination and secure Remove the master evinder Remove the push rod boot, and cirlip from the master cylinder body, on gour ‘SNAP RING PLIERS fi enero, seco eenmaveeeys one etl vi ple ta SS CYLINDER ae cx 7" [omer curey OC] nsion 3! ye? RD Seal ec WONDA MOTOR CO, LTD.© VSSMAGNA MASTER CYLINDER I.D. INSPECTION Mesure the master eylinder LD. (Check the muster cylinder for scores, seratches crnicks SERVICE LIMIT: 1593 mm (0627 in| MASTER PISTON 0.0. INSPECTION ‘Measure the master piston 0.0. SERVICE LIMIT: 1580 mm (0.622in| (Check the primary ard sscondary cups for damage before aserbiy. ASSEMBLY CAUTION: “Handle the master piston, spring, primary ‘cup and secondary cup asa St. Coat all parts with clan DOT-4 brake fluid before sssombly Insall the spring, primary cup and piston. CAUTION: Whe Installing the cups, do wot allow the ps totum nse cut, Install the cirlip making sure ici seated firmly in the groove, Intl dhe boot ard push rod, Ital the clutch switch, if twas removed, RESERVOIR COVER CLUTCH IAPHRAGM OLDER ‘CLUTCH LEVER pivoT BOLT ie PRIMARY CUP. PISTON ANO C/ SECONDARY CU? ee pusi’R00 | PUSH ROD END PIECE Date of fame: Dec. 1952 ©'HONDAMOTOR CO,, LTO, 7-7CLUTCH (> HONDA. (MLD V65MAGNA Place whe master cylinder on the handleber and inet the holder und the two mounting bolts Aligh the end ofthe holder with the puneh mark on the handlebar Tighten the top bot frst them the bottom bot TORQUE: 10-14 Nan (1.0-1.4 ken, 7—10 ftb) Instat the oll now withthe belt ad its two sealing Install the push rod ond piece into the chiten lee install the utc lever, clutch switeh. wires to. the switeh Fill the reuavoir and bleed the luteh system (ome 7-4), CLUTCH SLAVE CYLINDER DISASSEMBLY Remove the let crankcase rear cover Remove the lat crankese reer cover bracket Place a container under the slve cylinder, emove ‘hel bolt and disconnect the cc hose Nore: ‘Avoid swiling clutch fiuid on painted sur | # _} ernie the steve cylinder CRANKCASE REAR COVER (CRANKCASE REAR COVER BRACKET CLUTCH HOSE PUNCH MARK fe 7-8 Dave offer Dee, 1982 S HONDA MOTOR CO.,LTD.) HONDA @ V65MAGNA CLUTCH Femnove the piston from the eylirder 1H the piston removal iz hard, plece-a shep towel ‘over the piston to cushion the piston when itis ‘expelled, and position the cylinder with the pston owe ‘Apply compressed air to the fluid inlet to remove the piston, Use the air in short spurts Remove the spring rom the save cyinder. Remove the oil and piston sal ci n the piston groove with cluteh fui, ‘Check the piston spring for weakness or darnage. PISTON 0.D. INSPECTION Chock the piston for scaring o sratches, Mesure the outsige ciameter of the piston with a rmicromet ‘SERVICE LIMIT: 38.02 rum (1.497 in) SPRING OWL SEAL PISTON SEAL Datoot sun Dec, 1982 (HONDA MOTOR CO., LTO, 7-9(. ) HONDA “L) VO5MAGNA CLUTCH CYLINDER I.0. INSPECTION Check the slave cylinder for searing ar vratohes, Measure the inside diameter of the eylieder bor. SERVICE LIMIT: 38.18 mm (1.503 in) AsseMaLY SOREL Ayumi he sa cider inthe een oe ot | _/_/PSTONSEAL, i SLAVE CYLINDER BODY disassembly. The oll seals must be replaced with rer ew ores whenever mey nave been removed gaia Wengen says rss | \f AS ey Be certin the piston seal is yeated in the piston groove Siuicone Place the pision in the cylinder with the oil sat | GREASE fn facing Out INSULATOR SLAVECYLINDER CLUTCH HOSE Connect the elutzh hose with the ol bot and the two sealing washer Install the lft erankease rear cover Fill the uter uid reservoir with DOT-4 brake ‘iui, and blaed the cute systom (page 74) CRANKCASE REAR COVER, BRACKET 7-10 va Saree OIL BOLTCLUTCH CLUTCH COVER REMOVAL Drain the engine oi, Remove the brake Deda and ight footpeg, Remove the clutch cover, gaskst and dow pin. BRAKEPEDAL RIGHT FOOTPEG STARTER IDLER GEAR STARTER CLUTCH DISASSEMBLY Remove the starter idler get shat and gear € Remove the ltemator cover. Hold the flywhes! with a univers adder i= = eee ee Dore of esos Dee, 1082 7 HONDA MOTOR Co., LTO. " weCLUTCH (HONDA (WL) V65MAGNA Remove the starter clutch bot. the starter cluteh auembly and spacer. Shift me primary driven subgear wth a screw Griver to take preloed otf the primey driv over and remove the primary drive gear Remove the sarter driven gear ond needle bearing from the starter cute Ingpect the rollers for smoot) operetion. Remove the starter chiteh cover by removing sn tnree bo Remove the slutch rollers, plunger Check the rollers for excessive wear PRINARY DRIVEN SUBGEAR PRINARY ORIVEGEAR, STATER CLUTCH STARTER CLUTCH BOLT rg J 7-12 Date of nun: Dec, 198? HONDA MOTOR CO, LTD.(>) HONDA (yl) V65MAGNA STARTER DRIVEN GEAR INSPECTION Inspect the chiven gear for damene or excsssve Meaiure the driven gesr 0.0, SERVICE LIMIT: 64,16 mm (2132 in) CLUTCH DISASSEMBLY NOTE: ‘Do not operate the clutch lever after removing the clutch. To do 10 will cause ditficuty ning the elute, ‘the snap ina, lifter olate, lifter ude ring and lifter rod, Install the rer Brake peda ‘Shift the transmission into high gear ard apply the ‘ar brake, isnot in the frame, shift the transmiation ‘into. goat snd use the MAIN SHAFT HOLDER, P/N 07973~s290100. to | shat. Remove the lock nut and lock washer Remove the clutch spring set plate, clutch soring and washer CLUTCH SNAP BING LIFTER PLATE LIFTERGUIDE RELEASE BEARING CLUTCH SPRING LOCK NUT WRENCH 79164220000 Dave of tee: Dec, 1982 HONDA MOTOR CO., LTO,HONDA meee: ) V65MAGNA DISCS AND PLATES CLUTCH PRESSURE PLATE Remove the clutch pressure plate y x a Remove clutch center B ans the ore-way clutch 38 aserbly ONE WAY CLUTCH CLUTCH CENTER A WASHER . Remove clutch canter A and water. 7-14 oa SHONOA MOTOR €0. LTO(>) HONDA (SLD VoSMAGNA CLUTCH Remove the clutch outer and outer guide. INSPECTION CLUTCH OUTER, Check the slots in the clu outer for nicks, ets or lndentations made by the friction discs. (Check the clutch outer needle bearing for damage cor excenive pay 11 the needte bearing Is iticult 10 remove trom the teh housing, use the following tools Driver: 07749-0010000 ‘Attachment, 37 x 40.mm: 0746~-0910200 Pilot, 5mm: 07746-0080000 CLUTCH OUTER GUIDE Mesure the .0, of th clutch outer guide SERVICE LIMIT: 30,08 mm (1.184 in] CLUTCH OUTER CLUTCH OUTER GUIDE NEEDLE SEARING Date of aus: Dec 1960 BHONDA MOTOR CO.,LTD, 7-15CLUTCH @ VSSMAGNA CLUTCH SPRING ‘Measure the height of the clutch sein SERVICE LIMIT: 3.6 mm (0.14 in) Replace the spring if its height Is lest than the service iit CLUTCH Disc Replace the clutch discs if they show sings of scor ing oF dissoleraton, Measure the thickness of each SERVICE Lim 3.1 mm (0.12 in) Replace any discs that are thinnar than the wrvion Tie, CLUTCH PLATE Check the pl Teer gauge, SERVICE LIMIT: 0:30. mm (0,012in) warpage on a surface plate, using ‘ a 7-16 18 Date of sue, Dee, 198? HONDA MOTOR CO, LTO,@) HONDA SL) V65MAGNA ONE WAY CLUTCH INSPECTION CLUTCH Inspect the ane way clutch for smooth operation, (Chock the rollers for excessive wear Measure the'.0, of eluteh center 8. ‘SERVICE LIMIT: 74,50 mm (2.993 in) € Measure the 0.0, of the ove way luich inner SERVICE LIMIT: 87.7 mm (2.27 in) xX eof as De vor rr Sona WOTOR eo, L10, 7-17CLUTCH HONDA V6é5MAGNA CLUTCH ASSEMBLY Install the clutch outer quid over the mash. Insall the eee beeing into te clutch cute. ‘Align the holes in the clutch outer with the pins ‘onthe oi! pump drive sprocket and install thecluich ‘ute over the gud, Asal clutch canter A ard the washer Install the onewey duteh into clutch center 8 with its flanged cag facing in ONEWAY CLUTCH CLUTCHCENTER 8 ‘Date of lau. Dec, 198? (©HONDA MOTOR CO, LTO,© /,\HONDA (QL) V65MAGNA Install the clutch Inner into the oneway eluten by turning it elockwise. Instat the oneway clutehlluteh center B assembly NOTE: _ ‘Make sure the one way clutch installed “correctly. by turning canter B, The clu should tum counterclockwise frely ard should not tu dleckewee, {Goat the discs and plates with clean engine ot Inctal the clutch disc and plates shown, CAUTION: ‘Do net pull catch center B ou! aftr stalling | the des and plates or a plate with fall be ‘ween eluch centers A and 5, his will provent the clutch from dlsengagin feof haus: Dec, 1962 HONDA NOOR CO, LTD. 708 CLUTCH CLUTCH INNER 7-19CLUTCH & HONDA X V65MAGNA Install the clutch pressure plat, Install the elute spring set pet, elute spring, and NOTE: Tne a ale Sa Ba Soe ee ‘ Install the lock wether with its OUTSIDE mark facing out Install the lock nut, Place the transmis in Bh ge ‘Apply the brake and tighten the lock nut Nore: ‘When serving the Guteh with the ngine out of the tre, at the minions gat nd hold the eutput sat with the HOLDER 07823-6890101, Washer SET PLATE “LOCK NUT WRENCH CLUTCH PRESSURE PLATE ks eLuTcH CLUTCH SPRING 7-20 ‘Dawe of enue: Dee, 1980 |OHONDA MOTOR CO, LTD,() HONDA is / V6SMAGNA CLUTCH Insta the clutch liter rod Ital the clutch filter plate, lifter quide and bear c & esta the snap ing ‘STARTER CLUTCH ASSEMBLY Pa rey heeft eck SCREWDRIVER ShONOA MOTOR C0. Lo. e 7-21if P) HONDA cLUuTcH Ss) V65MAGNA Intall the thrust washer on the crankshaft, ue WEE intieceaneatet Insta the starter idler goa and shaft — STARTER IDLER GEAR ROLLER PLUNGER lostal the springs, plunges and rollers into the i} starter etch, Intl the ow in Install the starter clutch cover aligning the dowe! ‘in hole with the dowel pin and tighten the bolts, TORQUE: 26-30 Nim (2.620 hom, 19-22 fb) DOWEL PIN CLUTCH COVER STARTER DRIVEN GEAR Iewtall the starter driven gear by wurring i counter \ o clockwise, 7-22 v2 Dateof sue Deo, 1082 HONDA MOTOR CO,, LTO.(Dp) HONDA V6SMAGNA CLUTCH ‘Align the punch marks on the starter cluteh and crankshaft and install the starter cute Hold the fiywhes with a univeral holder and Llahten the starter clutch bolt to the specified torque TORQUE: 80-1008 (8.0-10.0 kgm, 5872 fb) CLUTCH COVER INSTALLATION Install the dowel pine and 3 new gasket, Datoot issu: Dee, 1982 HONDA MOTOR CO.,LTD,/ &) HONDA cuutcH SL’) V65MAGNA CLUTCH COVER Install the right footpeg an rear brake pedal Fill the crankcase with oil (aoe 2:3), BRAKE PEDAL RIGHT FOOTPEG 7 Daal ia Dee RE 7-24 QNONDA NOTOR CO. LTD.>) HONDA GEARSHIFT LINKAGE WL) VOSMAGNA 8-0 16 Dave of lou: Dec, 1982 - HONDA MOTOR CO, LTD,€ (>) HONDA @ V65MAGNA | SERVICE INFORMATION ‘TROUBLESHOOTING GEARSHIFT LINKAGE INSTALLATION | GEARSHIFT LINKAGE REMOVAL a2 SERVICE INFORMATION GENERAL ‘© The geurshitt spindle and stopper arms ean be serviced with the engine inthe frame 1 iF the shitt forts, drum and wanumission require servicing remove the engine and voparate the crankcase TROUBLESHOOTING Hard to site 1. Ale bubbioe in the clutch hydraulic system, 2. Shitt forks bent 3. Shift daw bent | Shift drum cam grooves damaged ‘Tranamissionjumos out of gear 1. Gear dogs worn 2 Shift shaft bent 3. Shift drum stopper broken 1 shift forks bene Dato of eave Dee, 1982 HONDA MOTOR CO., LTD. 77 8-1 8. GEARSHIFT LINKAGEGEARSHIFT LINKAGE (> HONDA (WD VosMAGNA GEARSHIFT LINKAGE REMOVAL Crain me engine ot Remove the left crankease rear cover Remove the left footpeg and gew shift peda Remove the cluteh cover and clutch assembly (ection 7), Remove the oi! pumpdriven sprocket bol. Remove the of pump drive chan, dive and driven sprocket. Remove the ol pump drive sprocket water. 8-2 LEFT CRANKCASE REAR COVER, GEARSHIFT PEDAL OIL PUNP DRIVE CHAIN OIL PUMP DRIVE SPROCKET OILPUMPORIVEN SPROCKET BOLT Te Dave of ese Dee, 1982 HONDA MOTOR CO.,LTD.(>) HONDA ( (LD Ve5MAGNA GEARSHIFT LINKAGE DRUM STOPPER ARM Remove the drum stopper arm nut, arm and spring, Pull the gearstitt spindle assembly out ofthe crank GEARSHIET SPINDLE Aerie the navi separ arm bolt, arm ane oo f Date ot esos Dae, 1982 1 ®HONDA MOTOR C9, LTD.HONDA GEARSHIFT LINKAGE V65MAGNA Remove the shift drum cam plage bolt and cam plate GEARSHIFT LINKAGE INSTALLATION Install the dowel pin in the hole ofthe shite Inger the five pine inthe holes of the car ‘Agn the eam pate hole with the dow shift drum ard! install the am slate Tighten the bolt securely, Insta the washer, seutral stopper arm spring and sem bit. Tighten the am bolt securely 7 Dae of ue De, 882 8-4 SWoHOAMOTOR ED, LTO(>) HONDA L.) VO5MAGNA ‘Assemble the gearshift spindle and return sprig and Install a stow Instat the waster, drum stopper arm, coll, sprig, washer and nut over the arm bok Tighten the nut seeurly Rotate the gearshit spindle and check th linkage for smooth opsration. hate Install the oll pump drive and driven sprockets with dive chain and thten the driven sprocket bolt securly, sprocket washer on the Nore: [The driven sprocket has an “IN mark that must face the ark, Instat the clutch assembly and cover (setion 7), Dawe of tan Dee, 1982 SS HONDA MOTOR CO,, LO, GEARSHIFT LINKAGE J (GEARSHIFT SPINDLE (UM STOPPER ARB 2 | | | | DRIVEN SPROCKET BOLT va 8-5()) HONDA GEARSHIFT LINKAGE ‘i, ) V65MAGNA GEARSHIFTFEDAL PUNCH MARKS Align the punch marks on the gearshift pedal and earshitt spindle and install the gearshift pedal Install the left crankcase rear cover and fill the crankcase with ofl (page 2-3). a ‘Da of Troe: Deo, 108 8-6 HONDA MOTOR CO, LTD.ALTERNATOR HONDA V65MAGNA 9-0 (60-100 kom, 88-72 fib) Date of Wave: Dee, 1002 HONDA NOTOR CO., LTD,ous 9. ALTERNATOR semviee weonueTion on FLYAHEEL REMOVAL ez serhTor HenOVAL os € STATOR INSTALLATION 9-3 FLYORIEEL METALLATION ei SERVICE INFORMATION GENERAL ‘This tection covers removal ard ist 2 of the aternator. (© eter to secion 18 for inspecting an¢ troubleshooting. za TORQUE VALUE ‘Alvarmatorrotor/Fiyw 80-100 Non (8.0-10.0 bpm, 68-72 Fo) a @ ie hae aa EI is sack Tate of saan Dec, 1082 Wz HONDA MOTOR CO., LTD. 9-1(>) HONDA ALTERNATOR ‘SL ) V65MAGNA FLYWHEEL REMOVAL arenwaron coven Place a container under the alternator cover to catch engine ol Remove the alternator cover. Hold the flywheel with a universsl holder and re: more he fywes! bolt ROTOR PULLER a : (0793333200001 (US.A.) or 07733-0020001 Femove the woocrut! key from the crankshaft UNIVERSAL HOLDER 7725-0030000 9-2 1% Date o ae Dae 1982 " GHONDA MOTOR CO, L7D,7 Ineal the ator and wire clamp. @) HONDA \SS/ V65MAGNA ALTERNATOR STATOR REMOVAL ALTERNATOR COUPLER Remove the seat and frame left side cover. Disconnect the alternator coupter and remove the wire bands Weccdsili STATOR WIRE CLAMP Remove the sttor by remoring the bolts and wire camp, STATOR INSTALLATION Route the atemator leads scording tothe diagram in Section 1 and connect te atemator wire coupler to the wire Sheura the sternator leet withthe wire bands Install the seat and frame eft sie cover Dateof aur Dec 1082 rrr HONDA MOTOA CO., LTO./>)\ HONDA (SL) V65MAGNA UNIVERSAL HOLDER FLYWHEEL INSTALLATION 07735 0030000 Install the woedrutf key into the crankshaft. Install the Tlywhesl by aignng ts keyway wih the key in the crarkshott Hold the flywheel with + universal holder and torque the flywhoa bot. ALTERNATOR TORQUE: 80-100 Nm (80-1 0 kgm, $8-72 Fs) Install the CGheck engine ail evel ard ade ol if necenary (page 23), v8 Das of Tue Ovo, 108 9-4 GHoWOA MOTOR CO, LTD.CYLINDER HEAD/VALVE V65MAGNA 126m (08-12 kgm, 6-9 Feb) O, a, OS 10-14 (.0-14 kom, 7-10 fe) : 48-20Nn aN SRO, 2-8 a) — aS, 21-2540 > ahd 2i-238m, 15-18 10) / hs Re 48-52 Nm a 3 (8°82 bpn, 25-28 eb) ~ ‘sy ~2%-— oy vy 20-25 Nm (20-25 kgm, 7-10fe») °% o y % \ 2 18-20 43-52 tm ~ (4.8-5.2 kom, 35-38 feb) 10-0 ba Shonda WOTOR C0, L79,)"ement 10. CYLINDER HEAD/VALVE SERVICE INFORMATION 10-1 VALVE GUIDE REPLACEMENT — 10-13 ‘TROUBLESHOOTING 10-2 VALVE SEAT INSPECTION/ REFACING 10-14 CAMSHAFT REMOVAL 10-3 CYLINDER HEAD ASSEMBLY 10-15 CYLINDER HEAD REMOVAL 10-7 CYLINDER HEAD INSTALLATION 10-16 CYLINDER HEAD DISASSEMBLY 10-9 CAMSHAFT INSTALLATION 10-19 SERVICE INFORMATION GENERAL, {© The cylinder head can be removed with the engine in the frame 1 I the cam sprockets of einer front or rear cylinder are removed, the val Iming ofboth cylinders must be checked during brieatig ol fed through an ol tine. Be sure the hole in the oil line i nat clogged During assenbiy, apply molybdenum disulfide to the edmuhatt holder surfaces to provide inital lubrication, © Theeylinder numbering i given Below: wm SOLU SPECIFICATIONS . ha © ‘STANDARD. SERVICELINIT Compras arse 132 Degen? (184+ 28 pa) = Canshatt | Cambeabe TW | 95335-25.495 mm(1.3911—-13874in) | 363mm (130i) [ex | 35.395-25.406 mm (1.3911—1.3974in) | 353mm _(1.38in) | = (0.10 mim (0.008 in) 005-025 mm (0002-0010 in| | 0.80 mm (0.012 | Oil dearance [eentee | 0.030-0.003 mm —(0.0012-0.0036 in| 0.085 mm (0.0037 inh Beth and] —04090-0.001 mm (0.00%2-0,0036 in) | 0.008 mm (00087 inl asker arm | Raskar arm 1 120000-12.018 mr (0472404791 n)_|_¥208 mm (0474 in She OD. ¥1965-19.084 mm (04711-04718) | 14.09, 10470 in) Vave Vale st 0. TH | 8475-8 400mm (62160-02107 m) | BAT mm (0.215) EX | 8A85-5.470mm _(02148-0.2164in) | BAB mm (0.216) Yaive guide 10, 5500-6.515mm (02165-0.21711m) | 8.85 mm (0219 in) ‘Stemtoguite clearance [IN| 0.010-0.040mm (0.0008-0.0016in) | 0.08 mm (0.00310) | EX | 0.090-0.960mm _(0.0012-0,0026 in) | 0.10 mm (0.004 in) [Wate sem runout - = (0.65 mm (0.002 in) | Valve length IN —(3437in) | 8685 mm (3.407 ind x (3.4190) {86.35 mm_ (3.400 in) Valve sat width (0.087 in) 1.5mm (0.06 in) SHONDA MOTOR CO. L1D. “ 10-1w HONDA CYLINDER HEAD/VALVE V65MAGNA Vaive sora | Free oth Ter | A085 mi (1608 ainn VSD —_wter aa an 1.9800) 43:1 mm (1.706). aaa Tet | exams pen Terenas ‘bina i) (ior 25m) ‘iter | 187=161 WaT. 7 mm (20-9848 | 2037.7 mm ol 1b. ieee! . [evade fea | Worpae = (0.05 mm (.002in1 TORQUE VALUES Cylinder head cover ‘Camshaft holder (6 mm) ‘Cam chain guide A Glinor head (20 me) line head (8 me) Focker arm shalt ‘Cam sprocket Tools Speciat Valve guide Valve gui Valve guide driver attachment TROUBLESHOOTING B12 Nm (08-1 29m, 6-9 ft) 10-14 Nom (1.0-1.4 kgm, 7—10 feb) 20-25 Nom (2.0-2.5 kgm, 14-1819) 48 52N-m (48-52 kgm, 96-28 fei) 21-25Nem (21-28 kom. 18-18 tt) 45-50 Nom (4.5-5.0 kgm, 33-38 f1b} Apply LOCTITE® to the threads 18-20 Nom (1.8-2.0 kgm, 13-14 ft) 197904~2000000 ‘070422200100 (07843-maaon0 Y (07787-0010000 Engine top-nd problems usually affect engine performance. These can be diagnosed by a compression test oF by tracing noises witha sounding rod or stethoscope. Low compression 1 Valver ~ Incorrect valve adjustment = Burned oF bent valves = Incorrect waive tening ~ Broken valve spring, 2. Cylinder head = Leaking or damayed head gusket = Warped or racked cylinder neat 3. Cylinder and piston (Refer to Section 12) ‘Compression too high 1. Excosive eatbon buildup on piston or ‘cembution chamber Excesive noize 1 Incorect valve adjustment 2. Sticking valve or broken valve eoring 3, Damaged or wom camshaft = 4 Loose or worn cam chain ', Worn or damaged cam chain tensioner 6, Warn cam sprocket teeth 7. Worn rocker arm and/or shaft 10-2 13 ‘Date of eae: Deo, 1952 HONDA MOTOR CO., LTD,» HONDA / V65MAGNA CYLINDER HEAD/VALVE CAMSHAFT REMOVAL Drain the coolant (99ge 63) and engine oil from the front eylinder head by removing the bolts and wathers Remove the radiator (pave 66) Remove the cylinder eae cover from the front evlind head Remove the cvlinder head cover and cover bate from the rear cylinder head, Remove the oll pipe and eam chein guide mounting bits and remove the cam chain gude. Rlemove the alternator cover and rotate the erank shalt clockwise unti the cam chain hae free pay. Remove the cil pipe while paling up an the middle ‘of the chain, Remove the exhaust pips (ection 8), Remove the earbureto (ection 4), Remove the engine mounting bolton rear eylinder head HONDA MOTOR CO., LTO, O1L DRAIN BOLT FRONTCYLINDER (COOLANT DRAIN BOLTS CYLINDER HEAD COVERS FRONTCYLINOER REAR HEAD COVER CYLINDER BASE CAM CHAIN GUIDECYLINDER HEAD/VALVE (>) HONDA sk) VO5MAGNA ‘Tum the crankshaft clockwise unt the 71.3 mark signs withthe rear crankease mating surtaces, Place rans or shon towels over the rear eylindar hese to prevent parts from being dropped into the eank: Femove the intake and exhaust cam sprocket bolt ‘Turn the crankshaft clockwive one turn (280°) and ‘Famove the other cam sprockt bolts Slide the com sprockets with the cam chain off the camshaft sprocket flanges Ferrove the car chain from the sprockets ard remove the camshaft holders. Mark the camsha't holders so thet they can be veinstalud in ther origina location. TAKE CAM SPROCKET TISMARK MATING SURFACE EXHAUST CAM SPROCKET CAMSHAFT HOLDERS CAM CHAIN ‘CAMSHAFT HOLDERS, 10-4 1 ot sve: Daw, 1082 HONDA MOTOR CO.,LTD,() HONDA (Mi) V65MAGNA CYLINDER HEAD/VALVE INTAKE CAMSHAFT DOWEL PINS. emave the cimshatt holder dowel pins and the ke and exhaust carshats Remowe the cam sprockets from the camshaft c ® [EXHAUST CAMSHAFT ‘CAMSHAFT HOLDER CAMSHAFT/CAM HOLDER ; INSPECTION Inspect the camshaft and holder journal surfaces for scoring scratches, or evidence of insufficient Ubrication, € CAMSHAFT RUNOUT \ check camshatt runout with a dial indicator Support both ange of the camshaft with V-biocks SERVICE LIMIT: 0.10 mm (0.004 in) BHiotoswaTOR co. Lro, “ 10-5CYLINDER HEAD/VALVE HONDA V65MAGNA CAM INSPECTION Using a micrometer, mesture cath cam lobe. SERVICE LIMITS: IN, EX: 35.3 mm (1.39 in) Check for wear er demage Wipe any oll from the journals Lay 4 trip of platiguuge lengthwie on top of each carahatt jourral Install the camshaft holders and. tghien ina NOTE Do not rotate he camehaft when plastgavge TORQUE: ‘A: mm BOLT: 10-14 Nem (1.0-1.4 kgm, 7-10 Fb) 8: Simm BOLT: 21-25 Nn (2.1235 kgm, 15-18 fetb) 10mm BOLT: 48-52 Nim (48-52 kom, 35-18 ft 10-6 ‘Dave of faser Dee, 1982 SHONDA MOTOR CO, LTD,“-)) HONDA ./ V65MAGNA Remove the comhatt holders and measure the width of each plastigupe. The west thickness ) HONDA ( (VL VeSMAGNA CYLINDER HEAD/VALVE ‘VALVE GUIDE DRIVER VALVE GUIDE REPLACEMENT o7942-3280100 Heat the cylinder head to 100°C (212°F) with a tot plate oF ov CAUTION: + Do mot wie a torch to heat the opine, itmay cause warping. + To avoid burns. wear heavy gloves when handling the heated eyinder hea. Support the eylieder head and deve out the old ‘uides from the combustion chamber sice of the VALVE GUIDE DRIVER 07942-3230100 Drive new guides in from the rocker sim side of the evlier head VALVE GUIDE DRIVER ATTACHMENT o7943-MB40000 VALVE GUIDE REAMER 1079842000000 Let the eylinder head cool to room temperature ‘and ream the new valve ques NOTE: * Use cutting cil on the reamer during the + Rotate the roamer in the same direction whan inserting ard removing it Feface the valve seat (page 10-14} and clean the fylinder ead thoroughly. to remove any metal parte HONoA MOTOR C0. LT. ie 10-13CYLINDER HEAD/VALVE VALVE SEAT INSPECTION / REFACING Clean all intake and exhaust values thoroughly 10 ramove carbon deporit ‘Apply a light coating of valve lapping compound to each valve face. Lap each valve and seat using {rubber hose or other hand lapping too NOTE: ‘Take care nat to allow the compound to enter between the valve stem and guide, After lop: ping, wash cut the compound completely ‘and apply a coat of engine oil to the valve face and Fmove the valve and inspect the face CAUTION: The valves conrot be ground. If the wlve {ace is rough, wor unevenly, or contacts the Scat improper, the valve must be replaced. nageet the valve sear 1f the seat i 100 wide, t00 narrow. oF haslow spots, the seat must be ground, SEAT WITH: 099-1,27 mn (0:039-0.080 in) SERVICE LMT. NOTE: 1.5 mm (0.06 in) Folow the vefacer manufacturers operating ‘After cutting the seat, apply lapping compound to the valve face, and lap the vale using taht ‘Aer lapping, wash any residuat compound off the cylinder head and vave IM: CUTTER [30mm¢) 1M, €X: CUTTER (20 mg) IN: CUTTER (29 mmo) EX: CUTTER (25mm) ‘OLD SEAT WIDTH Y EX: CUTTER (24.5 mm) os8-127 9m “ (0.938-0.080 in) OLD SEAT WITH 10-14 v Date of Tue Dee, 1087 HONDA MOTOR CO,, LTD.V65MAGNA CYLINDER HEAD/VALVE CYLINDER HEAD ASSEMBLY VALVESTEM SEAL RETAINER, disulfide grease and inert the val into the vale fide, To woid damage to the stem seal turn the talve slowly when inserting. it us VALVE COTTERS: Instat te vave cotter. CAUTION: * To prevent Tox of tention, da war Gorm ress the ya spring more than necessary ‘oinsal the vale keepers. * Position the large retainer on the compres sor attachment, 40 the compressor wil rt “Tap the voive stems gently with soft hammer to firmly sat the coters Note: ‘Support the cylinder head bene surface to prevent pos amuse. Shonda oro cO. Lro, a 10-15HONDA CYLINDER HEAD/VALVE V65MAGNA ROCKER ARM SHAFT aoLT Install the O-ring and spring onto the rocket sem shat ‘Apply LOCKTITE® to the rocker arm bolt tires, ‘Aoply engine oll tothe rocker arm shatt and install ‘the rocker arm Install anc tigiten the rocker arm shaft bot TORQUE: 45-50 Nm (4.5-5.0 kom, 33-36 feb) SPRING — ORING CYLINDER HEAD INSTALLATION CClean the cylinder head surface of any gasket aerial GASKET Inetal the dowel pine and new head gstket Install the rear cylinder cum chain guide DOWEL PINS 10-16 i Sona moTOa Co. L,CYLINDER HEAD/VALVE Ital the cylinder head and temporarily install the cylinder Mead Dott eylinder head batt at hie With the cam chain tensioner ri of the arrow, inst pin or piace of wi theo inthe tensioner hase ard tensioner. Pst the cam chain through the ca chain tensionoe and install the tensioner slipper as shown. Nore: |” Check that the lower end of the Wipper fits Fn the sipper tase correcty, CYLINDER HEAD BOLTS TENSIONER BASE HOLE TENSIONER TENSIONER BASE TENSIONER SLIPPER CLIP Date of te Dee, 1982 HONDA MOTOR CO.,LTD, = 10-17CYLINDER HEAD/VALVE Install the exterior ol pipe with washers onto the {eylinde and cylinger nea. Install the water pipes ana howe and tighten the howe bands securely, WATER HOSE 10-18 198 ‘Date of lave: Dec, 1082 ©HONDA MOTOR CO., LTD,)\ HONDA ub) V65MAGNA CYLINDER HEAD/VALVE CAMSHAFT INSTALLATION MARKS nore: * Follow this procedure from baying snd, even if you are only servicing one cylinder hes + Ohedk the camshaft marks so that you install each carnshatt in its correct location, “The ma ‘on the earitatt mean EX AR (ER): Row eviindor chaust IN AR (IR): Rear oylinder iniake EX FR (EF): Front cylinder exhaust |W FR (IF): Fronteytinder intake “The camshaft sprockets are interehange- oe ae a! Rear Cylinder Head Lubricate the cylinder head cam bearing surfaces with molybdenum diate pres ‘Tum the crankshaft clockwise until the 71-9 mark fon the flywheel rotor aban with tha mar crankeate mating surfscs CAUTION: When turning the crankihafi, make sure the ‘cam chains don't jam at the com chal ten- loners or at the crankshaft REAR CRANKCASE MATING SURFACE SHonoA MavOR €0. UTD. “e 10-19HONDA V65MAGNA CYLINDER HEAD/VALVE =/ Install the intake and exhaust camshett and spro: kets through the ear cyinder cam chan a shown, NOTE: 1 the front eylinder camabetts were not re moved, check that the font camshaft marks face up. If not, turn te srarkshart clockwise 380 degrees (one turn IY valve clearance adjuster keeps. tie camshaft ‘tom seating fully in the cylinder head, back the cjuster our all the way, CAUTION: _ If you force a vahe open while installing the ‘cumihafthokiers, you may damage the onnuerementr holders or the camshaft bearing surfaces lace the eamehalt holders in the same locations CAMSHAFT HOLDERS noted during removal. The groove in the bottom Of the holder must align with the camenaft locating ridge ‘CAMSHAFT HOLDERS Install the camshelt holder bots, but do net tignten ther yet v0 Dav of fnw: Dee 10-20 SHONOAMOTOR €0, LTD.S / HONDA yk) V65MAGNA CYLINDER HEAD/VALVE 11 the oylinders were not removed, lock the cam chain teasoner for minimum tension: push the look plate down while pulling or prying the tension arm ip: hold the arm em while you incerta pin oF wire ‘hough thelock holes. Check that the camshaft marks are stil facing uD, ‘hen align he sprocket index fines with the top of the rear eylindey head. Pace the cam ehsin on the rocker. Sige the sprockets onto the camshaft flanges, ard Install the sprocket bite in the exposed hole Check tat the sprocket index lines align at T1-3 Unlock the eam chain tensioner PULL.UP nN LOCK PLATE CANSHAET MARKS INDEX LINES Date of awe: Dee, 1952 HONDA MOTOR CO, LTD, " 10-21\ HONDA CYLINDER HEAD/VALVE / V65MAGNA Front Cylinder Head Nore: Install the rear cylinder head camshafts before You instal the front camiats | Lubricate the cylinder head cam bearing surfaces with molybdenum disulfide grease Rotate the crankshatt counterclockwise 90 degrees (1/4 turn), until the T24 mark aligns with the ear rankeata sting wi aces, CAUTION ee When suming the erankihajt, make wure the am chain doesn’t fam atthe cam chain tensioner or at the crankshaft. Install the Intake and exhaust camshafts and soro- kets, through the front cylinder cam chain 35 sown, Turn the earmuhalts co the camnatt marks fc wp. Rotate each front camshatt counterclockwise 45 degrees (1/8 tum) to seat the cam fully in the Pliner head If 2 valve adjuster keops the camshaft from seating fully In the cylinder head, back out the adjuster all lostall_the flont cylinder camshaft holders and ‘bolts, at described forthe rear cylinder head Do not tignten at this time Lock the cam chsin erxoner for minimum tenslon, ‘EXHAUST CANSHAFT 10-22 © SHOWA MOTOR CO, Lro,HONDA V65MAGNA CYLINDER HEAD/VALVE INDEX DOTS Align. the index dow on the front cylinder cam ‘sprockets with the top of the eylinger head (viewed from the let se of the engine), Pace the car chaby onthe spr, Site the sorackes onto the camstatt anges, nd instal the sprocket Dolts in the expomd holes (rote the crankahelt clockwise «litle If oecte Front/Rear Cylinders Check the frontio-ear cylinder carmshatt timing Nove: __ * When the TH mark aligns with the rer crankcase rratiog uric, the index tres on al cam rockets should gn with se top of thn einer Neate. +All eaminat marks wil sither fice up oF é a Abi Turn the cramkshatt 1 required to iostall the renaininggoracket belts a ll fur eamehalts, Tighten the eamshaft sprocket bolts to the specified rorque TORQUE: 18-20Nm (18 Okgm, 13-14 1H) ‘Tightun the tensor iw bolts wey, "TENSIONER BASE HONDA MGTOR eb. L70. = 10-23(>) HONDA CYLINDER HEAD/VALVE \ V65MAGNA CAM CHAIN GUIDE Turn the crankshaft util there Is maximum cam chan fee play, tren inal the of pipes under the cam chain, Install the cam chain guide on the oll pipe base Tighten the evlinder hesd 10 mm bite in + ere ros pattern in 2-3 steps, TORQUE: 48-52 Non (4.8-5.2 kom, 35-28 ftib) Tighten the cylinder head 8 mm belts in acrisecross patie in 22 steps TORQUE: 21-25 Nim (2. 2.8 kgm, 19-18 1b) Tighten the cam shaft holder 6 mm bots TORQUE: 10-14 Nom (1.0-1.4 kom, 10 fet) Lubricate tho cam lobes with oi ARROW CASTING [Adjust the valve dearance (page 3) Inspect the eylinder head cover gsket for damage or deterioration, nore: Clean the guiket before eppiying sealant, Apply salant of the head cover gasket, Install the front eylinder head cover and gaske. Festal er head cover bas, cove gashots, Be sure that the arco casting on Uh head cover faces the front af the engine Intall the remsining parts in the reverse order of HEAD COVER BASE REAR HEAD COVER 10-24 = BWONA MOTOR C0. LTD,CRANKCASEHONDA WL) V6sMAGNA 11. CRANKCASE SERVICE INFORMATION nA CRANKCASE DISASSEMBLY 2 € CRANKCASE ASSENBLY 1-3 SERVICE INFORMATION @ cenerar '* Toservice the piston, rankshatt, connecting rod and transmission, the crankcase halves must be separated, ‘© frre crankcave is installed, perform eountorhaft shim selection procedures (Page 1317), 12 The fllowing parte mint be removed before diaasembling the rarkease. : eter to action 2 Retr to section 2 + Water pump Rete to section 6 + Chutehstartercltch Refer to aeetion 7 © Gear shift tinkage Feler to section 8 + Alternator Reter to section & + Cylinder heads + Starter motor TORQUE VALUES 10 mm bolt 8mm bolt: 5mm belt TooLs ‘Special Driver © Benen Refer to section 10 Refer to section 21 43-47 Nom (4.3-4.3 komm, 31-24 feb} 21-25 Nim (21-215 kgm, 15-18 tb) 10-14 Nom (1.01.4 kG, 7—10 f) (07049-3710000 07946-3710200 Date of fieue Dee, 1982 HONDA MOTOR CO., LTO, 187 11-1)))HONDA CRANKCASE ‘i / V65MAGNA CRANKCASE DISASSEMBLY Remove the upper erarkcate bolts. Rafer to service Information General (page 11-1) for removal of necessary parts before dsasterbiling Cakes Remove the manshatt besting hekder by removing the sew and bots Remove the ousput gear ease mounting bolts and ‘Measure the thickress of the output gear case ‘giket and note it Nore: Remove the granhift indicator switch SIDE GEAR CASE TTT tiger a 08 11-2 ° SHONOA NOTOR CO, LTO& )) HONDA XC) V65MAGNA “Turn the engine over and remove the lower crank nore: Remove the bolts in hwo or move spr and in a crisiress pattrn to provent damage to the crankeas, Separate the crankease. Remove the follcwing pers ton and eannacting 1ode(Steton 12). ankshaft (Section 12 Shift fork and shift drum (Section 13). ‘© Tranwmission (Section 13) CRANKCASE ASSEMBLY ~ Drive the countershatt bearing into the crankcase CRANKCASE ‘COUNTERSHAFT BEARING ‘ATTACHMENT (979463710200 Riven’ / (07949-37100 Date ot teur Dee, 1982 [HONDA NOTOR CO., LTO, 11-3CRANKCASE (> HONDA ‘SG ) V65MAGNA Asta th following pars: 2" 'Shitt fork and shit drum (Section 13) ‘© Transmission (Section 13) © Cronkanatt (Section 12). # Piston and connecting rods Section 12. ‘Agply molybdenum dsutide grease to the shift Fork grooves of the M2, CB and CB gears. ce GEAR 11-4 of four: Dec, 1982 ®HONDA MOTOR CO, LTO,HONDA V65MAGNA CRANKCASE Clean the crankcaxe mating surfaces, Apt liquid seblant to the mating surface of the CAUTION: ‘Do not apply sealant to the area near the | | ‘ain bearings ‘AREA EST Ne, Install the dowel pin Assemble the crankcase halves, aligning the shift fork claws witn the gears the bots to the spiced torque val the sequence shown, TORQUE VALVES: 10 1rum bolt: 43—47 Nm (43-4. kom, 31-24 Fe) ‘8 mm bolt: 21-25 Nm (21-25 kom, 15-1040) rom bolt: 10-14 Nem (1.0-1.4 kgm, 7—10 fb} Tighten the ats in « enssooss pattern and in 2-3 BHONOAMOTOR CO. LTD. “ 11-5CRANKCASE HONDA | V65MAGNA ‘Tignten the upper crankcase bolts to the specified torgue in a erasers pattern and in 2-3 steps TORQUE: 8mm: 21-25 nim (21-25 kgm, 15-18 fe) Simm: 10-14 Nm (1.0-14 kpm, ‘e) {natal the goorah ft indenter ewite Insta he mainshatt bearing holder and tighten the serew and bolt Install «new output gear case gasket with one of ‘the eam thickness a: removed. NOTE: Early production engines had gaskets thet were nat marke + The gasket is crushes 0.08 mm when the | _ output sear case sinsale, Install the output gear ease with a new gasket Install the bolts and then tighten to the specified ‘ToRQues: 18 mm socket bolts: 21-25 Nim (21-25 kgm, 14-18 1b) 6 mmBOLT ‘Smm BOLT MAINSHAET BEARINGHOLDER one s ‘Bmm FLANGE BOLTS 8 mmm SOCKET BOLTS. 11-6 ‘Dain of tues Doe, 108 (HONDA MOTOR CO, LTO.(>) HONDA CRANKSHAFT/PISTON (WL) V65MAGNA Yo oe S., 30-34 (aD-2.4 kgm, 22-25 Fe) deme FRONT 12-0 = Sonos woroR c0, Lo.€ € XQ yowpe 19 CRANKSHAFT /PISTON SERVICE INFORMATION 12-1 BEARING INSPECTION 12-8 ‘TROUBLESHOOTING 12-2 BEARING SELECTION 12-10 CONNECTING ROD REMOVAL 12-8 CRANKSHAFT INSTALLATION = 12-12 PISTON REMOVAL 12-4 PISTON AND ROD INSTALLATION 12—12 CRANKSHAFT REMOVAL 12-7 SERVICE INFORMATION GENERAL '¢ All bearing inert are sleet it aac identified by color code, Select replacement bearings from te code tables, After installing ew bearings, recheck tiem with plasigauge to verify Cearance ‘© Appiy molyidenum dleulide grease to the main journals and crankpins during assembly, 1 Before removing the piston and connecting rod azzemblies, clean the top ofthe cylinder of any carbon deposit. © Forenicing the piston, connecting rod-ané erankahalt, the crankcase azambly must be capaatad (Section 11), SPECIFICATIONS i STANDARD Senvice uw Terankahatt [Connecting rod bg end de cearance | G10-090mm (0004-0012) [DA mm (016i) Runout = 0.03 mm (0.001 in) Crnisin olden {.028-0.052 mm _(00011-0,0020 | 0.07 mm (0003 in [Mas joural oil carne €.028-0.052 mm (0007109020 | 0.07 mm (0003 i Cxtnder [0 7800-7015 mn .1208-2.1905 i) | 79,60 mm (138m) Wore (002m) Pinon | Ringteesoe [Tos —*| 0016 -0.005 mm (00008-00078) (004i nan ‘Second 0,015-0,045 mm —_(0.0006-0.0018 in} (0.004 in) [id To | 020-038 nm (0.000-0.014 (002) ‘Sacond mr [oi tSie wi [620-070mm 10.008-0.028 n) | 08mm — (0038in Pinon OD 3.60-78400 mn (1289-31209 i) | 79. mm (3 128 Piston-to-cylinder clearance 0.01-O055 mm —(0.004-0.002 im) [0.10 mm (0.006 in) [Fis sin bore 20:002-20.008 nen (0.7875-0.7877 i) | 20.06 mm (0780 in) Piston in 0.0. | 19.864~20.000 mm (0.7872-0.7874 in) | 19.98 mm (0787 in| [rstontosiatn in dew {1002-00014 mm —(0.001-0.0005 in) | 0.04 mm (0002 in [Connecting rod wal end 1. 20.016-20.034 me (0.7800-07887 in) | 2008 mm (0791 in sion pinto comactingrod ckarance | 016-0.040 mm —(.0006- 00016 i) [0.030 mm 100024 Gan hain [Length akg BO 8) rion | SE. O6-9ED 40 wom 14280-14260) [264 0%mm_(167 i] TORQUE: Crank: 30-34 Nam (8.0-3.4 kei, 22-28 feb) TOOL Special Piston Ring Compressor ‘Commercially available compressor (Automotive syle) ——————— eee ShtoubamaToR co. LTO “ 12-13) ) HONDA (yb) V65MAGNA €é CRANKSHAFT/PISTON TROUBLESHOOTING Excesive noe 1. Crankshaft Worn rain pesring © Wom rod bearing 2, Piston and Connecting Rod 18 "Wor piston or eyinder ‘© Wom pston piv or pia note {© Wom rod smal ond Low compression or uneven compression 1, Worn evliner o aston ting Exceasve emokee 1. Worn cylinder, piston or piston tinge 2. Improperly installed piston rings 3. Damage piston or cylinder ‘Overheating 1. Excessive carbon build-up on piton head 2. Blocked of resicred flow of costant 43, Sticking rermostat Knocking oF sbnormal noise 1, Wom pistons and evlinders 21 Excessive carbon build-up on piston head 12-2 ve BhONDA MOTOR €0. LTD.) HONDA (yf?) ‘cs / V65MAGNA CRANKSHAFT /PISTON CONNECTING ROD REMOVAL Seperate the eronkente aiembly (Gection 11) Check the connecting rod side clearance, (C__ seRVICE LimrT 0.40 mm (0.016 in} a Remove the connecting rod beim caps and note ‘heir locations € Push the connecting rods and pistons out through the top of the eylnder bares, caumion _ On cranes wih Nh linge ape Whe ise fre rigs ar cove eee nite | Sint of te trae. Any ge mast e re ove wit en aomotbe (Pere reaner | before removing the pions 10 alow the Patvar ced ries posers th he Dave of rues Oe, 1987 7 HONDA MOTOR CO, LTO. 12-3CRANKSHAFT/PISTON Mark the rocs, lstons, bearings and cans 2s you the correct eylinder and PISTON REMOV, Remove the siston pin cls, Push the piston pin foutand remove the piston Mask the piston pins 10 indicate their correct piston orion. PISTON/PISTON RING INSPECTION Meesure the piston ring to-gr00w clearance, SERVICE LIMIT: 0.10 mm (0.004 in) (ToP/eCOND) Remove the piston rings and mark them to.indleate the correct eylinder and piston postion Clean the piston crown, moving all earben de- Inspect the piston for cacks or other damage and the ring grooves for excesive wear and carbon buildup, PISTON PIN CLIP 12-4 ‘Dawe of ese Doc, 1982 HONDA MOTOR €O,, LTD,CRANKSHAFT/PISTON Using s piston, push the ting into. the cylinder squarely and measure the end gap. SERVICE LIMITS: oe smn 0.02%) Weer... eerie € ha SS Meanure the piston 0.9, note: “Take measurements 10 mn (0.4 in) from the | ‘bottom, and 90" tothe piston pin Role. @ iets resect Insesct the cylinder bores for wear or damage Measure the cylinder LD. at thre levels in X and ¥ wie SERVICE LIMIT: 78.60 mm (3.134 in) Celeulae the pleten-t-evliner clearance SERVICE LIMIT: 0,10 mm (0.004 in) = oversize pistons are a the folowing sizes 0.25, 050,0.75 and 1.0mm. Date of true 2 HONDA MOTOR CO,, LTD,@ HONDA CRANKSHAFT/PISTON \Nis/ VOSMAGNA Measure each piston ain hole 1.0. SERVICE LIMIT: 20.06 mm (0.780 in) ‘Measure eich piston pin 0.0. SERVICE LIMIT: 19.98 mm (0.787 in) Ceautte he piston pint itn cern, SERVICE LNT: 0.04 mm (0.0029 Laeel Messure the connecting rod small end 1D. 1f the eating exceeds the sorvice mit, replace the rod. SERVICE LIMIT: 20.08 mm (0.791 in) 12-6 “ Biouos oton co. 70.()) HONDA we) V6SMAGNA CRANKSHAFT/PISTON CRANKSHAFT REMOVAL mean eveIoe cmANKSHAFT Remove the erankshat Femove the cam chai, CAM CHAIN (FRONT CYLINDER) CRANKSHAFT INSPECTION ‘Set the crankshaft on a stand ar Vee blocks Set a Gil indicator on the center main bearieg Journal. Rotate the crankshaft twa revolutions snd tad the runout ‘SERVICE LIMIT: 0,03 mm (0.001 in} CAM CHAIN LENGTH MEASUREMENT Pace the cam chain on the campatt sprockets with the punch marks postioned as indicated Shcure one camshaft sprocket and apply 12 ko {28 Ins) af tension to the other, Then measure the distance between the punch marks as shown, SERVICE LIMIT: 364.9 mm (1437 in) Note ‘The punch marke should be parlll bo wach 4, other Replace the cary chainif it is longer than the service SMonoawaTon eo. Lr ” 12-7CRANKSHAFT/PISTON BEARING INSPECTION CONNECTING RODS Insooct the bearing inserts for éamage or reparation, Clan all oll fram the beating inserts and erankpins. ut 0 piace of pletigaure on euch crankpin avoling CAUTION The bearing tabs should face toward the exhaust ports. Remember the froxt and rear eylinder exhaust ports face opposite direc tions Insta the beating caps and rods on the corect crankpins, and tighten them evenly TORQUE; 30-34 Nem (3.0-34 kgm, 22:25 fe) NOTE: [Do nat rotate the crankaheit Guving inmpec [ton "| Remove the caps and meauire the compressed Dlastigauge on each crankpin. Ol, CLEARANCE SERVICE LIMIT: (0.07 mm (0.003 in) (>) HONDA ‘Ss / V65MAGNA PLASTIGAUGE 12-8(P) HONDA \is / V6SMAGNA CRANKSHAFT/PISTON MAIN BEARINGS Inspect the bearing insets for damage oF separation. ‘Glenn al) oi! tram the bearing inserts and journals Put» piece of plastiguge on each Journal, woding the oil hoes, Install the main bearings o” the correct journal's ‘nthe lower cranketse anc tighten ther evenly (2-3 steps in te sequence sown TORQUE VALUES: Simm bolt: 1014 Nm (10-14 Kg, Sm bolt: 21-25 Nm (21-25kom, 15-18 feb) Wine bolt: 43-47 New (434.7 kom, 31-34 fe /—10 fu) note: [ Do for Toute te Grnkahalt during Inepes Remove the lower crankcase and measure the com: pressed plastigauge on each journal OIL CLEARANCE SERVICE LIMIT: (0.7 mm (0.03 in) ‘ate ot ue: Dec, 1982 @HONDA MOTOR CO,, LTD, 7m 42-9CRANKSHAFT/PISTON () HONDA (WE) V65MAGNA BEARING SELECTION 11 tod bearing clearance is beyond tolerance, select replacement bearingeas flows: CONNECTING ROD BEARING INSERTS Determine ard record the corresponding red 1D. code number nore The iumber 1 or on eech connecting red the code for each connecting rod 1. Determine and record she corresponding erankpin (0.0. cade number (or measure the erankpin 0.0.) Nore ‘The lettors A or 8 on each crank waight i the cod for eich erankpin O.D. Cross ceference the crankpin aed rod codes to deter ‘mine the replacement bearing color [oka BE woe | se00 BOO mm | NBM Cvalow) |B nen) BEARING INSERT THICKNESS: A (Brown): 1.498—1.498 mm (0.0588 1 (Green): 11490-1.494 mmm (0.060) C (Veliow!: 1.4861.490 mm (0,0585~0.0587 in) 1.0. Cove 0.0, CODE COLOR CODE 12-10 ‘Date of tue Oe 1962 HONDA MOTOR CO, LTD.CRANKSHAFT/PISTON MAIN BEARING Determine and record crankesse |.D, code nurrbers ‘Upper rear eank | case shown are che codes for the main journal ILD. tram lett to raht 1.0. €008 Determine and record the corresponding main Journal 0.0. code numbers (or mensue the mam Feurrat 0.0 NOTE: _ ‘A number 1 or 2 on wath erark weight _the code for the adjacent main una! 0.0 0.0 C008 (ross relerence the cate and journal codes 0 dete ‘mine the replacement beeing WAIN OORWAL OD) SE N8: 1 2 aeac2— | 19.4 ¢ TBAB iam | ISL am ‘ == 3g | 1 | $3200- | ctvetowi | 0 (eon 3 | | 3908, | eran | A ttromn WAIN BEARING INSERT THICKNESS: (Brown): 1.498—1.502 mm (0,0590-0.0591 in) 8 (Greer): 1.494—1.498 mm (C.0538-0.0590 in| © (¥elom); 1.4901 494 mm (6.0887-0.0588 in) ouon cope SheNDA NOOR C0. Uo, "= 12-11CRANKSHAFT/PISTON CRANKSHAFT INSTALLATION Install the mein bearings into the uoper crankeaee ‘Apply molybdenum disulfide grease to the upper and lower man bearings Trral the cranksnafe with the eam chain PISTON AND ROD INSTALLATION Clean the pieton domes, ring lands, and skirts Carefuly install the pietan rings onto te piston, ‘Stagger the ring end gaps as shown, NOTE: fal nat to damege the piston and pieton singe during assembly + AIL rings. should be installed with the markings facing up + After installing the rings they should rotate 12-12 ,) HONDA ‘V65MAGNA ‘SECOND SIDE RAIL G SPACER SIDE RAIL oar wal fnue Ove, 1082 HONDA MOTOR CO., LTD.(2) HONDA ;) V65MAGNA CRANKSHAFT/PISTON (Coat the rod small end with molybdarum disulfide grease ‘Anvemible the giatons and connecting rods with the pistone and piton clipe a folows Front cylinder connecting rod and piston asenbly, Note that the front cylinder connecting rod ate marked MBF. Install the pistons an the frant comecting rods so thatthe intake “IN” mark is facing apposite the all hole in 8 oe, Rear cylinder connecting rod and giston sseribly. Note that the rear cylinder connecting rods we marked MBAR, Install the pistons on the rear rods so that the intake IN" rratk i facing the same direction a5 the oil hale in the od. nore: De rot inrahange the pistons, piston pin oF connecting rods Make sure that the piston pin clips are Align the note in the connecting red bearing insert with the nole in sve connecting rod re install the FRONT CYLINDER oMeA-F* MARK “ane” MARK. oll HOLE REAR CYLINDER Mpa R MARK On HOLE: oi HoLes Date of esve Dee, 1982 DHONDAMOTOR CO., LD, " 12-13CRANKSHAFT/PISTON _ >) HONDA ‘i ) V65MAGNA Jnstall the connecting rod cap bearing inser. ‘Apply moiygdenum aiwitge grease to the connect Cost the cylinders, piston ringWareoves and pistons Install Uae od and piston assembles nto the cevindere from the top of the crankcase. Be sure teach assambly is returned ta its orginal postion as ‘owe during removal NOTE: The pation Tatake “IN” walks should | acing each other se shown Compress the piston rings with a ring eompresior and insert the piston an rod imo te cylinder NOTE: * Be careful not to damage the pistons or | ‘ings during assembly To prevent damage to the crarkpin jour ‘als, sip short sections of rubber nose over the tod bolts before instalation, 12-14 a CONNECTING ROD BEARING “IN MARKS PISTON RING COMPRESSOR (Commercially available) Data of non, Den, 108? @HONDA MOTOR CO, LTD,C& 7) ONDA (L) V65MAGNA CRANKSHAFT/PISTON Ingull and torque the connecting od caps. TORAUE: 30-34 Nim (3.0-3:4 komm, 22-25 fb) nore their correct lecstion se marked. during removal + Tightin the nuts in two oF mov steps Ate igening the ols check tt the 8 rods move freely without binding Assemble the erankcave (See page 11:3) ‘ot ane: Deo, 12 rs 42-15 HONDA MOTOR CO,, LTD,TRANSMISSION 13-0 = Shona MOTOR CO, LTO.Yanan 13. TRANSMISSION SERVICE INFORMATION 13-1._-—« HON: (WL) VeSMAGNA ‘TRANSMISSION INSPECTION check gear dogs, dog notes ant teeth for excessive or abnormal wear, or evidence of insufficient lubrication ‘Messure the 1. ofeach ger. SERVICE LiMITs: (MS, MS, C2, C3, C4 gear: 31.18 mm (1.228 in) ‘Measure the LD, and O.0. of the gear bushings. SERVICE LiMiTs: IME, MB, C2, C3, C4 goar bushing 0. 30.38 mm (1.218 in) IMs, CA gear bushing | 28.06 mn (1.104 in) Measure the 0.0, of the mainshatt and coumme: shaft. SERVICE LiMts: ‘A (at MS bushing): 27:92 mm (1.0991n) B [at C4 bushing); 27.82 mmm (1.099 in) Calculate the clearance between the gear and gear shatt or bushing, SERVICE LiMts: (M5, Me, €2, €3, C4 yer to-bushing: (0.10 mem (0.004 in) (MB, CA gear bushing to-tett: 0.05 mm (0.002 in) 10 “on, — 13-4 1 (Date ot ave. Ove, 1982 HONDA MOTOR EO, LTO.) HONDA (y) Ve5MAGNA TRANSMISSION DRIVE GEAR REMOVAL Remove the dowel pin and O-ings Pace the cutput gear cate in vie with soft jaws, being careful nat to datort the case Place the shaft holder tool on the output driven gear ‘shaft wedina it against the vse to lock the shaft. UUnstake the inner bearing race lock nut with» drill or grinder, Be cweful that metal particles do not tnter the bearing and that the heeads on the shat te not damaned, Remove the inner beating rao lock nut Diseara the nus DOWEL PIN (OUTPUT GEAR CASE SHAFT HOLDER 07923-6890101 DRIVE CEAR SHAFT SHAFT HOLDER (07922~6890101 LOCK NUT WRENCH, 42/65 mm 07916-84000 Date ot fue: Deo, 1052 @ HONDA MaTOR CO, LTD. 13-5‘TRANSMISSION () HONDA ‘ss / VOSMAGNA Remove the countarhatt tearing holder bolts and holder from the case Remove the output ceive gear and shim. Place the countershattholdar ina press, Press the countershaft out of the bearing hole: COUNTERSHAFT BEARING REPLACENENT NOTE: ‘The counieriai must be removed belore repiacing bearing Place the bearing folder in @ vise with sot jows for shop towel NOTE: Do not damage the bearing holder, especially the erankease mating surface. LUnwtake the outer rast lock mut with» punch, Remove the bearing outer race lock rut with a special tool. Diseard the lock nut, BEARING HOLDER \ LOCK NUT WRENCH, 42/56 mm 07916 -MB40900 13-6 ‘Date of tne Dee 1987 HONDA MOTOR CO, LTD.@) HONDA \Sis/ V65MAGNA TRANSMISSION Pace th bearing holier in a press and ramove the Serna ATTACHMENT, 62x68mm DRIVER Ore onres08 (077400010000 asd i PILOT, 38mm canine HOLoER (0746 0040000 Pace the bearing holder in vse with soft jans and install and tigyten new outer race lock nut 10 he specitiea torque vave TORQUE: 90-110'Nm (9.0-11.0 kgm, 65-80 tab) “Totque wrench sale reading: 80-100 Nm (8.0-10.0 kgm, 58-79 ft ‘Stake the new lock nut, COUNTERSHAFT INSTALLATION Nore: The counsel ond driven pur mint be replace at 4 at Wf thay the gear cate oF the bearing requira replacement. Place the coutershaft and countershatt berirg holder Into a press. Press the countershat into the bearing NOTE: Place the threaded end of the pilot into the countershat Pace the adjustment shim over the bearing hele NOTE: Wf the countershat/diven gear, bearing or ear case are replaced, anew adjustment shim ‘must be selected (page 13-18, Backlash Inpection) BEARING HOLDER: Lock NUT WRENCH, 42/5¢ mm 7916, MB40000 PILOT, 35mm 97746--0040800, Dataot ue: Oeo, 1982 HONDA MOTOR CO.,LTD. TerTRANSMISSION Place the countershatt/bearing holder and cortect fagjusting shir into the output pear cas. Install the belts and seating washers with the cover bracket Tighten the ols In a ersoross pattern until the drive gear bearing holder seste against the cise. Than tighten tothe specitied torque TORQUE: 30-38 Nm [3.0-34 kgm, 22-25 feb) Prac the ease ints a vise with eat jaw Instat and tighten a new counteshelt nut 10 the specified torque, TORQUE: 70-80 Nm (7.0-8.0 ke, 61-58 1b) ‘Torque weeneh scale reali (64-73Nim (647.3 kom, 46-53 fe15) ‘Stuke the lock nut 13-8 SHAFT HOLDER ‘97022-¢99010;, TOK NUT WRENCH, 42/56 mm -) HONDA (ic) V65MAGNA TRANSMISSION — OUTPUT DRIVEN GEAR REMOVAL Remove the ovtout driven gear il seal from the Placa the output gear case imo avise, clamping it et teste Unstake and Jcosen the output driven gear beaira inner race lack nut using » special lock mut wrench ‘and shaft holder € Remove the driver gear bearing holder mounting (batts and remove the oar ane holder trom the ca OIL SEAL LOCK NUT WRENCH, 30/64 mm DRIVEN GEAR ‘97916-M809000 BEARING HOLOER | | sHarTHoLoER BEARING INNER RACE ‘97923-s800101 Lock NUT A. BEARING OUTER RACE HOLDER Dateor teur Ove, 1082 HONDA MOTOR CO., LTO, v9 13-9TRANSMISSION ) HONDA iL) VO5MAGNA Remore the shim and Oring trom the bearing oder, OUTPUT DRIVEN GEAR BEARING REPLACEMENT Pace the output driven gear bealng holder io @ vin with soft jaws, Unite 30d remove the output driven gear bearing outer race Jock nut from the holder Press the output driven gear from the holder Place the bestieg Holder in a press and press the bearing out. NOTE: Be cavetul net te damage he bearing holder (2s eace mating artic, ORING BEARING HOLDER skim LOCK NUT WRENCH, 30/64 mm (97316-M800000 DAIVER (07749--0010009, ee Fein 13-10 Date of aus: Dee, 1982 @HONDA MOTOR CO,, LTD,HONDA ‘Ns V65MAGNA TRANSMISSION Fre in aw bearing and aku rotats iS oniven rrso-0ot0000 ATTACHMENT $2.x85mm PILOT, 30mm 7746-0010400, (07746--0040700 Place the bearing holder into a vse with soft js Install and tighten a new bearing outer race lock hut ta the specified torque value, TORQUE: 90-110 Nan (9.0-11.0 km, 65-80 tb) Oe LOSK NUT WRENCH] 30/84 mm (07816- mao0000 BEARING HOLDER OUTPUT DRIVEN GEAR © wsratation NOTE: ‘When the gear set, riven gear beating and” ‘F gear case has Been replaced, use a shim 10.20 mm {0.012 in) thick for iia re Pace the output driven otar bearing holder into res, ‘Then pres in the outour diven ger Install the ering and correct shim, See page 19-14 {or shim selection pocacre SHONDA MOTOR C0. LTD “ 13-11‘TRANSMISSION ‘Avvach the bearing holder onto the grar cas with the four hex bolts, Tighten the bots in a crisscross pattern into oF more sep, TORQUE; 30-34 Nm [3.03.4 Kym, 22-25 feb) Install «new bearing inner race lock rut znd tighten Ite the specied torque ‘TORQUE: 70-80 Nem (7.0-8.0 kp, 51-58 feib) ‘Torque wronch scale 64-73Nm (6, dio 3 kgm, 48-53 tab) ‘Stake both new lock ruts and install a new ol seal 13-12 HONDA V65MAGNA BEARING INNER RACE Lock NUT HOLDER 07923-89010) f LOCK NUT WRENCH, 30/68 mm 7916-20000 OIL SEAL ‘HONDA MOTOR CO.,LTD,(OUTPUT DRIVEN GEAR CASE BEARING REPLACEMENT HONDA V65MAGNA TRANSMISSION Heat te output gear ewe around the beating 10 aor (176°) (& caurion | ‘Always wear gioves when handling a heated sear case & BEARING BEARING REMOVER, 17 mm (07999—37 10900 ermove the bearing with the beating remover € ANOLE WeIGHT 07926-3710100 (07936-3710200 DRIVER 07749--0010000 Drive raw bearing into the output gear cae rf € f f ATTACHMENT, 42% 47mm PILOT, 17 mm ‘77460010200 07746--0040400 Ghonoa wovo# co. LTD = 13-13TRANSMISSION ,)\ HONDA (yb) V65MAGNA GEAR TOOTH CONTACT PATTERN CHECK Remove the drive and chiven gears (pages 125, 138), ‘Acply Prussian Blue to the driven gear teeth, and drven gears withthe standard Rotate the rive gear several times in the normal direction a rotation. ‘Check the gear tooth contact pattern after remoring the drive gear. Contact it normal if Prussian Blue in transfered tothe approximate contar ofeach tooth snd slightly tothe sce, Ifthe pattern isnot corect, remove and repiae the driven gear adjustment shir, Replace the shi pattem is 100 with 8 thinner one It the conttet DRIVEN GEAR/SHAFT sins: FACE) FLANKE SS TOO HIGH: FACE 4 ti DRIVE SIDE _ COAST SIDE 13-14 13 ‘Date of ue: Geo, 198 HONDA MOTOR CO., LTD,(HONDA. (0) V65MAGNA TRANSMISSION Replace the eriven_ gear acjustment shim with @ thicker one tte contact 190 ve The pattern will shift about 15-2.0 mm (0.06. 0.08 in) when the thickents af the shim is chanaed by 010mm (0.004 in) OUTPUT DRIVEN GEAR ADJUSTMENT SHIM: 10.40 mmm (0.016 in) (045 mm (0.018 in| (050 mm (0.020 in| (055 mm (0.022 in| (060 mm (0.024 in| BACKLASH INSPECTION Place the output gear casein vse with samt jaws or Set s horizontal type dial indicator on the counter shaft ae shown, Hole the ériven gear with the shaft holder aret rotate the countershalt by hand Until goar slick ie taken up. Turn the counteshstt back and forth to read STANDARD: — 0,08-0.28 mm (©:009-0.009 in) SERVICE LIMIT: 0.40 mm (0.016 ni Remove the cial indicator. Tum the countershalt 120" and measure backlsh. Repest this procadure Compare the differance of the three measurements DIFFERENCE OF MEASUREMENT SERVICE LIMIT: 0.10 mm (0.004 in) Geamsuarr. [— mi) TOO LOW: COUNTERSHAFT ¢ anne SIDE Date oF true: Deo, 1982 GHONDA MOTOR CO., LTD,‘TRANSMISSION V6SMAGNA the aliference in measurements exceeds the limit, it indiestes tht the bearing is not installed squarely. Inspect the besrings and reinstall neces: I backlash is exconive ear achustent shim with If the becktah § to0 smal, replace the counter that hie with a thicker on, Backlash is changed by about 0,060.07 mm {(0.002-0.003 inj when thickness of the shim is ‘hanged by 0.10 mm (0,008 in). (COUNTERSHAFT/OUTPUT DRIVE GEAR ADJUSTMENT SHINS: (0.40 mm (9.016 in) 0.45 mm (0.018 in) 0.50 mm (0.020 in) 10.58 mm (0.022 in) (0.60 mm (0.024 in) @ we | | 13-16 ‘Date of tsue Dec, 1982 HONDA MOTOR CO, LTD.& ) HONDA sb) V65MAGNA TRANSMISSION COUNTERSHAFT INSPECTION “pacer wlection sould formed whenever you replace ary of me following parte: * Crankease (Section 11) + Countershatt bearing (Section 11) + Courtershat Select the comeet output gear cave gasket. (pape 1318) Install the output geat cate atsrmbly and new gasket ‘nto the lower eae [Assemble the transmission with the orginal spacer Measure the clearance between the biting and spacer with a feler gauge CLEARANCE: 0.30.4 mm (0.012-0.016 in) It the clearance exceeds the obtain the correct clearance: SPACER/THICKNESS: (0.85 mm (0.033 in} (0.80 mm (0.035 in} (0.96 mm (0.037 in) 1.60 mm (0.039 in) 05 mm (0.041 in) mit, select a spacer to FEELER GAUGE COUNTERSHAFT cea | BEARING SPACER vil Date of ues Dee, 1962 SHONDAMOTOR CO,, LTD, 13-17G \ HONDA “TRANSMISSION S&) V65MAGNA FORK GUIDE SHIFT FORK AND SHIFT DRUM CENTER FORK RIGHTFORK SHAFT REMOVAL, Bend the lock washer tab down and remove the ceeter fork: mounting batt Remove the ehift fork shaft an! shift forks, LEFT FORE LOCK WASHER SHIFT ORUM. Remove the bearing stopper plates, Remove the shift drum, ase es sO BEARING STOPPER PLATES. GEAR SHIFT DRUM AND SHIFT FORK INSPECTION Inspect the shift dron de evidence of ingut 1s Yor scoring, scratches, {Check the sift drum grooves for dame, 13-18 * SoWoA Moreh €0. LTD.TRANSMISSION Inspect the shitt drum hole and shift fork shaft hale for soring or seratches Meature the shift fork shatt 0.0. at right and left shite fork surfaces Chock for scratches, scoring or evidence of nat: fice Wbrceton. SERVICE LIMIT; 13.90 mm (0.547 in) Measure the right and left shit fork LD Messure the shift fork elaw thickness SERVICE LIMITS: LD. (right and left fork): 14.04 mm (0.583 in) GLAWTHICKNESS: 6.1 mm (0.24 in) Dateor soe: Dec, 1952 SHONDA MOTOR CO.,LTD, rr) 13-19|) HONDA 1”) TRANSMISSION ‘Ss V65MAGNA SHIFT ORUM INSTALLATION ‘Apply 2 locking agent to the serew threads and install the bearing stopper plates. ae G BEARING STOPPER PLATES SHIET FORK SHAFT SHIET FORKS, Insta the shit forks and shat, CAUTION: Insiall the shift fork shaft 80 that the plugged nuts toward the tet sae. Install the lock washer ang tghtan the canter fork bot TORQUE: 16-20 Nem (1.6-20 kee, 12-14 ftlb) Bend the lock washer tabs up, PLUGGED END LOCK WASHER T3220 = SRSERETAEE uoGreat SG) VOSMAGNA TRANSMISSION caver \— TRANSMISSION ASSEMBLY a (077469030100 MAINSHAFT . é Install the mainshatt bearing with the special tools ‘shown e* e ATTACHMENT, 300mm 1.0. (07746--0030300 Check the gears for freedom of movement or rote tion on the shaft. [Check tat the snap rings are seated in the grooves. € Li antiga : Bek / Cag : a i fs € Date of te: ee 1087 a @WONDA MOTOR CO, LTD.(p>) HONDA ‘TRANSMISSION \Ms) V6SMAGNA COUNTERSHAFT Wefore plscing the counterhart In te cranks, intl the C4 and C8 gous, washers and cellar SPLINED COLLER caGeAR Install the C3 gear and spine colar Install the stopper washer while aligning te tab of the stopper washer with groove in the splined Assemble the C2, C5 and C1 gears, washers and ‘STOPPER WASHER 13-22 = Strona movch £0. LrHONDA ‘TRANSMISSION Install the lower erankease (Refer 10 Section 11), note [ Check the oil orfice for clooaing, before | (Gere & O1L ORIFICE Date oF ame: Dec. 1982 7 ®HONDAMOTOR CO.,LTD. 13-23HONDA DRIVE TRAIN V6S5MAGNA 8 mm: 23-28 Nn (23-28 tg, 17-20 ts) 10 mm: 35-48 Nm (95-45 tom, 26-23 feb) 100-120 Nn (10-12 kam 72-81 feb) ae, (45-7.0kgm, 33-51 feb) 14-0 ai Shops MOTOR CO. L10,& € € & HONDA we) eter 14. DRIVE TRAIN SERVICE INFORMATION 14-4 ‘TROUBLESHOOTING 14-2 FINAL DRIVE REMOVAL 14-3 | DRIVE SHAFT 143 FINAL DRIVE GEAR 1-6 FINAL DRIVE INSTALLATION 14-18 SERVICE INFORMATION GENERAL 1 The final deve gear assembly must be removed together with the drive shat tlic alo seals and Ons wrenever the Final drive gear assembly isiassemble, Check tooth contact pattern and gear backlash when the bearing, gears and/or gnar casa have been replace, SPECIFICATIONS STANDARD SERVICE LIMIT 170 ot (6:7 02s) atter disassembly = Hyooid.gear oil APL,GL-S. ‘Above §°C/41"F SAE #90 - | Boiow S°C/A1"F SAE #80 (0.08-0.18 rm (0:003-0.007 in) 0:30 men (0.072 nh 02-0.3Nem (2-3 4g-em, 1.72.6 inib) = ‘80. (2.702) = 85 rom (2.6 in) 3 mm 2.51) [| caoacity Recommended oil Final evar of Gear backlash (Gear assembly oreload [7 Damonr eam soring free lenath TORQUE VALUES Pinion bearing retainer Pinion nut Gea cate cover belt 10. Bam Fit gear ease attaching nut 100-120 Nim (10-12 kg-m, 72-07 fe) 300-120 Nm (10-12 kam, 72-87 ft) 35-a5 Nm (35-45 kam, 25-33 feb) 23-28 Nem (23-28 kgm, 17-20 fib) 45-10 Nim (4.57.0 kgm, 33~B1 feb) Date of han: Dee, 1902 S HONDA MOTOR CO.,LTD. 14-1DRIVE TRAIN HONDA V65MAGNA TOOLS Speci Drive shat di/aserty tool Divo shaft di/amembly too! © Retainer wrench Final pinion hole Shatt puller Bering rce insert attachment Bearing puller & driver attachment Ball race & Dearing ceiver attachment Common Driver ‘Attachment, 42x47 mm ‘Attachment, 52 x 58 rm ‘Attachment, 32 x 36 mm ‘Attachment, 37 x 40 mm Pilot, 30 mm Dever ‘Attachment, 25 mm 1.0, ‘Shock absorber eompresor TROUBLESHOOTING o7904-M1840100 7964_s400200 7910-ME80000 ‘07824—ME90000 ‘0791 -ME80000 or Pinion puller set 07835—-NB00000 ‘or Pinion puter 07931~8830200 and Pinion puller attachment kit ‘07931-0000 (079314620300 079344800000 (079453330300 07749-00100 977460010300 07746-0010200 07746.-0010100 077460010200 07746-0040700 07746-0030104 07746-00020 07a89 2290001 | or Diver 07048-2710200 1 Wom or reored ring gtar shalt and driven linge 2, Scored driven tango and wheel hut 3. Wom oF scored drive pinion and splines 44 Wom pinion and ring gears 5. Exeasive backlash between pinion and ring gear 6: Diliave too tow i teak 1. Glogore breather 2, Oil eve too high 3. Seals damaged Daw ot Tones Dee, 100 14-2 “ SWonoA MOTOR CO, LTD.V65MAGNA DRIVE TRAIN FINAL DRIVE REMOVAL Place the motoreycle on its center stand, Drain the final ear cil (page 2-10) ané remove the rear whee! (page 163). Remove the left hock absorber (pace 18:9) Pace an oll drain pan under the gear case and wing frm mating surfaces (© eater any damper can oil that may lak out during removal of the ger ese. Remove. the final gear case attaching outs and remove the gear ease fromthe swing arm. DRIVE SHAFT REMOVAL the crivrthate carne aut of the eving arm attach td to the final gear cave with it was removed, 6o the following: Inert the oxle through the gear casa and secure the sein 8 vie with sol nwa oF shop rage by clamp ing the axle. Place the shock mount between the Jaws for stably. Placa a oil drain pan undee the damper ease to eaten the damper oil tat wil spl out. Separate the demper unit from the tently revolving the damper in a eieular motion while togging Sihtly [After remozing the damper unit from the gar cave, temove and discard the outer sop ring that hee i the groove on the splined end of the damper. This fing server as an id i mass aeoduction, ad should ‘ot be installed when the final drive's eassombled. DISASSEMBLY Drain the gpa oil from the damper eas. Remove the lirge spring eli from the damper am to oid damaging it Compress the drive shaft with the fear shoek ab sorter compressor and atackment took. FIWAL DRIVE CASE ATTACHING NUTS Pull wi revolving OUTER stor RING. Discard it DIS/ASSEMBLY TOOL, (07964—MB40100 REARSHOCK ABSORBER ‘COMPRESSOR (07959-s290001 DISASSEMBLY TOOL © (079641800300 Dow of tous Dee, 1902 HONDA MOTOR CO.,LTD. “ 14-3HONDA V65MAGNA DRIVE TRAIN SPRING STOP RING Remove the spring stop ring and drive vat trom DAMPER LIFTER DAMPER CAN Remove the spring stop, damper cam and damper liter fom the dre shat Check the damper lifer and cam for wear oF CAUTION Discard the sop ring andl install « new one ‘pom reassembly FS SPRING STOP STOP RING DAMPER case Remove the ll seal art oil sat gute trom the damper coe Nore Reson ta mal iN a naw ow WR nore ong onseAL cue 7 ‘Dave of fies Oo 190 14-4 HONDA MOTOR CO, LTO.() )\ HONDA i / V65MAGNA DRIVE TRAIN DAMPER CAM SPRING emave the dampe: cam sorieg [Measure the damper cam sorng foe length, ‘SERVICE LIMIT: 63 rum (2.5 in) FREE LENGTH DAMPER CASE Remove the damper case and Orting trom the érive shart Uospect the Oing and repiace O-RING privé sHarr it necessary, ASSEMBLY ~ DRIVER & ¢ 97749-0010000, 7 Insta the damper cam spring into the dimer case, Drive me oll sea) guide and ol seal in with the diver fed attachment ‘Assamble the remaining parte in the rover ender of disasembly, ew cnes when resisembling the drive thaft ATTACHMENT, 37 x40mm —DIS/ASSEMBLY TOOL 07786-0010200 o796s—we40100 SHowoR MOTOR C0. U7. o 14-5DRIVE TRAIN (gt \ HONDA Ns) VO5MAGNA FINAL DRIVE GEAR RING GEAR REMOVAL Remove the distance cola Flomove the dust guard plate bolts. Remove the dust ‘uard plate by turing it clockwise flemove the eight case cover bolts and cover. Ifthe ring gear stays inthe cover, do the folowing: Place the cover in a press with the ring gear down Make sure the corer & well upportd, Prats the sing gear out of the cover with driver (07749.-0010000 and attachment 077460010100, Remove the ring gear trom the final drive ase Remove the O-ing guide by tapning it from the ‘opposite side DISTANCE COLLAR DUST GUARD PLATE case coven RING GEAR 14-6 0 ‘Date of aus Ove, 1982 SHONDA NOTOR CO.,LTD.HONDA (QC) VosMAGNA DRIVE TRAIN (RING GEAR BEARING REMOVAL Remove the ring gear bearing and ear adjusting sac. CASE COVER OIL SEAL REPLACEMENT Remave the ol sel from the ease cover and press é PINION GEAR REMOVAL © neat te pinion jo hate ote te pintnne sat erro piconet ee Fonevinetel epicn ot "ATTACHMENT, 32 x 35 mm 07746—0010100 PILOT, 30mm 077460040700 RING GEAR BEARING’ OWL SEAL, BEARING PULLER {COWMERCIALLY Janis PINION HOLOEA ‘97924—-MeE90000 Dateof aver Dec, 1982 © HONDA MOTOR CO., LTO,DRIVE TRAIN Bowt Lock Tas Remoue the retainer lock tb, RETAINER WRENCH (07810 MEBOOOO ol PINION HOLDER 07224-MEQ0000 PINION PULLER ATTACHMENT KIT WITH SHAFT PULLER, ‘OR 07931—MB00000 WITH PINION, 07931-Me40000 PULLAR 079314630200 Pall off the pinion aterbly with the pinion pul . ‘on PINION PULLER ‘07936—s"800000 72 ‘Dae of nan: Dee, T08 14-8 * Shronpa woTOR CO. LTO,|) HONDA @) V65MAGNA DRIVE TRAIN ORING PINION BEARING REMOVAL Remove the Oring from the pinion shat BEARING PULLER PINION BEARING (COMMERCIALLY AVAILABLE) Poll the outer and inner beating races ff the shaft ‘Remove the pinion adjustment space. pniven om seat 077490010000 PINION RETAINER OIL SEAL REPLACEMENT Feri) thi Oising’ or eid al ron thi pian Drive anew oi seal into the retain. Cost «new Oring with oil and install it onto the To install new oi! sel, use driver 07845-2330300, PINIONRETAINER O-RING ‘ATTACHMENT 07945-3330300 Daw ot aes Dee, HONDA MOTOR CO. LTD 14-9/(, \HONDA DRIVE TRAIN SS) V65MAGNA CASE BEARING AND OIL SEAL REPLACEMENT Hoot tho ghar cose BOC (176° F). Tap the gas case with a alastic hammer and remove the ring orar and Pinion bearings ‘Always wear gloves when handling the wear ‘ase after it has been heated. nore: DAIVER (077490010000 Remove the ing gear shat il sa Drive a new ol seal into the ease, using the special tool shown, Te + ‘ATTACHMENT oaiven ‘070453990360 1917490010000 Drive cow pinion and ring gear bearings into the ‘ATTACHMENT, “ATTACHMENT, 52 x 55 mm (07746-0010100 (07746 -0010400 14410 me ‘Dave of ues Ove 1987 (HONDA MOTOR CO, LTO.e py HONDA V65MAGNA DRIVE TRAIN BREATHER HOLE CLEANING Remove the breather hole cap and blow through the breather how with compresed a PINION BEARING PINION SPACER PINION GEAR ASSEMBLY Instat the original pinion gear spacer, Nore: SRR or inten eaten i” =) @ | S-s2erac2 ve . ia ‘) riven, oniven Gr Dogan OF eye 371200 ine ati accent * Sesser u ATTAGHMENT, 2m onine (07746-0020200 SNONOA MOTOR 0. LD. oF 14-11@ HONDA DRIVE TRAIN ‘is / V65MAGNA ATTACHMENT AETAINER WRENCH Place the pinion asembly into the gear housing. 07931—-4630300 07910-MEB0000 Deve the prion asemly ito the ear caw uth 4 pinion retainer tends cov engage wth the cme Sede ‘Apply onar oll to the Oxing and threads on the pinion retainer, Istll the O-ring guide tool Sc1ow In the pinion retainer to press the pinion bearing ie pce, thon tighten it to the spocitied torque ‘TORQUE: 100-120 Nem (10-12 kom, 72-87 feb) RING GEAR SPACER, RING GEAR BEARING RING GEAR ASSEMBLY ‘instal the orignal spacer onto the ring gear 7s, pinion bearing, ring gor bear | ing and/or gear ease Is replaced, Install 22.0 sm thick spacer. lice a new ring gear bearing on the sing gear shat Place the old bearing on top of i. Then, dive the new bearing onto the shaft withthe old bearing and ltiachment. Then remove the ld bearing, ATTACHMENT 14-12 “ SNoNDA NoTOR cD. Lo,(>) HONDA (yl) VosMAGNA DRIVE TRAIN Install 2 new Orring on the Oxing guide Apply grease 0 the Oring and crive the O-ring {ld onto the rng gor shat, Inatall the ring ger into the gear cae cover. Measure the clearance between the ring ge2r and the ing gear stoppin with «footer sauce. CLEARANCE: 0.30-0.60 mm (0.012-0.024in) If the clesrance exceeds the srvise limit, remove the ring gear. Heat the gear cise cover 10 approx tmateriy 80°C (176°F) and remove the stop pin by {epping the cow Always wear gloves wihien handling the gear | ase after I has ed. Install a stop pin shim 10 obtain the correct clea. SHIM THICKNES ‘0.10 rem (0.004 in} 180.15 mm (0,096 in} Install the shim and drive the stop pin ino the exsa ‘Date of tae, Ove 1982 HONDA MOTOR CO., LTD. river OnING GUIDE O-RING SE 07499010000 ATTACHMENT, 425 47 mm (07748-0910206 STOPPIN” FEELER. GAUGE GEAR CASE COVER 'STOPPIN RING GEAR (030-050 mm (0.912-0.024 in) STOFPIN, SHIN “ 14-13(;) HONDA DRIVE TRAIN \Sis) V65MAGNA Clean all sealing material off the mating surface of the geo" cave and cover Nore: ‘Koop dust and dirt aut of the gow cae Be ‘careful not to damage the mating | siete. Apply liquid sealant tothe mating srface of the russian BLUE Wave washer GEAR TOOTH CONTACT PATTERN beNs CHECK Apply a thin cost of Prustan Bive t2 the pinion eat teeth for a gear tooth contact pattern heck Place the wave washer and ring gear into the gear Apply gear oil to the tip of the all sel on the gear ase Corer and inwall the gear casa cover. Tighten the bolts in 2-3 steps unt the cover ‘vesly touchs the geer eas, then tighten the 8 ram bolts to the specified tora in a erasers pattern in two oF more ste. TORQUE: 23-28 Nn (2.3-2.8 kom, 17-2010) Then tighten the 10 mm bolts ‘TORQUE: 40-50 Nom (45-5.0kgm, 33-26 fe1b) 14-14 SHONOA MOTOR CO.,LTD.@ HONDA - ML) V65MAGNA DRIVE TRAIN FRemave the ol! filer cap from the final gear case direction of rotation. Check the gear tooth contact pattern through the oil filler hole, The pattern is Indicated by the Prussian Blue applied to the Binion before sserbly. Contact is normal if tye Prussian Blue is transfered to the approximate canter of each tooth and shy to the flank side If the patterns are not corset, remove and replace the pinion spacer. Replace te pinion spacer with a ‘hicker one f the contacts are 00 high, toward the then, Replace the pinion spacer with a thinner one ifthe ontacts are too low, tothe flank se, The pattems till shift shout 152.0 mm (0,06-0.08 in} when the thickneee of the pacar it ehanged by 0.10 ram (0.008 in). PINION SPACER: ‘182mm (0.072 in) B 1.88 mm (0.074 in} © 194mm (0076 in) 1 200. (0.079 in} Standard 206mm (0.081 in) F 212mm (0.084 in) G 218mm (0.088 in) NORMAL Paw! Foo HIGH ‘TooLow PINION SPACER "ae aS. | a FRY | rane pniyesiog _coasr sine Dae of hue: Dec, 1902 HONDA MOTOR CO.,LTD, 14-15DRIVE TRAIN BACKLASH INSPECTION Ferove te ol filer cap. Set the tinal gear assembly into a fg oF stand to hold it steady, Set a horizontal type dial Indicator nthe virg gra throu the ol filer hole Hold the pinion gear spline by hard, Rotate the ring gear by Rand until gear slack ie ten up. Turn the fing gear back and forth to read backlash STANDARD: 0.08-0.18 mm (0.003-0.007 in} SERVICE LiMiT: 0.30mm (0.02 n) Indicator, Turn the ring gear 120" and memure backlash. Repeat this procedure once Compare the difference ofthe three mesaurements, DIFFERENCE OF MEASUREMENT SERVICE LIMIT: 0.10 mm (0.008 in) I the difference in measurements exceeds the fini, it indicates that the bearing isnot installed squarely, Inspect the bearings and reinstall if necessary. 1 backlash is too smal, replace the tng Backlash is changed by about 0.96-0.07 mm (0002-0003 in) when thickness of the spacer Is changed by 0,10 men (01004 in RING GEAR SPACER: 1.82 mm (0.072 i) 1.38 mm (0.074 in) 1:96 mm (0.076 in) 2.00 mm (0.079 in) Stancar 2.06 mm (0.081 in) 2.12 mm (0.084 in) 2.18 mm (0.086 in) 2.24 mm (0.088 in) 12.30 mm (0.091 in) spicer zonnoam> RING GEAR SPACER 14-16 Daa of nue: Dec, 1908 @HONDA MOTOR CO, LTD.) HONDA ok) V65MAGNA (PINION JOINT INSTALLATION Install the appropriate pinion vetainer lock tab. NOTE: ‘Apply gear oll to the oll sal lip contact surface ‘of the pinion joint and install the pinion joint Insta te pinion joint holder tool and tighten the pinion nut. Ee qr =a Remove the pinion joint holder tool. Make sure thatthe gear assembly rotates smoothly (U_witostbindins by tuming fe pion je Lock TABS DRIVE TRAIN PINION HOLDER ‘07924—Meso000 Date or tem 1982 HONDA MOTOA CO.,LTD,(,) HONDA SL) VO5MAGNA DRIVE TRAIN Install the dust quar plate and torque the bot Insta me aistance colle FINAL DRIVE INSTALLATION Fill the damper caso with the recommended tyoe and amount of lubricant. RECOMMENDED O!L: HYPOID GEAR OIL API Gis ‘Above 57/41": SAE #00 5 Below 5°C/41"F:SAE 280 O1L CAPACITY: 80¢e 2.7 oe} FINAL GEAR CASE DAMPER SPRING Keeping the damper cae vertical, place the darmper Spring onto the damper cam and incall the final dive guar eaee over the damper sam, Nore: a Be exvatul not to damage the damper cae cil sal during assembly ‘Do not ie she gear case separate trom the |__ camper can othe ol wil spl os 14-18 “ BWoNDA MOTOR G0. L1D,HONDA V65MAGNA DRIVE TRAIN Make sure the uriversal joint in tine with the Ariveshaft. Then insert the riversheft into the faving arm aligning is splines with the outer sheft felines. Keep the gtorcaxe end damper eae together tr damper oi wil leak ot Secure the gear case to the swing arm withthe three atacning nuts. To eave axie hstalaion, do not Tighten the gear save mute until aftar the axle is Install the roar whee! [pape 188), Tighten the axle nut ronau 5-105 Nm (8.5105 kam, 61-76 Felb) Tighten the thre final gear cae attaching nuts TORQUE: 45-70 Nom (4.5-7.0 kom, 33-51 ftib) ‘Tighten the ante pinch bolt TORQUE: 20-30 Nm (2.0-3.0 kgm, 14-22 Fe) Install the shock absorber (pape 16-13}. Make sure that the drain bolt tightened Remove the ail filler cap ard pour in the specified ‘mount of recommended il RECONMENDED OIL: Hypold Gear Oil ‘Above §°C (41°F); SAE #90 Below 5°C (41°F): SAE #80 mL capacity: 370 0e (51021 Dry 190.¢ (4.4 02] Refill after draining FINAL GEAR CASE ATTACHING NUTS SOILDRAIN BOLT Dap of ane: Dee, 1982 BHONDA MOTOR CO. LTD, 14-19@ HONDA FRONT WHEEL/SUSPENSION V65MAGNA 40-50N-n (4:0-6.0 kam, 29-36 fob) 26-20 PS (25-3.0kom, 18-22 feb) 5 O-19N-m {03-13ten, 79%) a tsb 8tem, a. ea font stan, a é 22-38 tub) 18-30 13-20 'ei8) (1.8-3.0 kom, 13-22 tb) 20-45Nm (30-45 kom, 22-33") 15-0 = Dawot hws Dee 1652 HONDA MOTOR CO, LTD,w) "emcee 19, FRONT WHEEL /SUSPENSION SERVICE INFORMATION 15-1 IGNITION swiTcH 69 TROUBLESHOOTING 16-2 HANDLEBARS 16-10 FUSE/COUPLER BOX 15-3 FRONT WHEEL 6-15 HEADLIGHT 15-4 FRONT FORKS w-22 INSTRUMENTS 15-5 STEERING STEM 16-35 SERVICE INFORMATION GENERAL '¢ Alnce or other support is eauirad to support the motereysle SPECIFICATIONS STANDARD SERVICE LINIT [Axle shaft runout = 0.2mm (001 in) im rina Radial (0.3 rm (0.01 i) max 2.0mm (008in) Axal (0.3 rm (0.08 ink max. 20 mm (008 in} {803 mm (01607 Fork eping few gh iS VT 104mm (15.9) | Fort tae ninout [22mm orn | [Front for uid eapaty RieG65ce(1O1 on eRe (Gen | id Fa fork rem ¢-40 ea (0-0-4 ugfon?, 0-6) TORQUE VALUES Handlebar upper holder 40-50 Nem (6.0-8,0 kgm, 29-36 fb) Haneiebar pinen ort 25-30 Nem (25-3.0 kgm, 18-22 1-0) Caliper mototing bolt 90-45 Nem (3.0-4.0 hgrn, 22-29 fb) Front 15565 Non (5.5-6 5 kgm, 80-47 fb} ‘Axle pinch balt 48-30 Nem (1.8-3.0 kam, 13-22 ft-0) Front fork socket bolt 15-25 Nem (1 5-25 kgm, 11-18 ft.) Fork tute cap 18-30N-m (1/5-3.0 kgm, 11-22 tt) ‘Steering bearing acfustrent nut 14-16 Non (1.41.8 kgm, 10-12 eb) [See pages 16:38 and 39) Stoning stom rt 90-120 Nim {9.0-12.0 km, 65-87 Fb) Brake dive 25-30 Nom (2.6-3.0 kom, 18-22 fb} Front fork top pinch bolt 9-13 Nim (09-1.3k5-m, 7-9 ft) Front fork bottom pinch bolt 45-85 Nm (4.5-5.8 kom, 33-40 Trip) Front fork stabilizer bolts 18-26N-m (1.0-2.8 kgm, 13-2041) Front brake master evinder holder batt 30-14 Nom (1.0-1-4 kgm, 7-10 fet) Cluteh master evinder oder bot 40-14 Nom (1.01.4 kgm, 7-10 fb) Die ot nave Ove, tour a HONDA NOTOR CO., LTO, 15-1