Remove the seats and fuel tank page 412

Remove the left side cover and disconnect the ignition switch connectors < 3 P Whlte, 2 PrBlack Single lead RedT Condnuiiy should exert between the terminals indicated in each switch position. Engine Stop Switch '87 '90, 92 '93 Engine Stop Switch '87 '90, 92 '93 j Hl ) RIGHT SWITCH CONNECTOR 9P R f> r is actuated by the thermostatic switch of the radiator. If the fan moto does not start, disconnect the 2 PiBlack connector from the switch r is actuated by the thermostatic switch of the...

Pilot Screw

* The pilot screws are factory pre set and should not be removed unless the carburetors are overhauled. * The pilot screw plugs are factory installed to prevent pilot screw misadjustmerit. Do not remove the plugs unless the pilot screws are being removed, * Cover all openings with tape to keep metal particles out when the plugs are drilled. Center punch the pilot screw plug to center the drill point. Drill through the plug with a 4 mm 15 32 in) drill bit. Attach a drill stop to the bit 3 mm (1...

Clutch Outer Installation

Install the clutch outer guide onto the mainshaft. install the needle bearing into the clutch outer. Align the holes in the clutch outer with the pins on the oil pump dove sprocket and install the clutch outer onto the outer guide. Remove the 6 mm socket bolt from the primary gear. If the. 6 mm lock bolt is removed, posh the ciutch outer onto the mainshaft while aligning the primary drive gear and sub-gear teeth with a screwdriver, then while moving the oil pump driven sprocket, fit the pins on...

Rear Cylinder Note

* the 'roni cylinder was not serviced, remove the front cyb nder head cover and check the fornt cylinder camshaft position as follows Remove the timing hole cap, turn the crankshaft clockwise and align the FT mark on the primary drive gear with the Index mark on the right ctankcase cover,, then check the identification mark on the camshaft flange, if the F mark on the camshaft flange face up, turn the crankshaft clockwise 225 and begin installation of the rear camshaft. if the F mark faces down...

Connecting Rod Selection

An alphabetical weight code is stamped on the connecting rod. When replacing the connecting rod, perform the weight selection between the front and rear cylinder connecting rods in accordance with the selection table below. The O mark in the table indicates that matching is possible In the crossed codes. - T - - r

Thermometer

Rat them Is no continuity at room temperature end (tiiiy raise the coolant temperature. The d show continuity (close) at 93 -97 C (199 or 3 minutes to confirm continuity, emperature will cause an incorrect tween the thermometer and switch, thermometer touch the pan as it wilt E E lf* IPf E i IE IN SCH R Disconnect the Green Blue wire from the temperature sensor. Check tor continuity between the sensor body and ground. There should be continuity, if there is no continuity, check...

Inspection Axle

Set the axle in V blocks and lead the axle runout with a dial indicator. The actual axle runout is 1 2. of the total indicator re ad imp Actual runout is 1 2 the total indicator reading. Check the rim for runout hy placing the wheel in a truing stand. Spin the wheel slowly, and read the runout using a dial indicator. Radial runout 2.0 mm i0.08 in Axial runout 2.0 mm 10.08 in) The wheel cannot be serviced arid must be replaced if the shove limits ate exceeded. Wheel balance directly affects the...

Brake Shoepad Wear

,4 Aw replace the brake pads as a set to assure even disc pres sure Chock the 'or,-ike pads for wear by looking through the slot indicated by die arrow cast on the caliper assembly. Replace the brake pads if the wear grooves sn the pads are visible I page 'I 6-51. Replace the brake pads If either pad is worn to the bottom of the wear line (page 15-7). Replace the brake shoes If the arrow on the brake arm aligns with the reference mark A on full application of the rear brake pedal.

General

Some wires have different colored bands around them near the connector. These are connected to other wires which have same coior band, AH plastic connector have locking tabs that must be released before disconnecting, and aligned when reconnecting. The following color codes used are indicated throughout this section and on the wiring diagram. Bu Blue G Green Lg Light Green R Red ESI Black Gr Grey O - Orange W White Sr Brown Lb Light Blue P Pink Y Yellow To isolate an electrical failure, check...

Inspection

Check for continuity with an ohmmeter isee note belowh Connect the positive probe to the terminal and the negative probe to the terminal of the diode. There should be continuity. With the probe reversed, there should he no continuity. The test results shown are for a positive ground ohmmeter and the opposite results will be obtained when a negative ground ohmmeter is used.

Assemblyinstallation

Align the starter motor ease notch with the brush holder tab. - Do not forget to install the thrust washers. Install the rear cover, aligning its slot with the brush holder Shift the transmission into the neutral. Disconnect the connector from the starter relay. Measure the voltage between the yellow red and green red wire terminals of the connector at the harness side. Turn the ignition switch ON. There should be battery voltage while the starter switch is depressed. If the there is no...

Removal

* With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. fie move the fo lowing - the starter drive gear (page 8-2). --the exhaust pipes page 5-3). -starter motor cable from the motor. starter motor mounting bolts and the motor. Remove the three screws and rear motor cover. Remove the armature from the starter motor. * Note the location and number of thrust washers. Measure the brush spring tension with a spring scale. SERVICE LIMIT '87-'90,...

Troubleshooting

* Battery discharged - Faulty Ignition switch * Loose or disconnected wire or cable * La vv battery specific rjravity * Excessive resistance in circuit The starter motor can turn when the transmission is in the neutral position, or, when the side stand up, the clutch lever * pulieo m, and the transmission is in gear. Starter motor turns, but engine does not turn Faulty starter motor or idle gear Starter motor runs and engine turns, but engine does not start Measure the Voltage between the Green...

Ignition Control Module iCM

Remove the seats and fuel tank (page 4-12 . Disconnect the ICM 6P black connector. Measure the voltage between the black and green terminals of the ICM 6P connector. When the ignition and engine stop switches are ON, there should be battery voltage. Check the continuity between the blue yellow wire CM 6P connector-to-starter relay switch connector). If the ignition pulse generators, ignition coils, wiring and connector are good, and the Ignition timmp isnot wirhin specification replace the ICM...

Side Staid

Support the motorcvcie on a level surface. Check the rubber pari on the side stand for deterioration and Replace the rubber pad if wear extends to the wear line. - When replacing, use a robber pad VT1100C MM8 ON-L Y . Check the side stand spring for damage or loss of tension. Using a spring, .scale, measure the force required to retract the side stand, it should he within 2-3 kg 4.4--6.6 lbs), as show st. Check the side stand assembly for freedom of movement. Make sure that the side stand is...

Spark Plugs

Hor cold climate iBetaw B C 4 fo irk piug caps and clean away any dirt from tug bases. Measure the new spark plug gaps using a wire-type feeler gauge. SPARK PLUG GAP 0.8 0.9 mm (0.031 0.035 in) Adjust the gap by betiding the side electrode carefully and install the plugs TORQUE 14 N-m il ,4 kg-m, 10 ft-lb Connect the spark plug caps. irk piug caps and clean away any dirt from tug bases. Pet form this maifitenance with the engine at normal operating temperature and transmission in neutral, place...

Info

sure switch and connect an oil pressure nd gauge to the pressure switch hole. OB pressure gauge attachment 08 pressure gauge 07510 4220100 or equivalent commercially available in U.S.A. equivalent commercially available in U.S.A. Start the engine and check the oil pressure at 6,000 rpm. 441 kPa 4.5 kg cm*, 64 psi) at 8,000 rpm (80 C 176 F) Apply 3-BOND'5 No. 1211 sealant or equivalent to the pressure switch threads and install, Connect the oil pressure switch wire and start the engine. Check...

Evaporative Emission Control System California model only

Between the carburetor, EVAP CAV ative emission ffc'VAPi canister Also ging doe to bending or twisting. r damage, deterioration, clogging or t side cover and inspect the battery electrolyte l riears the lower level, remove the battery open the holder. negative cable first, then disconnect the pose battery breather tube. ' out, then remove the filler caps and add dis- he upper level line. tilled water. Tap water will shorten the service atterv. ITFOSITIV T RWN L 11 ' EG ATIV 'T RMTNA explosive...

Pinion Gear Removal

Assemble the pinion joint holder and attachment. Install the pinion joint holder and attachment, then remove the Pinion joint holder attachment the pinion retainer wrench. 07910-MESOOOO Reassemble the pinion puller set, or assemble the pinion puller Pull the pinion assembly off with the pinion puller. Pinion puller set Pinion pulier set attachment 07HMC MM80200 or 07935-MB00000 07HMC-MM80100

Brake Light Switch

Perform rear brake light switch adjustment after adjusting the btake pedal play and height. The front Drake light switch does not require adjustment. Adjust the brake light switch so that the brake light will come on when the brake pedal is depressed 20 mm (3 4 in), and brake engagement begins. Hold the switch body end turn the adjusting nut Do not torn the switch body.

Service Information

This section covers removal and installation of the alternator and starter clutch. Refer to section 21 for troubleshooting and inspection of the alternator. The alternator starter clutch service may be done with the engine in the frame. 16 25 N-m (1.6-2.5 kg-m, 12 18 ft-lb) Starter clutch socket bolts Flywheel bolt Starter gear cover bolt Left crank case cover bolt Slave cylinder mounting bolt Bearing remover set, 10 mm Torque limiter attachment Attachment, 24 x 26 mm Pilot, 10 mm Flywheel...

Disassembly

Remove the brake ever by removing the lock nut and pivot boit. Remove the brake light switch by removing the screw. Remove the snap ring from the master cylinder. Remove the master piston, primary cup, spring and check valve from the master cylinder. Ciean the coaster cylinder, reservoir and master piston in clean brake fuiid.

Clutch Oil Pressure Check

Warm the engine up to normal operating temperature. Stop the engine and support the motorcycle upright. Remove the clutch cover cap and the oil passage plug, install the oil pressure gauge attachment in the plug hole and connect the oil pressure gauge to the attachment. Oil pressure gauge 07756--3000000 Oil pressure gauge attachment 07510 4220100 Start the engine and check the clutch hydraulic oil pressure. OIL PRESSURE at 50--60 C 122- 140 F 100 kPa fl.O kg cmC 14 psi mtn. at 900 rprn 250 kPa...

Pinion Gear Assembly

Install the original pinion gear spacer. NOTE When the gear set, pinion bearing and or gear case are placed, use a 2,0 mm (0.08 in) thick spacer. (1) PINION GEAR (2) SPACER f (3) BEARING (1) PINION GEAR (2) SPACER f (3) BEARING Press the pinion bearing onto the shaft until It seats. Press only on the inner race. Driver, 40 mm I.D. 07748-0030100 Attachment, 25 mm I.D. 07748-0030200 Place the pinion assembly into the gear case and drive it until enough threads are visible to engage the pinion...

Ignition Pulse Generators

Disconnect the ignition pulse generator 4P white connector. Measure the resistance between the each wire terminals of the pulse generator 4P white connector at the harness side. STANDARD '87-'30 450-550 Q 2G C 68 F> After '91 400- 500 0 (20 C 68 F) WHITE BLUE AND BLUE WIRE TERMINALS REAR IGNITION PULSE GENERATOR WHITE YELLOW AMD YELLOW WIRE TERMINALS - If standard resistance is not obtained Remove the left side cover. Disconnect the pulse generator connector, measure the front and rear...

Left Crankcase Cover Removal

Remove the left crankcase rear covet. Remove the starter gear cover. Remove the gasket and dowel pins. Remove the starter drive year and starter torque ilmlter. Check the starter cover bearings for damage or excessive play. Replace, if necessary, using the following tool, Bearing remover set, 10 mm 07936-GE00000 Drive In a new bearing with the following tools. Attachment, 24 x 26 mm 07746-0010700 Hold the torque limiter in a vise with sheet copper or equivalent material. Check the torque...

Tireswheels

Tire pressure should be checked when tires are COLD. Check the 'ores tor cuts, embedded nails, or other damage. Check the front and rear wheels for trueness (Refer to sections 1.3 and 1 4 Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following Minimum tread depth Front 1.5 mm (1 16 in) Rear 2.0 mm (3 32 ml Recommended tire pressures and tire sizes 90 kg (2.00 lb si load to vehicle capacity load - Check that the contiei cables do not...

Batterycharging System

he battery fluid level should he checked regularly. Fill with distilled water when necessary. Quick charge a battery only in an emergency. Slow-charging is preferred. Remove the battery from the motorcycle when charging. If the battery must be charged on the motorcycle, disconnect the ______ , The battery gives off explosive gases keep sparks, flames, and cigarettes a way. Provide adequate ventilation when charging or using the battery its an enclosed space. ' The battery contains sulfuric...

Pinion Joint Installation

Install the appropriate pinion lock tab. NOTE There are two types of lock tabs as shown. Coat the oil seal lip contact surface of the pinion joint with oil and install the pinion joint. Assemble the pinion joint holder and attachment. Apply a locking agent to the pinion nut. Install the pinion joint holder and tighten the pinion nut. TORQUE 110 IM> m 111.0 kg m. 80 ft-ib) Pinion Joint holder 07926- -ME9 000 Make sure that the gear assembly rotates smoothly without binding. Measu re the final...

Evaporative Emission Carburetor Air Vent Evap Cav Control Valve Inspection California model

Disconnect the EVAP CAV Control Valve hoses from their com neeoons and remove the EVAP CAV control valve from its mount. Refer to the routing label on left side cover for hose connections. Connect a vacuum pump to the No. 10 hose that goes to the right carburetor body. Apply die specified vacuum to the EVAP CAV control valve. SPECIFIED VACUUM 250 mm (9.8 in) Hg A937X-Q41 -XXXXXor ST--- AH 260 MC7 (U.S.A. only) (2) TO OPEN AIR hit TO AIR (3) EVAP CAV CONTROL m EVAP PURGE CONTROL VALVE 13) TO...

Brake Fluid Draining

Fill the master cylinder reservoir with DOT 4 brake fluid from a sealed com airier. If a brake bleeder 1s not available, use the following procedure Pomp up the system pressure with the brake lever until there are no air bobbles in the fluid flowing out of the reservoir small hole. Connect the bleed hose to the bleed valve and bleed the system as follows 1 - Squeeze the brake lever, open the bleed valve 1 2 turn and then close the bleed valve. * Do not release the brake lever until the bleed...

Torque Values

Handlebar upper holder bolt Brake disc retaining bolt '87 '90) (After '911 Front axie bolt Front axle pinch bolt Caliper mounting bolt (87 - - 90, '92-iAfter '93) 40 N-m (4.0 kg m, 29 ft-lb) Apply oil to the thread. 43 N-m (4.3 kg-m, 31 fHbi 60 M-m 16.0 kg-m, 43 ft-lb) 22 M*m (2,2 kg-m, 16 ft-ib) '93) 35 N*m (3.5 kg-m, 25 ft-ib) 45 N-m (4.5 kg-m, 33 ft-ib) Do not reuse. 23 N-m (2,3 kg-m, 17 ft-ib) 1 1 N-m (1.1 kg-m, 8 ft-lb) 50 N-m (5.0 kg-m, 38 ft-ib) Apply oil to the thread. 21 N-m < 2.1...

Brake Fluid Replacementbleeding

* Check the fluid level often while bleeding the brake to prevent air from being pumped into the system. * Use only DOT 4 brake fluid from a sealed container. * When using a brake bleeding tool, follow the manufacturer's operating Instructions. It air Is entering the breeder from around the bleed valve threads, seat the threads with teflon tape. * 4 contaminated brake disc or pad reduces slopping power. Discard contaminated puds and clean the disc with a high quality brake degreming agent. 'ow...

Gearshift Linkage Removal

Remove the right crankcase cover (page 7-14). Remove the clutch assembly from the clutch outer. Remove the oil pipe. Remove the oil pump driven sprocket bolt. Remove the stopper arm, washer and return spring by removing bolt. Remove die shift drum center and dowel pin. ' ' - s* Remove the cam p a , using th scrsw driver 3S shown. To remove the gearshift spindle A, remove the following left crankcase cover (page 8-2) flywheel page 8-4) shift spindle guide plug. Remove the gearshift spindle with...

Set Idle Speed Honda Vt1100c

Force 3 self-tapping 4 mm screw IB C 069399, P N 93903 354 01 mo the drilled ping and continue turning the screw driver until the plop rotates with the screw, Ftili on the screw head with pliers to remove the plop. Use compressed air to dean the pilot screw area and remove roeta shavings. Ton,' each pilot. scmw in end carefully count the number of turns until it seats lightly - Make a note of this to use as a reference when reinstalling tho pilot screws. id return them to their original...

Clutch Slave Cylinder

Remove the left crankcase rear cover. Piace a container under the slave cylinder, and remove the oil (1 CLUTCH SLAVE CYLINDER ' .'ir ii' 'i- - - bolt arid oil pipe from the sieve cylinder. CAUTION * A void spilling clutch fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. Remove the piston from the cylinder. If piston removal is difficult, place a shop towel over the piston to cushion the piston and position the cylinder with the piston...

Clutch Fluid Replacement All Bleeding

* < not allots fon-ign material to enter the system when the diaphragm is removed, A -aid spilling fluid on primed, plastic, or rubber pans. Place a ' .' < ore*' these ports whenever the system is serviced. Remove the reservoir cover, set plate and diaphragm with the fluid reservoir pereliel to the ground. Remove the left crank case rear cover. Connect a bleed hose to the bleed valve. Loosen the slave cylinder bleed valve and pump the clutch Sever, Stop Derating the lever when no more fluid...

Honda Cbr Faulty Diode Stops Engine Starting

Engine stop switch OFF or faulty ('87-'90, '92--'33) Faulty ignition control module (ICM) Faulty ignition pulse generator Incorrect Ignition pulse generator air gap Engine stop switch OFF or faulty ('87-'90, '92 '93) Poorly connected, broken or shorted wires - Between Ignition switch and engine stop switch - Between ICM and engine stop switch Between ICM and ignition coil Between ignition coil and plug Between (CM and ignition pulse generator After '88 Faulty ignition coil Faulty ignition...

Performance Test

Check for the turn signal circuit connection properly before this test. Connect the terminals as indicated below White Green D.C. 12 V Positive i+i side connect the other side to ground (frame . If the turn signal relay fails on this tespreplacetherelay witha new one. RIGHT FRONT TURN SIGNAL 12V 33 3cp (23 8W) RIGHT REAR TURN SIGNAL 12V 32cp (23W> RIGHT FRONT TURN SIGNAL 12V 33 3cp (23 8W) RIGHT REAR TURN SIGNAL 12V 32cp (23W> BRAKE AND TAILLIGHT 12V 32 3cp(27 0W) LEFT REAR TURN SIGNAL...

Headlight Adjustment

Adjust vertically by turning the vertical adjustment screw. Adjust horizontally by turning the horizontal adjusting screw. * Adjust the headlight beam as specified by local laws and regulations. An improperly adjusted headlight may blind oncoming drivers or H may fail to tight the road for a safe distance.

Clutch Disassembly

* Ai clutch components, except for the clutch outer, can be serviced by removing the clutch cover. 'The right crankcase cover does not reed to be removed. Remove the clutch cover, gasket, Ooinp, and dowel pins. Shift the transmission into 4th gear and apply the 'ear brake. NOTE. * When tlie engine Is not in the frame, shift the transmission into 4th gear and hold the output dbven shaft with a shaft holder 057923 6890101). Lock nut wrench 07916 4220000 Remove die lock washer, spring set plate...

Bearing Race Replacement

Remove the upper bearing outer race with the ball race rernov-TOOL Ball race remover 07953 MJ10000 or Remove the lower hearing outer race with the ball race remover and attachment. Bali race rem over attachment Lower 07953 MG80100 Always replace the bearing and races as a set. Remove the lower bridge cover by removing the attaching d HEADLIGHT BRACKET Remove the headlight bracket by removing the mounting nuts from the steering stem bottom side. Gr * G,T rr (3) MOUNTINGNLlt (2.) STEERING STEM...

Voltage Regulatorrectifier

Disconnect the voltage regulator rectifier connectors. Remove the voltage regulator rectifier by removing the attaching bolts. Check the continuity between the leads with an ohmmeter. * The test results shown are for a positive ground ohmrneter and opposite results will be obtained when a negative ground ohmrneter is used. i i (51 IGNITION CONTROL MODULE R Red Bl Black W White Y Yellow Bu Blue G Green

Gear Tooth Contact Pattern Check

Remove the drive shaft and driven gear bearing holders. Apply Prussian Blue to the driven gear teeth. install the drive shaft and driven gear bearing holders with the standard shims. Rotate the drive gear several times in the normal direction of rotation. Check the QBcir tooth contact pattsrn 3it r removing ths drive Contact is normal if Prussian Blue is transferee to the approximate center of each tooth and slightly to the toe. If the pattern is not correct, remove and replace the driven gear...

Oil Strainer Oil Pump

To remove the oil pomp, perform the following - clutch assembly removal section 7 . gearshift linkage removal section 7 , Remove the oil pump driven sprocket. Remove the oil pump by removing the mounting bolts. Remove tire oil suction pipe and oil strainer from the oil pump 2 OIL. SUCTION PIPE body. relief valve from the oil pump. O-rfny from the relief valve relief valve snap ring. Disassemble the relief valve. Check the spring and piston for wear or damage. m n mwr Check the valve fo, dogging...

Valve Seat Refacing

Valve Refacing

Use a 45 degree cutter to remove any roughness or irregularities from the seat. Valve seat cutter 35 mm 07780 0010400 IN Vaive seat cutter 42 mm 07780-0010900 EX Valve seat cutter holder 8.6 mm 07781 0010201 or equivalent commercially available in U.S.A. Ref ace the seat with a 45 degree cutter when a valve guide Is replaced. Use a 32 degree cutter to remove the top 1 4 of the existing valve seat material, Valve seat cutter 33 mm 07780-0012900 IN Valve seat cutter 42 mm 07780-0013000 EX Vaive...

Specifications

Overall length Overall width Overs height Wheel base Seat height '87 - '90, '92 '93 After '931 87 '90, '92 - '93 After '93 Ground clearance '87 '90, '92 '93 Front suspension, travel Rear suspension, travel Gross vehicle weight rating Vehicle capacity load front Tire size Rear tire size 2,378 791 1,200 1,651 660 690 305 31 7 1 35 138 242 262 mm 93,5 in mm 31.1 in mm 47.2 in mm 65.0 in mm 25.9 in mm 27.2 in mm 12.0 in mm 1 2.5 in mm Ei.3 in mm 5.4 in kg 534 lbs kg 578 ibs 426 kg 1940 lbs US, 430...

Output Drive Shaft Bearing Replacement

Place the output gear case in a vise with soft jaws, being careful not to distort it. Place the shaft holder on the driven gear shaft, wedging it against the vise to lock the shaft. U.nstake the bearing inner race lock nut with a drill or grinder. Be careful that metal particles do not enterthe bearing andthe threads on the shaft are not damaged. Remove the bearing inner lock nut and discard it. TOOLS Lock nut wrench, 30 x 64 mm 07916 MB00001 Unstake the bearing outer lock nut with a punch....

Torque Value For Rear Axel Nut On Honda Vt 1100

Fsnal gear case attaching bolt Rear axle pinch holt Rear brake arm Shock absorber mounting bolt Upper Svvinganri right pivot bolt lock nut Damper lock nut '8 -'90 i I After 91 Brake torque link nut 90 N-m 9,0 kg-m, 65 ftdta 65 N-m 6.5 kg-m, 47 ftrlh 27 N-m 2.7 kg-m, 20 ft-ib 27 N-m 2.7 kg-m, 20 ftdb 23 N-m 2,3 kg-m, 1 ft-ib 35 N-rn 3.5 kg-m, 25 ft-ib 105 N-m 10.5 kg-m, 76 ft-ib 18 N-m 1.8 kg-m, 13 ft-ib 1 15 N-m 11.S kg-m, 88 ft-ib 33N m 3.3 kg-m, 24 ft-lbi 48 N-m 4.8 kg-m, 35 it-lb 22 N-m 2.2...

Clutch Assembly

TORQUE 40 iSJ-m 14.0 kg-m, 29 ft-Ifa Install the rear brake middle arm, aligning the punch marks on TORQUE 27 N-m 2.7 kg-m, 20 ft. ib Fill the crankcase with the recommended oil page 2-10 . Coat the clutch discs and plates with clean engine oil. Install the six discs and plates with the grooves in the discs d facing to the same direction as indicated on the clutch center, Install a new O-ring into the groove in the clutch center. Coat the O-ring with clean engine oil and install the pressure...

Valve Guide Replacement

Chill the replacement guides In the freezer section of a refrigerator for about an hour. Heat the cylinder head to SOCC'C 121 2 F with a hot plate or oven. To avoid hums, wear heavy gloves when handling the heated cylinder head. Do not use a torch to heat the cylinder head it may cause warping. Support the cylinder head and drive out the old guides from the combustion chamber side of the cylinder head. Valve guide remover 07742 0010200 or Avoid damaging the cylinder head. Drive new guides in...

Clutch Master Cylinder

Drain the clutch fluid from the clutch hydraulic system, page 7-4 . Remove the rear view mirror and clutch lever. Disconnect the clutch switch wires from the switch. Remove the clutch hose from the master cylinder. Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced. When removing the oil bolt, cover the end of the clutch hose to preven t con lam nation, Ramose the master cyllndei holder and master cylinder. Remove the dutch...

Cable Harness Routing

Note the following when routing cables and wire harnesses A loose wire, harness or cable can be a safety hazard. After q. clamping, check each wire to be sure it is secure, Do not squeeze wires against welds or clamps. Secure wires and wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses. Leave a little slack when routing harnesses. Avoid pulling the harness too tight...

Emission Control Systems

Environmental Protection Agency and California Air Resources Board fCARB require manufacturers to certify that tbe.r motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km 3,730 miles after the time of sale to the ultimate purchaser, when operated and maintained...

Engine Lacks Power

Raise wheels off ground and spin by hand 2. Check tire pressure. PRESSURE NORMAL 3. Accelerate rapidly from low to second, ENGINE SPEED DROPS WHEN CLUTCH IS RELEASED 4. Accelerate lightly. ENGINE SPEED INCREASES 5. Check ignition timing. CORRECT 8. Check hydraulic tappet conditions CORRECT 7. Test cylinder compression. NORMAL 8. Check carburetor for clogging. NOT CLOGGED 10. Check oil level and condition. CORRECT 11. Remove cylinder head cover and inspect i u b r i c a t. i o n. 2 Worn or...

Output Driven Gear Bearing Replacement

Remove the stopper ring out of the groove. Remove the output driven gear oil seal from the driven gear bearing holder. Remove the driven gear bearing holder mounting bolts and the hoidei from the output gear case. Lock nut wrench, 30 x 64 mm 07916--MB00001 Remove the O-ring and shim from the bearing holder. Remove the output driven gear bearing Inner race lock nut. Place the output driven gear bearing holder in a vise with soft jaws. Onstake and remove the output driven gear bearing outer race...

Cylinder Head Cover Installation

Honda Vt1100 Cam Timing Marks

Place the 'tappet in a container filled with kerosene Pia cs the tsppei bleeder into the tsppet, Moid the tappet upright and pump the tappet until air bubbles stop coming out. Remove the tool, and try quickly to compress the tappet by hand. You should not be able to compress it Remove the tappet from the fluid keeping it upright. 2 ALIGNMENT , ' ' SLOTS 31 EXHAUST ROCKER ARMSHAFT install the shims into each hydraulic tappet hole of the cylinder Install the hydraulic tappets into the cylinder...

Left Crankcase Bearings

Motorcycle Mechanics Institute

Remove the output gear assembly page 11-17 . Heat the left crankcase around the mainshaft and countershaft bearings to 80 C I176 F . Always wear gloves when handling a heated crankcase. Remove the mainshaft and countershaft bearings with following tools Bearing remover, 20 mm 07936 3710600 Remover handle 07936 3710100 Remover weight 07936- 3710200 or Drive new bearings into the left crankcase with following Attachment, 52 x 55 mm 07746-0010400 Install the output gear assembly page 11-29 ....

Hydraulic Tappet Adjustment

Tool Adjust Tepet Motorcycle Honda

Whenever replacing the following parts, the hydraulic tappet must be adjusted with shims. Valve stem, valve guide and valve seat refacing. Rocker arm and rocker arm shaft. Camshaft. After bleeding the oil in the hydraulic, tappets with the tappet bleeder, install the tappets into the cylinder head. Install the cylinder head cover and tighten the 6 mm bolts, 8 mm bolts and 8 mm and 10 mm cap nuts to the specified torque. 8 mm cap nut 27 N-m 12,7 kg-m, 20 ftdb 10 mm cap nut 40 N-m 4 0 kg-m, 23 ft...

Front Cylinder Note

If the rear cylinder has not been serviced, remove the rear cylinder head cover and check the rear cylinder camshaft position as follows Remove the timing hole cap, turn the crankshaft clockwise and align the RT mark on the primary drive gear with the index mark on the right crankcase cover, then check the indentification mark on the camshaft flange. If the R mark on the camshaft flange faces up, torn the crankshaft clockwise 495 and begin installation of tire front camshaft. If the R mark...