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    MANUAL DE SERVICIO HONDA VT750C2B PHANTOM

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    207 views622 pages

    Manual de Servicio Honda VT750C2B Phantom

    Uploaded by

    hugoDiaz1981

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    | eee ee herr N Vane Lys SHADOW SPIRIT™ VT75002B SHADOW PHANTOM™ HOW TO USE THIS MANUAL How To Use This Manual ‘This manual descibes te service procedures for te VI7S0C2/G2F/C2BICZS-A Tew ‘Note: Information whin this manual identified for the C2P mace! should also be used for tha C2 model Sections 1 and 3 apply tothe whole vehicle, Section 2 illustrates procedures for removalinstallation of components that may be required to pertorm service Gescribed in he flowing Sectinns, Section 4 through 22 deserve pars ol the motorcycle, grouped according to location. Follow the Maintenance Schedule recommendations to ensire that the vehicle js in peak operating concton Performing the fist Scheduled mainteneénce is very important. it compensates for the intial weat that occurs during the break-in period, Find the section you want on this page, then tm ¢o the table of contents on the fist page of the section ‘Most sections start with an assembly of system ilustration, service information and troubleshooting forthe section, The subsequent ‘pages give detailed procedure, Ifyou don't know the saurée af the trouble, go to Troubleshooting section 23 ‘Your safety, and the safely of others s very important. To help you make informed decisions we have provided safety ‘messages and other information throughout this manual. Of course, ii not practical or possible to wam you about all the hazards associated with servicing this vehice ‘You must use your own good judgement. ‘You wil find important safety information Ina varity of forms including + Safety Labels ~ on the vehicle + Safety Messages — preceded by # safely alent symbol A\ and eng cof thee signal words, DANGER, WARNING, or CAUTION. ‘Those signal words moan: WEBI 00 vit. be KiLL€D oF SERIOUSLY HURT it you don't fotow instructions PRAISE vou can be KILLED or SERIOUSLY HURT if you don't follow instructions. ERED you can be HURT ityou don't foiow instructions + Instructions ~ how to service this vehicle correctly andi safely, [As you read this manual, you wil find information that is preceded by a (ROME! symbol. The purpose ofthis message is to help prevent damage to your vehicle, other property, or te environment i HOw TO USE THIS MANUAL , SYMBOLS ‘The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifcally in the text without the use of the symbols, ’ 2 Replace the part(s) with new one(s) before assembly. Use the recommend engine oil, unless otherwise specified Use molybdenum oll solution (mixture ofthe engine oll and molybdenum gresse in a ratio of 1). Use mul-purpase grease (ithium based mult-purpose grease NLGI #2 or equivalent) Use molybdenum disulide grease (containing more than 8% mohybdenlm aisulids, NOGI #2 or equivalent) Example: + Molykote@ BR-2 plus manufactured by Dow Coming U.S.A. + Muit-purpese M-2 manufactured by Mitsubishi Oil, Japan. Use molybcenum disulfide paste (containing more than 40% molybdenum aisulids, NOGI #2 or ‘equivalent Example: ~ Molykate® 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. + Roco! Paste manufactured by Sumico Lubricant, Japan. Use silicone grease. mh. a a ia eH Se a) ‘Apply @ locking agent, Use @ medium strength locking agent unless otherwise specified se Apply sealant Use DOT 4 brake fuid. Use the recommended brake fluid unless otherwise specie. Use fork or euspension flu CONTENTS GENERAL INFORMATION En FRAME/BODY PANELS/EXHAUST SYSTEM Ha MAINTENANCE ENGINE AND DRIVE TARIN CHASSIS LUBRICATION sysTeM [FUEL SsYsTempomry) SS=~=S«di [_coounssysrem [ENGINE REMOVALINSTALLATION Ea [_SYLNDERHEADWALVE i. n° | LCLUTCHIGEARSHIFT LINKAGE ETN LLALTERNATORISTARTER CLUTCH EEN LCRANKSHAFTITRANSMISSION EE CFINALDRVE SSS RONTWHEELISUSPENSION/STEERING EEN FI REAR WHEEL/BRAKE/SUSPENSION - HYDRAULIC BRAKE ANTI-LOCK BRAKE SYSTEM (ABS; VT750C2S) ELECTRICAL BATTERY/CHARGING SYSTEM Eu WIRING DIAGRAMS ——=—S~S~S~S~S«i TROUBLESHOOTING Ea INDEX | | MEMO 1. GENERAL INFORMATION SERVICE RULES ~~ MODEL IDENTIFICATION GENERAL SPECIFICATIONS ~ LUBRICATION SYSTEM SPECIFICATIONS FUEL SYSTEM (PGM-FI) ‘SPECIFICATIONS - COOLING SYSTEM SPECIFICATIONS CYLINDER HEAD/VALVE ‘SPECIFICATIONS ~ CYLINDERIPISTON SPECIFICATIONS CLUTCHIGEARSHIFT LINKAGE ‘SPECIFICATIONS ~ ALTERNATOR/STARTER CLUTCH SPECIFICATIONS « CRANKSHAFT/TRANSMISSION ‘SPECIFICATIONS ~ FINAL DRIVE SPECIFICATIONS FRONT WHEELSUSPENSION/STEERING SPECIFICATIONS (VT750C2F/C2S) ~ FRONT WHEEL/SUSPENSION/STEERING ‘SPECIFICATIONS (V1750628} “4 13 REAR WHEEL/BRAKE/SUSPENSION ‘SPECIFICATIONS (VT750C2F/C2B) ~ 13 REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS (VT750C2S)- 1.14 HYDRAULIC BRAKE SPECIFICATIONS: (VT750C2F) ~ 114 HYDRAULIC (vT750C2B) TON! HYDRAULIC BRAKE SPECIFICATIONS (vT750C28)~ BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS: IGNITION SYSTEM SPECIFICATIONS. ELECTRIC STARTER ‘SPECIFICATIONS: LIGHTS/METERSISWITCHES SPECIFICATIONS (VT750C2F)-~ LIGHTS/METERS/SWITCHES SPECIFICATIONS (VT750C2B) LIGHTS/METERS/SWITCHES SPECIFICATIONS (VT750C2S)-~ STANDARD TORQUE VALUES: ENGINE & FRAME TORQUE VALUES: LUBRICATION & SEAL POINTS -~ CABLE & HARNESS ROUTING-~ EMISSION CONTROL SYSTEMS ~ GENERAL INFORMATION SERVICE RULES 1 2 3 Use genuine Honds or Honda-tecommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric fools when servicing the motorcycle, Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotier pins, and lock plates when reassembling ‘When tightening bots or nuts, begin withthe larger diameter or innar bott fst. Then lighten to the specified torque diagonally in Incremental sieps unless a particular sequence is specified Clean parts in cloaning solvent upon disassembly. Lubricate any sliding eurtaces before reassembly. Atier reassembly, check all parts for proper instalation and operation, Roule al electrical wires as shown in the Cable and Hamess Routing (page 1-26) ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. “Robrev term [Fina >7 (CKP sensor earth Fear sensor — oe DLC Data Link Connecior ore Diagnostic Trouble Code ECA Engine Control Module ECT sensor Engine Coolant Temperature sensor EEPROM Electrically Erasable Programmable Read Only Memory EOP swich [Engine OPressure switch HOS Honda Diagnostic System HISS: Honda Ignition Security Systeri = TACY, lale Air Control Valve 1 \AT sensor] _Inlake Air Temperature sensor SSS MAP sensor] Manifold Absolute Pressure sensor - [om Malfunction Indicator Lamp PAIR Pulse Secondary Air Injection PGM-FL Prograrnmed Ful injection { ‘SCS connector Service Check Short connestor TP sensor “Throtte Postion sensor VS sensor Vehicie Speed sensor } MODEL IDENTIFICATION Vr7sec2ic2ric2s shown: ST GENERAL INFORMATION 1-3 GENERAL INFORMATION SERIAL NUMBERS ‘The Vehiele Identification Number (Viti) is stamped on the right side of the steering head “The engine serial number is starnped on the right side of the crankcase. The throtle body identification number is stamped on the throttle positon sensor side cl the carburetor body. The safety certication labo! ig attached on the right side of the frame down lube 1-4 GENERAL INFORMATION LABEL ‘The color label is attached to the frame, behind of the let side cover. When ordering color-coded parts, aways specify the designated color code. The Emission Control Information Label is attached on the lef side of the frame down tube. GENERAL INFORMATION GENERAL SPECIFICATIONS TEM ‘SPECIFICATIONS. DIMENSION ‘Overal Teng VTFSOC2FIC2S: ASO min (65.7 in) 1750028: 2,395 mm (94.3 in) Overall width VI750C2FIC28: {835 mm (62.9 in) v1760028: 825 mm (32 5h) | Overall height VI 7S0C2F/VT7S0C28: 4,125 mm (44.3 in) vi1750028: Wheelbase VT75002F C28: 11655 mm (65.2 in) VT750028: 1,640 mm (64.8 in) Sesh halght {655 mm (25.8 in) Footpeg height 277 mm (10.9 in) Ground clearance 430 mm (6.1 in) ‘Curb weight VI7s002F: 246 kg (642 lbs) vi7s0c2s: 251 kg (659 Ibs) 1750628 (Canada 288 kg (549 Ibs) VI750028 (US.A) 250 kg (651 tes) Maximum VI7S0C2FIC28: 4184 kg (408 tbs) weight capacity VITS0C2B (U.S.A): 1750028 (Canada) 182 kg (401 Ibs) 186 kg (410 Ibs) FRAME Frame pe Frost suspension Front axle travel Rear suspension Rear axle travel Front tre size Rear tre size Tire brand (T750CzFr 2s) Tire brane (vT750C28) Front brake Rear brake Caster angle Trail length Fuel tank capacity vi7s002F/C2s: VTTs0628: vT7s002F C28: \VT750028: Front Rear Front Rear vr7s0c2s: VT750C2FIC28: vT75062F/C2s: \v7750628: VI 75002Fi028: 1750028: Double cradle Telescopic fork 115 mm (4.5 in) 117 mm (08 in) Swingarm 80 rom (3.8 in) -20!90-21MiC 54s 120/00-17M4C 648 +160/80-15MVC 758 EXEDRA G70 (BRIDGESTONE) D40aF (DUNLOP) EXEDRA G702 (BRIDGESTONE) D404 (DUNLOP) 6701 (BRIDGESTONE) DadaFG (DUNLOP) M002 (CHENG SHIN) 702 (BRIDGESTONE) (404 (DUNLOP) M6O11R {CHENG SHIN) Hyaraulie single dise Hydraulic singe dis Internal expanding show 34 30 38" 00 4158 mm (62 in) 161 mm (63 in) 14.0 Iters (3.70 US gal, 3.08 Imp gel) 11080 mm (42.9 in) - 1-6 GENERAL INFORMATION Starting system Charging system Regulatoriectiier Lighting system TEM PECIFIATIONS [ENGINE Gylinder arangement Tovinders 52" V wansverse Bote and stroke 79x 76mm (3.1 x30 in) Displacement 748 cm? (45.4 cuin) Compression ratio 96:1 Velve train Silent cam chain aiven, OH Intake valve ‘opens Front 6° BTOC (at 1 mii) Rear, 5 ATDG (at 1 mm it) closes 25" ABDC (at 1 mm lit) Exhaust vee pens 35° BBDC (at t mm it} closes, Front: 0° ATOG (al 1 mm ff Rear: BTDC (at 1 mm it) Lubrication system Forced pressure and wet sump On pump type Trochoid Cooling system Liquid cooled Aiefitation| Viscous paper element Engine dry weight 70.8 kg (156.1 lbs) Firing order Front- 308° Rear- 412° - Front Cytinder number Front: #2/Reer: #1 FUEL Type PGNEFT DELIVERY Throttle bore 34 mm (1.3in) SYSTEM, DRIVE TRAN |" Citch system Taateplate, wer Clutch operation system Cable operating Transmission Constant mesh, Sspeeds Primary reduction 41763 (67138) Secondary reduction 0.821 (92138) | Third reduction (Output drive recuction) 4.089 (18/17) Final reduction 3.081 (itt) Gear ratio st 2.400 (36/15) 2nd 1.860 (31/20) ara 4.174 27728) ath 0.960 (24/25) sth 0.882 (23/27) Gearshit pattorn Left col operated return system, 4eN-2-3-4-5 | ELECTRICAL Tgnion Systane Computercontoled cigtal Wansistorzed with electric advance: Electric starter motor Triple phase autput aternator SCR shorteditripie phase fullwave rectiica- tion Battery GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Uni: mm (in) TEM ‘STANDARD ‘SERVICE LMT Engine oT Capaciy Hi orainiog ZB iters ZEUS at. 2.21mp a = ‘Atob iter change 26 liters 2.7 US at 2.3imp ah = At disatsembl 3.2 ters (3.4 US at. 28 1mp at) = Recommended engine 6 Pro Honda GN4 4-stroke oil (USA. and ‘Canada) or an equivalent API service classification: $G or higher (except ois labeled as energy conserving - fon the circular API service label) Viscosity: SAE 10W-30 7 ASOT '903 standard: MA (Oi pressure at EOP switch 530 KPa (5.4 kgflem?, 77 pal) ai 5,000 | epmsig0°chi76"F) - ‘Oil pump rotor Tip cearance 0.15 (G06) 0.20 (0.008) Body clearance 0.15 ~0.24 (O008— 0008) —__~|_0.35 (0014) ‘Side clearance 0.02 = 0.08 (0.501 - 0.003) ~_ [5-10 (0.004) FUEL SYSTEM (PGM-Fl) SPECIFICATIONS Tew [SPEC IFIeaTIONS Taree Boy VITSOCRFICZS GOB3A identifeation number VITS0C26 GQSKA Engine idle speed 7200 # 100 pm Throttle grip freaplay = Bmm (716 — in) Fuel_ injector resstance | Front (2o"ci6s"F) Rear PAIR contol solenoid valve resistance @O°CSEF) Fuel pressure at idle 335— 353 KPa (4 — 36 Kalle 48— 51 pal) | Fuel pump flow (ot 12 Vj BOom* (17 US oz, 1.8 Imp oz) minimumMi0 seconds COOLING SYSTEM SPECIFICATIONS TEM ‘SPECIFICATIONS Coolant capacity Radiator and engine TE6 Hers (1.67 US at. +39 Imp qty Reserve tani 0.38 iter (0.40 US gt 0.33 Imp al) Radiata’ cap relict pressure TOS= 137 kPa (1.1 = 14 kglicm?, 16 20 pa) Thermostat Begints open BO- BAC (177 — 182°F) Fully open. ‘95°C (205"F) Valve if Bim (OT) minimum at S5°C (2OSFY Recommended antireeze Fro Honda HP coolant or an equivalent high qually ethylene alycol antifreeze containing silcate-free corrosion inhibitors ‘Skandard coolant concentration T= (midure with distilled water) 1 GENERAL INFORMATION CYLINDER HEAD/VALVE SPECIFICATIONS Unit: mm (in) TEN STANDARD] Cyne Gipression at 400 rp S879 ESRI E AOE TO RGIS 1ST ~ thos Valve dearance W018 4 002 oes TCHOT = EXT} 9204 0.02008 0.007) = ‘Cam chal ersioner wedge B ona = S(0zi Carshat Cam be het W ABU = BT 3E8 (AGT = ATOR, 37.16 CABS) EX ‘37.605 — 37.765 (7.4805 - 7.4868) 37.58 (7.480) Rinowt iiss = 0,05 (0.002) youre OD TIEX | 71.558 7.800 (0 5645-06864) 21.90 (0.862) ‘Oi cearanes IMEX —|~0'020 0.147 (00008-00086) O16 DOE) Rocker arm, | Rooker arm sha®B——| IWEX | “11.906 1.984 (04771 0.4718) 1183 (465) rocker arm Rocker arm 1.D. INIEX 12.000 - 12.018 (0.4724 - 0.4731) 42.05 (0.474) Stet Rect ao-shat learance 0.0f6 -0.052 (10006-00020) 2.07 005 Valo, Vaive slem OD. Ww 5.475 —5 490 (0.2156 - 0.2167) 345 (0.218) valve ude “EX 8.455— 5.470 (02TaO=87T8E) 541 0773) ‘Valve guide 11D. IN 5.500 - 5.510 (0.2165 - 0.2789) 5.56 (0.219) Ex | §500=8512 (02105-09170) 5 560.279) Siemie-guide Gearance [IN ——] 0.010 - 0.036 (0.0004 =0.00r4} OOO HOA) “EXT 0.080= 0057 (0.0012= 0.0020) 0.140.008) ave Gide pojecion | IN 187-189 (0796-0748) = above cyinder head EX) 72-174 (088-069) = Valve seat width IWEX) 0.80. 1.10 (0.035 - 0.083) 15 068) Vane sping | “Free feng WW 42.44 (1658) 40.58 (1588) Ba 171815 Bera (T707) Cynder Raat warpage = 0,10 (0.008) CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) rem STANDARO SERVICE LIMIT yinder TD: PE OO= THOS (G00 = 31TOBY 7708114) But-of-round = 0.06 (0.002) Taper = 106 002) Warpage = 0.100.008) Piston, Piston D0. a7 men 7) piston pin, baitom y 78.97 78,99 (3.108 9.140) 78,80 (3 106) Bistonrngs [Piston pn Bowe. 76.008 = 8.008 (07087 =0,TO5O) FOS OTH] Piston gin 0. 47,994 = 18.000 (0.7084 = 0.7087), 376 (0.708) Pistortoiston ph ceararae 602.014 (0.0001 - 0.0006) ga (0.002) Paonmngend gay Toe 0.15 0.25 (0006 - 0.010) os (ez) Second 028=040(0010= 0.018) TS 0.00) OneeeraN]—] 0.20080 (0.028— 003%) 101004) Patonmapiowe Too 0.025 = 0.085 (0.0010 = 0.0022) 108 (0.0037 —| groove clearance: ‘Second ‘0.015 = 0.045 (0.0006 = 0.0078) 0.07 (0.003) | ‘ylnderio-piion Gearono= ‘3.010 = 0.046 (0.0004 = 0.0018) c.1010 008) ——] Connecting rod small end TD, 1601S 18024 (© 7050=0.7100) 18.07 Oi ‘Connecting rodsto-piston pin clearance 0.016 =0.040 (0.0006 ~ 04016), 0.06 @002) GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm (in) ire STANDARD SERVICE LIMIT Ci versa =D wE= TY ¢ cies iat aa Text) BoE Dae hanes OBER Fer TT OTT) Paes Exiase | 2e8=Sealorte=oe aa Plate warpage = 0.30 (0.012) Cine oaT ae @ Foor =pa0i6 Osss—oR] — essen oo Srssg= 31898 1 2500— 72805) ster 267 Tasha OD ates ovr ge Piso? = 210 Osete=vatei| — 2125 (88h Guinot pu oonstal cares Sir 004s Ode -OaETS Saeco Cuter SE00U SE O88 (1 2558-1 2008] S209 (205 Cue evtero-ater gue dewanse oe6~T 006 (0010 0026) ee GON) Sipe de spot 5200592 81 2808 FEB] a2 TS LOitpinp sve Spock ouch our quae charence 0 080 fe (0020 0.0075 S380) ALTERNATORISTARTER CLUTCH SPECIFICATIONS Unit: mm {in) wre STANDARD SERVICE LIMIT Sater iver ae 7 Tomas ee Te [os Sra Br TB DI8G= 227) —| STS aT arr oe oT TEA Dh o GODOT POT] Peas oe) 1-10 GENERAL INFORMATION CRANKSHAFT/TRANSMISSION SPECIFICATIONS Unit: mm {in) Fs EW ‘STANDARD ‘SERVICE LIMIT Crankshaft |_Caniiecting od big end side clearance | 0105-0120 (0.002 - 0.008) 0.30 (0.012) Crankpin bearing oll learance {01028 = 0.052 (0.0011 - 0.0020), 0.07 (0.003), Main joufnal ol clearance 0.020 = 0.036 (0.0008 = 0.0075) 0.07 (0.003) Crankshaft runout = 0.030.001) Main journal O.D. ‘BE SBE SS WOO TE EES 2 0655) 52.876 (2.0857) ‘ain journal LO. {8.010 = 98.022 (2.2899 - 2.2643) 58,070 (2.2662) Shift fork, fork |_1D. 73,000= 18.018 (05118-05125) 13.03 (0.813) shaft Claw thickets 5.93 — 6,00 (0.283 0.236) 5.6 (022) Fork shaft OD. 72,566 — 12.964 (0.5105 - 05712) 72.50 (0.508) Shift drum 0.0. at left end 71.968 = 11.984 (0.4711 = 0.4716) 17,94 (0.470) Shift Grum joumal LD 12.000 - 12.016 (04724-04731) 72.05 (0.474 [Shift crumto-shit drum joural Gearanca 0.016 - 0.052 (010006 - 0.0020), 0,08 (0.035) Transmission | Gear. a 28,000 28.021 (1 1024 — ¥.1032) 8.04 (1.104) ones 31.000 = 31.025 (1.2205 - 1.2218) 31.05 (1222) 2 "24.000 = 24.021 (0.9645 —0.9457) 24.04 (0.946) Gear busing OD. |S, NE 27.969 ~ 27.980 1.1007 1.1018) 274 (1.400) CA.c4 30,850 — 30.975 (1.2185 = 1.2795) 30.83 (1218) G2 25.859 ~ 23,980 (0.8433 0.9441) | 23.98 (0.943) ‘Gearte-busting "| M3, MiB, CZ (0.020 ~ 0.062 (0.0008 — 0.0024) 0.10 (6.008) | Searance cies G.028- 0.078 (00010- 0.0080) | 2.44 008) | ‘Gear bushing (©. 11 25.000 ~ 26.021 (0.5643 -0.985i) | 2504 (0-888) [ee po.c00 = 20021 f.7874 = 0.7882) —1 2008 0 789) = Manshan OD. ‘ai MB bushing —|_24.959 - 24.980 (0 9626 - 0.5835) 24.94 (0.982) ‘CountershaR OD. | at C2 bushing | 18.980 19.993 (0.7666 - 0.787 12.96 (0786) | Bushing-to-shaft | M3 10.020 ~ 0.062 (0.0008 - 0.0022) 10.10 (0.004) clearance 2 {0.007 — 0.041 (0.0003 - 0.0016) 0.07 (0.003) ‘Output drive | Output gear. 24.000 = 28.021 (0.9848 - 0.9457) 24.04 (0.946) train Output gear bush> | OLD. 2,959 — 23,880 (0.9433 - 0.9444) 23.70 (0.833) a TD. "20.020 20.041 (0.7882 - 0.7890) 20106 (0.790) ‘Output dive gear shaft O.D. 19,979 = 20.000 (0.7866 - 0.7874) | 19.87 (0.785) | ‘Gear-o-bushing clearance 0.020 ~ 0.062 (0.0008 ~ 0.0028) 0.082 (0.0032) Gear bushing fo-shaft clearante 0.020 = 0.042 (0.0008 = 0.0017), 0.08 (0.003) ‘Ouiput gear damper soring tee leigih | 62.3 (245) 58 (23) | ‘Output drive goar backlash (0.08 ~ 0.25 (0.008 — 0.008) 0.40 (0.078) | Baciash Groce peweon Teste - 0.10 0.004) FINAL DRIVE SPECIFICATIONS Unit: mm (in) EW ‘STANDARD ‘SERVICE LIMIT Recommended final dive oi Hiypoid gear ol, SAE #80 = Final dive ot capacity At draining 160 em? (4 US 07.55 Imp Sz] = At disassembly 17o-en™ 5.7 US o2. 60Imp oz) = ("Finaranve gear backlash 10.05 - 0:18 (0.002 - 0.006) SO COTAY Backlash difference between measurements 0.10 (6.008) Ring geario-stop pin clearance THOS TOOIE- OORT = inal drive gear assembly pre-load ——=—~—SCSCS~S Nm OAT Ka ~ 01-03 bth) 1-11 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS (VT750C2F/C2S) nt an Tew STANDARD SERVICE LIT nar saad ap . Teor at He pes Op 0 SOK (OO aad Ta TOOTS Fa = sure Up fo maximum weight capacity ‘200 KPa (2.00 kaliom®, 29 pei = tte AO . DDT ‘neato [Raia = EO(OD8t Tahost ‘at = 200.08) Wheel bala Weg = Gog max ro agian ese Sou (3) Thott = oO} Recomended ToT 270 Fonda Sapa FTES STOW) Flue vel O07 3) = Fluid capacity 4784 2507? (16.2 4 0.08 US oz, — 16.8 + 0.09 Imp oz) Teanga ange EATER) = FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS (VT750C2B) Unt Go) [ TEM ‘STANDARD SERVICE Limit Winimur tre wead depth I = 1.5 (0.06) Cold fire pres- Up to $0 kg (200 Ths) load 200 kPa [2.00 kaffem™. 29 psi) = sure Up to maximum weight capacity 200 kPa (2.00 kgffcm”. 29 psi) = ‘Axle runout = 0.2 (0.01), ‘Wheel rim Radial = 2.0 (0.08) runout Axial 2.0 (0.08) Wheel BARR we = 609 mex. te rng ies ena TB EAB) 3864 (419) Tube runout = 0.2 (0.01) Recormensed Te fa Ps Honda Spansion FUTSSTTOWT z Fug eet 00183) = Fd coeecly Wa) Som TBOTOOSUS cz = 16.7 + 0.09 imp oz) ‘Steering head bearing pre-loed B.5-12.7N(0.9- TS kgf) = REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS (VT750C2F/C2B) Unie irew STANDARD SERVICE LMT mre eae He =m 20108 Cold He pes Up 190 (200 bs) oad Pou RPa ange Dp] Sore Lub mashum wepttespaayy 1280 ee @ soketent Sepa) [Caste aa ° a2 Ooi] Wheel rm | Radiat = “Tf 20(o08) wero Ea 251008 ‘hoe Balance war S Hig Brae dum LO. 800= 1803 709-770 tr) Bato pedal he To G.0 i) sbowe te top oe Or ° fe | Brake pedal freeple 20 - 30 (Ta16 - 1-SI16) ~ = Shock abso Suing preload ads seing rd pestion Z 1-12 GENERAL INFORMATION REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS (VT750C2S) nm TEM ‘STANDARD SERVICE LIMIT | ‘Minimum tre tread depth = 2.0 (0.08) Cold tre pres- | Up 0 WG (200 Bs) load ZOU KPa 2.00 Kgion®, 25 pal) = | sure. Upto maxmum weight capaci 250 KPa (2.50 KgWom, 36 psi) = i le AE . azoaiy 7 Wheel im [Racial = 2.0 (0.08) fect fat 201038) | Wheel balance weight 70 g max. SHIEK abSTBE sping io Tas uO SOTA Tepes = HYDRAULIC BRAKE SPECIFICATIONS (V1750C2F) Unit: men (in) Trem ‘STANDARD ‘SERVICE LIMIT Fesarmended Wale fu sora S Fron Sato aa Was $5 -82023-923) E07) Brake des ono 9 S5(097) | wisi Singer Too Fra ASTOR) —| 08 os [Mester piston 0.0, 10.957 = 10.084 (0.4314 - 04324) | 10.945 (0.4309) Gap ono. Fron =77 080 (roes0= roesG} —{ 27.060 (Loess) GaiperpsenoD oss 25008 10804 = 10817) 1268901080) HYDRAULIC BRAKE SPECIFICATIONS (VT750C2B) Unit: mm (in) = Tew STANDARD | SERVICELHT Recommended brake Nid ora Master pston 01D} 44 000 - 14.043 [05572-05520] 13.957 - 13 884 (0.5495 — 0.5508 Front Brake disc thickness 58 -€2 (23-02) 50(0.20) Brake disc warpage = (0.30 (0.012) | Master cylinder 1.0. 11.000 = 11.088 (0.4391 - OAGABY 11.05 (0.435) ‘Master piston O.D. _ | 70.957 = 10.984 (0.4314 = 0.4324) 10.945 (0.4308) Caliper cylinder LD. 25.400 - 25.460 (1.0000 1.0020) 725.460 (1.0024) Caliper piston 0.0, 25.335 - 25.368 (0.9974 — 0.9987) 25.320 (0.9968) HYDRAULIC BRAKE SPECIFICATIONS (VT750C2S) Unit: me (in) Tew ‘STANDARD ‘SERVICE LIMIT Recommended brake Tuid Dore = Front Brake disc thickness 48-52 (019-020) 40078) Brake disc warpage = (0.30 (0.012) Waster cylinder 10. 17.000 — 17.043 (0.4357 — 0.4948) 11,05 (0.435) "Master pision 0.0. 10.957 — 10.984 (0.4314 - 0.4324) 70.945 (0.4309) Caliper cylinder | Upper 27.000 = 27.045 (1.0830 — 1,0650) 27.060 (1.0654) [iiaste: 22.650 = 22.700 (0 8977 = 0,8034) 22.772 (0.8942) Lower 25.400 — 26.460 (1.0000 1.0020) 25.460 (1.0024) ‘Caliper piston O10. Upper 26.935 — 26.968 (1.0804 ~ 1.0617) 26.930 (7.0602), TMidcle 22.585 ~ 22.618 (0.8892 — 0.8905) 22.573 (0.5887) Loner 25.318 — 25.368 (0.9968 — 0.9088) 25.310 (0.9965) Rear Push rod length 5383) = Brake disc fhickiess 58-62 023-028) 507020) Brake disc warpage. 30 (0.012), Master cyinder 1D. 14.055 (0.5533) [Caliper eyinder 0 Caliper giinder 00. [13.845 (0.5400)_| 3B, 180) 38.230 (1.5051 = 1.5051) 36.24 (1.506) 38,098 — 38.148 (1.4999 1.5019) 36.19 (1.499) 1-13 GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS Tew ‘SPECIFICATIONS, Baty Capacity TEV = 112 Ah Current \eakage: mA max. vVotage Fualy charged 750-1327 : (20°CI88"F) Needs ar Below 124 ‘charging current | Normal TINS 0h ‘Quick SSATOR ‘Allernator Capacty, 7.3 ke5, 000 Fem (Charging col resistance (2OCI6TF) Oi=100 IGNITION SYSTEM SPECIFICATIONS EW ‘SPECIFICATIONS: ‘Spark plug ‘Standard DPRTEAS (NGK), X22EPR-US (DENSO) For exiended high speed riding DPRBEA-G (NGK), X24EPR-U8 (DENSO) Spark plug gap ‘OB — 0.9 mm (0.03 — 0.04 in) Tantion coll primary peak voqage: 100.V minimum Ignition timing (Fark) Be ETOC at le “CKP sensor peak voltage (at 20°Ci6S"F) ‘OV minimum ELECTRIC STARTER SPECIFICATIONS TEM STANDARD SE ELM Sa TG BA Tang 250A) E5025) LIGHTS/METERS/SWITCHES SPECIFICATIONS (VT750C2F) TEN ‘SPECIFICATIONS Bubs Faaaight Ta V— 6055 W. [Brakehai Tight =] 12V= 2115 W. Tieanse ight ZV -5W Front tum signalposiion ight I TEV— Zi WHE Fear ium signal ight i i2V= 21 Wa? Tasieument ight LeDea lun signal incicator —— LED High beam incieator aV-34W Fuel reserve indicator iZV=3dW Neutral incicator TED Oil pressure indiaior LEO Coolant temperature inlcator TED) Mi TED Fuse Main fase 30A Fuse 153A Sub use TOANS, ZANT ECT sensor | 50°C (127-F) 68-74 KD resistance 80°C (176°F) 21=26kH 120°C (24°F) O87 KA 1-14 GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS (VT750C2B) Tew SPECIFICATIONS Babe Headlight TV=6055W Brakehal ight i2V=718 W sans ight *2V=5 Front turn signaliposton ight T2V=2BWEE Rear rn signal ight 12V=21 Wx? instrument ight LED x6 Tum signal inciator 2-38 High beam incieator w2V=34W | Fust reserve incistor 72V=54W Neutral ndeaior lz ‘Oi pressure indicator LED Goolant temperature indicator TED L. ML Le0. Foe Main ues 3A Flfuse 158A Sub fus6 WOAxS, 20A¥7 ECT sensor | 50° (1227) 38-7410 resistance [eC 76) 21-2840 | Ta G48) 8-07 j LIGHTS/METERS/SWITCHES SPECIFICATIONS (VT750C2S) Tew ‘SPECIFICATIONS. ‘Bulbs Headlight 12 BOS W [Braker gat) T2V= 216 W, License light T2V-5W Front turn signalipasition ight WV = 75 Wx Rear tum signal ight 12V~ 21 Wx? Instrument ight LED x6 “Tur signal insicsior LED High bear indicator 2V-3aW Fuel reserve indicator T2V=3.4W ‘Neutral inseator TED Gilpressure ingicstor TED | Cooiant temperature indTcavor TED. Mil TED ‘ABS indicator LED Fuse Main fuse. 308 Fifuse 2A ‘Sub fu86, I0AX6,20Ax1, 30x? ECTsensor —_|_50°C (120°F) 68=7.4k0 resistance ‘0° (176°F) 24-28 kO 20°C (248°F) gs-07K 1-15 GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE | ym (kgtm, Ib) FASTENER TYPE Nem (kgtm, bf) Sm bolt and nut 52(05.38) | Smmecrew 4.2 (04, 3.1) - 6 mm bolt and nut 10(1.0.7) & mm scrow 9109, 68) 8 mm bolt and nut 222.2, 18) | 6 mmflange bolt (8 mrn head, smal ange) 9(0.9,6.6) 410 mm bolt and rut 34 (8.5.28) 6 mm flange bal (8 mm head large flange) 92(12.9) 12mm bott and nut 55(66.41) | 6mm flange bolt (10 mm head} end nut 3211.2.) 8 mm flange bolt and nut 27 (2.8, 20) “01mm fangs bolt and nut 39 (4.0, 28) - ENGINE & FRAME TORQUE VALUES + Torque specifications listed below ars for important fasteners. + Others should be tightened to standard torque values listed above, ENGINE FRAMEIBODY PANELSIEXHAUST SYSTEM THREAD TORQUE TEM TY | bia. (mm) | Nm (kgf Ft) REMARKS eR crankcase rear cover sockat bal 7 3 7070, 7) Exhaust pipe joint stud bolt 4 8 - See page 2-12 (Over head cover socket bolt 8 6 40(4.,7) i MAINTENANCE : THREAD TORQUE TEM OTY [DIA (mm) _|_Nem (kgm, tot) REMARKS Spare plug 7 72 78 (1.8, 13) Timing hole cep 1 14 10(40,7) ‘Aoply grease tothe threads - Crankshaft hole cap 1 30 15(4.5,11) | Apply grease to the threads Vale adjusting screw lock nut 6 7 23(23.17) | Apply engine ol tothe tveads ‘end Seating surface Engine oil fer cartridge 20 26(2.7, 19) | Apply engine cil tothe threads Oil fit boss (crankcase side) 20 18(18.13) | Apply locking agent o the threads Engine ol drain bolt 1 14 29(80,21) - Alternator cover socket bot 3 6 30.6.7) LUBRICATION SYSTEM f THREAD TORQUE TEM GY | DIA (mm) _|_Nm (kgm, Its) REMARKS EOP Swen 7 Pri 12(12,3) Apply sealant to tre Wieads . EOP switch termina screw 1 4 1.9(0.2,1.8) i pump assembly bot 3 6 131.310) FUEL SYSTEM (PGM-FI) : THREAD TORQUE TEM SITY | bia. (mm) _| Nm (kgf, A) REMARKS PAIR Check Va Cove" BOT # 3 7 (07,82) - {insulator band screw (Throtle body side) 1 - - See page 5:53 Insulator band screw (nlake manifold j sido) 1 - |} - | See page 5-58 Sensor unit torx screw 3 5 | 3403.25) Fuel injector mounting bot 2 5 541(05.38) IAC set plate torx srw 2 5 2402.13) . Throttle cable guide screw 2 5 54/0325) ECT sensor 1 2 24.525, 18) 1-16 GENERAL INFORMATION ‘COOLING SYSTEM THREAD TORQUE men SY | pa. (mm)_| Nm (kgm, IFA) REMARKS Water pump cover Daft 5 é 13(13, 10) CYLINDER HEADIVALVE THREAD TORQUE TEM CTY DIA. emm)_|_ Ne (kgf, FA) REMARKS | Cylinder head saver bol 7 6 70(1.0.7) Cynder head bot 4 8 23(2.3,17) | Apply engine ol tothe threads and seating surtace Cynder head nut 8 10 47 (48,98) | Apply engine clio the treads ‘and seating surface ‘Cam sprocket bolt 4 7 23(23,17) | Apply locking agent to the tiveads ‘Gam chain tensioner bot 4 8 40 (10,7) See page 8-24 ‘Gamshett holder bolt 6 8 23(23,17) Gamshaft holder nut 4 8 2323.17) CYLINDERIPISTON y | THREAD {~~ TORQUE J oRewarxe TEM GY DIA. (mm) _|_ Nim (kgm, toe) REMARKS Cynder std bot 2 3 = S56 page 5S Cynder stud bott 8 10 - See page 8 Gyiinder stud bot 2 12 = Soe pags 98 CLUTCHIGEARSHIFT LINKAGE sy | THREAD TORQUE vem OTF | iA. (mm)_| Nim (kam. lt) REMARKS ‘Tiuch Ter plate bot 7 ® 1212, 9) Giutch center lock nut 1 8 128(13.4,94) | Lock nut; replace with @ new one and stake Apply engine ol to the threads ‘and seating surface 011 pump driven sprocket bor 1 6 15(15,11) | Apply locking agent to the threeds| Clutch cover socket bolt 5 6 40(1., 7) Primary dive gear bot 1 2 185(8.0.65) | Apply engine olto the threads and Seating surface j Gearshift spindle return spring pin 1 8 23 (23,17) Gearshit spindle cil seal stopper plate bot 1 6 19413, 10) __| ALTERNATORISTARTER CLUTCH T THREAD TORQUE 7 TEM LOT | pik (mm) Nm (katim, tort) REMARKS Fiywheal Bat 7 2 128 (13.1, 84) | “LefThand treads ply engine ol tothe treads ‘and Seating surface Stator socket bolt 3 6 12(12,9) Apply locking agent to tho threads ‘Starer one-way clutch outer socket bolt | 6 8 3021.22) | Apply locking agent to the threads Stator wir holder socket bolt 1 6 12(1.2,) Apply locking gent to the threads 1-17 GENERAL INFORMATION ‘CRANKSHAFTITRANSMISSION THREAD ToRAUE TEM QTY | pIA. (eam) _|_ Nem (kgf, tt) REMARKS rankeate bol 5 3p eR Goarshit cam plato bot 1 6 12(1.2,9) | Anply locking agent to the tireoes Crankpin bearing cap nut 4 8 33(6.4,24) | Apply engine oto the treads and seating surface uit gee case mounting bot a | 8 31(8.2,23) | Apply sealant tothe threads Output dive gear assembly mounting \ bot 2 ® 210.2,23) | Apply engine ll tothe threads and seating surface Output crven gear assembly mounting ookot bok 4 @ 31 (8.2.23) | Apply engine of the treads ‘and seating surface Output drive gear bearing lock nut | imme) 4 30 73.(74, 64) Lock nut; replace with a new cone and stake Apply engine oil to the threads | and seating surface 98 (10.0, 72) Lock nut; replace with a new fone and stake Apply engina ol to the threads and seating surface (outer) 1 64 Output driven gear bearing lock nut inner) | 4 30 73.74, 54) Lock nut: replace with anew cone and stake Apply engine oll to the threads and Seating surface (outer) | 4 e 198 (100, 72) Lock nut; replace with a new cone and stake ‘Apply engine oll to the threads and seating surface Output drive gear shaft bolt 1 10 __ 48,60, 36) ELECTRIC STARTER eT THREAD] TORQUE] — eM QTY | DIA. (mmm)__Nem (kgm, tft) REMARKS Stavier motor cable terminal nut 1 6 10 (1.0, 7) Starter motor assembly bolt 2 5 4905.38) Negative brush screw 4 5 3704.27) _ LIGHTSIMETERSISWITCHES . THREAD TORQUE eM SY | Dia. (mm) __ Nam (kam, oF) REMARKS Neutral site 7 0 12 (2, 9) \VS sensor mounting bolt 4 6 98 (1.0.72) 1-18 GENERAL INFORMATION FRAME FRAME/BODY PANELSIEXHAUST SYSTEM THREAD TORQUE ew GY BUA. (mim) __ Nem (kgf, a) REMARKS Seat mounting set bat z seers) Grab rai mounting bot 6 10 84 (65.47) Exhaust pipe joint nut 4 8 2525, 18) utr stay mounting bot 4 8 46 (45,22) Mutler mounting nut 2 10 48 (65,32) Mutter bracket bolt 2 8 27 (28,20) MAINTENANCE sry | THREAD] TORQUE) ew SY | Ya. (mm) _| Nm (kgm, It) REMARKS ‘if cleaner cover soarer BOF 5 3 Tonia) Final eve ol ler cap 1 20 1212.9) Final rive ol cain ot 1 2 124213) _ FUEL SYSTEM (PGM-FH) TORQUE ITEM QTY DIAL (mm) | Nim (kgm, Ibf-A) REMARKS Fost tank mourting Blt 7 3 228, 2) Arcleaner cnamber mounting screw 1 5 1407.08) ‘Ar cleaner chamber comecting tube band sore 1 4 07 (04,05) Or sensor 18 44 (4.5.92) COOLING sysTEM THREAD] TORQUE TEM ory DIA. (mm) Nem (kgf-m, Ibf-ft) REMARKS an motorrmauntng bot 3 3 31 (05.38) Cooling fan mounting nut 1 5 27 (03,20) Apply locking egentto the threads Radiator file mourtin bolt 2 8 1000.7) Termostat housing cover bot 2 8 10(40,7) Wiator nase Bend screw “ - = See page 6-10 Fan motor assembly mounting bolt 3 6 8409.62) ENGINE REMOVALINSTALLATION — THREAD TORQUE treM QTY DIA. (mmm) | _Nem (kgf-m,Ibf A) REMARKS Engine mounting not a 0 54 (55,40) | 1 Engine nanger plete bolt 8 a 26(27,19) | Main fotpe9 bracket mounting bat 3 10 39 (4.0.28) { Main footpeg bracket mourting nut 1 10 2960.29) | _Gearshit aim pinch bot 1 6 1202.9 CLUTCHIGEARSHIFT LINKAGE THREAD TORQUE TEM QTY IA. (mm) | _Nem (kofm, Ibfft) REMARKS CGaarahi pedal pvr BOE T 10 3560, 2) 1-19 GENERAL INFORMATION FINAL DRIVE THREAD | ~~ TORQUE — em OY [DIA (mm) _|_ Nim (kgm, ttt) REMARKS inion retainer 7 64 108 (17.0, 60) Pinion retainer lock tab bott 1 6 10(1.0,7}, Pinion joint aut 1 16 108(17.0,80) | Apply locking agent o the threads Dust guard plate bolt 1 6 10(1.0.7), Final gear case cover bolt 2 10 47 (48,35) | Apply locking agent tothe threads Final gear case cover bolt 6 8 25 (25, 18) Final gear case assembiy mounting nu | 4 10 64 (6.5.47) Final gear case stud bolt 4 10 - See page 13:22 Rear shock absorber lower mounting bolt (left side) 1 e | aia. 18) FRONT WHEEL/SUSPENSION/STEERING THREAD TORQUE L mem CTY bis (mm)_|_ Nem (kgf, Ibt REMARKS ‘Guuch lever BWOTBSE 7 6 7 (0-1, 07) Giuteh lever pvot aut 1 6 6 (0.8, 44) Handlebar upper holder bot 4 a 23(23,17) Handlebar lover holder nut 2 8 23 (23,17) Front brake disc bot 6 8 42(43,31) | ALOC bot; replace with a new fone Spoke 52 Bos 42(04,3.1) Front axe bolt 1 14 58 (60, 44) Front axie pinch bot 2 8 22(22, 18) Fark center socket bolt 2 0 28.5(30,22) | Appl locking agent tothe ‘treads Fork cep 2 38 22.4 (23,16) Front fork cover bot (VT750C28) 2 6 22(1.2,9) 2 8 26 (27,18) Tire valve nut 1 evi 404,30) Fork top bridge pinch bott (VT750CS) 2 8 22,22, 16) Fork top bridge pinch bolt (VT760C28/ | 2 8 27 (28,20) 28) Fork bottom bridge pinch bolt 2 10 49 (6.0, 36) ‘Steering top thread 4 6 - See page 14-42 Steering top thread lock nut 1 26 - See page 14-43 | Steering stem nut 4 24 103 (10:5, 76) REAR WHEEL/BRAKE/SUSPENSION THREAD TORQUE eM QTY | DIA. (mm)_|_ nem (kgm, fot) REMARKS ‘Spoke 8 BCA 42 (04, 5.1) Tire valve nut 1 av 4(04, 30) Rear brake disc bot (VT750C2S) 8 8 42(43,31) | ALOC bol, replace with a new Rear axe nut 1 8 88 (8.0, 65) Usrut Rear axle pinch bot 1 8 27 (28,20) Rear brake stopper arm nut 1 8 2222, 16) (vT780C2F C28) Rear brake arm pinch bolt 1 8 26(27, 19) (VT780C2F/C28) Rear shock absorber upper mounting batt 2 8 2627, 19) Rear shock absorber lower mounting bolt (ight sido) 1 10 2425, 25) Stopper plate bolt 5 6 20(2.0,15) | ALOG bott replace with @ now one ‘Swingarm et pivot bot 1 30 103 (10.5, 76) Swingarm right pivot bot 1 30 - See page 16-32 Swingarm night piv bot losk nut 1 30 4103 (10.8, 76), 1-20 GENERAL INFORMATION HYDRAULIC BRAKE (VT750C2F/C2B) oy) THREAD TORQUE rem SY | pia. (emmy |_nem (kgm, tot) REMARKS Brake caper Blood valve 7 8 35 (08, 4.1) Front masior cylinder reservoir cap screw 2 4 1502, 41) Brake pad pin 1 1 18 (18,13) Brake pad pin plug 1 to 25 (03,18) Brake hose ol bol 2 10 34 (35, 25) Brake lover pivot bolt 4 6 1 (0.1.07) Brake lever pivot nut 1 6 5 (0.6, 44) Front brake light switch screw joa 4 12(0:4.09) Front master cylinder holder bolt 2 6 12(4.2.9) Front brake cafper bracket pin ; 8 12 (12.8) Apply locking agent to the ‘treads Front brake caliper pia 1 8 27(28,20) | Apply locking agent tothe threads Front brake caliper mounting bolt 2 8 3031.22) | ALOC bot replace with anew fone HYDRAULIC BRAKE (V175002S) cy) THREAD TORQUE] — | TEM OY | pia. (mm) Nm (kgm, tbe) REMARKS Front brake caliper Bleed valve z 5 55 (06,41) Front master cylinder reservoir cap seew 2 4 15 (02,44) Front brake pad pin 1 10 18(18, 13) Brake hose oi bot 2 10 34 (35,25) Brake lever pivot bolt 1 6 4 (0.1.0.7) Brake lever pivot nut 1 6 8008.44) | Front brake light switch sorow 4 4 420,08) Front master cylinder holder bolt 2 6 12(1.2,9) Front brake calper bracket pin jt 8 12(12:8) | Apply locking agent io tho | threads Front brake caliper pin 1 8 27 (28,20) | Apply locking agent to the threads Front brake caliper mounting bolt 2 8 30(8.4,22) | ALOC bolt replace with a new Rear caliper stopper pin bolt 1 18 69(7.0,51) | ALOC bolt replace with a new Rear caliper pin bolt 2 10 45 (48,33) | Rear brake caliper bead valve 2 8 55(08.41) Rear brake pad pin 1 10 18.(1.8, 13) Rear brake pad pin Pig 1 10 25 (03,18) Reat master cyinder reservoir cap | 2 4 45(02. 41) | Rear mastereyinder push rod iocknut_| 1 8 46(1.8.13) _ ‘ABS (VT750625) oy) THREAD “TORQUE TEM Ty | tee | Nm tote beh) REMARKS “| Brake bipo nt rut 70 74 (14, 10) | Apply brake Mo the threads] BATTERTICHARGING SYSTEM - THREAD TORQUE mew OT | OIA nm) Nan fegtim eA REMARKS Battery Case cover sctow 7 6 101,07) ‘| 1-21 GENERAL INFORMATION LIGHTS/METERS/SWITCHES. THREAD TORQUE mem DIA. (mm) _|_Nom (kgf. IDF) REMARKS Headlight unt mounting bok 2 41 (04, 30) Brakertil ight mounting nut 6 6.3(06,46) | Speedometer mounting socket boit 6 40(1.0.7) Fgniton switch mounting bolt 6 42(1.2,9) Ignition switch cover screw 4 101,07) Sidestand switen bolt 6 10(1.0, 7) ALOC bolt; replace with a new one Fuel reserve sensor 18 23 (23, 17) Hom mounting bolt 8 2112.1, 18) OTHERS | THREAD | TORQUE a eM QTY DIA. (mm) _|_N-m (kgm, tht) REMARKS ‘Sidestand pivot Bott 7 70 303,68) ‘App Grease to the Siang Sur face Sidestand pivot lock nut 1 10 30 (3.4, 22) Sidestand bracket bott 2 10 48 (5.0, 36) Tool box screw 2 4 2 (02,18) 1-22 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE [| WATERIAL Molybdenum disulfide cl (@ mixture of 1/2 en- gine oll and 1/2 molyb- denum disulfide grease) Engine oil Mul-pupete grease Liquid soar (Tree Bond 12078 oF equivalent) LOCATION Camshaft lobes and joumal éurface Valve stem (valve guide stiding surface) Rocker arm slipper surface Rocker arm shaft outer surface Cranigin beating thrust surface Crankshaft main journals Clutch outer guide outer surface ‘Transmission gear shift fork groove Transmission bushing sliding surtace Connecting rod small end inner surface Piston outer surface Piston ring outer surface Piston pin outer surface Primary drive gear bol threads and seating surface Flywheel boll threads and seating suriace Starter oneway clutch sprag Starter idle and reduction gear shaft outer surface Clutch center lock aut threads and seating surface Clute lifter arm sliding surface of the rignt crankcase cover Clutch lifter arm siging surface and sit Clutch dises and plates Cylinder wall Cylinder stud bolt threads Valve adjusting screw lock nut threads and seating surface Shift fork shaft whole surface CCrankpin bearing cap nut threads and seating surface ‘Output drive gear assembly mounting bol threads and seating sur- face (Output driven gear agsembly mounting socket boll threads end ‘eating surface (Output drive gear bearing lock nut {inneriouter) threads and seating surface ‘Output arven gear be ing surface Cylinder head bolnut threads and seating surface. ‘Transmission gear tooth Engine ol filer cartidge threads Crankshaft main journal beating surface Oil pipe seal Injector seal ring Each bearings rotating area Each O-rings (Crankshaft hole cap threads Timing hole cap threads Each ol seal lps TEOP switch threads Right and left crankcase mating surface Right crankcase cover mating surface Lett crankcase cover mating surface Output gear case mounting bolt threads ing lock nut (innerfouter) threads and seat. REMARKS Do not apply to the seal- antto the head 34mm (01-2 in) 1-23 GENERAL INFORMATION MATERIAL LOCATION REMARKS: Locking agent Cam sprocket bal threads Slarter one-way clutch outer socket bolt threads Oil pump driven sprocket bolt threads Final gear case stud bok threads (gear case side) Stator wire holder sockst bolt threads Coating width 651mm (0.26 + 0.04 in) Gearshift cam plate bolt threads Coating with: 651mm {0.26 4 0.04 in) Transmission bearing setting plate bolt throads. Coating with: 66£1mm (25 # 0.06 in) Cam chain tensioner setting plate bolt threads Coating width: 652 1mm (0.26 0.04 in) Stator socket bolt threads Coating width: 6521mm (0.26 0.04 in) i fiter boss crankcase side threads Coating wicth: 6521mm {0.26 + 0.04 in) Loft crankcase cover bot threads (marked “A) Pro Hondabond A, Pro | Cylinder head cover-to-gasket aroove Honda Handgrip ' Ce- ment (USA. only) oF equivalent 1-24 GENERAL INFORMATION FRAME ‘WATERTAL Liquid sealant (Three dond 12078 or equivalent) “LOCATION. Final gear case cover meting surface REMARKS TMull-purpose grease ‘Sidestand pivot Main step sliding area Pilion step sliding area ‘Throttle pipe flange groove and sliding surface Clutch lever pivot bolt sliding surface Gearshift spindle of seat ips Goarshit pedal dust seal ips Front axle slicing surface ‘Shock absorber mount inner surtace Rear brake middle rod joint pivot and dust seat lips Rear brake cam sliding surface Brake shoo-to-anchor pin sliding surface Brake pedal pivot sliding surface Brake padal dust seal ips Rear brake joint pins Front whee! cust soa ips Final gear case O-ing ina! gear case oil seal ips Fooly 3 Spreading 0.2-0.3.9 Spreading 02-03 g Spreading 05-109 Urea Based mulirpur [Steering head bearings ‘Reply 3~ 8 9 for each pose orease with ox bearing treme pressure agent Steering head bearing dust seal ips (exemple: EXCELITE ‘Swingarm pivot bearing needle rollers Apply 1.0 - 15 9 for crameracuee > ‘each bearing kyO00 Ys, ‘Swingarm pivot dust seal ips ‘Molybdenum disulfide ‘Output drive gear and damper cam splines ‘Apply 1 9 grease Final drive shatt oil seal lip Apply 0.5.9 Final drive shaft spines (universal joint site) Apply t 9 Final drive pinion joint splines Apply 29 Molybdenum aiaulfde | Final driven Tange (rear wheal hub rang eurlacay ‘Apply 05-109 paste Final driven flange O-ring Final gear case O-ring guide and driven flange joint surface Apply 4-5 “Thrust washer and rear wheel hub end (final driven flange side] Apply 2~3.9 ‘Cable lubricant Throttle cable cuter inside Clutch cable outer inside Pro Hordabond A, Pro | Handleber gp inside Honda Handgrip Cement | Handlebar and throttle pipe outer surface (grip rubber contacting ar- | (U.S.A. only) or equiva. ea) lent _ Engine ol ~ ‘Siearag top threais Rear brake cam felt seal ‘Sileone grease Brake lever pivot bolt siding surtace ApPVOTS Brake lever-io-master piston contacting area Apply 0.1 a Brake caliper and bracket pin boot inside Apply 0.4 9 BOT 4 brake Fuld Brake caliper dust seal Brake masiet piston and cups Brake caliper piston and piston seals ro Honda Suspension Fluid $$-8 (10W) Tocking agent Fork dust seal and ol seal ips Fork cap O-ring Pinion joint ut threads Final gear case cover 10 mm bolt threads Fork center sockel bolt threads Front brake caliper bracket pin threads Front brake caliper pin treads Final gear case stud bolt threads ‘Cooling fan mounting nut threads 1-25 GENERAL INFORMATION CABLE & HARNESS ROUTING VT750C2F \VT750C2F type shown. VT750C2B and VT75002S type illustrations that difer are shown later. FUEL RESERVE INDICATOR CLUTCH CABLE THROTTLE CABLES FRONT BRAKE HOSE CLUTCH SWITCH WIRE FRONT BRAKE LIGHT SWITCH WIRE RIGHT HANDLEBAR SWATCH WIRE FRONT TURN SIGNAL LIGHT WIRES LEFT HANDLEBAR SWITCH RIGHT HANOLEBAR SWITCH FRONT TURN SIGNAL LIGHT 3 CONNECTORS: 6P (BLACK) CONNECTOR 6 (RED) CONNECTOR LIGHT BLUE. RIGHT TURN SIGNAL, ORANGE: LEFT TURN SIGNAL Leet WIRE HARNESS HANOLEBAR: ‘SWITCH WIRE INDICATORS. WIRE RIGHT HANDLEBAR SWITCH WIRE FUEL RESERVEIHIGH BEAM INDICATOR 4P (WHITE) CONNECTOR | MAIN WIRE HARNESS \ FOG LIGHT 3P (WHITE) LEFT HANDLEBAR Sironse unex) CONNECTOR (Option) CONNECTOR LEFT HANDLEBAR SWITCH HEADLIGHT aP (WHITE) 6 (BLUE) CONNECTOR CONNECTOR 1-26 GENERAL INFORMATION ue THROTTLE CABLES Let side CLUTCH CABLE RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLES GHT FRONT TURN SIGNAL LIGHT WIRE, GENERAL INFORMATION SPEEDOMETER 12 CLUTCH CABLE (WHITE) CONNECTOR LEFT HANDLEBAR SWITCH WIRE 1-28 GENERAL INFORMATION (1) MAIN WIRE HARNESS (2) FUEL TANK BREATHER HOSE (G) SIPHON HOSE. (@) BANK ANGLE SENSOR WIRE (6) THROTTLE CABLE FUEL TANK BREATHER HOSE PAIR CONTROL SOLENOID VALVE WIRE OSE FUEL FEED HOSE, SIPHON Hi FUEL HOSE HORN WIRE, FUEL VAPOR RETURN HOSE LEFT FRONT SPARK PLUG WIRE FUELRESERVE SENSOR WIRE SECONDARY AIR FuEl HOSE surrey noses FUELFEEDHOSE eT REAR SPARK PLUG WIRE SECONDARY AIR SUCTION HOSE EVAP PURGE CONTROL, ‘SOLENOID VALVE HOSE. (California type) 1-29 GENERAL INFORMATION (1) SIDESTAND SWITCH WiRE (2) IMMOBILIZER RECEIVERIIGNITION SWITCH WIRE G)IGNITION SWITCH WiRE (@) ALTERNATOR WIRE (6) NEUTRALIEOP SWITCH WIRE (6) VS SENSOR WIRE (7) IMMOBILIZER RECEIVER WIRE (8) REGULATORIRECTIFIER WIRE (@) RELAY BOX WIRE INSIDE BOOT CONNECTORS: (10) WIRE HARNESS of (1), (5), (6) \VS SENSOR 3P (WHITE) SIDESTAND SWITCH 2P (GREEN) NEUTRALIEOP SWITCH 2° (BLACK) INSIDE BOOT CONNECTORS: ' REGULATORIRECTIFIER 2P (WHITE) : ; INSIDE BOOT CONNECTORS: ALTERNATOR 3P (WHITE) ! ‘ ' IGNITION SWITCH 2° (WHITE) (1 REGULATOR! = RECTIFIER WIRE a 0 o © ALTERNATOR WIRE REGULATORRECTIFIER WIRE e HW ‘OP SWITCH WIRE GROUND CABLE SIDESTAND SWITCH WIRE VS SENSOR WIRE 1-30 GENERAL INFORMATION FUEL TANK BREATHER HOSES (Except California type) SIPHON HOSE REGULATOR! RECTIFIER WIRE RADIATOR RESERVE TANK BREATHER HOSE 1-31 GENERAL INFORMATION { Right side FUEL VAPOR, Rear side RETURN HOSE — SUB FUEL TANKIFUEL PUMP WIRE FUEL FEED HOSE 1-32 GENERAL INFORMATION INSIDE BOOT CONNECTORS: CKP SENSOR 2° (RED) FAN MOTOR 2° (WHITE) REAR BRAKE LIGHT SWITCH 3P (LIGHT GRAY) \ THROTTLE CABLES BANK ANGLE FUELTANK SENSOR WIRE BREATHER HOSE \ MAIN WIRE HARNESS SENSOR UNIT! IACV WIRE FUEL TANK BREATHER HOSE soot ECT SENSOR WIRE RIGHT FRONT SPARK CRANKCASE PLUG WIRE BREATHER HOSE SECONDARY AIR SUCTION HOSE CP SENSOR WIRE CLUTCH CABLE REAR BRAKE LIGHT SWITCH WIRE 1-33 GENERAL INFORMATION FUEL TANK BREATHER HOSE THROTTLE CABLES ‘SENSOR UNITAACY SUB HARNESS BANK ANGLE SENSOR BANK ANGLE SENSOR WIRE INJECTOR SUB HARNESS No.2 FRONT INJECTOR 2P (GRAY) CONNECTOR MAIN WIRE HARNESS: No.1 REAR INJECTOR 2 (GRAY) CONNECTOR SENSOR UNIT 5P IAGV 4P (BLACK) CONNECTOR (BLACK) CONNECTOR (eK) 1-34 GENERAL INFORMATION 1-35 GENERAL INFORMATION (1) MAIN WIRE HARNESS (2) LEFT REAR SPARK PLUG WIRE (@) RIGHT REAR SPARK PLUG WIRE RIGHT REAR SPARK PLUG WIRE 6) 0 ea a - we ‘ad | STARTER MOTOR CABLE BRAKE/TAIULICENSE LIGHT WIRE nue, — Jf CO \errena sone PLUG WIRE STARTER TURN SIGNAL RELAY RELAY SWITCH FUSE 80x \, ENGINE STOP RELAY 1P. BATTERY POSITIVE ‘\_ WHITE) CONNECTOR (CABLE INSIDE BOOT CONNECTORS RIGHT REAR TURN SIGNAL LIGHT 2P (LIGHT BLUE) LEFT REAR TURN SIGNAL LIGHT 2P (ORANGE) BRAKE/TAILILICENSE LIGHT 3P (WHITE) PRIMARY WIRES. REAR IGNITION COIL 1-36 GENERAL INFORMATION FUEL VAPOR FUEL FEED HOSE RETURN HOSE — ) N° by \ sues ramet sae ‘SUB FUEL TANKIRUEL PUMP. BATTERY NEGATIVE PICABLE exrteRy PosiTivE BATTERY, a mons ECM ECM 33° (GRAY) ECM 33® (BLACK) CONNECTOR CONNECTOR 1-37 GENERAL INFORMATION RIGHT REAR TURN, Lee REAR To SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE LICENSE LIGHT 2 (WHITE) ‘CONNECTOR LICENSE LIGHT WIRE BRAKE/TAILILICENSE LIGHT WIRE 1-38 GENERAL INFORMATION VT750C2B FRONT BRAKE HOSE CLUTCH swiTcH THROTTLE CABLES WIRE: HIGH BEAM INDICATOR TURN SIGNAL CLUTCH CABLE FRONT RAKE LIGHT SHITCH WARE LEFTHANOLEBAR ~ SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE FUEL RESERVE INDICATOR FRONT TURN SIGNAL LIGHTWIRES TURN SIGNAL INDICATOR 2P FUEL RESERVEIHIGH BEAM INDICATOR 4P (WHITE) CONNECTOR (WHITE) CONNECTOR \ | LEFT HANDLEBAR SWITCH 6 (BLACK) CONNECTOR RIGHT HANDLEBAR SWITCH 6P (RED) LEFT HANDLEBAR SWITCH 2 (BLACK) CONNECTOR RIGHT TURN SIGNAL 3P LEFT HANDLEBAR (LIGHT BLUE) CONNECTOR SWITCH SP (@LUE) CONNECTOR LEFT TURN SIGNAL 3P. (ORANGE) CONNECTOR FOG LIGHT 3 (WHITE) CONNECTOR HEADLIGHT 3P (WHITE) CONNECTOR 1-39 GENERAL INFORMATION THROTTLE CABLES CLUTCH CABLE RIGHT HANDLEBAR ‘SWITCH WIRE THROTTLE CABLES FRONT BRAKE HOSE CLUTCH CABLE 1-40 GENERAL INFORMATION MAIN WIRE HARNESS LEFT HANDLEBAR CLUTCH CABLE 4 SWITCH WIRE SPEEDOMETER 12° (WHITE) CONNECTOR RIGHT SRONT TURN RIGHT FRONT TURN SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE LEFT HANDLEBAR LEFT FRONT TURN, SWITCH WIRE SIGNAL LIGHT WIRE LEFT FRONT TURN. SIGNAL LIGHT WIRE HORN WIRE FAN MOTOR WIRES: 1-41 GENERAL INFORMATION MAIN WIRE HARNESS ‘SPEED METER CONNECTOR 12° CONNECTOR CLAMP RESET SWITCH SPEEDOMETER COVER ‘SPEEDOMETER COVER MAIN WIRE HARNESS, 1-42 GENERAL INFORMATION VT750C2S Left side C7 > f\ THROTTLE CABLES ‘CLUTCH CABLE RIGHT HANDLEBAR, SWITCH WIRE FRONT WHEEL SPEED SENSOR WIRE REAR BRAKE SUB HOSE FRONT BRAKE HOSE FRONT BRAKE HOSE FRONT BRAKE HOSE REAR BRAKE SUB HOSE 1-43 GENERAL INFORMATION LEFT HANDLEBAR ‘SWITCH WIRE MAIN WIRE HARNESS Ld MI A) se see { (WHITE) CONNECTOR LEFT HANDLEBAR SWITCH WIRE LEFT FRONT TURN, SIGNAL LIGHT WIRE LEFT FRONT TUR SIGNAL LIGHT WIRE FAN MOTOR WIRES 1-44 GENERAL INFORMATION (1) MAIN WIRE HARNESS. (2) FUEL TANK BREATHER HOSE (@) SIPHON HOSE (4) BANK ANGLE SENSOR WIRE (5) THROTTLE CABLE FRONT BRAKE PAIR CONTROL SOLENOID VALVE PIPER 2P (BLACK) CONNECTOR (4) FUEL TANK BREATHER HOSE SIPHON HOSE © ° by “TURN SIGNAL RELAY : , FRONT WHEEL SPEED SENSOR WIRE HORN WIRE, \ SA, Bi \ OS3 Q LEFT FRONT SPARK PLUG WIRE FUELRESERVE SENSOR WIRE LEFTREAR SPARK SECONDARY AIR FUEL FEED HOSE PLUG WIRE ‘SUPPLY HOSES SECONDARY AIR, EVAP PURGE CONTROL SUCTION HOSE ‘SOLENOID VALVE HOSE (California type) 1-45 GENERAL INFORMATION IGNITION SWITCH WIRE INSIDE BOOT CONNECTORS: VS SENSOR 3P (WHITE) IMMOBILIZER RECEIVER WIRE SIDESTAND SWITCH 2P (GREEN) NEUTRALEOP SWITCH 2P (BLACK) INSIDE BOOT CONNECTORS: bic REGULATORIRECTIFIER 2P (WHITE) ALTERNATOR 3P (WHITE) RIGHT REAR SPARK PLUG WIRE LEFT REAR SPARK PLUG WIRE GROUND CABLE STARTER MOTOR CABLE ABS BATTERY 2P (WHITE) CONNECTOR RELAY BOX WIRE PSS Cour rt RECTIFIER WIRE i \VS SENSOR WIRE IGNITION SWITCH 2° (WHITE) CONNECTOR ‘ABS BATTERY ALTERNATOR aes WIRE EOF SWITCH WIRE BATTERY POSITIVE SIDESTAND SWITCH WIRE () CABLE STARTER MOTOR CABLE 1-46 GENERAL INFORMATION - INSIDE BOOT CONNECTORS: CP SENSOR 2P (RED) FAN MOTOR 2 (WHITE) REAR BRAKE LIGHT SWITCH 3° (LIGHT GRAY) FUEL TANK BREATHER HOSE BANK ANGLE MAIN WIRE HARNESS ee ie THROTTLE CABLES SENSOR UNIT) - up ACV WIRE OX t \ as ‘ORANKCASE j Renae, BREATHER HOSE REAR BRAKE SUB PIPE FUEL TANK BREATHER HOSE FRONT BRAKE PIPEA ~ ECT SENSOR WIRE RIGHT FRONT SPARK PLUG WIRE t . OM | SECONDARY AIR REAR BRAKE LIGHT SUCTION HOSE I SWITCH WIRE CLUTCH CABLE (KP SENSOR WIRE 1-47 GENERAL INFORMATION BANK ANGLE SENSOR WIRE THROTTLE CABLES BANK ANGLE SENSOR No2 FRONT FUEL. INJECTOR WIRE No.2 FRONT FUEL INJECTOR, 2P (GRAY) CONNECTOR peonrenate < Wie 4 REAR BROKE Ya S i ‘\ } No. REAR INJECTOR 2P (GRAY) CONNECTOR IACV 4P (BLACK) CONNECTOR \ SENSOR UNIT 5P. (BLACK) CONNECTOR 1-48 GENERAL INFORMATION RIGHT REAR SPARK PLUG WIRE MAIN WIRE HARNESS: REAR BRAKE ARK PLU SUB PIPE \ FRONT BRAKE PIPES Rearsrake PIPE A a ( SQ fs FRONT BRAKE PIPEA LEFT REAR SPARK PLUG. WIRE ABS MODULATOR, 5 (GREEN) ‘CONNECTOR } REAR WHEEL SPEED SENSOR 2 (BLUE) CONNECTOR INSIDE BOOT CONNECTORS: RIGHT REAR TURN SIGNAL LIGHT 2° (LIGHT BLUE) LEFT REAR TURN SIGNAL LIGHT 2P (ORANGE) BRAKE/TAIULIGENSE LIGHT 3P (WHITE) 1-49 GENERAL INFORMATION FUEL VAPOR RETURN HOSE FUEL FEED HOSE FUEL HOSE SUB FUEL TANK/FUEL PUMP 2P (BLACK) CONNECTOR ‘SUB FUEL TANWFUEL PUMP INSIDE BOOT CONNECTORS: MPN ABS SERVICE CHECK SP (NATURAL) OPTION 6° (WHITE) Y = BATTERY i? BATTERY NEGATIVE \ (CABLE BATTERY POSITIVE (+) CABLE 2 Siecn ECM ECM 33° (GRAY) OM 33° (BLACK) CONNECTOR CONNECTOR 1-50 GENERAL INFORMATION REAR BRAKE |, PIPE REAR BRAKE HOSE 8 REAR BRAKE HOSE A REAR WHEEL SPEED SENSOR 2P (BLUE) CONNECTOR REAR BRAKE PREC REAR BRAKE HOSE A REAR BRAKE HOSE B ~ REAR WHEEL SPEEO SENSOR WIRE i REAR BRAKE HOSE A 1-51 GENERAL INFORMATION EVAP CONTROL SYSTEM (U.S.A. type only) EVAP PURGE CONTROL EVAP PURGE CONTROL, SOLENOID VALVE SOLENOID VALVE HOSE (lo tottle body) EVAP CANISTER HOSE EVAP CANISTER HOSE (to tel tank) EVAP CANISTER AIR VENT HOSE EVAP CANISTER EVAP CANISTER DRAIN HOSE 1-52 GENERAL INFORMATION EMISSION CONTROL SYSTEMS EXHAUST EMISSION REQUIREMENT The U.S Environmental Protection Agency (EPA), California Air resources Board (CARB) and Transport Canada require manufactures to corty that their motorcycles comply with applicable exhaust emissions standards during thelr useful life, when ‘operated and maintained according ta the instructions provided. NOISE EMISSION REQUIREMENT ‘The EPA also requires that motorcycles built fler January 1, 1983 comply with applicable noise emission standards for one year ot 6,000 km (3,720 rriles) after the time of sale Io the ulimate purchaser, when operated and maintained according to the instructions rrovides. WARRANTY COMPLIANCE Comptiance with the terms of the Distributor's Limited Warranty for Honda Motoroycle Emission Control System is necessary in order to keep the emission system warranty in effect SOURCE OF EMISSION “The combustion process produces carbon monoxide (GO), oxldes of nitrogen (NOx) ané hydrocarbons (HC). Control of carbon monoxide, oxides of nitrogen and hydrocarbons is very important because, under certain conditions, they react 10 form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but Is toxic, Fuel evaporation algo produces HC emissions, Honda Motor Co., Ltd, ulizes various systems, to reduce carbon monoxide, oxides of nitrogen and hydrocarbons, CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with a closed crankcase system te prevent discharging crankcase emissions into the alrmosphere. Blow-by {98 is returned to the combustion chamber through the air cleaner and thrall body. AIR. CLEANER HROTTLE BODY / FRESH AIR BLOWSY GAS, 1-53 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM ‘The exhaust emission contol system is composed of a pulse secondary alr supply system and an oxidation catalytic converter PGM-FI sysiom, No adjustment should be rade except idle speed adjustment with the throtle stop screw. The exhaust emission control system is separate from the crankcase emission control system, SECONDARY AIR SUPPLY SYSTEM ‘The pulse secondary air supply system introduces fitered air into the exhaust gases in the exhaust port. Fresh air is drawn into the ‘exhaust port by the function of the PAIR (Pulse Secondary Air Injection) control solenoid valve. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and ‘carbon monoxide into relatively harmless carbon gioxide and water vapor. ‘The teed valve prevents reverse air flaw through the systern. The PAIR control solenoid valve is operated by the solenoid valve. The solenoid valve is controlled by the ECM, and the fresh air passage is openediclosed according fo the running condition (ECT? IATITPNMAP sensor and engine revolution), No adjustments to the secondary alr supply system should be made, although periodic inspection of the components is recommended, PAIR CONTROL SOLENOID VALVE PAIR CHECK VALVE EXHAUST PORT } Lower Leve. —>| RECOMMENDED ENGINE OIL: Pro Honda GNé 4-stroke oil (U.S.A. and Canada) or an equivalent API service classification: SG or higher (except olls labeled as oneray conserving on the circular ‘API service label) Viscosity: SAE 10W-30 JASO T 803 standard: MA NOTE Other viscosities shown inthe chart may be used when | 30-20 AB—9 jo 20 30-40 30 ate the average température in your riding area is within the tas 83 8a io oF indicated range. OL ViSCOSITIES Check that the O-ring is In good condition, replace it if necessary. Coat the O-ing with engine ol and install Reinstal the of lec capidipstick For engine oll change (page 3-12) MAINTENANCE ENGINE OIL FILTER NOTE. Change the oll with engine warm and the motoreyete on its sidestand to assure complete and rapid draining. Start the engine, warm it up and stop it. Remove the cil filer cap/dipstick (page 3-11). Remove the oll drain bolt, sealing washer and drain the all Remove the oil fter cartsidge using tne special tool and let the remaining oil rain out TOOL: Oil filter wrench O7HAA.PJ70101 oF O7AMA-MFJA100 (USA. only) Coat 2 O-ring with engine oll Apply engine oil io the threads of a new oil fter cartridge. Install the oll fter cartidge end tighten it to the specified torque. TOOL: Oil filter wrench OTHAAPJ70104 or O7AMA-MFJA100 (USA. only) TORQUE: 26 Nim (27 kgfm, 19 IbF ft) Install the oll drain bolt with @ new seating waster and Ughten it to the specified torque. ‘TORQUE: 28 Nim (3.0 kgm, 21 IF) Fil the crankcase with the recommended engine oil (page 3-11), OIL CAPACITY: 2.5Iiters (2.6 US at, 2.2imp qt) at draining 266 liters (2.7 US qt, 23 Imp qt) at oil filter change 3.2 liters (3.4 US @f, 2.8 Imp qt) at disassembly ‘Check the engine oil level (page 3-11]. Install the oll lier capidipstick (page 3-11). ‘Make sure there are no oil leaks, 3-12 MAINTENANCE RADIATOR COOLANT ‘Check the coolant level of the reserve tank. ~ Eo Me ‘The level should be belween the "UPPER" and S . “LOWER” level nes with the motorcycle in an upright, poston If the level is low, remove the resetve tank cap, and 3 | ~ oo thetant'c he USBER wel ioe wine | 1 mire & ‘lula water and anfecce cole preparston a os) a RECOMMENDED ANTIFREEZE: P \ Xe roHonde HP coclart er an equivalent high qual We ity ethylene glycol antifreeze containing sllicate- free corrosion inhibitors Check to see if there are any coolant leeks when the | ‘LOWER oN “UPPER” LEVELLINE Coolant level decreases very rapidly. Sees If the reserve tank becomes completely empty, there is «3 possibilty of a getting into the cooling system. ‘Be sure to remove any air from the cooling system tage 6-7). COOLING SYSTEM (Chock the radiator air passage for clogs ar damage. BATON IRE NSEAGE Straighten bent fins with 2 small, Nat blade screwdriver and remove insects, mud or other obstructions with ‘Compressed air o* low pressure water, Replace the radiator if the air flow Is restiicted over more than 20% of the radiating surface. For radiator replacement (page 6-11). 3-13 MAINTENANCE Remove the steering side covers (page 2-4). Check for any coolant leakage from the water pump, water hoses and hose joints, Check the radiator hoses for ccacks or deterioration and replace if necessary. Check that all water hose bands are tight (page SECONDARY AIR SUPPLY SYSTEM + This medel is equipped with a builtin secondary air supply system. The pulse secondary alr supply system is located on the cylinder head covers, + The secondary air supply system introduces fitered air ino exhaust gases in the exhaust port The secondary aris drawn into the exhaust port whenever there 's negalive pressure pulse in the : exhaust syslem. This charged secondary eit promotes burning of the unbumed exhaust gases, ‘and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water PAIR CHECK VALVE CYLINDER HEAD COVER EXHAUST PORT Remove the fuel tank (page 5-48) Irtne noses show Check the PAIR air supply hoses between the PAIR ‘any signs ofheat control solenoid valve and cylinder head cover for ‘damage, aspect deterioration, damage or loose connections. Make sure the PAiR check thal the hoses are nol cracked vats ne Check the ar suction hose between thea cleaner and oft De PAIR canal solenoid vale for dattraton, damnoge cover 080099 oato connectors. (P2572). Make sure that the hoses are not kinked, pinched or cracked 3-14 MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM ‘Check the hoses betitaer the fuel tank, EVAP canister, EVAP purge control valve for deterioration, damage of loose connections. Gheck the EVAP canister for cracks or other damage. EVAP CANISTER FINAL DRIVE Oi OIL LEVEL CHECK Place the motorcycle on its sidestand on @ level surface. Remove the oll filer cap from the final gear case. Check that the ol level is up tothe lower edge of the of filer hole Check for leaks if the oll level is low. Fill the recommended final drive cil though the ol! filer hole Unit reaches the lower edge of the hole. RECOMMENDED FINAL DRIVE OIL Hypold gear oll, SAE #80, ‘Coat 2 new O-ring with of! and instal it onto the al fler aa ‘ ae I Z d 4 LOWER EDGE OF OL oy cap. Install and tighten the a filer cap to the specified forque. TORQUE: 12 Nm (1.2 kaf-m, 9 IBF) 3-15 MAINTENANCE, ‘OIL CHANGE. Suppor the motorcycle securely and raise the rear whee! off the ground: Remove the ol filer cap, drain bolt and sealing washer from the final geer cese, slowly turn the rear wheel and drain the ol, ‘OIL FILLER CAP. ‘with a new sealing washer and tighten it lo the specitiod torque. TORQUE: 12 N'm (1.2 kam, 9 IDF) Fit the final gear case with the recommended final drive fill fo the correct level (page 3-18). OL CAPACITY: 160 cm? (5.4 US oz, 5.6 Imp oz) at draining 470 em? (8.7 US oz, 6.0 imp oz) at disassembly @s dN 7 BP SEATING WASHER ‘Oil DRAIN BOLT BRAKE FLUID (VT750C2F/C2B) NOTICE Spilled Fuld can demage painted, plastic or rubber “paris. Place a rag over these parts whenever the system is serviced. NOTE: + Do fot mix different types of fluid, as they are nat ‘compatible with each other. + Do net allow foreign material to enter the system when fling the reservoir. When the fluid level is low, check the brake pads for wear (page 3-18). ‘low fuid level may be due to wear of the brake pads. Ifthe brake pads are worn and the caliper pistons are pushed out, this accounts for alow reservoir level. Ifthe brake pads are not worn and the fluid level Is low, check the entire system for leaks (page 3-20). Tum the handlebar to the left side so the resenair is level and check the front brake reservoir fluid level ‘through the sight glass. SIGHT GLASS If the fluid level is naar the "LOWER" level mark, remove the screws, reservoir cap, set plate and diephragm, 3-16 MAINTENANCE Fill the reservoir with DOT 4 brake fluid from a sealed ‘ontainer tothe casting ledge iat cag at pte sr ap. Hn | Grn cap ae athe putas on TORQUE:1.5 N-m (0.2 kgfim, 1.1 Ibfft) | CASTING LEDGE BRAKE FLUID (VT750C2S) NOTICE Spilled uid can damage painted, plastic or rubber parts. Place @ /ag over these parts whenever the ‘system is serviced. NoTE *+ Do not mix different types of fluid, as they ere not ‘compatible with each other. + Do not allow foreign material to enter the system when fling the reserve When the fuid level Is low, check the brake pads for wear (page 3-19), 4 low fluid level may be due to wear of the brake pads If the brake pads are wom and the caliper pistons are pushed out, this accounts for a low reservoir level. Fhe brake pads are not worn and the fluid (evel slow, check the entire system for leaks (page 3-20) FRONT ‘Tur the handlebar fo the loft side so the reservolr is level and chack the front brake reservoir uid level ‘through the sight glass. SIGHT GLASS IK the fuid level is near the "LOWER" level mark, remove the screws, reservoir cap, set plate end diaphragm. MAINTENANCE Fill the reservoir with DOT 4 brake fluid from a sealed cantainer to the casting ledge. Install the diaphragm, set plate and reservoir cap, then tighten the cap screws to the specified torque. TORQUE: 1.5 Nem (0.2 kgf-m, 1.1 IbFt) REAR Support the motorcycle upright on @ level surface, (Check the rear brake reservoir fluid level If the fuid level 1S near re "LOWER® level mark, remave the socket bolt and reservcir cover. Remove the screws, reservoir cap, set plate and diaphragm Fill the reservoir with DOT 4 brake fui from 2 seated ‘oniainer tothe casting ledge SET PLATE Install the diaphragm, set plate and reservoir cap, then tighten the cep screws to the specified torque. DIAPHRAGM TORQUE:1.5 Nem (0.2 kgf, 1.1 IDF) UPPER LEVEL Install the reservoir cover and tighten the socket bolt securely. [screws RESERVOIR COVER SOCKET BOLT 3-18 MAINTENANCE BRAKE SHOES/PADS WEAR (VT750C2F/C2B) FRONT BRAKE PADS (Check the brake pad for wear. BRAKE PADS Alnaysrepace tho Roplace the bake pads if eithor pad is warn othe wear trae sade 8a stim grooves foassir ver 3° Fee erate pad replacement (page 16-18) REAR BRAKE SHOES CCheck the indicator plate postion when the brake pedal apples. If the artow on the indicator piate aligns with the "A' mark, inspect the brake cei (page 18-20). Ifthe brake drum 1.0. fs within the service limit, replace the brake shoes (page 15-20), NoTe Ine adjustment remains before the wear indicator limit is reached, this indicates excessive wear and the brake shoes nead to be replaced, BRAKE PADS WEAR (VT750C2S) FRONT BRAKE PADS Check the brake pad for wear. Alnaye repace the Replace the brake pads if ether pad is worn to the wear brake psds asa set_limit grooves. {o-esur wen For brake pad replacement (page 16-18) BRAKE PADS: | 4 WEAR LIMIT GROOVES 3-19 MAINTENANCE REAR BRAKE PADS Check the brake pad for wear. WEAR LIMIT GROOVES Aways reclace the Replace the brake pads if either pad is wor to the wear | | brake pads as a sot_limit grooves. To assue 160 88 For broke pad repiacerent (page 18-16) BRAKE SYSTEM (VT750C2F/C2B) Flrmly apply the brake lever, and check that no air has: entered the system, If the lever feels soft or spongy when operated, bleed the air from the system. For alrbleoding procedures (page 16-8), Inspect the brake hose and fitings for deterioration, cracks, damago or sians of leakage. Tighten any loose fitings. Replace the hose and fitings as required BRAKE HOSE, BRAKE PEDAL HEIGHT (Check the brake pedal height BRAKE PEDAL HEIGHT: 75 mm (3.0 In) above the top of the footpeg To adjust Loosen the lock nut and tum the stopper bolt as tequired Tighten the lock nut securely. ‘Alter adjusting the brake pedal height, check the following: = Brake pesel freeplay (page 3-21) = Rear brake light Switch operation (page 3-22) 3-20 MAINTENANCE BRAKE PEOAL FREEPLAY NOTE Perform brake pedal treepiay adjustment afer adjusting - brake pedal height, Check the brake pedal treoplay. FREEPLAY: 20 30 mm (13/18 ~ 5-9/6 in) Mako eure the cut- I necessary, adjust the brake pedal treeplay by turning cour onthe adjusting the adjusting nut nuts seated on th Nore et pin OPP ator adlusting the brake pedal freeplay, check the rear - brake light switch operation (page 3-22), BRAKE SYSTEM (VT750C2S) Firmly apply the brake lever or pedal, and check that no ait has entered the systern Ifthe lever feels soft or spongy when operated, blood the air from the system. Fora bleoding procedures (page 1-8) Inspect the brake Nose and ‘itings for deterioration,

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