Page 3 Honda investigate all such ways . Anyone using service procedu res or tool s , whether or not recommended by Honda, m ust satisfy h imself...
Page 4: Table Of Contents
This Model S pecific Manual includes every service proce Frame/Body Panels/Exhaust System d u re that is of a specific nature to this particular m odel . Basic service procedu res that are common to other Honda Maintenance M otorcycle/Motor Scooter/ATVs are covered in the Com...
Page 5: How To Use This Manual
How To Use This Manual Finding The Info rmation You Need This manual is devided into sections which cover each of the • m ajor comonents of the motorcycl e . T o quickly find t h e section you a r e i nterested in, t h e first page of each sections is m arked with a black tab that lines up with one of the t h u m b index tabs before this page .
Page 6 Example: Molykote® G-n Paste manufactured by Dow Corning , U . S . A . Honda Moly 60 ( U . S . A . only) Rocol ASP manufactured by Rocol Limited , U . K . Rocol Paste manufactured by Sumico Lubricant, Japan �...
Page 7 MEMO...
Page 8: General Information
General Information Lubrication & Seal Points 1-17 General Safety Cable & Harness Routing 1-20 Model Identification Emission Control System (U.S.A. Only) 1-27 Specifications 1-12 Torque Values Emission Control Information Labels 1-30 (U.S.A Only) 1-15 Tools General Safety Carbon Monoxide Used Engine/Transmission Oil If the engine must be running to do some work, make sure the area is well ventilated.
Page 9: Coolant
General Information Coolant Nitrogen Pressure For shock a bsorbers with a gas-fi lled reservoir: Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible . If the ethylene glycol does ignite, you will not see any flame, but you can be burned .
Page 10: Model Identification
General Information Model Identification '94 MAGNA VF750C shown ( 1) FRA M E SERIAL N U M BE R ) The frame serial number is stamped on the r i g h t side o f t h e steering head .
Page 11: Specifications
General Information General Specifications Item '94-'00 Overall length 2,332 mm (91.8 in) After 2,338 mm ( 9 2 0 in) width Overall 854 mm (33.6 in) height OveraA (VF750C) 1,136 mm (44.7 in) (VF750CD) 1,1go mm (46.9 in) 1,652 mm Wheelbase Seat height 7 10 mm (28 in)
Page 12 General Information General (Cont'dl Item Specifications Carburetor Carburetor type CV (Constant Velocity) type, with flat valve Venturi diameter 33 mm (1.30 in) Clutch system Multi-plate, wet Drive Train Clutch operation system Cable operating Transmission 5 speeds Primary reduction 1.939 (64/33) Secondary reduction Third reduction Final reduction...
Page 13 US qt, Imp qt) at oil filter change 3. 1 ( 3. 3 2. 7 Use Honda GN4 4-stroke Oil or equivalent Recommended engine oil API Service Classification: SF or SG OIL VISCOSITIES Viscosity: SAE 1 0W - 40 Other viscosities shown in the chart may...
Page 14: Cylinder Head
General Information Unit: mm (in) Cylinder Head ---- -- -- -- -- --.- -- -- -- -- -- -- -- -.- -- -- -- -- -, Item Standard Service Limit 1,275 (184.9 13.0 Cylinder compression psi, kg/cm2)/ Cylinder compression synchronization difference 0.16 0.02 (0.006 0.001)
Page 15 General Information Unit: mm (in) Standard Service Limit Item 10-20 (0.4-0.8) Clutch lever free play 24.995-25.012 (0.9841-0.9847) 25.08 (0.987) Cl utch outer guide I . D . 44.4 (1. 75) 41.2 (1.62) Clutch spring free length 2.5 (0.10) 2.92-3.08 (0.115-0.121) Clutch disc thickness A 2.92-3.08 (0.115-0.121) 2.5 (0.10)
Page 16 General Information Unit: mm ( i n ) Transmission -- -- -- -- -- -- --.- -- -- -- -- -- -- -- -- -,- -- -- -- -, Service Limit Item Standard Transmission gear I . D . M 5 2 8 .
Page 17: Front Suspension
General Information Unit: mm ( i n ) Wheel/Tires Standard Service Limit Item 1.5 (0.06) Minimum tire tread depth (FR) 2.0 (0.08) (RR) (2.50 (200 Cold tire pressure U p to lb) load (FR) kg/cm2, psi) (200 (2.50 Up to lb) load ( R R ) k P a kg/cm2,...
Page 18 General Information Unit: mm (in) attery/ harging System Item Standard Service Limit Alternator/charging coil resistance (at 20°C/68°F) 0.1-1.0 0 Regulator/rectifier regulated voltage/amperage 14-15.5 V/below 0.5 A/3, 000 rpm Battery capacity 12 V-10 Ah Battery charging rate (Normal) 1.2 A (5-10h) (Quick) 5 A (1h) Battery voltage (fully charged 20°C/68°F)
Page 19: Torque Values
General Information Torque Values Standard Torque Torque Fasteners Type Fasteners Type N·m (kg-m, ft-lb) N·m (kg-m, ft-lb) 5 (0.5, 3.5) 4 (0.4, 3) mm hex bolt and nut mm screw 9 (0.9, 7) 10 (1.0, 7) mm screw mm hex bolt and nut 22 (2.2, 16) 9 (0.9, 7) mm flange bolt (8 mm head )
Page 20 General Information Engine Thread Torque Item Q'ty Remarks dia. (mml N·m (kg-m, ft-lb) Clutch/Gearshift Linkage 12 (1.2, 9) Right crankcase cover bolt Clutch cable holder bolt 23 (2.3, 171 Clutch spring bolt 12 (1.2, 9) ('94) C l utch center lock nut 90 (9.0, 65) N ote 5, '94)
Page 21 General Information Frame Torque Thread Remarks Item O'ty N•m (kg-m. ft-lb) dia. (mm) Front Suspension : 23 (2.3, 17) Handlebar upper holder bolt 12 (1.2, 9) Front fender bolt page 12-12 105 (10.5, 76) Steering stem nut lock nut 30 (3.0, 22) Steering head bearing adjusting nut 27 (2.7, 20) Fork pinch bolt (upper)
Page 23 General Information Description Tool Number Applicability Rear Wheel/Suspension : Bearing remover shaft 07746-0050100 07746-0050600 Bearing remover head, 07746-0010300 Attachment, 07746-0040500 Pilot, 07746-0010400 Attachment, 07746-0010500 Attachment, 07746-0040600 Pilot, 07959-3290001 Shock absorber compressor Driver shaft 07946-MJ00100 07949-3710001 U.S.A. only 07946-1870100 Attachment, 07746-0041000 Pilot, 07746-0010100 Attachment,...
Page 24: Lubrication & Seal Points
VaJve lifter outer sliding surface Camshaft lobes/journals M3/4, C5 and shifter gear (shift fork grooves) Shift fork shaft sliding area Shift drum Primary drive gear sliding area Each gear Cylinder head cover gasket mating surface Honda Bond A (cover side) 1-17...
Page 25 General I nformation ngme Location Material Remarks Right crankcase cover rubber plate bolt threads Locking agent Clean and apply to the threads Drive chain guard bolt threads Apply are a : 5.5-7.5 Crankcase sealing bolt threads Oil pump d riven sprocket bolt threads Cam chain tensioner sli pper bolt threads Cam chain slipper bolt threads Mainshaft bearing set plate bolt threads...
Page 26 Speedometer cable Steering stem lock nut threads Flywheel bolt threads and flange surface Handle grip inner surface Honda Bond Honda Hand Grip Cement (U.S.A. only} Silicone grease Front brake lever pivot and piston tips Brake caliper pin bolt sliding surface...
Page 27: Cable & Harness Routing
General Information Cable & Harness Routing ( 1) LEFT HANDLEBAR (8) RIGHT HANDLEBAR SWITCH WIRE HARNESS SWITCH WIRE HARNESS (6) COMBINATION METER WIRE HARNESS (2) CLUTCH CABLE (5) HIGH BEAM/TURN "SIGNAL/ NEUTRAL INDICATOR WIRE HARNESS 3) SPEEDOMETER CABLE (10) 9P-RED CONNECTOR (TURN SIGNAL SWITCH HORN SWITCH, DIMMER SWITCH)
Page 28 General Information (5) IGNITION SWITCH WIRE (2) EVAPORATI VE HARNESS EMISSION PURGE CONTROL VALVE (3) CLUTCH CABLE 1-21...
Page 30 General Information FRONT PULSE SECON DARY A I R I NJECT I O N CONTROL VALVE (CALI F O R N I A TYPE O N LY) EVAPO RATIVE E M I S S I O N CAR B U R ETOR AIR VENT C O NTRO L VALVE (CALI F O R N I A TYPE ONL Yl FUEL TAN K B REATHER...
Page 34: Emission Control System
Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons. Crankcase Emission Control System The crankcase emission control system routes crankcase emissions through the air cleaner and into the combustion chamber.
Page 35 General Information Exhaust Emission Control System (Pulse Secondary Air Injection System) California type only The exhaust emission control system consists of a pulse secondary air injection system which introd uces filtered air i nto the exhaust gases i n the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system .
Page 36 General I nformation Evaporative Emission Control System ( California Type Only) This vehicle compl ies with the Cal ifornia Air Resou rces Board req uirements for control of evaporative em issions . Fuel vapor from the fuel tank and carburetor is routed into the evaporative emission canister where it is a bsorbed and stored while the engine is stopped .
Page 37: Emission Control Information Labels (U.s.a Only)
General Information Emission Control Information labels (U.S.A. Only) An Emission I nformation Label is located on t h e frame a s show n . T h e right s i d e cover must be removed t o v i e w i t . It g ives basic tune-up specifications.
Page 38: Frame/Body Panels/Exhaust System
2 . Frame/Body Panels/Exhaust System 2- 3 Service Information 2- 1 Front Side Cover Removal/I nstallation 2- 1 Exhaust System Removal/I nstallation Trou bleshootin g 2- 7 Seat Removal/Installation Rear Fender Removal /Installation U pper Fairing Removal/Installation Fuel Tank Removal/Installation (VF7 50C D ) Side Cover Removal/Installation Service Information...
Page 39 Frame/Body Panels/Exhaust System Seat Removal/Installation Remove t h e seat b y removing t h e th ree mounting bolts . BOLTS During seat installation, align the seat hook with the frame hook and holes of the seat with the bosses on the side covers . I nsta ll the three mounting bolts .
Page 40 Frame/Body Panels/Exhaust System Side Cover Removal/Installation P u l l t h e cover bosses from t h e grom mets . Slide the cover boss down from the hole in the seat and re ( 1 ) HOLE move the side cover. NOTE Be careful not to damage the boss .
Page 41 Frame/Body Panels/Exhaust System Exhaust System Removal/Installation ( 1 4) 2 1 ( 2 . 1 . 1 5) 39 ( 3 . 9. 28) ( 2 ) 4 4 ( 4 . 4 , 3 2 ) ( 8 ) 21 ( 2 .
Page 42 Frame/Body Panels/Exhaust System NOTE When insta l l i ng the exhaust pipe/muffler, always tig hten the exhaust pipe joint nuts first, then tighten the mounting • fasteners, see next pag e . Q 'ty Procedure Remarks Removal Order I nstallation is in the reverse order of removal . I nstal lation (page 2-61 ( 1 ) Rear exhaust pipe protector...
Page 43 Frame/Body Panels/Exhaust System Rear Exhaust Pipe Protector Installation I nstal l the rubber cap to the rear exhaust pipe hoo k . A l i g n t h e h o o k o f t h e rear exhaust pipe with groove o f t h e rear exhaust pipe protector .
Page 44 Frame/Body Panels/Exhaust System Rear Fender Removal/Installation ( 1 ) ( 5) NOTE Route the wire harness properly (page 1 -20) . • Requ isite Service Side covers removal/installation (page 2-3) Seat remova l/installation (page 2-2) . • • Procedure O'ty Remarks Removal Order I nstal lation is in the reverse order of remova l .
Page 45 Frame/Body Panels/Exhaust System Upper Fairing Removal/Installation (VF 7 50CD) CAUTION Do not scratch and damage the windscreen . • Procedure Q'ty Remarks Removal Order I nstal lation is in the reverse order of remova l . ( 1 ) Upper fairing mounting bolt Upper fairing At i nstallation, align the tab of the upper fairing stay with the hole of the cable g u i g e .
Page 46 Frame/Body Panels/Exhaust System Windscreen Replacement ( 1 ) STAYS Remove the screws, plastic washers and rubber washers . Remove the wi ndscreen and upper fairing stays . I nsta llation is in the reverse order of remova l . (3) PLASTI C WAS H E R (4) SCREW...
Page 47 MEMO...
Page 48: Maintenance
3 . Maintenance 3- 1 Valve Clearance Service I nformation 3 -8 Service Access G u ide Drive Chain Headlight Aim 3- 1 0 Maintenance Schedule 3- 5 Air Cleaner Service Information Refer to Common Service Manual for items not included in this manual . •...
Page 49 Maintenance Service Access Guide The following shows the locations of the parts that m u st be removed for the m a i ntenance items listed below. • Refer to the Common Service Manual for items not included in this manual . Refer to section 2 ( F rame/Body Panels/Exhaust System ) .
Page 50 Maintenance ( 1 ) Synchronization Adjusting Screw ( 1 3) Air Cleaner (Carbu retor synchronizatro n ; page 5- 1 4) ( Contamination, clogging, replacement; page 3-5) M iddle cover Fuel tank • • ( 1 2) C l utch lever ( Free play) (2) Fuel line (Damage, leakage) ( 1 1 ) Steering Head Bearing ( Damage) ( 1 0) Suspension...
Page 51: Maintenance Schedule
Steering Head Bearings Note Should be serviced by an authorized Honda dealer, unless the owner has the proper tools and service data and is mechani cally qualified . * * I n the i nterest of safety, we recommended these items be serviced only by an authorized Honda dealer.
Page 52: Valve Clearance
Maintenance Air Cleaner A I R D UCT STO PPER Remove the fuel tank (page 2-2) . Remove the front side cover (page 2-3 ) . Remove t h e two screws a n d airduct stopper. Remove the air duct by sliding it backward . Remove the nine screws and air cleaner housing cover/air cleaner.
Page 53 Maintenance Turn the crankshaft clockwise and align its "T 1 " mark with ( 1 ) I N DEX MARK the index mark on the right crankcase cover. Make sure that N o . 1 piston is at TDC (Top Dead Center) on the compression stroke.
Page 56 M aintenance locate the crim ped pin ends of the master li nk from the out side of the chain and remove the li n k with the d rive chain cutter . Drive chain cutter 07HMH-MR 1 0 1 02 or 07HMH-MR 1 0 1 0B ( U .
Page 58: Lubrication System
Lubricatio n System 4- 1 Oil Pump Removal/Installation Service Information Oil Pump Disassembly I Assembly 4- 1 Troubleshooting Lubrication System Diagram Service Information If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an •...
Page 59 Lubrication S y stem Lubrication System Diagra m AFTE R '94 CAM SHAFT ( 1 ) (9) OIL PRESS U RE RELIEF VALVE...
Page 60 Lubrication S y stem Oil Pump Removal/Installation 18 (1.8 , 1 3 ) : 0-ring N OTE Use ca re to keep dust or d i rt out of the engine. • After in sta l l ation, check that there a re no oil leaks. •...
Page 61 Lubrication S y stem Oil Pu mp Disassembly Assembly ( 1 3) ( 1 2) ( 1 1 ) ( 1 0) ( 1 ) NOTE If any portion of the o i l p u m p is worn beyond the specified service l i m it, replace it as a n assem bly. •...
Page 62: Fuel System
Fuel System 5- 1 4 Service Information Carburetor Synchronization 5- 1 6 Troubleshooting Pilot Screw Adjustment Air Cleaner Housing Removal/ High Altitude Adjustment 5- 1 7 Installation (U .S.A. Only) Carburetor Removal/Installation Evaporative Emission Canister (EVAP Canister) Removal/Installation Carburetor Separation 5- 1 8 (California Type Only) Carburetor Disassembly I Assembly...
Page 63: Troubleshooting
Fuel S y stem Troubleshooting Afterburn When Engine Braking is Used Engine Won't Start Too m uch fuel getting to the engine Lea n m ixtu re i n slow circuit • - Air cleaner clogged Ai r cut-off va lve ma lfu nction •...
Page 64: Air Cleaner Housing Removal/Installation
Fuel System Air Cleaner Housing Removal/Installation Requisite Service Fuel ta n k remova l/i nsta l lation (page 2-2) Air cleaner remova l/i nsta l lation ( page 3-5) • • Procedure Q'ty Remarks Removal Order Insta l l ation is in the reverse order of remova l . ( 1 ) Left m i d d l e cover stay bolt Right m iddle cover stay bolt...
Page 65: Carburetor Removal/Installation
Fuel S y stem Carburetor Removal/Installation...
Page 66 Fuel System Gasoline is extremely flammable and is explosive under certain conditions. • Work i n wel l venti lated a rea. Smoking or a l l ow flames or spa rks i n the worki ng a rea or where gasol i n e is stored ca n •...
Page 67: Carburetor Separation
Fuel S y stem Carburetor Separation ( 1 ) � (26) 5 -6...
Page 68 Fuel S y stem Requisite Service Carbu retor remova l/i nsta l lation ( page 5-4) Carbu retor synchron ization ( page 5- 1 4) • • Procedure Q'ty Remarks Separate No. 4 carb. from No. 1 /2/3 carb. ( 1 ) Air cha m ber screw Lock plate Air cham ber/a i r fu n nel...
Page 69: Carburetor Disassembly I Assembly
Fuel System Carburetor Disassembly Assembly (23) ( 1 2) ( 1 5) ( 1 4) � : 0-ring, gasket...
Page 70 Fuel S y stem N OTE Vac u u m cham ber, float chamber and jets ca n be serviced with out sepa rati ng the carbu reto rs. • N ote the location of the each ca rburetor parts so they can be back i n thei r origi na l locati o n. •...
Page 72 Fuel S y stem NOTE No. 1 carbu retor is the base carbu retor. Before tighte n i ng the carbu retor con necti ng bo lt/n ut, check there is no cleara nce between each of the carbu retor joi nts.
Page 73: Installation (California Type Only)
Fuel System Jet Needle Holder Removal/Installation ( 1 ) J ET N E E DLE HOLDER Removal Remove the vacu u m piston ( page 5-8) . Te m p o ra r i l y i n st a l l the 4 m m sc rew or e q u i v a l e n t (Exam ple;...
Page 75 Fuel S y stem Carburetor Synchronization � ( 1 ) V C U U M PLUG NOTE Refer to section 2 of the Co m m o n Service M a n u a l • for carbu retor synchron ization proced u re. Synchron ize the carbu retors with the engine at nor...
Page 76 Fuel S y stem Sta rt the engine. ( 1 ) THROTTLE STOP SCREW KNOB Turn t h e t h rott l e sto p sc rew knob and a dj u st t h e i d l e speed .
Page 77: Pilot Screw Adjustment
1 0. Perform steps 8 a nd 9 fo r the No. 2, 3 a nd 4 carbu retor pilot screws. 5- 1 6 Revised: July, 1 995, '94 - '95 Magna VF750C/CD © 1 995 American Honda Motor Co., Inc. - All Rights Reserved...
Page 78 T h i s adj u stment m u st be made at h i g h a ltitude to • ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER. ensure proper h i g h a ltitude operati o n .
Page 79 Fuel System Evaporative Emission Can ister (EVAP Canister) Removal/Installation (California Type Only) Disconnect the No. 4 tube. Disconnect the No. 1 tube. Remove the bolts and EVAP ca n i ster. Insta l lation is i n the reverse order of remova l . Pulse Secondary Air Injection ( 1 )AIR I N J ECTIO N HOSE Control Valve (PAIR Control Valve)
Page 80: Cooling System
Coo l i n g System 6- 1 Service Information Thermostat Removal/Installation 6- 1 Troubleshooting Radiator Removal/Installation Radiator Disassembly I Assembly System Flow Pattern Coolant Draining Water Pump Removal/Installation Service Information Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot •...
Page 81: System Flow Pattern
Cooling System Flow Pattern ( 1 ) SIPHON TU BE (5) TH E R MOSTAT (2) RESERVE TAN K (3) WATE P U M P 6 -2...
Page 83: Coolant Draining
Thermostat Removal/Installation Requisite Service Coolant d ra in i n g ( page 6-3) Coo l a nt refi l l i n g (Section 5 of the Com m o n Service • • M a n u a l ) Procedure Q' ty Remarks...
Page 84: Radiator Removal/Installation
Radiator Removal/I nsta l lation Requisite Service Coolant d ra i n i ng ( page 6-3) Front side cover rem ova l/i nsta l l ation ( page 2-3) • • Coolant refil l (Section 5 of the Common Service Manual) •...
Page 85: Radiator Disassembly I Assembly
Radiator Disassembly Assembly llli ii ii i' CAUTION Be careful not to damage the radiator core. Requisite Service Radiator remova l/i nstal l ation ( page 6-5) O 't y Procedure Remarks Assem bly is in the reverse order of d i sasse m bly. Disassembl y Order Radiator g ri l l R e l ease the two g rooves fro m u nd e r of rad i ator, t h e n...
Page 86: Water Pump Removal/Installation
�GN Water Pump Removal/Installation O I L P U M P S HAFT Requisite Service Coo l a nt refi l l ( S e ct i o n 5 of t h e C o m m o n S e rv i c e Coolant d ra i n i n g ( page 6-3) •...
Page 87 MEMO...
Page 88: Engine Removal/Installation
Removal/Instal lation Engine 7 - 1 Service Information Engine Removal/Installation Service Information During remova l and i n sta l lation, su pport the motorcycle using a safety stand or hoist. • The fol l owing components can be serviced with the engine i nsta l led i n the frame. •...
Page 90 Engine Removal/Installation CAUTION Do not support the engine using the oil filter. • NOTE S u pport the m otorcycle using safety sta nd or a hoist. • A floor jack or other adjusta ble su pport is req u i red to support a nd m a neuver the engine. The jack height m u st be •...
Page 91 En g ine Mounting Bolt lightening Procedure Loosely i n sta l l a l l engine m o u nting bolts, n uts a nd engine mounting bracket. Tig hten the 1 0 mm front cyl i nder head m o u nting bolts ®...
Page 92: Cylinder Head/Valves
Cyl i nder Head/Va lves 8- 1 Service Information Cylinder Head Removal/Installation Cylinder Head Disassembly I Assembly 8- 1 Troubleshooting Camshaft Removal Camshaft Installation Service Information F ront a n d rea r cyl inder head service ca n be done with the engine i n the fra me. •...
Page 94 N OTE Service the front cyli nder camshaft using the sa me proced u re as the rea r cyl i nder. • Remove the ca m chain tensioner before removi ng the camshaft. • The "T1 " ti m i n g ma rks on the sta rter cl utch a re for rea r cyl inder head service. •...
Page 95 Cyl inder · Head Removal/Installation ( 2 ) 44 (4.4, ( 1 ) 1 2 ( 1 .2, 9) 13 ( 1 .3, 9)
Page 96 NOTE Service the front cyl i nder head using the sa me proced u re as the rea r cyl i nder. • Apply e n g i n e o i l to the seat a n d threads of the cyl i nder head bo lts. •...
Page 97 Cylinder Head Disassembly Assembly HANDLAPP I N G TOOL DOWN ( page 1 - 1 5) � () � (3) G ROOVE �( 9 1 ---- --� ( 1 0) ( 1 1 )
Page 98 NOTE Service the front cyl inder head using the sa me proced u re as the rea r cyl i nder head. • M a rk a l l pa rts d u ring d i sassem bly so they can be placed back thei r orig i n a l position. •...
Page 99 AFTER ' 9 5 ( Except some '96 early production units) 1 2 ( 1 .2, ( 9) ( 1 ) 8 - 8 Revised : July, 1 995, '94 - '95 Magna VF750C/CD © 1 995 American Honda Motor Co., Inc. - All Rights Reserved...
Page 100 ( 1 1 ) Head cover gasket NOTE Apply Honda Bond A or equ iva lent to the head cover • a nd i n sta l l the gasket with " I N " m a rk facing the i ntake side.
Page 101 Camshaft Installation ( 1 ) EX or I N MAR K E a c h ca m s h a ft h a s an i d e ntificat i o n m a rk. I n sta l l t h e camshafts i n the correct positions, noting t h e identification m a rks below: Front Intake:...
Page 102 Cylinder Head/Valves Rear cylinder (cont'dl • Torq u e t h e c a m s h aft h o l d e r bo lts i n the seq u e nce shown. Torque: 1 2 N·m ( 1 .2 kg-m, 9 ft-lb) Turn the ca m chain tensioner shaft fu lly in (clockwise) secu re it using special tool .
Page 104 Front cylinder (cont'd) • ( 1 ) TE NS ION E R S HAFT Turn the cam chain tensioner shaft com pletely in (clock wise) and secu re it using the stopper tool . Th is tool c a n easily b e made from a thi n ( 1 m m thick ness) piece of steel.
Page 105 I nsta l l the ca mshaft holder dowel pins in the rea r cyl i nder head. Lubricate the camshaft journal su rfaces, ca mshaft holder and cam lobes with molybden u m d isu lfide oil. I n sta l l the camshafts onto the rea r cyl i nder head. Check that the "...
Page 107 I nsta l l the ca mshaft holders in the correct positio ns, check i n g the i ndetification m a rks on the holders an d cyl i nder head. I nsta l l the cam cha i n g u ide. (2) IDE NTIFICATIO N MARKS To rq u e the cam sh aft h o l d e r bo lts in the seq u e nce as shown .
Page 108 Remove the cam chain tensioner stopper tool . I n sta l l the cam chain tensioner sea l i n g bo lt a n d washer. Make s u re the ti m i n g ma rks on the camshaft sprockets a re level with the cyl inder head u pper edge.
Page 109 MEMO...
Page 110: Clutch System
Clutch System 9 - 1 Service Information Clutch Removal 9· 1 Troubleshootin g Clutch Installation Right Crankcase Cover Removal/ Installation Service Information Cl utch mai ntenance can be done with the engine i n the frame. • Transm ission oil viscosity a n d level have a n effect on cl utch d isengagement. When the c lutch does not d isengage or •...
Page 111 Clutch S y stem (6 ) 1 2 ( 1 . 2. 9) 27 (2.7. 20) 27 (2.7. 20) 20 - 30 m m 9 - 2...
Page 112 Clutch S y stem Requisite Service E n g i ne o i l d ra i n i n g/refi l l i n g • Procedure Q'ty Remarks Removal Order Insta l lation is in the reverse o rder of remova l , ( 1 ) Brake peda l pivot bolt/nut ( 2)
Page 114 Clutch S y stem N OTE When rem ovi ng the o i l p u m p d riven sprocket, loosen the sprocket bolt before removi ng the cl utch assem bly. The • bolt is treated with a locki ng agent so be ca refu l not to damage the bolt when loosen i ng . Requisite Service Right c ra n kcase cover rem oval ( page 9-2) Sta rter cl utch remova l ( page 1 7- 1 0)
Page 115 Clutch Clutch Installation ( 1 0)
Page 116 Clutch S y stem Requisite Service Sta rter cl utch in sta l lation ( page 1 7- 1 0) Right crankcase cover i nstallation ( page 9-2) • • Q'ty Procedure Remarks Installation Order ( 1 ) Col l a r C l utch outer guide NOTE Lubricate the i n ner and oute r sliding s u rfaces with...
Page 118: Gearshift Linkage
1 0. Gearsh ift Li n kage 1 0- 1 Service Information Gearshift Linkage Removal/ 1 0-4 Installation 1 0- 1 Troubleshooting Drive Sprocket Cover Removal/ 1 0-2 Installation Service I nformation The gearsh ift l i nkage m a i ntena nce ca n be done with the e n g i n e i n the fra me. •...
Page 119 Gearshift Linka g e Drive Sprocket Cover Removal/Installation (3 ) 1 0 ( 1 .0, 7) ( 1 2) ( 1 3) ( 1 4) 1 2 ( 1 .2, 9) 1 0- 2...
Page 120 Gearshift Linkage Procedure Q'ty Remarks Removal Order I nsta l lation is in the reve rse order of rem ova l . ( 1 ) Cl utch ca b le ho ld e r bolt ( 2 ) C l utch cable/h o l der Drive sprocket cover bolt Drive sprocket cove r G asket...
Page 121 Gearshift Linkage Gearshift Linkage Removal/Installation S H I FTE R PLATE ASSEM BLY ( 1 ) 1 0 -4...
Page 122 Gearshift Linkage N OTE G e ars h ift l i n kage service can be perfo rmed with the e n g i n e in the fra me. • When removi ng the wate r pu m p, it is not necessa ry to d iscon nect the water h oses. •...
Page 123 MEMO...
Page 124: Crankshaft/Piston/Transmission
1 1 . Cra n kshaft/ Piston /Tra nsmissio n 1 1 - 1 1 1 - 1 2 Service Information Countershaft Disassembly Assembly 1 1 - 1 1 1 - 1 4 Troubleshooting Crankcase Combination 1 1 -2 1 1 - 1 6 Crankcase Separation Crankshaft Bearing Replacement 1 1 - 1 8...
Page 126 Crankshaft/Piston/Transmission N OTE Before rem ovi ng the parts, m a ke a note of their locati on fo r correct i n sta l l ati on . • Requisite Service 7-2) E n g i n e remova l ( page 1 5- 1 0) Alte rnator cove r re m ova l (page •...
Page 127 Crankshaft/Piston/Transmission Crankshaft/Con necting Rod Removal/Installation AFTE R '94 1 2 ( 1 .2, 1 2 ( 1 .2. --:7J ( 1 ) 1 2 ( 1 .2, 33 (3.3, 1 2 ( 1 .2, ROTATI N G D I R ECTIO N 1 1 -4...
Page 128 Crankshaft/Piston/Transmission N OTE M a rk a l l pa rts d u ri n g d i sassembly so they can be re placed i n the i r ori g i n a l locations. • A l l bea ring inserts a re se l ect fitted a n d a re identified by co lor code. Select repl acement bea ri ngs from the code •...
Page 129 Crankshaft/Piston/Transmission Piston Disassembly Assembly ( 1 ) " I N " MARK I DE NTIFICATI O N ( 1 0) i n ) OR M OR E 1 1 -6...
Page 130 Crankshaft/Piston/Transmission N OTE Apply mo lybden u m d isu lfide o i l to the connecti ng rod sma l l end an d piston p i n . • Requisite Service 1 1 -4) Pisto n rem ova l ( page •...
Page 131 Crankshaft/Piston/Transmission Transmission Removal/Installation , (1) 1 1 -8...
Page 132 Crankshaft/Piston/Transmission N OTE Turn the m a i nshaft a n d cou ntershaft to ensure that the gears turn smoothly after reassem bly. • After i nsta l lati o n , l u b ricate gears with clean reco m m ended e n gin e o i l . •...
Page 135 Crankshaft/Piston/Transmission Countershaft Disassembly Assembly ALI G N O I L HOLES (22) ( 1 4) ( 1 5) (23) ( 1 5) ( 1 0) ( 1 8) ( 1 2) ( 1 3) ( 1 6) ( 1 7 ) ( 1 9 ) (20) S H I FTE R G EAR...
Page 136 Crankshaft/Piston/Transmission N OTE Apply mo lybde n u m o i l so l ution to the sh ifte r gear g rooves. Apply o i l to a l l s l i d i n g su rfaces of the m a i n shaft, c o u n •...
Page 137 Crankshaft/Piston/Transmission Crankcase Combination 1 2 ( 1 . 2, 91 3 1 (3. 1 , 2 2 1 ALI G N 23 (2.3, 1 71 < 1 1 1 - 1 4...
Page 138 Crankshaft/Piston/Transmission CAUTION Install the oil orifice with the larger inner diameter side facing the lower crankcase. • If the lower crankcase installation is difficult, make sure the transmission assembly is installed correctly. • N OTE Refe r to page 1 1 - 1 8 fo r cra n kcase sea l a nt a rea and deta i l of the bolt l ocati ons. •...
Page 140 Crankshaft/Piston/Transmission Connecting Rod Bearing Selection I n spect the con necti ng rod bea ring and cra n kpin oil clea r a n ce (See section of the Co m m o n Service M a n u a l ) . ( 1 , 2 Record t h e con necti ng r o d I .
Page 141 Crankshaft/Piston/Transmission Connecting Rod Selection T h e weight code is sta m ped on t h e co n n ecti ng rod u s i n g a n a l p h a betical code. I f a co n n ecti n g rod req u i res re p l a ce m e nt, you s h o u l d select a rod with the same weight code a s t h e o rig i n a l .
Page 142 Crankshaft/Piston/Transmission Loose ly i nsta l l a l l the u pper cra n kcase bo lts, the sea l i n g U PPER CRAN KCASE S I D E : was h e rs a n d ca b l e g u i de. To rq u e the 1 0 bo lts, a n d then the 6 bo lts.
Page 143 MEMO...
Page 144: Front Wheel/Suspension/Steering
1 2. Front Wheel/Suspension/Steeri n g 1 2- 1 1 2-6 Service Information Fork Removal/Installation 1 2- 1 1 2-8 Troubleshooting Fork Disassembly 1 2-2 1 2 - 1 0 Handlebar Removal/Installation Fork Assembly 1 2-4 1 2- 1 2 Steering Stem Removal/Installation Front Wheel Removal/Installation 1 2-5...
Page 146 Front Wheel/Suspension/Steering Contaminates in the system may cause a reduction or loss of braking ability. • N OTE U s i n g wi res, h a n g the front bra ke master cyl i n der at l east as h i g h as the positi on it was orig i n a l l y i n sta l l e d at to •...
Page 147 Front Wheel/Suspen sion/Steering Front Wheel Removal/Insta llation 59 (5.9, 43) ( 2 ) ( 1 ) 2 2 (2.2. 1 6) A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated • disc with a high quality brake degreasing agent. CAUTION Do not use the oil filter as a jack point.
Page 148 Front Wheel/Sus p ension/Steering Front Wheel Disassembly Assembly ( 2 ) ( 2 ) ( 1 ) 42 (4.2, 30) A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated • disc with a high quality brake degreasing agent. N OTE Always replace wheel bea rings as a set.
Page 149 Front Wheel/Suspen sion/Steering Fork Removal/Installation ( 9 ) 27 ( 2 . 7 , 20) 1 2 ( 1 . 2 , 9) ( 1 ) ( 1 0) 39 (3.9, 28) (5 ) ., 3 1 (3. 1 , 2 2 ) 1 2-6...
Page 150 Front Wheel/Sus p ension/Steerin g CAUTION Support the removed caliper so that it does not hang from the brake hose. Do not twist the brake hose. • N OTE If the fork legs wi l l be d i sassem bled, tem porarily tig hten the bottom bridge pinch bolt to l oosen the fo rk cap. •...
Page 151 Front Wheel/Sus p ension/Steering Fork Disassembly (10) lr--- --. ..Ja!:§i l�l!'i( ( 1 2 � (4) ---- -- -s ( 1 8) � ( 1 9 � (7) � (15) lB--- -- -< 1 6) 1 7 1 1 2-8...
Page 152 Front Wheel/Sus p ension/Steering The fork cap is under spring pressure. Use care when removing it. Use face protection. • N OTE If the fo rk piston m oves with the socket bolt d u ri n g rem ova l , tem po ra ri l y i nsta l l the spri ng, spacer a n d the fo rk •...
Page 154 Front Wheel/Suspension/Steerin g N OTE Always replace the o i l sea ls with new ones. • Coat the new o i l sea l with the reco m mended fo rk o i l a n d i nsta l l it with its m a rk fac i n g u p . •...
Page 155 Front Wheel/Sus p ension/Steering Steering Stem Removal/Installation ,,, c 30 (3.0, 1 - 1 5) -� NOTE (5 ) 1 2- 1 3) ( 1 5) 1 2-1 3) (13) Use the specified grease : Urea based multi-purpose grease for EXCELITE SHOR T ER TABS: Extre m e pressure (example:...
Page 156 Front Wheel/Suspension/Steering N OTE Replace the bea rings a n d races as a set. • At i n sta l latio n , a p p ly g rease to a l l bea ring a rea. • Check the stee ring head bea ring preload ( page 1 - 1 0) after torq u i n g the ste m n ut. •...
Page 157 Front Wheel/Sus p ension/Steering Handlebar Lower Holder Nut Tightening Procedure I nsta l l the h a n d lebar l owe r h o l d e r. Loose ly i n sta l l the washers a n d n uts. I nsta l l the h a n d lebar and upper h o l d e r ( page 1 2-2).
Page 158: Rear Wheel/Suspension
1 3 . Rea r Wheel/Suspensio n 1 3- 1 1 3-6 Service Information Shock Absorber Removal/Installation 1 3- 1 1 3-7 Troubleshooting Shock Absorber Disassembly Assembly 1 3-2 1 3-9 Rear Wheel Removal/Installation Swingarm Removal/Installation 1 3-4 1 3- 1 1 Rear Wheel Disassembly Assembly Swingarm Disassembly...
Page 159 Rear Wheel/Suspension Rear Wheel Removal/Installation ( 1 5) ( 1 8) ( 7 ) 22 ( 2 . 2 . 1 6) 1 2 ) 93 (9.3, 63) ( 2 ) ( 9 ) ( 1 0) 1 3-2...
Page 160 Rear Wheel/Suspension Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry • brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers. A contaminated brake drum or shoe reduces stopping power.
Page 161 Rear Wheel/Suspension Rear Wheel Disassembly Assembly 1 08 ( 1 0.8, 79) ( 1 1 ) ( 1 0) 1 3-4...
Page 162 Rear Whee/Sus p ension Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry • brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers.
Page 163 Rear Wheel/Suspension Shock Absorber Removal/Installation 2 7 (2.7, 20) N OTE When servicing the shock a bsorber, support the m otorcycle u s i n g a safety sta nd or hoist. • Adj ust the shock a bsorber to the softest position fo r d i sasse m b ly. •...
Page 164 Rear Wheel/Sus p ension Shock Absorber Disassembly Assembly (3 ) Requisite Service Rea r shock a bsorber remova l/i nsta l lation ( page 1 3-6) • Procedure Q'ty Remarks Disassembly Order Assem bly is i n the reverse order of d i sasse m bly. U pper seat See page 1 3-8.
Page 165 Rear Wheel/Sus p ension Spring, Upper Seat Removal/Installation ( 1 ) COMPRESSOR I n sta l l t he sh ock a bsorber com presso r o n the s h ock a b sorber. Shock absorber compressor 07959 - 3290001 C o m p ress t h e s h oc k a bs o r b e r s p r i n g a n d re m ove t h e u pper seat.
Page 166 Rear Wheel/Suspension Swingarm Removal/Installation C as -� (7 1 (8.9, 651 39 (3.9, � 3 7 (3 . 7 , 2 7 ) Requ isite Service 1 3 -2) 10-2) Rear wheel rem ova l/i nsta l lation ( page Drive s procket cove r remova l/i nsta l latio n ( page •...
Page 167 Rear Wheel/Sus p ension ( 1 ) L O CK N UT Frame Pivot Adjustin g Bolt Adjustment � Removal Remove the pivot lock bolt. Remove the adjusting bolt lock n ut. NOTE R e m ove the lock n ut w h i l e h o l d i n g t h e a dj u sti n g •...
Page 168 Rear Wheel/Sus p ension Swingarm Disassembly Assembly ( 5 ) 22 (2.2, 1 6) � 6 (0.6, 431 (7 ) N OTE F o r p ivot bea ring replacement, see next page. • Requisite Service Swi n g a rm rem ova l/i nsta l l ation ( page 1 3-9) •...
Page 169 Rear Wheel/Sus p ension Swingarm Pivot Bearing Replacement Press the rig ht pivot bea ring ( b a l l bea ring) out of swi ngarm. 07946 - MJ00100 or Driver Shaft 07949 - 37 1 0001 (U.S.A. only) Set the need l e bea ring rem over o nto the l eft pivot bea ring ( need le bea ri n g ) as shown .
Page 170: Brake System
1 4. Bra ke System 1 4- 1 Service Information Front Master Cylinder Removal/ 1 4-5 Installation 1 4- 1 Troubleshooting Front Master Cylinder Disassembly 1 4-2 Front Brake Pad Replacement 1 4-6 Assembly Front Brake Caliper Removal/ Rear Brake Panel Disassembly 1 4-3 Installation 1 4-7...
Page 171 Brake System Front Brake Pad Replacement ALI G N ( 2 ) 2 .5 ( 0 . 2 5 . 1 .8 ) ------- . - - - A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated •...
Page 172 Brake S y stem Front Brake Caliper Removal/Installation ( 3 ) 3 5 ( 3 .5 , 2 5 ) ( 1 ) ( 5 ) A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contam inated •...
Page 173 Brake S y stem Front Brake Caliper Disassembly Assembly 23 (2.3, 1 7) CAUTION Avoid spilling brake fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is • serviced. Requisite Service F ront bra ke ca l i pe r rem ova l/i nsta l latio n ( page 1 4-3) •...
Page 174 Brake S y stem Front Master Cylinder Removal/Instal lation ( 1 0) ( 2 ) 1 (0. 1 , 0.7) ( 1 ) 12 ( 1 .2, 9) CAUTION Avoid spilling brake fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is •...
Page 175 Brake S y stem Front Master Cylinder Disassembly Assembly 1 . 5 (0. 1 5, 1 . 1 ) ( 2 ) NOTE Replace the master piston , spring, cu ps, stopper p late, s n a p ring a n d boot as a set. •...
Page 176 Brake S y stem Rear Brake Panel Disassembly Assembly � 29 (2 .9, 2 1 ) ( 1 ) � ( 1 0) Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry •...
Page 177 Brake System Brake Pedal Removal/Installation ( 1 4) 27 (2.7, 20) Procedure Q' ty Remarks Removal Order I n sta l l ation is i n the reverse o rd e r of rem ova l . ( 1 ) B rake rod adj usti ng n ut ( 2 ) B rake rod spri ng...
Page 178: Charging System/ Alternator
1 5. Charg i n g System/ Alternator 1 5- 1 1 5-6 Service Information Charging System Inspection 1 5-2 1 5-7 System Location Regulator/Rectifier 1 5-3 1 5-9 Troubleshooting Alternator 1 5-5 1 5- 1 0 Battery Removal/Installation Alternator Removal/Installation Service i nformation The battery gives off explosive gases;...
Page 180 Troubleshooting Battery Overcharging Fa u lty reg u lato r/rectifier • Battery Undercharging N OTE I n order to o bta i n an accu rate test read i n g when c h a rg i n g the system , the battery m u st be fu l l y c h a rged a n d i n •...
Page 181 Abnorm a l Check t h e voltage between t h e reg u lat o r/recti- Open c i rc u it in wire h a rness fi e r batte ry c h a rg i n g l i n e a n d g ro u n d l i n e Poorly connected con n ecto rs •...
Page 182 Battery Removal/Installation N OTE Always turn the i g n ition switch OFF befo re re m ovi n g or i nsta l l i n g the batte ry. • Requisite Service Seat rem ova l/i nsta l lation ( page 2-2) •...
Page 183 Charging System Inspection ( 1 ) A M M ETER Leakage Test Turn the i g n ition switch off, a n d d iscon n ect the g ro u n d (-) cable from the battery. Connect the a m m eter (+) probe to the g ro u n d ca b l e a n d the a m m eter (-) probe t o the battery (-) term i n a l .
Page 184: System Inspection
Disco n n ect the sta rte r re lay switch con n ecto r a n d remove ( 1 ) (+) PR OB E: R E D/WH ITE the m a i n fuse (30 A). Reco n n ect the co n n ecto r o nto the re lay switc h. C o n n ect the a m m eter betwee n the fuse h o l d e r term i n a l s as shown.
Page 185 Charging System/ Alternator Unit Inspection Provided the ci rc u it on the wi re h a rness side is n o rm a l a n d there a re no loose co n n ections a t the co n n ecto rs, i n spect t h e reg u l ator/rectifi e r u n it by m e a s u r i n g t h e res i sta nce between the term i n a ls.
Page 186 Alternator N OTE It is not necessa ry to remove the stato r to m a ke this • test. Remove the fuel ta n k ( page 2-2 ) . Disco n n ect the a lternator 3P con n ecto r. Measu re the resista nce between the Ye l l ow wi re term i n a l s a n d c h e c k fo r n o conti n u ity betwee n e a c h term i n a l a n d body g ro u n d .
Page 187 Alternator Removal/Installation 0 12 (1. 2 , 9) ( 7 ) ) c 12 (1. 2 , 9) LIQU I D SEALANT AREA 1 5- 1 0...
Page 188 N OTE The e n g i n e o i l wi l l run out when the l eft cra n kcase cove r is re m oved . Set a clean o i l pa n u nd e r the e n g i n e a n d a d d •...
Page 189 MEMO...
Page 190 1 6. I g n ition System 1 6- 1 1 6-9 Service Information Ignition Coil Removal/Installation 1 6-2 System Location Ignition Control Module (ICM) 1 6- 1 0 Removal/Installation 1 6-3 Troubleshooting Ignition Pulse Generator 1 6-8 Ignition System Inspection 1 6- 1 1 Removal/Installation 1 6-8...
Page 192: Troubleshooting
Troubleshooting I n spect the fo l lowi ng befo re d iagnosing the system . • - Loose spa rk p l u g caps o r spark p l u g wi re con nections. - Wate r i n the spa rk plug ca p. - Loose o r poo r contact of i g n ition system co n nectors.
Page 193 Ignition System C h eck the n e utra l switc h at the i g n ition con trol module (ICM) co n n ector ( page 1 6-8). Connection: Black/Light green - Ground Standard: Continuity in neutral Abnormal No continuity in any gear except neutral N o r m a l Connection: Light green/Red - Ground...
Page 194 No Spark At Either Ignition Group If there is no spa rk at either g ro u p, the problem is proba bly i n the primary coi l side of the i g n ition system ( i g n ition •...
Page 195 No Spark At One Plug (Trouble In Secondary Coil Side) Fau lty spark p l u g is m ost l i kely. • R e p l a c e ( s u s p e c t e d bad s p a r k p l u g ) w i t h known g o o d s p a r k p l u g a n d c o n d u ct s p a r k test.
Page 196: Ignition System
Engine Starts, But Side Stand Switch Does Not Function NOTE The side sta nd switch s h o u l d fu nction as fo l l ows: When the tra nsm ission is sh ifted i nto a gear from neutra l with the side sta n d down, the i g n ition s h uts off a n d the •...
Page 197: Ignition System Inspection
Ignition System I nspection N OTE C h eck t h e syste m co m po n e nts a n d wi res ste p- by • ste p a c c o r d i n g to t h e t ro u b l e s h o ot i n g c h a rt o n pages.
Page 198: Ignition Pulse Generator Inspection
R e m ove the fuse b o x stay bo lts a n d fra me grou n d ca b l e . 1 6-9 Revised: July, 1 995, '94 - '95 Magna VF750C/CD © 1 995 American Honda Motor Co. , I n c . - All Rights Reserved...
Page 199: Ignition Control Module (Icm) Removal/Installation 1 6- 1
(2) P R I MARY WIRES Remove the spark p l u g caps from spark pl ugs. ( 1 ) BOLTS Discon nect the i g n ition coi l pri m a ry wi res from the coi l . Remove the i g n ition coil m o u nting bolts a n d fro nt i g n ition coils.
Page 200 Ignition Pulse Generator Removal/Installation Requisite Service R i g ht cra n kcase cover re mova l/i nsta l lation ( page 9-2) • F u e l ta n k rem ova l/i n sta l l ation ( page 2-2) •...
Page 201: Ignition Liming
Ignition liming N OTE The i g n ition co ntro l m o d u l e ( I C M ) system is facto ry • p re - s et a n d c a n n ot be a d j u st e d . I g n i t i o n t i m i n g i nspection proced u res a re g iven to i n spect the fu nc...
Page 202: Electric Starter/Starter Clutch
1 7 . E lectric Starter /Starter Cl utch 1 7- 1 1 7-8 Service Information Starter Motor Disassembly/Assembly 1 7-2 1 7- 1 0 System Location Starter Clutch Removal/Installation 1 7-3 1 7- 1 2 Troubleshooting Starter Clutch Disassembly/Assembly 1 7-7 Starter Motor Removal/Installation Service Information...
Page 204 Electric Starter/Starter Clutch Troubleshooti ng N OTE Check fo r the fo l l owi ng befo re tro u b l eshooti ng the system . • - B l own m a i n fuse (30 A ) o r s u b fuse ( 1 0 A). - Loose batte ry and sta rte r motor cable.
Page 205 Electric Starter/Starter Clutch Abnormal C h eck fo r l oose or poorly c o n n ected sta rte r Poorly con nected batte ry te rm i na l s moto r cable, a n d o p e n ca ble. O p e n c i rc u it i n sta rte r m otor ca b le •...
Page 206 Electric Starter/Starter Clutch N o Vo lta ge C o n n ect the sta rte r re l a y switc h co n n ecto r. Fau lty i g n ition switch With t h e i g n i t i o n switc h O N a n d t h e sta rte r Fau lty e n g i n e sto p switch •...
Page 207 Electric Starter/Starter Clutch Abnormal Check the cl utch switch operatio n . F a u lty cl utch switch • N o r m a l A b n o r m a l Check the side sta nd switch ( page 1 8-9) . Fau lty side sta n d switch •...
Page 208 Electric Starter/Starter Clutch Starter Motor Removal/Installation With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. • N OTE R oute the wi re a n d cables properly ( page 1 -20). •...
Page 209 Electric Starter/Starter Clutch Starter Motor Disassembly Assembly ( 1 ) 5 (0.5, 3.6) ( 1 6) ( 2 ) ( 3 ) � ALI G N 1 7-8...
Page 210 Electric Starter/Starter Clutch Requisite Service Sta rte r m otor re m ova l/i nsta l lati o n ( page 1 7-7 ) . • Q'ty Remarks Procedure Disassembly Order Asse m bly is i n the reve rse order of d isasse m b ly. ( 1 ) Case bolt A l i g n the i ndex m a rks on the fro nt cove r a n d case .
Page 211 Electric Starter/Starter Clutch Starter Clutch Removal/Installation W I D E G ROOVE 90 (9.0, 1 7- 1 1 ) SCREW DR IVE R 1 7- 1 0...
Page 212 Electric Starter/Starter Clutch Requisite Service 9-2) 1 6- 1 1 ) R i g ht cra n kcase cover re mova l/i n sta l lati on ( page Pu lse generato r re m ova l/i nsta l lati o n ( pa g e •...
Page 213 Electric Starter /Starter Clutch Starter Clutch Disassembly Assembly (7 ) ( 1 ) ( 2 ) 4 0 ( 4 . 0 , 2 9 ) Requisite Service Sta rter cl utch rem ova l/i nsta l latio n ( page 1 7- 1 0 ) . •...
Page 214: Lights/Meters/Switches
1 8. Lig hts/Meters/Switch es 1 8- 1 Service Information Combination Meter Disassembly 1 8-8 Assembly 1 8-2 System Location 1 8-9 Ignition Switch Replacement 1 8-3 Troubleshooting 1 8-9 Side Stand Switch 1 8-5 Bulb Replacement 1 8-6 Headlight Removal/Installation Combination Meter Removal/ 1 8-7 Installation...
Page 216 Troubleshooting Coolant Temperature Indicator Turn the i g n ition switch O N , check that the tem perat u re i n d icato r l ig ht comes on fo r 3 seconds then goes out. • Coolant Temperature Indicator Remain ON I nd icator Disco n n ect the coo l a nt tem perat u re i n d icator 1--- S h o rt c i rc u it i n Li g ht g ree n/B lack wi re...
Page 217 Lights/Meters/Switches Coolant Temperature Indicator Remains OFF I n d icator does not come on Disco n n ect the cool a nt tem peratu re i n d icato r 1--- -- -- --. B l own i n d icator b u l b •...
Page 218: Headlight Bulb
Bulb Replacement ( 1 ) R ETAI N E R Headlight Bulb A halogen headlight bulb becomes very hot while • the headlight is ON, and remain hot for a while after it is turned OFF. Be sure to let it cool down before servicing.
Page 219 Headlight Removal/Installation An improperly adjusted headlight may blind on-comil'!g drivers, or it may fail to light the road for a safe distance. • N OTE Adj ust the hea d l i g ht bea m as specified by loca l laws a n d reg u l ations. •...
Page 220 Combination Meter Removal/Installation N OTE Ro ute the wi res a n d cables properly ( page 1 -20). • Requisite Service U pper fa i r i n g re mova l/i nsta l latio n (VF750CD: page 2-8) F ront side cove r re mova l/i nsta l lati o n ( page 2-3) •...
Page 221 Combination Meter Disassembly Assembly ( 1 ) SCREWS Remove t h e screws a n d c l a m ps. Remove the meter rea r cover and mete r stay. P u l l the i n d icator b u l bs out of the m eter. Remove the wi re h a rness c l a m p .
Page 222 Ignition Switch Replacement Remove the l eft m i d d l e cover stay assem bly ( page 5-4). Remove the screw a n d i g n ition switch cove r. Remove the i g n ition switch m o u nti ng bo lts us i ng a d ri l l, then rem ove the switc h .
Page 223 MEMO...
Page 224: 19. Wirin G Dia G Ra M
19. Wirin g Dia g ra m '94 - 2000 : ,.,..,. . UGMT 12Y1.4WI2 11¥32/!CP � liLAC< ..BROWN YELlOW ORANGE BLUE LIGHT BLUE . GREEN · · · · · · STARTDtS'I'lT'OI UGHT GREEN "...
Page 225 ..After 2000: lAOCIMEltJI UGII T 12V1.4W X 2 IIIGH T II[AR TIA'I $1GML lAAlE AND l.t.llltc»>T 12V32/3cp REAR lAAKE UGtiT SWITCH 00 00 IQNITlCfi COIL BUCK 8< BROWN YELLOW ORANGE llltlE "' LIGHT lUI: GA£EN LIGHT GREEN PINK WHITE "' GRAY...
Page 226: Technical Feature
Tech n ical Featu re CT Bolt ( 1 ) STA N DARD TH R EAD Some pa rts of this m oto rcycle a re tig htened with the CT b o lts, i . e . C o m b i n a t i o n T h re a d b o lts w h i c h m a ke t h e fe m a l e th reads when they screw i n .
Page 227 MEMO...
Page 228: Troubleshooting
2 1 . Troubleshooti ng 2 1 -4 Engine Does Not Start Or Is Hard Poor Performance At High Speed 2 1 - 1 To Start 2 1 -4 Poor Handling 2 1 -2 Engine Lacks Power Poor Performance At Low And Idle 2 1 -3 Speeds Engine Does Not Start Or Is Hard To Start...
Page 229 Troubleshooting Engine Lacks Power Possible Cause 1 . Raise wheels off the g ro u n d W h e e l s Do N ot S p i n F reely B ra ke d ragg i n g a n d spin b y h a n d Worn or d a m aged wheel bearings Drive c h a i n too tig ht...
Page 230 Troubleshooting Possible Cause 1 1 . Check for e n g i n e ove rheati n g -- Overheati n g Excessive ca rbon b u i lt-u p in com- • ---- -- -- -- -. bu stion cha m be r N ot Overheati n g Use of poor q u a l ity fue l •...
Page 231: Poor Performance At High Speed
Troubleshooting Poor Performance High Speed Possible Cause 1 " Check i g n ition t i m i n g F a u lty I C M • Fau lty i g n ition p u lse g e n e rato r •...
Page 232: Air Cleaner
I ndex Air Cleaner I g n ition contro l Mod u l e ( I C M ) ..............Ho u s i n g Rem ova l/I n sta l lati on .
Page 233: Index
Index 1 5-2 System Location (Charg i n g System/Alternator) . . • . 1 7-2 ( E lectric Sta rter/Sta rter Cl utc h ) ....1 6-2 ( I g n ition System ) .
Page 234: Part Numbers
23. Appendix: Part Numbers Air Cleaner 23-2 Mark VF750C (1994-1997) 23-33 Air Suction Valve 23-3 Mark VF750C (1998-2003) 23-34 Alternator Mark VF750CD (1996-1997) 23-4 23-35 Battery Mark VF750C2 (1998-2000) 23-5 23-36 Bikini Cowl Muffler 23-6 23-37 Cam Chain 23-7 Oil Pump 23-38 Camshaft 23-8...
Page 235 Appendix A: Part Numbers Air Cleaner Description Q’ty Price Description Q’ty Price CLIP, DRAIN TUBE $2.45 STOPPER $11.42 15772-GB5-670 17259-MZ5-000 AIR CLEANER $47.21 TUBE A, BREATHER $3.22 17210-MZ5-000 17355-MZ5-000 COVER, A/CLNR HSG $67.73 SCREW (5X12) $2.02 17220-MZ5-000 90105-MB1-000 AIR CLEANER HOUSING $88.79 SCREW, PAN (5X19) $3.65...
Page 236 Appendix A: Part Numbers Air Suction Valve Description Q’ty Price Description Q’ty Price CLIP B, FUEL HOSE $4.67 PIPE, R. FR. AIR $47.54 16968-MC7-000 18640-MZ5-740 JOINT, VACUUM TUBE $12.51 GSKT, AIR FEED PIPE $1.96 17201-MG9-000 18645-MT4-730 CLIP, BREATHER TUBE $2.78 PIPE, L.
Page 237 Appendix A: Part Numbers Alternator Description Q’ty Price Description Q’ty Price GASKET $12.98 BOLT, FLANGE (6X60) $3.93 11636-MY7-000 90001-GHB-750 COVER, ALTERNATOR $329.16 BOLT, FLANGE (10X35) $4.76 11641-MZ5-920 (replaces 11641-MZ5-000) 90003-MN4-000 FLYWHEEL $386.83 BOLT, SOCKET (6X40) $3.18 31110-MZ5-004 90116-375-000 STATOR $332.99 WASHER (10X25X4) $4.76 31120-MZ5-004...
Page 238 Appendix A: Part Numbers Battery Description Q’ty Price Description Q’ty Price BATTERY (YTX12-BS) $69.17 BOX ASSY., BATTERY $86.89 31500-HF1-678 (replaces 31500-HA0-686, 50330-MZ5-000 31500-HF1-677, 31500-KM1-836, 31500- BODY, KEY $2.76 KM1-837) 83507-422-000 CABLE $25.07 STOPPER, KEY BODY $2.04 32401-MZ5-000 83508-KBG-000 (replaces 83508-438-000) CABLE, STARTER MOTOR $51.75 BOLT, SOCKET (5X9)
Page 239: Bikini Cowl
Appendix A: Part Numbers Bikini Cowl Description Q’ty Price Description Q’ty Price CLIP, SCREEN MOLDING $3.58 STAY B, R. COWL $17.18 64102-MJ0-000 64508-MZ5-870 MOLDING, WINDSCREEN $8.60 STAY B, L. COWL $17.18 64105-MZ5-870 64509-MZ5-870 WINDSCREEN $218.56 BOLT, SPECIAL (6X17) $2.84 64150-MZ5-870 90085-MZ1-000 WASHER $1.62...
Page 240 Appendix A: Part Numbers Cam Chain Description Q’ty Price Description Q’ty Price GSKT, TENSIONER HOLE $1.78 GUIDE, RR. CAM CHAIN $51.58 12194-HC5-740 14625-MZ5-000 GSKT, TENSIONER HOLE $1.67 STAY $23.11 12194-KW3-880 14627-MZ5-000 CHAIN, CAM $89.02 BOLT, FLANGE (6X10) $2.47 14401-MZ5-921 (replaces 14401-MZ5-003) 90004-GHB-600 (replaces 90001-GHB-600) TENSIONER, FR.
Page 241 Appendix A: Part Numbers Camshaft Description Q’ty Price Description Q’ty Price SEAL, EX. VALVE STEM $8.07 SHIM, TAPPET (1.375) $6.78 12208-ML0-721 14908-KT7-013 SEAL, VALVE STEM $7.69 SHIM, TAPPET (1.400) $6.78 12209-MZ5-003 14909-KT7-013 CAMSHAFT, FR. IN. $261.83 SHIM, TAPPET (1.425) $6.78 14110-MZ5-000 14910-KT7-013 CAMSHAFT, RR.
Page 242 Appendix A: Part Numbers Description Q’ty Price Description Q’ty Price SHIM, TAPPET (1.875) $6.78 SHIM, TAPPET (2.425) $6.78 14928-KT7-013 14950-KT7-013 SHIM, TAPPET (1.900) $6.78 SHIM, TAPPET (2.450) $6.78 14929-KT7-013 14951-KT7-013 SHIM, TAPPET (1.925) $6.78 SHIM, TAPPET (2.475) $6.78 14930-KT7-013 14952-KT7-013 SHIM, TAPPET (1.950) $6.78 SHIM, TAPPET (2.500)
Page 243 Appendix A: Part Numbers Carburetor Assembly 23-10...
Page 244 Appendix A: Part Numbers Description Q’ty Price Description Q’ty Price ROD SET, LINK $45.42 STAY, JOINT $21.11 16018-MZ5-600 16169-MZ5-670 JOINT SET $31.65 COLLAR $19.36 16026-MZ5-600 16172-MZ5-670 JOINT SET, FUEL $28.47 COLLAR $15.85 16027-MB6-671 16173-MZ5-670 JOINT SET $31.65 COLLAR $19.36 16027-MZ5-600 16174-MZ5-670 LEVER SET, LINK $31.51...
Page 245: Carburetor Components
Appendix A: Part Numbers Carburetor Components Description Q’ty Price Description Q’ty Price GASKET SET A $32.85 SCREW $1.73 16010-MZ5-600 16108-MW0-750 NEEDLE SET, JET $34.20 PISTON, VACUUM $119.21 16012-MZ5-600 16111-MZ5-600 NEEDLE SET, JET $33.85 PLATE, STAY $13.64 16012-MZ5-670 16119-MZ2-600 FLOAT SET $36.55 PLATE, STAY $13.96...
Page 246: Carburetor Side Cover
Appendix A: Part Numbers Carburetor Side Cover Description Q’ty Price Description Q’ty Price CVR, CARBURETOR SIDE $72.38 KEY, BLANK (TYPE1) $7.38 17255-MZ5-000 35121-MR1-770 BASE, R. $48.58 KEY, BLANK (TYPE2) $7.38 17256-MZ5-000 35122-MR1-770 BASE, L. $46.88 GROMMET, A/CLNR HSG $3.18 17266-MZ5-000 83551-GE2-000 PROTECTOR $12.13...
Page 247: Caution Label
Appendix A: Part Numbers Caution Label Description Q’ty Price Description Q’ty Price DIAGRAM $3.27 LABEL (R201) (TYPE1) $2.16 87135-MZ5-740 87565-MZ5-670ZA LABEL, HIGH ALTITUDE $5.02 LABEL (NH1) (TYPE2) $2.16 87139-463-670 87565-MZ5-670ZB LABEL, TIRE $3.78 LABEL (Y124) (TYPE3) $2.16 87505-MZ5-670 87565-MZ5-670ZC LABEL, DRIVE CHAIN $3.78 LABEL, FUEL (TYPEG) $2.33...
Page 248 Appendix A: Part Numbers Clutch Description Q’ty Price Description Q’ty Price SPROCKET $28.64 ROD, CLUTCH LIFTER $24.56 15131-ML7-000 22850-MZ5-000 CLUTCH (OUTER) $349.77 GEAR, PRIMARY DRIVE $167.74 22100-MZ5-010 (replaces 22100-MZ5-000) 23110-ML7-010 GUIDE, CLUTCH $22.93 SPRING $2.33 22116-MB0-000 23115-MG8-300 COLR, CLUTCH (OUTER) $8.11 BOLT-WASHER (6X25) $2.33...
Page 249 Appendix A: Part Numbers Crankcase Description Q’ty Price Description Q’ty Price CRANKCASE SET $2,318.80 O-RING (7.7X2.3) $1.45 11000-MZ5-000 91301-PC9-003 (replaces 91308-283-000, 91313-393-003) GUIDE, HOSE $7.62 11337-MZ5-000 PIN, DOWEL (8X14) $1.00 94301-08140 RECEIVER $22.47 22821-MZ5-000 BOLT, FLANGE (6X12) $0.72 95701-06012-00 SWITCH, OIL PRESSURE $32.20 35500-MJ4-024 BOLT, FLANGE (6X28)
Page 250 Appendix A: Part Numbers Crankshaft Description Q’ty Price Description Q’ty Price RING SET, PISTON $39.05 BRG B, RR. CONN ROD $9.09 13011-MT4-315 13235-ML7-690 RING SET (OS 0.25) $35.42 BRG C, RR. CONN ROD $10.18 13021-MT4-315 13236-ML7-690 RING SET (OS 0.50) $38.65 BRG D, RR.
Page 251: Cylinder Head Cover
Appendix A: Part Numbers Cylinder Head Cover Description Q’ty Price Description Q’ty Price COVER, BREATHER $73.92 PLUG, HEX. (6MM) $3.55 12230-MZ5-000 12392-MJ0-000 GASKET, BTHR CVR $12.02 CLIP B, TUBE $2.38 12231-MZ5-920 (replaces 12231-MZ5-000) 16106-KW7-900 COVER, FR. CYL HD $166.66 BOLT, CYL HD CVR $8.53 12311-MZ5-A00 (replaces 12311-MZ5-000) 90002-MZ5-000...
Page 252: Evaporation Canister
Appendix A: Part Numbers Evaporation Canister Description Q’ty Price Description Q’ty Price CLIP, TUBE $1.62 RUBBER $9.24 15772-MB3-000 17451-ME5-760 CLIP, BREATHER TUBE $3.09 TUBE $8.38 15772-500-010 (replaces 15772-500-013) 17525-MZ5-740 JOINT, FUEL TUBE $8.29 TUBE $12.94 16958-MB0-000 18630-MZ5-740 JOINT, VACUUM TUBE $12.51 JOINT B, WASHER TUBE $4.57...
Page 253 Appendix A: Part Numbers Frame Description Q’ty Price Description Q’ty Price COLR, FR. WHEEL SIDE $3.76 BOLT, FLANGE (8X25) $3.09 44311-045-670 90103-MZ5-000 FRAME $1,794.77 BOLT, FLG (12X265) $17.84 50100-MZ5-600 (replaces 50100-MZ5-000) 90105-MM8-880 FRAME $1,794.77 BOLT $3.51 50100-MZ5-740 90107-MJ1-000 PLATE, R. FR. $21.64 BOLT $22.76...
Page 254: Front Brake Caliper
Appendix A: Part Numbers Front Brake Caliper Description Q’ty Price Description Q’ty Price SEAL SET, PISTON $8.67 BOLT A, PIN $11.71 06451-GE2-405 45131-ML7-921 PAD SET, FR. $40.00 PIN, BOLT $6.00 06455-MS9-405 45131-166-016 SCREW, BLEEDER $5.07 BUSH, PIN $4.29 43352-568-003 45132-166-016 CAP, BLEEDER $3.96 BOOT B...
Page 255: Front Brake Master Cylinder
Appendix A: Part Numbers Front Brake Master Cylinder Description Q’ty Price Description Q’ty Price SWITCH, FR. STOP $15.44 MASTER CYLINDER SET $38.51 35340-MM5-600 45530-MN9-305 HOSE, FR. BRAKE $55.67 LEVER, R. HANDLEBAR $14.31 45126-MZ5-003 53175-MR1-671 BOOT $9.24 BOLT, R. $7.15 45504-410-003 90114-MA5-671 SPRING $4.15...
Page 256: Front Cylinder Head
Appendix A: Part Numbers Front Cylinder Head Description Q’ty Price Description Q’ty Price CYLINDER HEAD, FR. $834.03 BOLT, SOCKET (6X28) $1.60 12010-MZ5-315 90012-MZ5-000 CYLINDER HEAD, FR. $834.03 BOLT, FLG (6X45.5) $2.62 12010-MZ5-316 90017-MA6-000 GUIDE, VALVE (OS) $16.15 BOLT, FLG (6X39.5) $2.25 12204-MT4-305 90019-MA6-000...
Page 257: Front Fender
Appendix A: Part Numbers Front Fender Description Q’ty Price Description Q’ty Price CLAMP B, BRAKE HOSE $16.56 FENDER, FR. *R201* $154.96 45158-MZ5-000 61100-MZ5-000ZE GUIDE, FR. $5.15 PLATE, FR. FENDER $11.33 45451-473-000 61103-MZ5-000 FENDER, FR. *NH1* $154.96 BOLT (6X25) $3.07 61100-MZ5-000ZC 90080-MG8-000 FENDER, FR.
Page 258: Front Fork
Appendix A: Part Numbers Front Fork Description Q’ty Price Description Q’ty Price FORK ASSY., R. FR. Call For Price RING $3.55 51400-MZ5-912 (replaces 51400-MZ5-671) 51447-KA4-711 SPRING, FR. FORK $66.38 BOLT, FR. FORK $44.11 51401-MZ5-671 51454-MM9-671 COLLAR, SPRING $18.24 SEAL SET, FR. FORK $25.16 51402-KV3-701 51490-MN8-305...
Page 259: Front Wheel
Appendix A: Part Numbers Front Wheel Description Q’ty Price Description Q’ty Price WEIGHT (10G) $9.07 TIRE (120/80-17) $138.46 42704-MB0-000 44711-MZ5-024 WEIGHT (20G) $10.36 BOX ASSY. $73.35 42705-MB0-000 44800-ML7-691 WEIGHT, BALANCE (20) $10.36 GEAR, SPEEDOMETER $22.22 42705-MCF-D60 44806-ML7-691 WEIGHT, BALANCE (30) $10.36 WASHER $2.25...
Page 260: Fuel Tank
Appendix A: Part Numbers Fuel Tank Description Q’ty Price Description Q’ty Price CLIP, OIL DRAIN TUBE $5.73 RUB, RR. FUEL TANK $12.55 15771-551-000 17613-MR7-000 CLIP, BREATHER TUBE $3.20 CAP, FUEL FILLER $66.87 15772-500-010 (replaces 15772-500-013) 17620-KR3-751 T-JOINT $10.18 PROTECTOR, HOSE $4.04 16180-195-731 64233-MR7-300...
Page 261: Gasket Kit A
Appendix A: Part Numbers Gasket Kit A Description Q’ty Price Description Q’ty Price GASKET KIT A $171.63 GASKET, CYL HD $46.67 06111-MZ5-010 (replaces 06111-MZ5-000) 12251-MT4-014 (replaces 12251-MT4-004) GSKT, TENSIONER HOLE $1.78 GASKET, CYL HD CVR $22.42 12194-HC5-740 12391-MT4-000 GSKT, TENSIONER HOLE $1.67 GASKET, EX.
Page 262: Gearshift Drum
Appendix A: Part Numbers Gearshift Drum Description Q’ty Price Description Q’ty Price FORK, R. GEARSHIFT $52.64 COLLAR, DRUM STOPPER $6.36 24211-MZ5-000 24434-MR7-000 FORK $58.36 SPRING $3.40 24212-ML7-000 24435-KBV-000 FORK, L. GEARSHIFT $66.61 SPINDLE, GEARSHIFT $79.90 24213-ML7-000 24610-MR7-000 SHAFT $35.95 SPRING $5.71 24261-ML7-000 24651-MR7-000...
Page 263: Handle Switch Cables
Appendix A: Part Numbers Handle Switch Cables Description Q’ty Price Description Q’ty Price CABLE A, THROTTLE $25.63 BOLT, CABLE ADJ. $5.45 17910-MZ5-910 (replaces 17910-MZ5-000, 53192-268-000 17910-MZ5-770) MIRROR ASSY., R. $56.29 CABLE B, THROTTLE $25.63 88110-MZ5-003 17920-MZ5-910 (replaces 17920-MZ5-000, MIRROR ASSY., L. $56.29 17920-MZ5-770) 88120-MZ5-003...
Page 264 Appendix A: Part Numbers Handlebar Description Q’ty Price Description Q’ty Price HANDLEBAR $142.97 BOLT, SOCKET (8X32) $4.47 53101-MZ5-000 90154-ME9-000 HLDR, HANDLE (UPPER) $14.58 NUT, STEERING STEM $15.02 53131-MM8-000 90304-415-000 HLDR, HANDLE (LOWER) $25.84 NUT, FLANGE (8MM) $2.98 53231-MM8-000 90309-428-731 BRIDGE, FORK TOP $217.98 WASHER $3.51...
Page 265 Appendix A: Part Numbers Headlight Description Q’ty Price Description Q’ty Price HDLT (12V 60/55W) $182.85 BULB (12V60/55W) $7.65 33100-MK7-671 34901-MC7-601AH (replaces 34901-MC7- 601) RIM, HEADLIGHT $47.61 33101-MK7-671 CASE, HEADLIGHT $73.70 61301-MN0-003 STAY $8.07 33102-MK7-671 COLLAR $2.73 61304-292-000 SCREW, BEAM ADJ. $3.22 33103-MK7-671 STAY, HEADLIGHT...
Page 266 Appendix A: Part Numbers Mark VF750C (1994-1997) Description Q’ty Price Description Q’ty Price MARK A (TYPE1) $34.98 MARK A (TYPE3) $34.98 87121-MZ5-300ZA 87121-MZ5-300ZC MARK A (TYPE2) $34.98 87121-MZ5-300ZB 23-33...
Page 267 Appendix A: Part Numbers Mark VF750C (1998-2003) Description Q’ty Price Description Q’ty Price MARK (TYPE5) $24.02 MARK (TYPE7) $22.60 87121-MZ5-A00ZA 87121-MZ5-M10ZA MARK (TYPE6) $20.96 87121-MZ5-A40ZA 23-34...
Page 268 Appendix A: Part Numbers Mark VF750CD (1996-1997) Description Q’ty Price Description Q’ty Price MARK (TYPE10) $20.29 MARK (TYPE4) $21.73 64221-MZ5-870ZA 87121-MZ5-A10ZB MARK (TYPE9) $20.29 STRIPE, R. (TYPE1) $93.75 64221-MZ5-870ZB 87123-MZ5-950ZA STRIPE, RR. (TYPE1) STRIPE, R. (TYPE2) $93.75 80111-MZ5-950ZA 87123-MZ5-950ZB STRIPE, RR. (TYPE2) $96.40 STRIPE, R.
Page 269 Appendix A: Part Numbers Mark VF750C2 (1998-2000) Description Q’ty Price Description Q’ty Price STRIPE, RR. (TYPE5) $70.87 STRIPE, RR. (TYPE7) $71.89 80111-MZ5-A30ZA 80111-MZ5-A50ZA STRIPE, RR. (TYPE6) STRIPE, RR. (TYPE8) $73.13 80111-MZ5-A30ZB 80111-MZ5-A70ZA 23-36...
Page 270 Appendix A: Part Numbers Muffler Description Q’ty Price Description Q’ty Price MUFFLER, R. EX. $699.35 RUB, MUFFLER SETTING $4.98 18100-MZ5-003 18421-MB0-000 MUFFLER, L. EX. $699.35 COLLAR $5.22 18200-MZ5-003 18422-MB0-000 GASKET, EX. PIPE $4.22 CVR, L. FR. EX. PIPE $106.57 18291-MN4-920 18440-MZ5-003 RUBBER $1.95...
Page 271: Oil Pump
Appendix A: Part Numbers Oil Pump Description Q’ty Price Description Q’ty Price PAN, OIL $151.28 BOLT-WASHER (6X12) $4.00 11211-MZ5-000 90021-MM5-000 GASKET, OIL PAN $10.31 NUT, U (6MM) $2.15 11315-MY7-000 90301-473-003 FILTER SET, OIL $21.67 O-RING (6X2) $1.87 15010-MCE-H51 (replaces 15010-MW0-000) 91307-ML7-004 PUMP ASSY., OIL Call For Price...
Page 272 Appendix A: Part Numbers Pedal Description Q’ty Price Description Q’ty Price PEDAL, GEARSHIFT $54.18 BOLT, SOCKET (10X52) $5.04 24705-MZ5-700 (replaces 24705-MZ5-000) 90153-MW0-000 RUBBER, DUST SEAL $3.51 $0.55 24706-MK3-770 90201-700-000 ARM, GEARSHIFT $35.67 WASHER (10.3MM) $1.44 24706-MZ5-000 90527-230-000 COVER, DUST $5.67 DUST SEAL (17X23X3) $2.98 24724-422-000...
Page 273: Pulse Generator
Appendix A: Part Numbers Pulse Generator Description Q’ty Price Description Q’ty Price GEAR (21T/83T) $76.41 WASHER (12X30X4.5) $7.91 28101-ML7-920 90401-KK9-960 PIN (10X36.5) $6.56 WASHER (18X10.2) $2.84 28102-ML7-000 90405-ML7-000 GEAR (48T) $109.19 PIN, DOWEL (8X8) $2.73 28110-MB0-010 90702-MB0-000 FLANGE $73.01 BEARING (30X35X17) $26.51 28115-MZ5-000 91022-MB0-004 (replaces 91022-MB0-003)
Page 274 Appendix A: Part Numbers Radiator Description Q’ty Price Description Q’ty Price RADIATOR COMP $612.40 CLAMP B, WATER HOSE $6.13 19010-MZ5-P00 (replaces 19010-MZ5-671) 19506-KS6-700 SHROUD $57.00 CLAMP, HOSE (30-37) $10.95 19015-MZ5-003 19516-GAG-003 FAN, COOLING $42.05 CONNECTOR, GROUND $1.33 19025-MN4-003 32152-MB3-000 MOTOR ASSY., FAN $240.71 REFLECTOR, FR.
Page 275: Rear Brake Panel
Appendix A: Part Numbers Rear Brake Panel Description Q’ty Price Description Q’ty Price SHOE KIT, BRAKE $40.27 INDICATOR, RR. BRAKE $4.58 06430-MZ5-003 43145-ME5-000 AXLE, RR. WHEEL $47.41 SPRING, RR. $4.64 42301-MZ5-003 43151-346-000 COLR, RR. WHEEL SIDE $16.18 ARM, RR. BRAKE $26.58 42311-MZ1-610 (replaces 42311-MZ1-000) 43410-MZ5-000...
Page 276: Rear Cylinder Head
Appendix A: Part Numbers Rear Cylinder Head Description Q’ty Price Description Q’ty Price CYLINDER HEAD, RR. $834.03 BOLT, SOCKET (6X28) $1.60 12020-MZ5-315 90012-MZ5-000 CYLINDER HEAD, RR. $834.03 BOLT, FLG (6X45.5) $2.62 12020-MZ5-316 90017-MA6-000 GUIDE, VALVE (OS) $16.15 BOLT, FLG (6X39.5) $2.25 12204-MT4-305 90019-MA6-000...
Page 277: Rear Fender
Appendix A: Part Numbers Rear Fender Description Q’ty Price Description Q’ty Price REFLECTOR, REFLEX $10.55 SUB-FRAME, RR. $149.92 33741-MS6-921 80125-MZ5-000 RUB, METER CUSHION $2.33 GROMMET, SIDE COVER $2.25 37215-MA6-008 83601-MN5-000 GROMMET, ENG HGR $1.51 RUBBER $3.11 50370-HA2-770 84702-MF2-670 RUBBER, BATTERY $3.24 BOLT (8X56) $3.55...
Page 278: Rear Shock Absorber
Appendix A: Part Numbers Rear Shock Absorber Description Q’ty Price Description Q’ty Price SHOCK ABSORBER, RR. $306.24 BOLT, FLANGE (8X16) $3.18 52400-MZ5-672 (replaces 52400-MZ5-671) 90106-MB2-000 BUSH, RR. SHOCK $3.76 WASHER, PLAIN $1.91 52485-KR3-003 90501-MZ5-000 COLLAR, RUBBER BUSH $2.91 BOLT, FLANGE (10X35) $1.23 52486-GA7-003 95817-10035-00 (replaces 95801-10035-00)
Page 279: Rear Wheel
Appendix A: Part Numbers Rear Wheel Description Q’ty Price Description Q’ty Price SPROCKET (40T) $127.81 WEIGHT, BALANCE (30) $10.36 41200-MZ5-770 (replaces 41200-MA3-000, 42706-MCF-D60 (replaces 42706-MB0-000) replaces 41200-MZ5-670) TIRE, RR. $152.63 ARRESTER, NOISE $8.29 42711-MZ5-024 (replaces 42710-MZ5-004, 41212-MK4-010 (replaces 41212-MK4-000) 42711-MZ5-004) DAMPER, RR.
Page 280 Appendix A: Part Numbers Right Crankcase Cover Description Q’ty Price Description Q’ty Price COVER, R. CRANKCASE $405.03 BOLT, FLANGE (6X28) $2.16 11330-MZ5-920 (replaces 11330-MZ5-000) 90004-GHB-680 (replaces 90001-GHB-680) CAP (45MM) $25.67 BOLT, FLANGE (6X32) $2.96 11332-MZ5-000 90001-GHB-690 PLATE, R. COVER $14.84 O-RING (48.1X3.6) $3.11 11333-MV8-900...
Page 281 Appendix A: Part Numbers Seat Description Q’ty Price Description Q’ty Price RUB, SEAT MOUNTING $3.96 RUBBER B $3.96 77110-KA3-730 77215-GC2-000 SEAT ASSY. $308.50 SEAT ASSY., RR. $188.28 77200-MZ5-000 77300-MZ5-000 STAY A, RR. SEAT $15.89 BOLT (8X12) $3.07 77206-MZ5-000 90125-KR3-000 STAY B, RR. SEAT $12.82 NUT, FLANGE (6MM) $0.23...
Page 282: Side Cover
Appendix A: Part Numbers Side Cover Description Q’ty Price Description Q’ty Price RUBBER B, STOPPER $2.09 CVR, R. SIDE *R201* $142.83 50354-428-000 83650-MZ5-000ZE CAP, STEP HOLDER END $2.16 COVER, L. SIDE *NH1* $84.82 50713-ML0-720 83750-MZ5-000ZC GROMMET, A/CLNR HSG $2.96 CVR, L. SIDE *Y124P* $84.82 83551-300-000 83750-MZ5-000ZD...
Page 283 Appendix A: Part Numbers Speedometer Tachometer 23-50...
Page 284 Appendix A: Part Numbers Description Q’ty Price Description Q’ty Price BULB (12V3W) $1.68 CUSHION, RUBBER $2.44 34908-KM1-671 37255-MZ5-008 BULB (12V1.7W) $1.95 GROMMET, TACHOMETER $5.13 34908-MB9-871 37257-MK4-601 BULB (12V1.4W) $2.27 SOCKET $43.49 34908-MN8-700 37562-MZ5-008 METER, COMBINATION $974.79 BOX ASSY., PILOT $80.14 37100-MZ5-671 37600-MZ5-008 SPEEDOMETER ASSY.
Page 285 Appendix A: Part Numbers Stand Description Q’ty Price Description Q’ty Price SWITCH, SIDE STAND $41.75 BOLT $6.31 35070-MZ5-A80 (replaces 35700-MZ5-305) 90108-MR5-000 BAR, SIDE STAND $69.70 BOLT, SPECIAL (6X16) $1.84 50532-MZ5-000 90147-MCE-950 (replaces 90147-MK6-671) SPRING, SIDE STAND $6.04 NUT, SIDE STAND $2.84 50541-KV3-830 90203-MF9-710...
Page 286: Starting Motor
Appendix A: Part Numbers Starting Motor Description Q’ty Price Description Q’ty Price MOTOR ASSY., STARTER $455.40 RING $2.58 31200-MZ5-003 31207-KS5-901 TERMINAL SET, BRUSH $17.73 NUT-WASHER (6MM) $1.53 31201-KS5-901 90071-MB0-000 SPRING, CARBON BRUSH $2.20 O-RING $2.93 31204-KS5-901 91309-MA6-000 BOLT, SETTING $3.93 O-RING $1.82 31205-MN0-008...
Page 287: Steering Stem
Appendix A: Part Numbers Steering Stem Description Q’ty Price Description Q’ty Price CLAMP A, BRAKE HOSE $10.53 SCREW (6X12) $1.25 45131-MZ5-000 90164-028-000 CLAMP $6.60 THREAD $16.51 53105-MZ5-000 90302-425-830 STEM, STEERING $320.76 WASHER, LOCK $5.67 53200-MZ5-000 90506-425-830 DUST SEAL $9.20 BEARING, HEAD PIPE $30.15 53213-MB4-771 91015-KT8-005...
Page 288 Appendix A: Part Numbers Step Description Q’ty Price Description Q’ty Price PIN, STEP BAR JOINT $2.55 BAR, PILLION STEP $25.25 50603-033-010 50715-MN0-000 BAR, R. STEP $21.58 BOLT, HEX. (6X12) $0.53 50612-MR1-000 92101-06012-0A BRACKET, R. STEP $88.37 BOLT, CAP (6X12) $1.75 50615-MZ5-000 92501-06012-0A SPRING, STEP RETURN...
Page 289: Swingarm @ Drive Chain
Appendix A: Part Numbers Swingarm @ Drive Chain Description Q’ty Price Description Q’ty Price CHAIN SET, DRIVE $168.18 BOLT, FLANGE (6X12) $1.67 06405-MZ5-P20 (replaces 06405-MZ5-405) 90154-ML0-000 CHAIN SET, DRIVE $307.34 NUT, U (14MM) $3.05 06405-MZ5-407 90305-GE8-003 CHAIN SET, DRIVE $168.18 WASHER A $1.04 06405-MZ5-P20...
Page 290 Appendix A: Part Numbers Taillight Description Q’ty Price Description Q’ty Price TAILLIGHT UNIT $103.47 COLLAR $9.98 33701-MZ5-671 80135-MZ5-000 LENS, TAILLIGHT $22.96 SCREW, TAP (4X40) $3.87 33702-MC4-671 90105-GAM-000 SOCKET, TAILLIGHT $51.15 WASHER (5MM) $2.33 33703-MZ5-671 91409-VM0-770 GSKT, TAILLIGHT LENS $3.31 BOLT, HEX. (5X35) $1.28 33709-KB7-003 92101-05035-0A...
Page 291 Appendix A: Part Numbers Tools Description Q’ty Price Description Q’ty Price BAG, SERVICE BOOK $3.38 SCREWDRIVER 1 (NO.2) $1.75 77251-GR1-000 99003-10000 TOOL SET $52.58 SCREWDRIVER 3 (NO.2) $0.82 89010-MZ5-000 99003-30000 WRENCH, PLUG (16.5) $19.29 GRIP $1.80 89216-MT3-000 99003-50000 WRENCH, HEX. (5MM) $4.22 HANDLE (12MM) $2.60...
Page 292 Appendix A: Part Numbers Transmission Description Q’ty Price Description Q’ty Price MAINSHAFT (13T) $146.95 WASHER (20X1.00) $2.02 23211-ML7-920 90454-428-000 PLATE $8.73 WASHER B (22MM) $3.89 23212-ML7-000 90455-ML7-000 COUNTERSHAFT $223.89 WASHER A (22MM) $3.89 23220-MT4-000 90456-ML7-000 GEAR (37T) $110.83 WASHER C (22MM) $3.89 23421-ML7-000 90457-ML7-000...
Page 293: Turn Signal
Appendix A: Part Numbers Turn Signal Description Q’ty Price Description Q’ty Price SUB-WIRE, R. RR. $14.73 TURN SIGNAL ASSY. $49.11 32360-MZ5-000 33600-MR1-000 SUB-WIRE, L. RR. $10.69 REFLECTOR, R. RR. $27.04 32365-MZ5-000 33605-MR1-000 WINKER LIGHT ASSY $49.09 TURN SIGNAL ASSY. $49.11 33400-MK7-P00 (replaces 33400-MN0-003) 33650-MR1-000 LENS, FR.
Page 294: Water Pipe
Appendix A: Part Numbers Water Pipe Description Q’ty Price Description Q’ty Price CLIP B, TUBE $2.38 BOLT, FLANGE (6X12) $2.33 16106-KW7-900 90004-GHB-610 (replaces 90001-GHB-610) PIPE, CONNECTING $17.71 GSKT, CONNECTING CAP $3.05 19507-MB0-000 91301-MB0-000 CAP A $32.62 O-RING (18.3X2.3) $1.42 19508-MZ5-000 91301-147-023 CAP B $41.04...
Page 295: Water Pump
Appendix A: Part Numbers Water Pump Description Q’ty Price Description Q’ty Price COVER, L. CRANKCASE $360.59 BOLT (6X95) $8.53 11340-MZ5-000 90025-MZ5-000 RUBBER, L. $33.87 BOLT, FLANGE (6X25) $2.11 11342-MZ5-300 90121-MV9-670 GASKET, L. $4.57 WASHER (6.5MM) $2.25 11343-MZ5-000 90463-ML7-000 GUIDE, DRIVE CHAIN $16.04 WASHER, TANK RUBBER $2.06...
Page 296: Wire Harness
Appendix A: Part Numbers Wire Harness Description Q’ty Price Description Q’ty Price RUBBER $4.22 SUSPENSION $3.71 30401-GB6-000 38306-GE7-000 RUBBER, SPARK UNIT $19.40 INDICATOR UNIT $66.65 30405-MT6-000 38710-MZ5-003 MODULE, IGN CONT $502.46 BRACKET, RR. $21.73 30410-MZ5-671 50333-MZ5-000 COIL, IGNITION $89.99 BRACKET, FR. $21.58 30510-KT7-023 50334-MZ5-000...
Page 297 MEMO...
Page 298 24. Appendix: Gasket Diagrams Alternator Cover Gasket 24-2 Cam Chain Tensioner Gaskets 24-3 Oil Pan Gasket 24-4 Right Crankcase Cover Gasket 24-5 Shift Cover Gasket 24-6 Sprocket Cover Gasket 24-7 NOTE • Diagrams must be printed without using any scaling to fit paper. •...
Page 299: Appendix: Gasket Diagrams
Appendix B: Gasket Diagrams Alternator Cover Gasket Description Part Number Alternator Cover Gasket 11636-MY7-000 Material Thickness Paper 0.0218” NOTE • Grey area is a thin bead of sealant 24-2...
Page 300: Cam Chain Tensioner Gaskets
Appendix B: Gasket Diagrams Cam Chain Tensioner Gaskets Description Part Number Cam Chain Tensioner Gasket - Front 12194-KW3-880 Cam Chain Tensioner Gasket - Rear 12194-HC5-740 Material Thickness Paper 0.0218” 24-3...
Page 301: Oil Pan Gasket
Appendix B: Gasket Diagrams Oil Pan Gasket Description Part Number Oil Pan Gasket 11315-MY7-000 Material Thickness Paper 0.0218” 24-4...
Page 302: Right Crankcase Cover Gasket
Appendix B: Gasket Diagrams Right Crankcase Cover Gasket Description Part Number Right Crankcase Cover Gasket 11394-MY7-000 Material Thickness Paper 0.0218” 24-5...
Page 303: Shift Cover Gasket
Appendix B: Gasket Diagrams Shift Cover Gasket Description Part Number Shift Cover Gasket 11632-MY7-000 Material Thickness Paper 0.0218” 24-6...
Page 304: Sprocket Cover Gasket
Appendix B: Gasket Diagrams Sprocket Cover Gasket Description Part Number Sprocket Cover Gasket 11343-MZ5-000 Material Thickness Paper 0.0218” 24-7...
Page 306 D RC 3750 .03.08 6 1 MZ509 H O N DA M OTO R CO. , LTD. TOKYO, JAPAN P R I NT E D I N U SA M A D E F R O M 5 0 % RECYCLED PAPER M I N I M U M 1 0% POST-CONSUMER CONTENT...

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Magna vf750cd

Honda Magna VF750C Service Manual

Introduction

1 General Information

5. Fuel System

6. Coo L I N G System

1 6. I G N Ition System

23. Appendix: Part Numbers

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Chapters

Troubleshooting

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