Haynes Honda VFR750 & 700 V-Fours Owners Workshop Manual 1563921014, 9781563921018

Citation preview

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VERZ750 & 700 V-Fours

Owners Workshop Manual

by Jeremy Churchill and Mark Coombs Models covered: Honda VFR750F. 748cc. US 1986, and 1990 through 1994 Honda VFR750F. 748cc. UK 1986 through 1994 Honda VFR700F & FIl. 699cc. US 1986 and 1987

Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

Acknowledgments Our thanks to Andy Stokes and P.R. Taylor & Sons of Chippenham who supplied the VFR750F-L, to Paul Branson Motorcycles of Yeovil who supplied the VFR750F-H, and to Bridge Motorcycle Worid of Exeter who supplied the VFR750F-R model. We would also like to thank NGK Spark Plugs (UK) Ltd for supplying the color spark plug condition photos and the Avon Rubber Company for supplying information on tire fitting.

© Haynes North America, Inc. 1995 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Owners Workshop Manual Series Printed by J. H. Haynes & Co. Ltd., Sparkford, Nr Yeovil, Somerset BA22 7JJ, England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 101 4 Library of Congress Catalog Card Number 95-75235 British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library We take great pride in the accuracy of information given in this manual, but motorcycle manufacturers make alterations and design changes during the production run of a particular motorcycle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

94-280

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Introductory pages About this manual Introduction to the Honda VFR700 & 750 V-Fours Identification numbers

0-6 0-6 0-7

Buying parts

0-9

General specifications Maintenance techniques, tools and working facilities Safety first! Motorcycle chemicals and lubricants Troubleshooting

Chapter 1 Tune-up and outine maintenance

0-9 0-10 0-16 0-18 0-19

1-1

Chapter 2 Engine, clutch and transmission

2-1

Chapter 3 Cooling system

3-1

Chapter 4 Fuel and exhaust systems

4-1

Chapter 5 Ignition system

5-1

Chapter 6 Frame, suspension and fina! drive

6-1

Chapter 7 Brakes, wheels and tires

7-1

Chapter 8 Fairing and bodywork

8-1

Chapter 9 Electrical system

9-1

Wiring diagrams

9-29

Conversion factors

9-39

Index

0-4

VFR750 & 700 V-Fours

Right side view of the 1987 Honda VFR750F-H

Right front view of the 1988 Honda VFR750F-J

VFR750 & 700 V-Fours

Right front view of the 1994 Honda VFR750F-R

About this manual Its purpose The purpose of this manual is to help you get the best value from your motorcycle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs or steps.

At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (ar paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word ‘Chapter’ apply to Sections and/or paragraphs in the same Chapter. For example, ‘see Section 8’ means in the same Chapter. References to the left or right side of the vehicle assume you are sitting on the seat, facing forward. Motorcycle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Even though we have prepared this manual with extreme care, neither the publisher nor the authors can accept responsibility for any errors in, or omissions from, the information given.

NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the

Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction to the Honda VFR700 & 750 V-Fours The Honda VFR750F (and VFR7O0F) is a high-performance sport/touring motorcycle. The engine is a liquid-cooled, 90° Vee-four with double overhead camshafts and four valves per cylinder. The only significant change to the engine unit occurred in 1990 when revised cylinder heads and valve gear were fitted. Fuel is delivered through four Keihin CV carburetors. The front suspension is by a pair of oil-damped, coil spring, telescopic fork legs. The forks on early (1986 through 1989) models are

equipped with a mechanical anti-dive system. The rear suspension uses Honda’s Pro-Link design, which employs a shock absorber/spring unit mounted ahead of the swingarm. The suspension provides a progressive damping effect. On early (1986 through 1989) models, the swingarm is of the conventional type, and on later (1990-on) models the swingarm is of the single-sided Pro-arm type. The front brake uses dual discs and the rear brake use a single

disc.

28

0-7

Identification numbers The frame serial number is stamped into the right side of the steering head, and is also stamped on the identification plate attached to the right side of the frame. The engine number is stamped into the right upper side of the crankcase, directly above the clutch unit. Both of these numbers should be recorded and kept in a safe place so they can be furnished to law enforcement officials in the event of a theft. The frame serial number, engine serial number and carburetor identification number should also be kept in a handy place (such as with your driver’s license) so they are always available when purchasing or ordering parts for your machine.

at

a are

2

Identifying codes The procedures in this manual identify each model letter. The model code (e.g. VFR750FL) is printed on the label, stuck to the rear fender (mudguard) under the seat. code and production year can also be determined from the frame serial numbers as follows:

Frame number is stamped on the right side of the steering head

by its code color code The model engine and

.

4

%

3

3

Model code is printed on the color code label located on the rear fender (mudguard)

Frame number can also be found on the identification plate on the right side of the frame

Engine number is stamped on the right side of the crankcase

0-8

Identification numbers

(a

SR

TTS

ESS

2A

California models 700 models VFR700F-G (1986) VFR7OOFII-G (1986) VFR7OOFII-H (1987)

Engine number RC26E-2000008 to 2004359 RC26E-2000237 to 2001470 RC26E-2100002 to 2102665

Frame number RC261-GM000000 to GM001036 RC263-GMO000001 to GMO000500 RC263-HA105346 to HA105615/RC263-HM100001

to HM100490

750 models

VFR750F-G (1986)

VFR750F-L (1990) VFR750F-M (1991) VFR750F-N (1992) VFR750F-P (1993) VFR750F-R (1994)

RC24E-2000519 RC36E-2006122 RC36E-2100001 RC36E-2201399 RC36E-2300001 RC36E-2400001

on to 2010154 to 2104645 to 2202943 on on

RC241-GM000002 RC361-LM000011 RC361-MM100001 RC361-NM200006 RC361-PM300001 RC361-RM400001

on to LM000227 to MM100403 to NM200186 on on

US models (except California) 700 models

Engine number

Frame number

VFR700F-G (1986) VFR700FII-G (1986) VFR7OOFII-H (1987)

RC26E-2000004 to 2004121 RC26E-2000065 to 2001875 RC26E-2100001 to 2101798

RC260-GMO000000 to GM001826 RC262-GM000001 to GM001000 RC262-HA105001 to HA105395/RC262-HM100001

750 models VFR750F-G (1986) VFR750F-L (1990)

Engine number

Frame number

VFR750F-M (1991)

VFR750F-N (1992) VFR750F-P (1993) VFR750F-R (1994)

UK models

VFR750F-G VFR750F-H VFR750F-J VFR750F-K VFR750F-L VFR750F-M VFR750F-N VFR750F-P VFR750F-R

(1986) (1987) (1988) (1989) (1990) (1991) (1992) (1993) (1994)

RC24E-2000485 RC36E-2006112 RC36E-2100001 RC36E-2201394 RC36E-2300006 RC36E-2400068

on to 2010294 to 2104057 to 2208553 on on

Engine number RC24E-2000101 RC24E-2100065 RC24E-2202367 RC24E-2300001 RC36E-2000085 RC36E-2101280 RC36E-2200020 RC36E-2300001 RC36E-2400024

to to on on to to to on on

RC240-GM000008 RC360-LM000009 RC360-MM100001 RC360-NM200008 RC360-PM300001 RC360-RM400003

on to LM000788 to MM101581 to NM200817 on on

Frame number

2013035 2104493

2013323 2112012 2208633

RC24-2000068 RC24-2100061 RC24-2202353 RC24-2300001 RC36-2000067 RC36-2101254 RC36-2200020 RC36-2300001 RC36-2400015

to to on on to to to on on

2009621 2104084

2010938 2108971 2206995

to HM101781

0-9

Buying parts Once you have found all the identification numbers, record them for reference when buying parts. Since the manufacturers change specifications, parts and vendors (companies that manufacture various components on the machine), providing the ID numbers is the only way to be reasonably sure that you are buying the correct parts. Whenever possible, take the worn part to the dealer so direct comparison with the new component can be made. Along the trail from the manufacturer to the parts shelf, there are numerous places that the part can end up with the wrong number or be listed incorrectly. The two places to purchase new parts for your motorcycle - the

accessory store and the franchised dealer - differ in the type of parts they carry. While dealers can obtain virtually every part for your

motorcycle, the accessory dealer is usually limited to normal high wear items such as shock absorbers, tune-up parts, various engine gaskets, cables, chains, brake parts, etc. Rarely will an accessory outlet have major suspension components, cylinders, transmission gears, or

cases. Used parts can be obtained for roughly half the price of new ones, but you can’t always be sure of what you’re getting. Once again, take your worn part to the wrecking yard (breaker) for direct comparison. Whether buying new, used or rebuilt parts, the best course is to deal directly with someone who specializes in parts for your particular make.

General specifications Wheelbase GUAT OUGI ITIOC ONS eereccenee egesecst ceeteessesecsaeiacrasseceqeesrscecenscryaertarssescs PRIMO CIOMWANCiemrerrrcessrsectte ceertesteetest saeestaendecccs}occrasaasestvesensturtretscvecs Overall length

CG LMOLIGMININIOCG|Suaere

ites etetenes. ice ervteeetnac ress cscscstecs-netectessagrece

Pe OUC Mat OU Ol Stesceceereteseeretsaes saverwancss-ecrdesaars sssnerscecctremtereeesneesses FRiImOC el Steereeteeccetercecerrereercrssesceace sebotees ects eons toes: acterssasscrtanccsseeaxcortes Overall width GaTMKOUGH KC MOGEIS) cereseeecetcccesreseersctst cabcsosacchuarncarersonesatteoesecanrssuastens DetROUGMIE MmOGelS tcc. cercesrecsecscssccesesssocsssreeserexcartsctonenrsgnchs-naryonnzse= FRUIIOCI GIS seesereeseeteente cece ces seuce seace st ccn seers texsresencarinnca sscpeacswasseseosaecsstesece=

1480 mm (58.3 in)

1470 mm (57.9 in)

2175 mm (85.6 in) 2180 mm (85.8 in) 2100 mm (82.7 in) 730 mm (28.7 in) 700 mm (27.6 in)

720 mm (28.3 in)

Overall height GTANGIIMOGES eerceeceetece eesett ee cctsncestkerscrscne

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Index A

Cc

Air filter element - change, 1-10 Air filter housing - removal and installation, 4-17

Camshaft and followers - removal, inspection and installation, 2-15 Camshaft pulse generator (G models) - check, removal and installation, 5-6

Alternator rotor removal and installation, 2-54

Alternator stator coils - check and replacement, 9-25 Asbestos, 0-16

Battery

charging, 9-5 check, 1-5 inspection and maintenance, 9-4 Bearings connecting rod selection, 2-61 main, 2-68 main and connecting rod, general note, 2-61 Brakes brake light switch check and replacement, 9-10

fluid change, 1-21 fluid level check, 1-4 front caliper removal, overhaul and installation, 7-6 front disc inspection, removal and installation, 7-8 front master cylinder removal, overhaul and installation, 7-9 front pad replacement, 7-4 pad wear check, 1-6 pipe and hose inspection and replacement, 7-15 rear caliper removal, overhaul and installation, 7-11 rear disc inspection, removal and installation, 7-14

rear master cylinder removal, overhaul and installation, 7-14 rear pad replacement, 7-9 system bleeding, 7-15 system general check, 1-6 Break-in, engine, 2-78 Buying parts, 0-9

Carburetors disassembly, cleaning and inspection, 4-6 idle adjustment, 4-5 overhaul, general information, 4-5 reassembly and float height check, 4-15 removal and installation, 4-5 separation and reassembly, 4-13 synchronization check and adjustment, 1-17 Centerstand maintenance, 6-4 Chain drive, 1-8

drive - removal, cleaning and installation, 6-26 Charging system alternator stator coils, check and replacement, 9-25 leakage and output test, 9-25 regulator/rectifier coils check and replacement, 9-26 testing, general information and precautions, 9-24 Chemicals, general, 0-18

Choke operation check, 1-7 Choke cable - removal and installation, 4-17 Clutch check, 1-8 fluid change, 1-21

fluid level check, 1-5 master cylinder, 2-38 removal, inspection and installation, 2-33 system - bleeding, 2-41 Clutch switch - check and replacement, 9-20 Clutch switch diode - check and replacement, 9-20

Compression test, 1-11

IND-2 eS

Index SSS

SSeS

LS

SSS

Coolant level check, 1-5 Coolant hoses - removal and installation, 3-8 Coolant reservoir removal and installation, 3-2

Cooling fan check and replacement, 3-3 Cooling system check, 1-17 draining, flushing and refilling, 1-18 general information, 3-2 radiator, 3-6 thermostat, 3-5 water pump, 3-7 Cowl, single seat - removal and installation, 8-12 Crankcase - separation and reassembly, 2-57 Crankcase components - inspection and servicing, 2-59 Crankshaft, 2-68 Cush drive, check and replacement, 6-28 Cylinder head - removal and installation, 2-23 Cylinder head disassembly and reassembly, 2-26

starter motor clutch, 2-31 transmission shafts - disassembly, inspection and reassembly, 2-71 transmission shafts, removal and installation, 2-70 valve clearance check and adjustment, 1-14 valve cover removal and installation, 2-13 valves, seats and guides - servicing, 2-26 Evaporative Emission Control (EVAP) system - check, 1-19 Evaporative emission control system, 4-23 Exhaust system - check, 1-19 Exhaust system - removal and installation, 4-19

F Fairing panels - removal and installation, 8-2 Fairing stay - removal and installation, 8-11 Fan motor replacement, 3-3 Fan switch replacement, 3-4 Fan, cooling system, 3-3

E Electrical system

battery charging, 9-5 battery inspection and maintenance, 9-4 brake light switch check and replacement, 9-10 fuse check and replacement, 9-5

handlebar switch check, 9-18 handlebar switch removal and installation, 9-18 headlight aim check and adjustment, 9-8 headlight assembly removal and installation, 9-8 headlight bulb replacement, 9-7 ignition (main) switch, 9-17 Instrument and warning light bulb replacement, 9-16 lighting system check, 9-6 neutral switch check and replacement, 9-18 sidelight bulb replacement (UK models only), 9-7 sidestand switch check and replacement, 9-19 starter motor overhaul, 9-23 starter motor removal and installation, 9-21 starter relay check and replacement, 9-21 troubleshooting, 9-3 turn signal assembly removal and installation, 9-10 turn signal circuit check, 9-10 turn signal, taillight and license plate bulb replacement, 9-9 Engine camshaft and followers - removal, inspection and installation, 2-15 crankcase components inspection and servicing, 2-59 crankcase separation and reassembly, 2-57 crankshaft and main bearings, 2-68 cylinder head disassembly and reassembly, 2-26 cylinder head removal and installation, 2-23 disassembly and reassembly - general information, 2-13 gearshift mechanism, 2-47 idle speed check and adjustment, 1-16 initial start-up after overhaul, 2-78 main and connecting rod bearings, general note, 2-61 oil and filter change, 1-10 oil cooler, 2-47 oil level check, 1-4 oil pan - removal and installation, 2-41 oil pressure relief valve, 2-46 oil pressure switch, 9-17 oil pump, 2-42 piston rings, 2-68 pistons and connecting rods, 2-61 recommended break-in procedure, 2-78 removal and installation, 2-8 shift drum and forks, 2-60 specifications, 2-1

Fasteners - check, 1-20 Fender/mudguard front fender mudguard removal and installation, 8-11 rear fender/mudguard removal and installation, 8-11 Filter air, 1-10 fuel, 1-20 oil, 1-10 Fluid levels - check, 1-4

Footpegs and brackets - removal and installation, 6-3 Forks, front disassembly, 6-7 inspection, 6-10 installation, 6-7 reassembly, 6-11 removal, 6-6 Frame - inspection and repair, 6-3 Fuel pump - check and replacement, 9-27 Fuel system

carburetor synchronization, 1-17 check and filter cleaning, 1-20 evaporative emission control system check, 1-19 Pulse Secondary Air Injection System check, 1-19 Fuel tank - removal and installation, 4-3 Fuses - check and replacement, 9-5

G Gearshift mechanism, 2-47 Grab rail removal and installation, 8-12

H Handlebar switches - check, 9-18 Handlebar switches - removal and installation, 9-18 Handlebars - removal and installation, 6-5 Headlight aim, check and adjustment, 9-8 bulb replacement, 9-7 headlight assembly removal and installation, 9-8 Horn - check and replacement, 9-20

Identification numbers, 0-7

Index ee Identifying codes, 0-7 Idle speed - check and adjustment, 1-16 Ignition (main) switch - check, removal and installation, 9-17 Ignition system camshaft pulse generator (G models), 5-6 coil check, 5-3 coil installation, 5-5 coil removal, 5-5 pulse generator check, removal and installation, 5-5

spark unit removal, check and installation, 5-7 system check, 5-2 Ignition timing, 5-7 Instrument and warning light bulbs - replacement, 9-16 Instrument panel removal and installation, 9-11

IND-3

R Radiator cap check, 3-2 removal and installation, 3-6 Rear suspension linkage - removal, inspection and installation, 6-18 Regulator/rectifier unit - check and replacement, 9-26

S ; eatery suey ote ; , Seat - removal and installation, 8-12 Shift drum and forks, 2-60 Shock absorber, rear installation, 6-18

L

preload adjuster check, 6-16

Lighting system - check, 9-6 Lubricants, recommended, Lubrication - general, 1-14

1-2

removal, 6-15 Sidestand maintenance, 6-4 Sidestand switch - check and replacement, 9-19 Spark plugs - check and replacement, 1-12 Spark unit - removal, check and installation, 5-7 Specifications brakes, 7-1

cooling system, 3-1 electrical system, 9-1 M

engine, 2-1

Maintenance intervals, 1-3 Maintenance techniques, 0-10 Maintenance, introduction to, 1-4 Meters and gauges - check and replacement, 9-13 Mirrors, rear view - removal and installation, 8-10

Mudguard/fender front mudguard/fender removal and installation, 8-11

rear mudguard/fender removal and installation, 8-11

N Neutral switch - check and replacement, 9-18

frame, suspension and final drive, 6-1

fuel system, 4-1 general, 0-9 ignition system, 5-1 maintenance, 1-1 Speedometer cable (G through P models) removal

'

and installation, 9-12

Speedometer drive unit (R models) - removal and installation, 9-12 Sprocket coupling, check and replacement, 6-28 Sprockets - check and replacement, 6-27 Starter motor - removal and installation, 9-21 Starter motor clutch, 2-31 Starter motor overhaul, 9-23 Starter relay switch - check and replacement, 9-21 Steering stem bearing check and adjustment, 1-19 stem bearing inspection and replacement, 6-14 stem removal and installation, 6-13 Swingarm bearing check, 6-22

O

inspection and bearing replacement, 6-25 removal and installation, 6-22

Oil - engine oil and filter change, 1-10 pressure switch check and replacement, 9-17 Oil cooler, 2-47 Oil pan - removal and installation, 2-41

TF

Oil pressure relief valve, 2-46 Oil pump, 2-42 Operations possible with the engine in the frame, 2-7

Temperature gauge check and replacement, 3-4 Temperature sender check and replacement, 3-4 Thermostat - removal, check and installation, 3-5

Operations requiring engine removal, 2-8

Throttle freeplay check and adjustment, 1-7 Throttle cables - removal and installation, 4-16 Tires general check, 1-7

Pp

tubeless, general information, 7-28

Tools, general usage, 0-11

Piston rings, 2-68

Transmission shafts - disassembly, inspection

Pulse generator - check, removal and installation, 5-5

Transmission shafts - removal and instaliation, 2-70

Pistons and connecting rods, 2-61

and reassembly, 2-71

Pulse Secondary Air Injection (PAIR) system, 4-23

Troubleshooting, 0-19

Pulse Secondary Air Injection (PAIR) system - check, 1-19

Turn signal assemblies - removal and installation, 9-10

i IND

IND-4 Turn signal circuit - check, 9-10 Turn signal, taillight and license plate bulbs - replacement, 9-9

Index W Water pump - check, removal and installation, 3-7 Wheel bearings - removal, inspection and installation, 7-20 Wheels

V

alignment check, 7-17 front wheel removal and installation, 7-17

P : Valve cover - removal and installation, 2-13

general check, 1-7 inspection and repair, 7-16

Valves - engine

clearance check and adjustment, 1-14

Valves, seats and guides - servicing, 2-26

rear wheel removal and installation, 7-18

Windshield - removal and installation, 8-10 Working facilities, 0-15

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