Professional Documents
Culture Documents
Workshopmanual-Vf750f Interceptor 1983 - 1984-24022021-1908
Workshopmanual-Vf750f Interceptor 1983 - 1984-24022021-1908
SHOPMANUAL
vF70/0,FtvF750
INTETICEPTOFI
-1-l|E-
\-
IMPORTANT NOTICE
SAFETY
@ Indicotes a strong possibility of severe personal inlury or loss o! trJe tl instructions are
not tollowed.
Indie'qtes a possibilit.t' of personal or equipment damqge if instruc'tions ore not
follov'ed.
NOTE:Giveshelpfulinformation.
Detaileddescriptionsof standardworkshop procedures,safetyprinciplesand serviceoperationsare not
included.lt is importantto note that this manual containssome warnings and cautionsagainstsome
specificservicemethodswhich couldcausePERSONALINJURY to servicepersonnelor coulddamagea
vehicleor renderit unsafe.Pleaseunderstandthat thosewarningscouldnot coverallconceivableways in
which service,whether or not recommendedby Honda might be done or of the possible hazardous
consequencesof each conceivableway, nor could Hondainvestigateall such ways. Anyone using service
proceduresor tools,whether or not recommendedby Honda must satlsfyhimselfthoroughlythat neither
personalsafety nor vehicle safetywill be jeopardizedby the service method or tools selected.
t
IIONTTDA
VF7OOI750
INTERCEPTOR
L HOWTOUSETHISMANUAT G E N E R A LI N F O R M A T I O N
TROUBLESHOOTING
E X H A U S TA N D N O I S EE M I S S I O C
N O N T R O LS Y S T E M 1-13
'84: EVAPORATIVE
EMISSION
CONTROLSYSTEM
(California
modelonly) 1-14
EMISSIOC
N O N T R O LI N F O R M A T I O N
LABEL 1-15
GEl{ERAL
SAIETY
EME@
If the engine must he running to do some work, make sure The batter.y electrolyte contains su$'uric acid. Protect ),our
the area ip well-ventilated.Never run the enginein o closetl eyes, skin and clothing. Itr caseof contoct, flush thoroughty
area. The exhaust contains poisonous carbon monoxide with \eater and call a doctor if electolyte gets in )tsyy gyss.
gos.
SERI|ICE
RUTES
t .U s e g e n u i n e H O N D A o r H O N D A - r e c o m m e n d e dp a r t s a n d l u b r i c a n t so r t h e i r e q u i v a l e n t .P a r t s t h a t d o n o t m e e t H O N D A ' s
d e s i g ns p e c i f i c a t i o n m
s a y d a m a g et h e m o t o r c y c l e .
2 . U s e t h e s p e c i a tl o o l s d e s i g n e df o r t h i s p r o d u c t .
J . U s e o n l y m e t r i c t o o l s w h e n s e r v i c i n gt h i s m o t o r c y c l e . M e t r i c b o l t s , n u t s , a n d s c r e w sa r e n o t i n t e r c h a n g e a b l w e ith English
f a s t e n e r sT. h e u s e o f i n c o r r e c tt o o l s a n d f a s t e n e r sm a y d a m a g et h e m o t o r c y c l e .
4 . I n s t a l l n e w g a s k e t sO , - r i n g s ,c o t t e r p i n s . l o c k p l a t e s ,e t c . w h e n r e a s s e m b l i n g .
5 . W h e n t i g h t e n i n g b o l t s o r n u t s , b e g i nw i t h l a r g e r - d i a m e t eorr i n n e r b o l t s f i r s t , a n d t i g h t e n t o t h e s p e c i f i e dt o r q u e d i a g o n a l l y ,
u n l e s sa p a r t i c u l a rs e q u e n c ei s s p e c i if e d .
\/ 6 . C l e a np a r t s i n c l e a n i n gs o l v e n tu p o n d i s a s s e m b l yL. u b r i c a t ea n y s l i d i n gs u r f a c e sb e f o r e r e a s s e m b l y .
7 . A f t e r r e a s s e m b l yc, h e c k a l l p a r t sf o r p r o p e r I n s t a l l a t i o na n d o p e r a t i o n .
\F
Dateof lssue:October,1983
O H O N D A M O T O RC O . .L T D . 1-1
IIONTf,DA
V45 INTERCEPTOR
G E N E R A LI N F O R M A T I O N
l|lODEL
IDENTIFICATIO
1.I
*d*
B E G I N N I N GF r a m eN o .J H 2 R C 1 5 0 * D M 0 0 0 0-0 1 The color labelis affixedto the rearfender,underthe seat.
E n g i n eN o . R C 15 E - 2 0 0 0 0 0 1-
M
T h e e n g i n es e r i a ln u m b e ri s s t a m p e do n t h e r i g h t s i d eo f The carburetor identificationnumbersare stampedonto
the uppercrankcase. eachcarburetor.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1-2 O H O N D AM O T O RC O . ,L T D .
ITONTTDA
VF7OOI750INTERCEPTOR
G E N E R A LI N F O R M A T I O N
SPECIFICATIONS
ITEM SPECIFICATIONS
D I M E N S I O N S Overalllength 2 , 1 6 0m m ( 8 5 . 0i n )
Overallwidth 77Omm (30.3in)
Overallheight 1 , 2 1 5m m ( 4 7 . 8i n )
Wheelbase 1,495mm (58.9in)
Seat height 82Omm (32.3in)
Foot peg height VF7SOF: 348 mm (13.7in)
VFTOOF: 343 mm (13.5in)
Ground clearance 1 5 5m m ( 6 . ' li n )
'83-'84VF7SOF: ks (487lb)
Dry weight 221
'84
VF700F:22Oks(485 lb)
After '84 VFTOOF: 223k9 (492 lb)
C u r bw e i g h t 243 ks (536 lb)
ITEM S P E C I IFC A T I O N S
CARBURE. Carburetortype/throttlebore K E I H I NV D / 3 2 m m ( 1 . 2 6i n )
TION l d e n t i f i c a t i onnu m b e r Referto page4-1
Referto page4-1
P i l o ts c r e wi n i t i a ls e t t i n g S e ep a g e4 - 1 6
Fl o a t l e v e l 7 . 0 m m ( 0 . 2 8i n )
DRIVE Cl u t c h Wet,multi-plate
TRAIN Transm ission 5-speed
P r i m a r yr e d u c t i o n 2.152
F i n a lr e d u c t i o n V F 7 5 0 F2: . 5 8 8
VF700F:2.750
G e a rr a t i o I 2.733
G e a rr a t i ol l 1,895
G e a r a t i ol l l 1.500
G e a rr a t i o l V 1.240
G e a rr a t i oV 1.074
Gearshift pattern Leftfoot operated
returnsystem, l-N-2-3-4-5
EL E C T RI C A L lgnition F u l l t r a n s i s t oirg n i t i o n
l g n i t i o nt i m i n g" F " m a r k V F 7 5 0 F :1 0 oB T D Ca t i d l e
V F 7 0 0 F :l 5 " B T D C a t i d l e
Fulladvance 3 7 ' B T D C a t 3 . 3 0 0r p m
S t a r t i n gs y s t e m Startingmotor
Alternator V F 7 5 0 F :3 0 0 W / 5 , 0 0 0 rpm
V F 7 0 0 F :3 5 0 W / 5 , 0 0 0r p m
Batterycapacity 12V-14 AH
S p a r kp l u g NGK ND
,''
Standard DPR8EA.9 X24EPR.U9
F o r c o l dc l i m a t e
DPR7EA.9 X22EPR-U9
(Below 5"C,41oF)
For extended
DPR9EA.9 X27EPR.U9
h i g hs p e e dr i d i n g
S p a r kp l u g 0.8-0.9mm (0.031-0.035
in)
Fi r i n go r d el'o 1-4-3-2
F u s e / m a ituse
n' 15A/30A
LIGHTS H e a d l i g h(th i g h / l o wb e a m ) 60/55W
Tail/stoplight 8127w (.3132
cpl SAENO, 1157
F r o n t t u r n s i g n a l / r u n n i nl igg h t 2318W (3213cpl SAENO.1034
R e a rt u r n s i g n a l 23 W (32cp) SAENO.1073
I n s t r u m e nlti g h t s 3W
N e u t r a il n d i c a t o r 3W
T u r n s i g n ailn d i c a t o r 3W
H i g hb e a mi n d i c a t o r 3W
D a t e o f l s s u e :J u l v , 1 9 8 4
1-4 O H O N D A M O T O RC O . . L T D .
I1IOTVDA
V45 INTERCEPTOR
G E N E R A LI N F O R M A T I O N
TOROUT
I|ALUES
O ENGINE
O CHASSIS
\.t
D a t eo f l s s u eO
: c t o b e r1. 9 8 3
O H O N D AM O T O RC O . ,L T D . 1-5
:-*---J
IIONTf,DA
V45 INTERCEPTOR.
G E N E R A LI N F O R M A T I O N
O S T A N D A R DT O R O U EV A L U E S
TorqueValues TorqueValues
Item Item
N ' m ( k g - m f, t - l b ) N . m ( k g - m f, t - l b )
5 m m b o l t a n dn u t 4-6 {0.4-0.6,3-4) 5 mm screw 3-5 (0.3-0.5,2-4)
6 m m b o l t a n dn u t 8 - 1 2 ( 0 . 8 - 1. 2 , 6 - 9 1 6 mm screw 7 - 1 1( O . 7 - 1 . 1 , 5 - 8 )
8 mm bolt and nut 18-25 (1.8-2.5,13-18) 6 mm f langebolt and nut 1 0 - 1 4( 1 . 0 - 1. 4 , 7 - 1 O l
1 0 m m b o l t a n dn u t 30-40 (3.0-4.0,22-291 8 mm flangebolt and nut 24-30 (2.4-3.0,17-221
12 mm bolt and nut 50-60 (5.0-6.0,36-43) 1 0 m m f l a n g eb o l t a n d n u t 35-45 (3.5-4.5,25-33)
Dateof lssue:October,1983
1-6 @ H O N D AM O T O RC O . ,L T D .
IIONTf,DA
V45 INTERCEPTOR
G E N E R A LI N F O R M A T I O N
TOOLS
O SPECIAL
TOOL TOOL
DESCR
IPTION A L T E R N A T ET O O L R E F .P A G E
NUMBER NUMBER
Oil pressure gaugeattachment 07510-4220100 _ E q u i v a l e tnot o l c o m m e r c i a l l y 2-5
Compression gaugeattachment 0 7 5 1 0 - M 8 0 0 1 a v a i l a b lien U . S . A . 3-12
Carburetorpilot screwwrench 07908-4220201 3-11
S n a pr i n gp l i e r s 07914-3230001 E q u i v a l e nt ot o l c o m m e r c i a l l y 7-5,14-21
a v a i l a b lien U . S . A . 14-27,16-8
1 61- 6
Steeringstem socket 07916-37 10100 14-32,14-35
Hex wrench,6 mm 07917-3230000 E q u i v a l e nt o
t ol commercially 14-20
a v a i l a b lien U . S . A .
'07924-MC70001
Primarygearholder 07924-MC70002 or Gearholdermodified- ---f .07924-MC70000
t 7-11,7-22
L -07924-4150000
N e e d l eb e a r i n gr e m o v e r -M470000 N o t a v a i l a b lien U . S . A .
07931 15-15
Bearingraceremover 07946-3710500 14-33
- ;Steering stemdriver 07946-3710601
Steeringstemdriver 07946-MB00000 14-34
LAttachment 07964-M800200
F o r ks e ad l river 07947-4630100 14-27
Driver 07949-3710000 11 - 3
Ball raceremover 07953-4250002 14-33
Oil sealdriverattachment 07965-MC70100 15-9,15-10
Attachmentring 07965-ME701 00 15-10
O i l s e ad l river 07965-M8001 00 15-10
Sealremoverpump -M010004 U . S . A .o n l y
07971 15-19
V a l v eg u i d er e a m e r5, . 5 m m 07984-2000000 10-12,10-13
l g n i t i o nt i m i n gi n s p e c t i ocno v e r 07998-M800000 or 07404-0020000or 18-5
Vacuumgauge 07404-00301100 V a c u u mg a u g e( U . S . A o. n l y ) M9378_021_XXXXX
3 -1 0
Oil pressure gauge 07506-3000000 E q ui v a l e nt o o l c o m m e r c i a l l y 2-5
a v a i l a b lien U . S . A .
Pressure pump sT-AH-255-MC7 r U . S . A .o n l y - l n c l u d e di n
4-19
V a c u u mp u m p sT-AH-260-MC7 l- Turbo kit
O COMMON
TOOL TOOL R E F .P A G E
DESCRIPTION A L T E R N A T ET O O L
NUMBER NUMBER
Float levelgauge 07401-0010000 4-6
L o c k n u t w r e n c h ,1 0 x 1 2 m m 07708-0030200 3-9
E o u i v a l e nt o
t ol
Lock nut wrench,17 x 27 mm 07716-0020300 ' c o m m e r c i al yl a v alia b l e 7-11,7-19
Lock nut wrench,30 x 32 mm 07716-0020400 i n U . S . A . 14-31,14-36
Extension 07716-0020500 7 - 1 ,17 - 1 9
14-31,14-36
U n i v e r s ahlo l d e r 07725-0030000 7-12,7-19
\-, Flywheelholder 07725-0040000 Bandstrapwrench-commer- 9-2,9-3
c i a l l ya v a i l a b lien U . S . A .
Rotor puller 07733-0020001 R o t o rp u l l e r 07933*3290001 9-2
V a l v eg u i d er e m o v e r5, . 5 m m 07742-0010100 Valveguidedriver 07942-3290100 10-13
Driver 07746-00301
00 13-9
fDriver 07945-3710200
Attachment,25 mm l.D. 07746-0030200 13-9
Dateof lssue:October,1983
O H O N D AM O T O RC O . .L T D . 1-7
sreffil A'
GENERALil NFORMATION
v45 ffi{rc*cEPTOR
TOOL TOOL
DESCRIPTION ALTERNATE
TOOL R E F .P A G E
NUMBER NUMBER
Attachment,32x 35 mm 07746-0010100 15-5
Attachment,3Tx 40 mm 07746-0010200 7-16,15-15
A t t a c h m e n t , 4 2 x 4 7m m 07746-0010300 14-15,14-33
Attachment, 52 x 55 mm 07746-0010400 11-3,14.34
15.6 \__
Attachment,62 x 68 mm 07746*0010500 15-6
P i l o t ,1 5 m m 07746-0040300 14-15
P i l o t ,1 7 m m o7746-0040400 1 5 - 51
Pilot,20 mm 07746-0040500 15"6,15.15
Pilot, 26 mm 07746-0040600 15-6
P i l o t , 3 5m m
Driver
07746-0040700
07749-0010000
7-16 L_.
7-16,14-15
14.33,14-34
15-6,15-15
Valvespringcompressor 07757-0010000 1 0 . 1 01, 0 . 1 5
Bearingremovershaft 07746-0050100- Equivalenttool 14-14;15-5
Bearingremovercorret, 15 mm 07746-0050400- .comrnercially available 14-14
Bearingremovercorret, 20 mm 07746-0050600- i n U . S . A . 15-5
\.--
\-
Dateof lszue:January,1983
1-8 O HONDAMOTORCO.,LTD,
ITONTXDA
V45 INTERCEPTOR
G E N E R A LI N F O R M A T I O N
& ]|ARIITSS
CABTE ROUTIl{G
Note the following when routing cablesand wire
harnesses.
A loosewire,harnessor cablecan be a safetyhazard.
After clamping,check each wire to be sure it is
secure. X
Do not squeezewires againstthe weld or end of
its clampwhena weld-onclamp is used. G,
Secure wires and wire harnesses to the frame
wire bandsat the designated
with their respective
locations.Tighten the bands so that only the --/'-^
insulated surfacescontact the wires or wire
harnesses.
o
tectivetapeor replacethem.
m
Also avoid the projected ends of bolts and
screws.
L-.
D a t eo f l s s u eJ: a n u a r y 1, 9 8 3
@ H O N D AM O T O RC O . .L T D . 1-9
IICDT$f,DA
G E N E R A LI N F O R M A T I O N
V45 INTERGEPTOR
C H O K EC A B L E
FRONT F U S EB O X
BRAKE COUPLER
HOSES METER
HEADLI
COUPLER LLUMINATION
LER
C L U T C HP I P E
SPEEDOMETER
F R O N TB R A K EH O S E S
CABLE
S P E E D O M E T ECRA B L E
T H R O T T LC
EA B L E S
CHOKE
CABLE
I G N I T I O NC O I L
H I G HT E N S I O N4
MAINHARNESS
WIRES
THERMOSTAT B R A K EH O S E
O I L P R E S S U RSEW I T C H
:\
THERMOSTATIC
S W I T CW
H IRE
Dateof lssue:January,1983
1-10 O H O N D AM O T O RC O . ,L T D .
IIONTTDA
V45 INTER,CEPTOR
G E N E R A LI N F O R M A T I O N
T U R NS I G N A L
ELAY
ELCUT.OFF
RELAY
RADIATOR REGULATOR/
RESERVE RECTIFIER
TANK REGULATOR/
RECTIFIER
COUPLER
F A NM O T O RR E L A Y
C L U T C HH O S E
---
A L T E R N A T O RW I R E
IGNITION
COIL
S T A R T E RR E L A Y
S P A R KP L U G
BATTERY
CABLE CAP
OILPRESSURE
SWITCH
\-'
B R A K EL I G H T
S W I T C HW I R E
R E A RB R A K EH O S E
G R O U N DC A B L E
\./
S T A R T E RM O T O R
L-
R A D I A T O RB R E A T H E RT U B E
B A T T E R YB R E A T H E RT U B E
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 1-11
IIONIf,DA
G E N E R A LI N F O R M A T I O N
V45 INTERCEPTOR
HEADLIGHT F U S EB O X C O U P L E R
COUPLER
STARTERi H E A D L I G HD
TIMMER/
ENGINE H O R NS W I T C HC O U P L E R
STOP
SWITCH
COUPLER
TURN C O O L I N GF A N F U S E
SIGNAL
SWITCH
COUPLER
T U R NS I G N A L
WIRE
C H O K EC A B L E
C H O K EC A B L E T H R O T T L EC A B L E S
C O O L I N GF A N M O T O R S
I G N I T I O NC O I L S
WIRES
H I G HT E N S I O N
MAINHARNESS
R A D I A T O RH O S E
RESERVE
TANK
F U E LP U M P
B R A K EA N D T A I L L I G H T
S P A R KU N I T
R. REAR
TURN
SIGNAL
WIRE
L . R E A RT U R N
S I G N A LW I R E
S P A R KU N I T
B R A K EA N D T A I L
L I G H TS E N S O R
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
1 -1 2 O H O N D AM O T O RC O . ,L T D .
ITOilTf,DA
V45 INTER,CEPTOR G E N E R A LI N F O R M A T I O N
tl'|rssr0r{
c0ilTR0r
sYsTEMs
The U.S.Environmental ProtectionAgencyand CaliforniaAir Resources Board(CARB)requiremanufacturers to certify that
their motorcyclescomply with applicableexhaustemissions standards duringtheir usefullife, when operatedand maintained
accordingto the instructionsprovided,and that motorcyclesbuilt after January 1, 1983 comply with applicablenoise
emissionstandardsfor one year or 6,000 km (3,730 miles)after the time of saleto the ultimate purchaser,when operated
and maintainedaccordingto the instructionsprovided.Compliance with the termsof the Distributor'sWarranties for Honda
MotorcycleEmissionControlSystemsis necessary in orderto keepthe emissionwarrantyin effect.
E F EMISSIONS
SOURCO
The combustionprocessproducescarbon monoxideand hydrocarbons.Control of hydrocarbonsis very importantbecause,
under certain conditions,they react to form photochemicalsmogwhen subjectedto sunlight.Carbonmonoxidedoesnot
reactin the sameway, but it is toxic.
Honda Motor Co,, Ltd. utilizes lean carburetor settingsas well as other systems,to reduce carbon monoxide and
hydrocarbons.
E l E X H A U SE
TMT S S T C
ONON T R OL
S Y S TEM
E shouldbe madeexceptidle
The exhaustemissioncontrol systemis composedof leancarburetorsettings,and no adjustments
3 speedadjustmentwith the throttle stop screw.
C R A N K C A SE M I S S I O N
C O N T R O LS Y S T E M
T h i se n g i n ei s e q ui p p e dw i t h a c r a n k c a s e m i s s i o nc o n t r o sl y s t e mw h i c h r o u t e sc r a n k c a s e m i s s i o n tsh r o u g ht h e a i r c l e a n e r
a n d i n t ot h e c o m b u s t i o nc h a m b e r C . o n d e n s e cdr a n k c a s ve a p o r sa r e a c c u m u l a t e d i n a s t o r a g et a n kw h i c h m u s tb e e m p t i e d
p e r i o d i c a l l yS.e et h e M a i n t e n a n c eS c h e d u l ei n S e c t i o n3 .
AIRCLEANER
G= : FRESH
AIR
CARBURETOR <--- : BLOW-BYGAS
BREATHER
SEPARATOR
D R A I NT U B E
D R A I NP L U G
\-.
R e v i s e dJ:u l y , 1 9 8 4
@AmericanHondaMotorCo.,Inc.1984- All RightsReserved
MSV 7227 8407
1-13
ITONIT'A
V45 INTERCEPTOR
G E N E R A LI N F O R M A T I O N
C O N T R O LS Y S T E M( C a l i f o r n i m
EMISSION
IEUIEVAPORATIVE a o d e lo n l y )
F U E LT A N K
F R E S HA I R
2 CANISTER
ONEWAYVALVE
C O N T R O LS Y S T E M
N O I S EE M I S S I O N
T A M P E R t N GW | T H T H E N O I S E C O N T R O LS Y S T E Ml S P R O H I B I T E D :F e d e r alla w p r o h i b i t st h e f o l l o w i n ga c t so r t h e
causingthereof: (1) The removalor renderinginoperativeby any person,other than for purposesof maintenance, repairor
replacement, of any deviceor elementof designincorporatedinto any new vehiclefor the purposeof noisecontrol prior to
its saleor deliveryto the ultimatepurchaseror while it is in use;or (2) the useof the vehicleafter suchdeviceor elementof
designhasbeenremovedor renderedinoperativeby any person'
A M O N GT H O S EA C T SP R E S U M E DT O C O N S T I T U T ET A M P E R I N GA R E T H E A C T S L I S T E DB E L O W :
1. Removalof , or puncturingthe muffler, baffles,headerpipesor any other componentwhich conductsexhaustgases'
3. Lackof propermaintenance.
4. Replacingany movingpartsof the vehicle,or partsof the exhaustor intakesystem,with partsother than thosespecified
by the manufacturer.
R e v i s e dJ u l y , 1 9 8 4
HondaMotorCo.,lnc.1984- All RightsReserved
1 -1 4 @American
MSV 7227 8407
IIONf,DA
VT7OOI750INTERCEPTOR
G E N E R A LI N F O R M A T I O N
EMISSION
CONTROL
INFORMATION
LABET E M I S S I O NC O N T R O L
I N F O R M A T I OLNA B E L
An EmissionControl InformationLabel is located
on the rear fender under the seat as shown. lt
gives basictune-up specifications.
E M I S S I OC
NO N T R OI N
L FORMATION
V E H I C L EE M I S S I O NC O N T R O L
UPDATE LABEL
INFORMATION UPDATELABEL
After makinga high altitudecarburetoradjustment
( p a g e4 - 1 8 ) , a t t a c h a n u p d a t e l a b e l o n t h e r e a r
fender under the seat as shown. Instructionsfor
o b t a i n i n gt h e u p d a t e l a b e l a r e g i v e n i n S e r v i c e
Letter No. 132.
V A C U U M H O S E R O U T I N GL A B E L
(After'83 California model only) VACI.',U;I FICSE ROUTING DIAGRAT
tl|itIt il|il.Y - tNt0l1E4108
tf^mlllllt flrltY - 8110
The Vacuum HoseRoutingLabelis attachedto the uUf0tlil tflilctt
fuel tank below the seat. Routethe vacuum hoses
as describedon this label.
V A C U U MH O S ER O U T I N GL A B E L
F R O N TC Y L I N D E R
EX.CAMSHAFT
F R O N TC Y L I N D E R
I N .C A M S H A F T
( T O R E A RC Y L I N D E R )
S H I F TF O K S H A F T
o t Lo I FI C E
OILPUMP
OILFILTER
OILSTRAINER COUNTERSHAFT
Dateof lssue:January,1983
2-O O H O N D AM O T O RC O . ,L T D .
IIOilTTDA
INTERCEPTOR
VF7OO/750
2. TUBRICATION
SERVICEINFORMATION 2-1 O I L P R E S S U RC
EH E C K 2-4
TROUBLESHOOTING 2-2 OIL P U M P 2-5
E N G I N EO I L L E V E L 2-3 CONTROLCABLELUBRICATION 2-9
E N G I N EO I L & F I L T E RC H A N G E 2-3 LUBRICATION POINTS 2-10
O I L S T R A I N E RC L E A N I N G 2-4
IIIFORMATION
SERVICE
GENERAL
to removethe rightsidecoverandwaterpumpassembly.
To servicethe oil pump,it is necessary Seesection6 for water
pumpremovaland installation.
SPECIFICATIONS
E n g i n eo i l
'83-'84:
Oil capacity 2 . 9 l i t e r s( 3 . 1 U S q t , 2 . 5 l m p q t ) a f t e r d r a i n i n g
'84:
After 2.7 liters (2.9 US qt,2.4lmp qt) after draining
3.0 liters (3.2 US qt, 2.6 lmp qt) after disassembly
-10 10
Oil pressure
(at oil pressure
switch) 5.4 t O.7 kg/cm2 (77 ! 10 psi) at 5,OOOrpm (80oC/176oF)
Oil pumpdelivery 47.8 liters (5O.5US qt),zminat 5,000 rpm of oil pump speed
T O R O UV
EA L U E S
E n g i n eo i l d r a i np l u g 35-40 N.m(3.5-4.0kg-m,25-29f t - t b )
E n g i n eo i l f i l t e r 1 5 - 2 0N . m( 1 . 5 - 2 . 0k g - m1. 1 - 1 4ft.tbl
Oil pressure switch 15-20N.m{1.5-2.0ks-m.1l-14 ft-lb)
TOOLS
Special
Oil pressure
gauge 07506-3000000-r
Oil pressure
gaugeattachment or equivalent
O7S1O_422O1g9_l- toolscommerciallV
available.
\-,
TR0UBrtSlr0ffirl{0
Oil leueltoo low
1 . E x t e r n aol i l l e a k s
2 . W o r np i s t o nr i n g s
3 . W o r nv a l v eg u i d eo r s e a l
Oil contamination
1 . O i l o r f i l t e r n o t c h a n g eo
df t e ne n o u g h
2. Headgasketfaulty
3 . W o r np i s t o nr i n g s
No oil pressure
1 . O i l l e v el o w
2 . O i l p u m pd r i v ec h a i nb r o k e n
3 . O i l p u m pf a u l t y
4 . I n t e r n aol i l l e a k a g e t
Dateof lssue:January,1,983
2-2 O H O N D AM O T O RC O . ,L T D .
IIONITDA
V45 INTER,CEPTOR
LUBRICATION
ENOIIIT
OItLEIJEL OILFILLER /DIPSTICK
OIt& FIITTR
ENOINE C|IAI{GE
NOTE
Changeengineoil with the enginewarm and
the motorcycleon its center stand to assure
completeand rapiddraining.
C h e c kt h a t t h e s e a l i n gw a s h e ro n t h e d r a i n p l u g i s
i n g o o d c o n d i t i o na n d i n s t a l tl h e p l u g . R e p l a c e
the L O W E RR - A D I A T O R OILFILTER
o i l f i l t e r w i t h a n e w o n e . C h e c kt h a t t h e o i l f i l t e r
O-ring is in good condition, and coat it with oil
before installingit. lnstallthe lower radiatormount
bracket, lower radiator mount bolts and lower
radiatorcowl.
M O U N TB O L T M O U N TB R A C K E T
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . .L T D . 2-3
IIONTf,DA
V45 INIERCEPTOR,
LUBRICATION
CIEANIl{G
OItSTRAII{ER
NOTE:
T h e o i l s t r a i n e rc a n b e r e m o v e dw i t h t h e
e n g i n em o u n t e di n t h e f r a m e .
Removethe lowerradiatorcowl.
Removethe exhaustchamber.
D r a i nt h e e n g i n eo i l ( p a g e2 - 3 ) .
R e m o v et h e o i l p a nb o l t sa n do i l p a n .
OILPAN
R E L I E FV A L V E
R e m o v ea n d c l e a nt h e o i l s t r a i n e r .
Check the operation of the pressurerelief valve.
M a k e s u r e t h e O - r i n g i s i n g o o d c o n d i t i o nw h e n -
everthe reliefvalveis removed.
I n s t a ltl h e o i l s t r a i n ear n do i l p a n .
I n s t a ltl h e e x h a u spt i p e s .
F i l l t h e c r a n k c a swe i t h t h e r e c o m m e n d eodi l ( p a g e
2-1t.
O I LS T R A I N E R R E L I E FV A L V EO . R I N G
CI|ECI(
OItPRESSURE
W a r m t h e e n g i n eu p t o n o r m a lo p e r a t i n gt e m p e r -
a t u r e( a p p r o x i m a t e 8l y0 ' C / 17 6 " F ) .
S t o p t h e e n g i n ea n d d i s c o n n e ctth e o i l p r e s s u r e
s w i t c hw i r e .
Remove the oil pressureswitch and connect an
oil pressure gauge to the pressure switch hole
( p a g e2 - 5 ) .
C h e c kt h e o i l l e v e l .
O I L P R E S S U RSEW I T C H
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
2-4 O H O N D AM O T O RC O . ,L T D .
IilOlVDA
V45 INTER,CEPTOR
LUBRICATION
Q I L P R E S S U RGEA U G E
0 7 5 0 6 - 3 0 0 0 0 0 0O R E O U I V A L E N TT O O L I N U . S . A .
Start the engineand checkthe oil pressure
at 5,000
rpm.
OIL PRESSURE:
5.4 ! O.7 kglcm2 |.77! 10 psi) at 5,000 rpm
(80"c/176'F)
S t o pt h e e n g i n e .
A p p l y 3 - B O N D @s e a l a n to r e q u i v a l e n tt o t h e
pressure switchthreadsand install.
TOROUE: 15-20 N.m (1.5-2.0 kg-m,11-14 ft-tbl
C o n n e ctth e o i l p r e s s u rsew i t c hw i r e .
Startthe engine.
Checkthat the oil pressurewarningindicatorgoes
out after one or two seconds.
l f t h e o i l p r e s s u rw
e a r n i n gi n d i c a t o rs t a y so n , s t o p
t h e e n g i n ei m m e d i a t e layn dd e t e r m i n e thecause. O I L P R E S S U RG E A U G EA T T A C H M E N T
O 7 5 1 O _ 4 2 2 O 1O
0 0R E O U I V A L E N TT O O L I N U . S . A .
OItPU]'|P
REMOVAL
NOTE
T h e o i l p u m p c a n b e r e m o v e dw i t h t h e e n g i n e
mounted in the f rame.
Removethe lowerradiator
Drainthe engineoil. Removethe exhaustsystem.
Removethe right crankcase cover.
R e m o v et h e o i l p u m p d r i v e ns p r o c k e bt y r e m o v i n g
t h e b o l t a n dw a s h e r .
O I L P U M PD R I V E NS P R O C K E T
O I L P A S SP I P E
R e m o v e t h e o i l s t r a i n e r( p a g e2 - 4 ) a n d t h e o i l
p a s sp i p e .
M a k es u r et h e O - r i n g sa r ei n g o o dc o n d i t i o n .
O.RING
Dateof lssue:October,1983
O H O N D A M O T O RC O . .L T D . 2-5
ITONTf,DA
LUBRICATION
V45 INTERCEPTOR
OIL PUMP
Removethe oil pump by removingthe mounting
bolts.
O I LS T R A I N ETRU B E
Straightenand removethe cotter pin holding the
oil strainertube.
Removethe oil strainerstay.
Removethe oil pump body cover.
O I L P U M PB O D YC O V E R
D O W E LP I N O-RINGS
Removethe dowelpin.
Removethe innerrotor and drivepin.
I N N E RR O T O R
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
2-6 O H O N D AM O T O RC O . ,L T D .
IiIONTf,DA
V45 INTERCEPTOR, LUBRICATION
M e a s u rteh e r o t o rt i P c l e a r a n c e .
S T A N D A R D :0 . 1 5 m m ( 0 . 0 0 6i n )
S E R V I C EL I M I T : 0 . 2 0m m ( 0 . 0 0 8i n )
Measure thepumPbodYclearance.
STANDARD : 0.15-0.22mm (0'006-0.009 inl
S E R V I C LEI M I T :0 . 3 5m m ( 0 ' 0 1 4i n l
R e m o v et h e r o t o r s h a f ta n d m e a s u rteh e p u m p
e n dc l e a r a n c e .
S T A N D A R D :0 . 0 2 - 0 . 0 7m m ( 0 . 0 0 1 - 0 . 0 0 3i n )
S E R V I C EL I M I T :0 . 1 0m m ( 0 . 0 0 4i n )
Dateof lssue:January,1983
O H O N D AM O T O RC O . ,L T D . 2-7
IIONTDA
LUBRICATION V45 INTERCEPTOR
O U T E RR O T O R R O T O RS H A F T
ASSEMBLY
I n s t a l lt h e o u t e r r o t o r i n t o t h e b o d y a n d i n s e r t h e
rotor shaft.
I n s e r t h e d r i v ep i n i n t o t h e r o t o r s h a f t .
A l i g n t h e s l o t si n t h e i n n e rr o t o rw i t h t h e d r i v ep i n .
D R I V EP I N I NNER
I
D O W E LP I N O-RINGS
A
I n s t a l l t h e d o w e l p i n a n d o i l pump body cover.
Make sure the oil strainertube O - r i n g sa r e i n g o o d
condition.
/ \
# l \
\.
r l \
ffi mi \
%i
OILSTRAINER
TUBE
C O T T E RP I N
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
2-8. O H O N D AM O T O RC O . ,L T D .
IIONIXDA
V45 INTER,CEPJOR LUBRICATION
O R I F I C E( 4 . 3m m L D . ) DOWEP
L INS
Installthe orifice,O-ringand dowel pin.
NOTE
Mad"r* lh" O-ringsare installedon the
oil pipe.
O-RING
D R I V E NS P R O C K E T D R I V EC H A I N
Placethe oil pump driven sprocketinto the drive
chain.
NOTE
The "lN" mark on the drivensprocketshould
facethe crankcase.
lnstallthe exhaustsystem.
oil (page
Fill the enginewith the recommended
2-1t.
WASHER
TUBRICATIOI{
CABTE
CONTROT
Periodically,disconnectthe throttle cables at
their upperends.Thoroughlylubricatethe cables
and their pivot points with a commerciallyavail-
ablecablelubricantor a light weightoil.
Dateof lssue:January,1983
O H O N D A M O T O RC O . ,L T D . 2-9
IilONTf,DA
LUBRICAT!ON V45 INTERCEPTOR
S P E C I A LL U B R I C A N T
LIJBRICATIOl{
POIl{TS
o S H O C KA B S O R B E R U P P E RM O U N TB U S H I N G( p a g e1 5 . 1 1 )
o S U S P E N S I OLN I N K A G EN E E D L EB E A R I N G
( B U S H I N GF O R ' 8 3 ) ( p a g e1 5 - 1 2 )
.i
1* C A B L EL U B R I C A N T
T H R O T T LA
EN D
CHOKE CABLE R E A RS H O C K
ABSORBER
-Gl (A.T.F.)
r i
C L U T C HA N D B R A K E BRAKE
L E V E RP I V O T S P E D AP
Lr v O T i
T H R O T T LG
ER I P I
C A B L EL U B R I C A N T
SPEEDOMETER F O O TP E G
CABLE PIVOT
STEERING
HEAD
BEARINGS
WHEEL /
BEARINGS
(Whenreplaced)
.t*ltrilEil
FOOTPEG WHEEL
GEARSHAFT PIVOT B E A RI N G S
SPEEDOMETER P E D A LP I V O T (Whenreplacedl
DRIVE
GEAR
F R O N TF O R K D R I V EC H A I N
(A.T.F.) ( S A E8 0 _ 9 0 G E A R O I L )
S I D EA N D
CENTER
STANDA
PIVOT
Dateof lssue:October,1983
2-10 O H O N D AM O T O RC O . .L T D .
IIOTVIDA
Y45 INIERCEPTOR
3. MAII{TE1{A1{
S E R V I C EI N F O R M A T I O N 3-1 EVAPORATIVEEMISSION CONTROL 3_12
MAINTENANCE SCHEDULE 3-3 SYSTEM
F U E LL I N E S 3-4 C Y L I N D E RC O M P R E S S I O N 3-13
FUELFILTER 3-4 DRIVECHAIN 3-15
T H R O T T L EO P E R A T I O N 3-5 BATTERY 3-16
CARBURETOC RHOKE 3-6 BRAKEFLUID 3-17
AIR CLEANER 3-6 BRAKE SHOE/PADWEAR 3-17
C R A N K C A S EB R E A T H E R 3-7 BRAKE SYSTEM 3-17
S P A R KP L U G S 3-7 BRAKE LIGHT SWITCH 3-18
VALVE CLEARANCE 3-8 H E A D L I G H TA I M 3-18
CARBUR E T O RS Y N C H
R O NI Z A T IO N 3-10 CLUTCH 3-18
C A R B U R E T OIRD L ES P E E D 3-11 SIDE STAND 3-19
R A D I A T O RC O O L A N T 3-11 SUSPENSION 3-19
R A D I A T O RC O R E 3-12 NUTS, BOLTS, FASTENERS 3-21
COOLINGSYSTEMHOSES WHEELS 3-21
& CONNECTIONS 3-12 S T E E R I N GH E A D B E A R I N G S 3*21
\- SERYICE
l1{t0RilATl0tl
G E N ER AL
o E n g i n eo i l S e e p a g e2 - 3
o E n g i n eo i l f i l t e r S e e p a g e2 . 3
SPECIFICATIONS
( E n g i n e)
Sparkplugs:
Standard F o r c o l dc l i m a t e( b e l o ws o c , 4 1 " F ) F o r e x t e n d e dh i g h s p e e dr i d i n g
NGK ND NGK ND NGK ND
DPR8EA.9 X24EPR.U9 DPR7EA.9 X22EPR-U9 DPR9EA.9 X27EPR.U9
S p a r kp l u gg a p : 0 . 8 - 0 . 9 m m ( 0 . 0 3 1 - 0 . 0 3 5i n )
Dateof lssue:January,1983
3-1
O H O N D A M O T O RC O . ,L T D .
l
IIONIIDA
MAINTENANCE VF7OOI750INTERCEPTOR
l g n i t i o nt i m i n g
At idle: VF75OF:1O"BTDC
VFTOOF:1s"BTDC
Advancestarts: 1 , 5 0 0r p m
F u l la d v a n c e : 37"BTDCat 3,300 rpm
V a l v ec l e a r a n c e
C o l d ( B e l o w3 5 ' C , 9 5 o F ) : I n t a k e / E x h a u s0t .: 1 2 m m ( 0 . 0 0 5i n )
l d l es p e e d : V F 7 5 0 F : 1 , 0 0 0t 1 0 0 r p m
V F 7 0 0 F : 1 , 2 0 0t 1 0 0r p m
C a r b u r e t osry n c h r o n i z a t i o n : A l l c a r b u r e t o rws i t h i n 6 0 m m 1 2 . 4i n l H g o f e a c ho t h e r
C y l i n d e cr o m p r e s s i o n : 1 , 3 0 0t 2 0 0 k P a( . 1 3 . 0t 2 . O k g l c m 2 , 1 8 5r 2 8 p s i )
T h r o t t l eg r i p f r e ep l a y : 2 - 6 m m ( 1 1 8 - 1 1 4i n l
>
< CHASSIS
Drivechainslack: 15-25 mm (5/8-1 in)
Tires:
Front Rear
T i r es i z e
M120/80-16 M 130/80-18
U p t o 9 0 k S ( 2 0 0l b s )
load
22512.25,321 22512.25,32l.
kpa (kg/cm2,psi)
Cold tire pressure,
90 kg (200 lbs) load
22512.25,
321 280 (2.80,40)
t o v e h i c l ec a p a c i t yl o a d
Bridgestone G511 G510
T i r eb r a n d
Dunlop F11 K627
TOOLS
Special
Vacuumgause 07404-0030100or 07404-0020000or M937B-021-XXXXX (U.S.A.onty)
Carburetorpilot screwwrench 079084220201 \
Compression gaugeattachment 07510-M800101
\-,
Common
Lock nut wrench,10 x 12 mm 07708-0030200or equivalentin U.S.A.
Dateof lssue:
June,1984
3-2 @AmericanHondaMotor Co., Inc. 1984- All RightsReserrad
ITONIf,DA
VF7OOI750INTERCEPTOR MAINTENANCE
MAINTENANCE
SCHEDULE
P e r f o r mt h e P R E - R I D IEN S P E C T I OiN
n t h e O w n e r ' sM a n u a l a t e a c h s c h e d u l e dm a i n t e n a n c ep e r i o d .
I: INSPECA T N D C L E A NA , D J U S T ,L U B R I C A T EO, R R E P L A C E IF NECESSARY.
C: CLEAN. R: REPLACE, A: ADJUST
WHICHEVER R E A D I N G( N O T E4 )
ODOMETER
FREOUENCY COMES
FrRSr
/ c
I "B{
ITEM EVERY
F U E LL I N E S I I 3-4
F U E LF I L T E R R 3-4
THROTTLE
OPERATION I I I 3-5
* CARBURETOR-CHOKE I I I 3-6
a AIR CLEANER NOTE1 R R R 3-6
t! CRANKCASEBREATHER NOTE2 c c c c c c 3-7
E SPARKPLUGS R R R R R R 3-7
o I 3-8
LlJ VALVECLEARANCE
-l
ENGINE OIL YEAR R R R R 2-3
LIJ
E E N G I N EO I L F I L T E R YEAR R R R R 2-3
z CARBURETOR- SYNCHRONIZATION 3 - 10
I C A R B U R E T O R - I DSLP EE E D I I 3 - 11
a
I RADIATORCOOLANT *R 3-11
t! RADIATOR CORE I 3-12
C O O L I N GS Y S T E MH O S E S&
I I 3-12
CONNECTIONS
E V A P O R A T I VEEM I S S I O N
NOTE3 I I 3-12
CONTROLSYSTEM
D R I V EC H A I N I EVERY 3-15
3OOmi (5O0km)
BATTERY MONTH I I I 3-16
a B R A K EF L U I D M O N T HI *R *R
I I 3-17
ul 2 YEARS*R
F
BRAKEPAD WEAR I I 3-17
uJ BRAKESYSTEM I I 3-17
F
I
LrJ
BRAKELIGHTSWITCH I I 3-18
E H E A D L I G HATIM I 3-18
z C L U T C HF L U I D M O N T HI
o I *R I *R 3-18
a 2 YEARS*R
Q
CLUTCHSYSTEM I I 3 - 18
+
z
S I D ES T A N D I I 3 - 19
SUSPENSION I I 3-19
z
N U T S .B O L T S F
, ASTENERS I I 3-21
WHEELS I I 3-21
* H E A DB E A R I N G S
STEERING 1 3-21
* S H O U L DB E S E R V I C E B DYA N A U T H O R I Z EH
DO N D AD E A L E RU, N L E S S T H EO W N E RH A SP R O P E T RO O L SA N D S E R V I C E
DATA AND IS MECHANICALLY OUALIFIED.
* * I N T H EI N T E R E SO
T F S A F E T YW
, E RECOMMEND T H A TT H E S EI T E M SB E S E R V I C E O
D N L YB YA N A U T H O R I Z EH
DO N D A
DEALER.
NOTES: 1. SERVICE M O R EF R E O U E N T LWYH E N R I D I N Gl N D U S r y A R E A S .
2. SERVICE M O R EF R E O U E N T LWYH E N R I D I N GI N R A I NO R A T F U L LT H R O T T L E ,
'83)
3. CALIFORNIA TYPEONLY(After
R E A D I N G SR, E P E A T
4 . F O RH I G H E RO D O M E T E R A T T H E F R E O U E N CIYNTERVAE L S T A B L I S H EH
DE R E .
Date of lssue: October,1984
@AmericanHondaMotor Co.,Inc. 1984 - All RightsReserved 3-3
IIONTTDA
V45 INTERCEPTOR
MAINTENANCE
ruErLtl{ts
Remove the seat and left side cover.
Check the fuel lines and replace any parts which
show deterioration, damageor leakage.
F U E LL I N E S
TITIER
TUEI ELECTRIC
PANEL
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
3-4 O H O N D AM O T O RC O . ,L T D .
IIO1Vf,DA
V45 INTERCEPTOR
MAINTENANCE
Tl|ROTTLE
OPERATIO}I
Checkthat the throttle grip openssmoothlyto full
throttle and fully closesautomatically,in all steer-
ing positions.
Check the throttle cablesand replacethem if they
aredeteriorated, kinkedor damaged.
L u b r i c a t et h e t h r o t t l ec a b l e s( p a g e2 - 1 1 ,l i t t h r o t t l e
operationis not smooth.
2-6 mm
Measure
f lange.
t h r o t t l e g r i p f r e e p l a y a t t h e t h r o t t l eg r i p
(1/8-1t4 '"rbt
F R E EP L A Y : 2 - 6 m m ( 1 1 8 - 1 1 4 i n l
L O C KN U T
Adjustment can be made at either end of the
throttle cable.Minor adjustmentsare madewith the
upperadjusterand major adjustments are madewith
the lower adjusterafter removingthe fuel tank and
air cleanercase.
Adjust the looseningthe lock nut and turning the
adjuster.
Tightenthe lock nut and recheckthrottle operation.
UPPER
ADJUSTER
L O W E RA D J U S T E R
\*-
L O C KN U T
D a t eo f l s s u eJ: a n u a r y 1. 9 8 3
O H O N D AM O T O RC O . ,L T D . 3-5
I'IOIVfDA
MAINTENANCE
V45 INTERCEPTOR
CARBURETOR
Gl|Ol(E C H O K EL E V E R
C H O K EC A B L E
AIRCtEAl{TR A I R C L E A N E RC A S EC O V E R
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
3-6 @ H O N D AM O T O RC O . .L T D .
ITONIf,DA
V45 INTERCEPTOR
MAINTENANCE
S E TS P R I N G
R e m o v et h e s p r i n gc l i p a n d t h e a i r c l e a n eer l e m e n t .
Discardthe elementin accordancewith the main-
tenanceschedule.
A I R C L E A N E RE L E M E N T
BREAT]|ER
CRAl{I(CASE
R e m o v et h e p l u gf r o m t h e d r a i nt u b et o e m p t ya n y
deposits.
I n s t a ltlh e d r a i np l u g .
NOTE
S e r v i c em o r e f r e q u e n t l yw h e n r i d i n g i n r a i n
o r a t f u l l t h r o t t l e ,o r i f t h e d e p o s i tl e v e lc a n
b e s e e ni n t h e t r a n s p a r e nste c t i o no f t h e d r a i n
t ub e .
SPARI(
PTUGS
RECOMMENDES
D P A RK P L U G S
NGK ND D R A I NP L U G
Standard DPRSEA-9 X24EPR-U9
F o r c o l dC l i m a t e CENTER
( B e l o w5 " C . 4 1 ' F ) D P R T E A - 9 X 2 2 E PR - U 9
E L E C T R O D ES I D EE L E C TR O D E
\\
For extended
h i g h s p e e dr i d i n g
DPR9EA.9 X27EPR.U9
\
I
t 0.8-0.9 mm
( 0 . 0 3 1 - 0 . 0 3 5i n )
t e s p a r kp l u gc a p s .
D i s c o n n e ct h
ffi1
C l e a na n y d i r t f r o m a r o u n dt h e s p a r kp l u gb a s e s .
R e m o v ea n dd i s c a r dt h e s p a r kp l u g s .
M e a s u r et h e n e w s p a r kp l u gg a p su s i n ga w i r e - t y p e
\- feelergauge.
S P A R KP L U GG A P : 0 . 8 - 0 . 9 m m ( 0 . 0 3 1 - 0 . 0 3 5i n )
i F,;tri,-
A d j u s t b y b e n d i n g t h e s i d e e l e c t r o d cea r e f u l l y .
W i t h t h e p l u g w a s h e ra t t a c h e dt,h r e a d e a c h s p a r k
plug in by handto preventcrossthreading. Continue
\/ tighteningby hand until the spark plug bottoms.
Then,tighten the sparkplugsanother1/2 turn with
a spark plug wrench to compressthe plug washer.
Connectthe sparkplugcaps.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D 3-7
IIONIf,DA
V45 INTER,CEPTOR
MAINTENANCE
CTEARANCE
t,ATlJE R E A RC Y L I N D E RH E A DC O V E R N o . 3C Y L I N D E R
NOTE
Inspect and adjust valve clearance while the
e n g i n ei s c o l d , ( B e l o w 3 5 ' C , 9 5 ' F )
Removethe lowerradiatorcowl.
Drain coolant from engine and lower radiator
( p a g e6 - 3 ) .
NOTE
Drain the coolant into a clean containerfor
reuse.Scheduledcoolant replacement is every
24,OOO miles(38,400km).
N o . 4C Y L I N D E R N o , 2C Y L I N D E R
T 1 . 3M A R K
INSPECTION
Measureand adjust the intake and exhaustvalve
asdescribedbelow.
clearances
M A T I N GS U R F A C E
R E A RC R A N K C A S E
Dateof lssue:October,1983
3-8 O H O N D AM O T O RC O . ,L T D .
IIOilTf,DA
V45 INIER,CEPTOR,
MAINTENANCE
l/ATlJE
CLTARANCE R E A RC Y L I N D E RH E A DC O V E R N o . 3C Y L I N D E R
NOTE
Inspectand adjust valveclearancewhile the
e n g i n ei s c o l d .( B e l o w3 5 o C ,9 5 ' F )
Removethe lowerradiatorcowl.
Drain coolant from engine and lower radiator
( p a s e6 - 3 ) .
NOTE
Drain the coolant into a clean containerfor
reuse.Scheduledcoolant replacement is every
24,OOO miles(38,400km).
N o . 4C Y L I N D E R N o . 2C Y L I N D E R
T 1 . 3M A R K
INSPECTIOI\
Measureand adjust the intake and exhaustvalve
asdescribedbelow.
clearances
b;
M A T I N GS U R F A C E
R E A RC R A N K C A S E
: c t o b e r 1, 9 8 3
D a t eo f l s s u e O
3-8 @ H O N D A M O T O RC O . .L T D .
IIOIVfDA
V45 INTERCEPTOR MAINTENANCE
FEELER
GAUGE
Check the valve clearances for the No. 1 cylinder
usingtwo feelergaugesfor eachpair of valves;one
for each valve that sharesa common rocker arm.
V A L V E C L E A R A N C E( I N . E X } :
0 . 1 2 m m ( 0 . 0 0 5i n )
?o'-
lf adjustmentis needed,loosenthe lock nuts and
turn the adjustingscrewsuntil there is a slightdrag
on both feeler gauges.Both feeler gaugesshould
remaininsertedduringadjustment.
CAUTION
i
The lock nuts will come loose if not tightened
to the correct torque value.
I
I
Recheckthe valveclearance.
I
to align
I
Rotatethe crankshaft90o counterclockwise I
the T2.4 mark with the crankcasematingsurfaces L O C KN U TW R E N C H , I
for the No.4 cylinder.
and checkthe valve.clearances 07708-0030200
Adjust usingthe procedures
for the No. 1 cylinder. ll
i
Rotate the crankshalt 27O" counterclockwiseto TABS lI
align the T1.3 mark with the crankcasemating I
l
l
Adjust usingthe proceduresfor the No. 1 cylinder. lI
Rotate the crankshaft 9Oo counterclockwise to I
i
C h e c k t h e e n g i n eo i l l e v e l :
F i l l t h e r a d i a t o r w i t h c l e a n c o o l a n t t o t h e s p e c i fi e d
level.
NOTE
A f t e r f i l l i n gt h e r a d i a t o r s, t a r tt h e e n g i n ea n d
r e v i t a t l e a s tt h r e e t i m e s t o r e m o v ea n y a i r
b u b b l e sf r o m t h e c o o l i n gs y s t e m .A d d m o r e
c o o l a n tm i x t u r ea sn e c e s s a r y .
I n s t a l lt h e r a d i a t o rc a o .
N O . 2C Y L I N D E R N O .1 C Y L I N D E R
H E A DP O R T
CARBURETOR
SYN 1{IZATIOl{
CHRO H E A DP O R T
NOTE
S y n c h r o n i z teh e c a r b u r e t o rw
s ith the engine
a t n o r m a lo p e r a t i n tge m p e r a t u r et r, a n s m i s s i o n
i n n e u t r a la n d m o t o r c y c l e
on thecenterstand.
R e m o v et h e p l u g s f r o m t h e N o . 1 , 2 , 3 a n d 4
c y l i n d e r h e a d p o r t s a n d i n s t a l lt h e v a c u u mg a u g e
aclapters.
C o n n e ctth e v a c u u mg a u g e s .
NOTE
T h e N o . 4 c a r b u r e t ocr a n n o tb e a d j u s t e dl;t i s
the basecarburetor.
S t a r tt h e e n g i n ea n d a d j u s t h e i d l es p e e d .
I D L ES P E E D :
V F 7 5 0 F : 1 , 0 0 0t 1 0 0 r p m
V F 7 0 0 F : 1 , 2 O O t1 0 0 r p m
C h e c kt h a t a l l c a r b u r e t o rasr ew i t h i n 6 0 m m ( 2 . 4 i n )
Hg.
.rv
Dateof lssue:June,1984
3- 10 @AmericanHondaMotor Co., Inc. 1984- All RightsReserved
IIONTTDA
INTERCEPTOR
VF7OOI750
MAINTENANCE
C A R B U R E T OPRI L O TS C R E W
N o . 2A D J U S T I N G
SCREW wRENCH 07908-4220201
\_. Synchronize to specification by turning the ad-
.iusting screws with carburetor pilot screw rench
(0790842202011.
R e c h e c kt h e i d l e s p e e da n d s y n c h r o n i z a t i o n .
Remove the gauge adapters and install the plugs.
N o . 3A D J U S T I N G N o . 1A D J U S T I N G
SCBEW SCREW
CARBURETOR
IOLE
SPEED T H R O T T L ES T O PS C R E W
NOTE
o Inspect and adjust idle speedafter all other
e n g i n e a d j u s t m e n t sa r e w i t h i n s p e c i f i c a t i o n s .
r T h e e n g i n e m u s t b e w a r m f o r a c c u r a t ea d j u s t -
m e n t . T e n m i n u t e s o f s t o p - a n d - g or i d i n g i s
sufficient.
W a r mu p t h e e n g i n es, h i f t t o N E U T R A L ,a n d p l a c e
the motorcycle o n i t s c e n t e rs t a n d .
T u r n t h e t h r o t t l e s t o p s c r e wa s r e q u i r e dt o o b t a i n
t h e s p e c i fe d i d l es p e e d .
I D L ES P E E D :
V F 7 5 0 F : 1 , 0 0 0t 1 0 0 r p m
V F 7 0 0 F : 1 , 2 0 0t 1 0 0 r p m
RADIATOR
COOLA}IT RESERVE
TANKCAP
, , U P P E RM
" ARK , , L O W E RM
" ARK
D a t e o f l s s u e :J u l y , 1 9 8 4
O H O N D AM O T O RC O . , L T D . 3-11
IIONTEDA
VJ7AOI750INTERCEPTOR
MAINTENANCE
RADIATOR
CORE
Checkthe air passagesfor cloggingor damage.
S t r a i g h t e nb e n t f i n s a n d c o l l a p s e dc o r e t u b e s .
Removeinsects,mud or any obstructionwith com-
pressedair or low water pressure.
Replacethe radiatorif the air f low is restrictedover
more than 2Oo/o of the radiatingsurface.
COOLING
SYSTEM
HOSES
& c0NNECTr0tus
Inspectthe hosesfor cracksor deterioration,
replaceif necessary.
C h e c kt h e t i g h t n e s so f a l l h o s ec l a m p s .
WATERHOSES
EVAPORATIVE
EMISSION
CONTROT
'83 SYSTEM P U R G EC O N T R O V
L ALVE
(After Galifornia
modelonly)
Checkthe fuel tank breathertube betweenthe tank
cap and the canister,andthe vacuumtube between
the canisterand the purge controlvalvefor deteri-
oration, clogging,damage or loose joints or con-
nections.
CANISTER
COMPRTSSION
CYIIl{DER
W a r mu p t h e e n g i n e .
S t o p t h e e n g i n e ,t h e n d i s c o n n e ctth e s p a r k p l u g
c a p sa n d r e m o v et h e s P a r kP l u g s .
I n s e r t h e c o m p r e s s i ogna u g e .
Open the throttle all the way and crank the engine
with the startermotor.
'\_- NOTE:
C r a n k t h e e n g i n e u n t i l t h e g a u g er e a d i n g
s t o p sr i s i n g .T h e m a x i m u mr e a d i n gi s u s u a l l y
reachedwithin 4-7 seconds.
C O M P R E S S I OPNR E S S U R E :
1 , 3 0 0t 2 0 0 k P a( 1 3 . 0t 2 . Ok g l c m 2 ' , 1 8 t5 2 8 p s i )
Dateof lssue:October,1983
O H O N D AM O T O RC O . ,L T D . 3- 13
ITONTTDA
MAINTENANCE
V45 INTERCEPTOR
DRIUE
CHAIN
Turn the engineoff, place the motorcycleon its
centerstandand shift the transmission into neutral.
C h e c ks l a c ki n t h e d r i v ec h a i nl o w e rr u n m i d w a vb e -
tweenthe sprockets.
SLACK: 15-25 mm (5/8-1 in)
CAUTION
Excessivechain slack, 50 mm (2 in) or more,
may damagethe frame.
1 5 - 2 5m m
(5/8-l in)
R E A RE N DO F
SWINGARM G R A D U A T E DS C A L E AXLE NUT
A d j u s ta sf o l l o w s :
L o o s e nt h e a x l en u t -
L o o s e nt h e a d j u s t i n g
b o l t l o c kn u t s .
T u r n b o t h a d j u s t i n gb o l t sa n e q u a ln u m b e ro f t u r n s
until the correct drive chain slack is obtained.
CAUTION
Make sure that the samealignment marks on
both adiusting plates align with the ends of
the swingarm.
T i g h t e nt h e a d j u s t i n b
golt locknuts.
T i g h t e nt h e r e a ra x l en u t .
T O R O U E :8 5 - 1 0 5 N . m ( 8 . 5 - 1 0 . 5k g - m ,
61-76 ft-tb)
ADJUSTING
BOLT LOCKNUT ADJUSTING
PLATE
R e c h e cckh a i ns l a c ka n df r e ew h e e lr o t a t i o n .
L u b r i c a t et h e d r i v e c h a i n w i t h S A E 8 0 o r 9 0 g e a r
oil. R E DZ O N E R E A RE N DO F S W I N G A R M
C h e c kt h e c h a i nw e a r l a b e l .l f t h e r e d z o n eo n t h e
l a b e la l i g n ,o r i s b e y o n d ,t h e r e a re n d o f t h e s w i n g -
arm after the chain has been adjusted,the chain
must be replaced.
REPLACEMENT
C H A I N : D . l . D .5 0 V o r R K 5 0 M O
D a t eo f l s s u eO
: c t o b e r 1, 9 8 3
3- 14 O H O N D AM O T O RC O . .L T D .
IIONIf,DA
V45 INIER,CEPTOR, MAINTENANCE
ffi
sprocket which is damagedor excessivelyworn.
NOTE
Neverinstalla new drive chain on worn spro-
chetsor a worn drivechainon new sprockets.
Both chain and sprocketsmust be in good
condition or the replacementchain or spro-
cketswill wearrapidly.
NORMAL
U P P E RL E V E L H O L D E RB O L T
BATTERY
Removethe right frame sidecoverand inspectthe,
batteryf luid level.
When the fluid level nearsthe lower level,remove
the battery and add distilled water to the upper
l e v e l i n ea sf o l l o w s :
LEVEL
LOWER
POSITIVE
CABLE F I L L E RC A P S
Disconnectthe negativecable at the battery,then
disconnectthe positivecable.
Disconnectthe battery breather hose from the
battery.
Pull the battery out, removethe filler caps and
add distilledwaterto the upperlevelline.
Reinstallthe filler capsandthe battery.
NOTE
Add only distilled water. Tap water will
shortenthe servicelife of the battery.
: c t o b e r1, 9 8 3
D a t eo f l s s u eO
O H O I \ ' D AM O T O RC O . ,L T D . 3- 15
J
IIOTVXDA
MAINTENANCE
V45 INTERCEPTOR,
TTUID
BRAI(E U P P E RL E V E L
CAUTION
. Do not remove the cover until the handle-
bar has been tumed so that the reservoiris
level.
' Avoid operating the brake lever with the
cap removed. Brake fluid will squirt out if
the lever is pulled.
' Do not mix different types of
fluid, as they
are not compatible. L O W E RL E V E L
UPPEL
RE V E L
BRAI(E
PADII|TAR L O W E RL E V E L
CAUTION
Always replace the brake pads in pairs to
assureevendisc preswre,
BRAIfi
SYSTEM
lnspect the brake hosesand fittings for deterio-
ration, cracks and signs of leakage.Tighten any
loosefittings.
Replacehosesand f ittingsas required,
B R A K ED I S C ARROW ARROW B R A K ED I S C
Dateof lssue:October,1983
3- 16 O H O N D AM O T O RC O . .L T D .
IIONTXDA
V45 INTER,CEPTOR MAINTENANCE
NUT
ADJUSTING
TIG}|T
BRAI(E SltlITC]| B R A K EL I G H TS W I T C H
AIM
]|EADLIO]|T
SCREW
H O RI Z O N T A LA D J U S T I N G
Adjust vertically by turning the verticaladjusting
screw.Turn the adjustingscrewclockwiseto direct
the beamdown.
NOTE
Adjust the headlight beam as specifiedby
locallawsand regulations.
V E R T I C A LA D J U S TI N G S C RE W
CL|JTC1|
Checkthe clutchfluid reservoirlevel'
CAUTION
. Do not remove the cover until the hand-
lebar has been tumed so that the reservoir
is level.
. Avoid operating the clutch lever with the
cap removed. Fluid will squirt out if the
lever is pulled.
. Do not mix different types of fluid, as
they are not comPatible. L E V E LM A R K
LOWER
Dateof lssue:October,1983
O H O N D AM O T O RC O . ,L T D . 3-17
IIONTTDA
V45 INTERCEPTOR.
MAINTENANCE
SIDE
STA1{D
Check the rubber pad for deterioration or wear.
R e p l a c ei f a n y w e a r e x t e n d s t o w e a r l i n e a s s h o w n . GOOD NOGOOD
C h e c k t h e s i d e s t a n d s p r i n g f o r d a m a g ea n d l o s s o f
t e n s i o n , a n d t h e s i d e s t a n d a s s e m b l yf o r f r e e d o m
of movement. Make sure the side stand is not
bent.
NOTE
' W h e nr e p l a c i n gu,s ea r u b b e rp a d w i t h t h e WEARLINE
m a r k " O v e r2 6 0 l b sO N L Y " .
' S p r i n gt e n s i o n i s c o r r e c t i f t h e m e a s u r e -
ments fall within 2-3 kg (a.a-6.6 tb),
w h e n p u l l i n gt h e s i d es t a n dl o w e re n dw i t h
a s p r i n gs c a l e .
SlJSPENSION
FRONT
AIR VALVE
Dateof lssue:October,1983
3- 18 O H O N D AM O T O RC O . ,L T D .
ITONTDA
V45 INTERCEPTOR MAINTENANCE
S Y S T E MI N S P E C T I O N
ANTI-DIVE
L I G H TA N T I . D I V E
MEDIUM
HARD
MAXIMUM ANTI-DIVE
ADJUSTER
Inspectand if necessary, repair the system (Refer
t o s e c t i o n1 4 ) .
REAR
P l a c et h e m o t o r c v c l eo n i t s c e n t e r s t a n d .
M o v e t h e r e a r w h e e l s i d e w a y sw i t h f o r c e t o s e e i f
t h e s w i n g a r mb e a r i n g sa r e w o r n .
R e p l a c et h e b e a r i n g si f t h e r e i s a n y l o o s e n e s s( p a g e
15-14t.
for leaksor damage.
Checkthe shockabsorber
all rearsuspension
Tighten nutsandbolts.
NOTE
Check the air pressurewhen the shock ab-
sorberis cold.
AIR VALVE
Dateof lssue:October,1983
O H O N D A M O T O RC O . ,L T D . 3- 19
IIONTf,DA
V45 INTERCEPTOR
MAINTENANCE
I[UTS,
BOITS,
FASTENERS
Check that all chassisnuts and bolts are tightened
to their correct torque values (Section 1) at the
i n t e r v a l s h o w ni n t h e M a i n t e n a n cSec h e d u l e( P a g e
3-3).
Check all cotter pins, safety clips, hose clamps
and cablestays.
tY}|EETS
NOTE
T i r e p r e s s u r es h o u l d b e c h e c k e dw h e n t i r e s
a r eC O L D .
R E C O M M E N D E DT I R E S A N D P R E S S U R E S :
Front Rear
up to
90 kg
Cold (200 lbs) 225 (2.25.321 225 Q.24,32l.
ti re
Io a o
pres-
s ur e 90 kg
psi ( 2 0 0l b s )
kPa, load to
(kg/cmz veh icle
22512.25.321 2 8 0( 2 . 8 . 4 0 )
psi) capacity
Io a o
t'r1tu(lE-
Tire G 5 11 G 5 10
STON E
Drano
D U NL O P K527 A K627
|{EAD
STIERIl{O BEARIl{GS
NOTE
C h e c k t h a t t h e c o n t r o l c a b l e sd o n o t i n t e r '
f e r e w i t h h a n d l e b a rr o t a t i o n .
Dateof lssue:October,1983
3-20. O H O N D AM O T O RC O . .L T D .
II{E Nf.f,DA
V45 INTER,CEPTOR
MAINTENANCE
MEMO
lI
i
\--
lI
I
Dateof lssue:October,1983
O H O N D AM O T O RC O . ,L T D . 3-21
IIOTVXDA
FUEL SYSTEM
V45 INTERGEPTOR
fp
0 E
c
E
&DD 0
tuo @o
F
@D
'-F
\,
\,
#
tr# K \ @
\ a
%
's--\
\,
\,
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
4-o O H O N D AM O T O RC O . .L T D .
ITOTVEDA
VJ7OOI750]NTERCEPTOR
4. FUELSYSTEM
SERVICEINFORMATION 4-1 CARBURETORINSTALLATION 4-15
TROUBLESHOOTING 4-2 PILOTSCREWADJUSTMENT 4*16
CARBURETOR REMOVAL 4-3 FUELTANK 4-17
VACUUMCHAMBER 4-4 AIR CLEANER 4-17
FLOATCHAMBER 4-6 F U E LP U M P 4-18
PILOTSCREW 4-8 HIGHALTITUDEADJUSTMENT 4-18
CARBURETOR SEPARATION 4-9 (USAonly)
CARBURETOR ASSEMBLY 4-12 EVAPORATIVE EMISSION 4-19
CONTROLSYSTEM
(After'83 Californiamodelonly)
INFORMATION
SERVICE
GENERAL
Gasoline is extemely.flommable and is explosive under certain conditions. Work in a v'ell ventiloted area. Do not smoke
or allow.flames or sparks in the w'ork area.
SPECIFICATIONS
Dateof lssue:October,'1984
@American HondaMotorCo.,Inc.1984- All RightsReserved 4'1
E|IONIf,DA
V45 INTER,CEPTOR,
FUEL SYSTEM
CARBURETOR
RElt|OI'AT A I R C L E A N E RC A S E
CHOKE
CABLE
Removethe heat insulatorplate.
Disconnectthe choke and throttle cablesfrom the
carburetor,
T H R O T T L EC A B L E S
Dateof lssue:January,1983
O H O N D AM O T O RC O . ,L T D . 4-3
ITONIXDA
V45 INTER.CEPTOR
FUEL SYSTEM
I'ACUU]||
C]|AillBER
REMOVAL
R e m o v e t h e f o u r v a c u u m c h a m b e rc o v e r s c r e w sa n d
cover.
cAuTtot{
Do not interchangevacuumchambercovers,
springs,pistons or iet needlesbetweencar-
buretors.
COVER
C O M P R E S S I OSNP R I N G
R e m o v et h e c o m p r e s s i o n s p r i n g ,d i a p h r a g ma n d
v a c u u mp i s t o n .
I n s p e ct h e v a c u u mp i s t o nf o r w e a r ,n i c k s s, c r a t c h e s l
o r o t h e rd a m a g e .
M a k e s u r et h e p i s t o nm o v e su p a n d d o w n f r e e l yi n
thechamber.
NOTE
N o . 1 a n d N o . 3 c a r b u r e t o r su s e t h i n n e rj e t
needlesand shorterspringsthan the No. 2 and
No.4 carburetors.
DIAPHRAGM
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
4-4 O H O N D AM O T O RC O . ,L T D .
IIOIVTDA
V45 INTERCEPTOR
FUEL SYSTEM
N E E D L EH O L D E R
I SPRING
I
I
-r@&
, \ \ J
,/ \rrn - |
/ t
N E E D-L E E \
N E E D LH
EOL
INSTALLATION
Installationis essentially
the reverseof removalbut
to keep from distortihgthe diaphragm,install the
vacuumpiston/diaphragm asfollows:
Insertthe vacuumpiston into the carburetor.Stick
your finger into the carburetorbore and hold the
vacuum piston in the full throttle position, then
turn down the diaphragmso its lip fits into the
carburetorgroove.
Install the chambercover,aligningits cavity with
the hole in the carburetor,and securewith at least
two screwsbeforereleasing the vacuumpiston.
NOTE
Be sure the thinner jet needlesand shorter
springsare installedin the No. 1 and No. 3
carburetors.
CAVITY
Dateof lssue:October,1983
O H O N D A M O T O RC O . .L T D . 4-5
IIONIXDA
V45 INIERCEPTOR
FUEL SYSTEM
TLOAT
C||A]'|BER F L O A TC H A M B E R
REMOVAL
Removethe four float chamberscrewsand the float
chamber.
SCREWS
FLOAT
F L O A TL E V E L
Measurethe float levelwith the carburetorinclined
15"-45" from vertical and the float tang just
contactingthe float valve.
F L O A T L E V E L : 7 . 0 m m ( 0 . 2 8i n )
F L O A TL E V E LG A U G E
07401 -0010000
F L O A TP I N
F L O A TA N D J E T S
Removethe float pin, float and float valve.
Dateof lssue:January,1983
4-6. @ H O N D AM O T O RC O . ,L T D .
IIONTDA
V45 INTER,CEPTOR FUEL SYSTEM
VALVE SEAT
Inspectthe float valvefor groovesand nicks.
Inspectthe operationof the float valve.
F L O A TV A L V E
FLOATVALVE
MAINJET SEAT
Removethe starteriet, mainjet and slowjet.
R e m o v et h e f l o a t v a l v es e a ta n df i l t e r .
S T A R T E JRE T
ASSEMBLY
Assemblethe float chamber componentsin the
orderof disassemblY.
reverse
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
@ H O N D AM O T O RC O . .L T D .
4-7
IIONTf,DA
FUEL SYSTEM V45 INTERCEPTOR
PITOT
SCREli|
REMOVAL
NOTE
'The pilot screwsare factory pre-setand
shouldnot be removedunlessthe carbure-
tors areoverhauled.
. The pilot screwplugsare factory installed
to p.reventpilot screwmisadjustment. Do
n o t r e m o v e t h e p l u g s u n l e s st h e p i l o t
screwsarebeingremoved.
. Coverall openingswith tapeto keepmetal
p a r t i c l eos u t w h e nt h e p l u g sa r ed r i l l e d .
CAUTION
Be careful not to dill into the pilot screw.
All pilot screwsmust be replacedevenif only
one requiresit for properpilot screwadjust-
ment(page4-16).
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
4-A O H O N D AM O T O RC O . .L T D .
IIONTfDA
V45 INTER,CEPTOR
FUEL SYSTEM
T u r n e a c h p i l o t s c r e w i n a n d c a r e f u l l yc o u n t t h e
numberof turns beforeit seatslightly.
Make a note of this to use as a referencewhen
r e i n s t a l l i ntgh e p i l o t s c r e w s .
CAUTION
Damage to the pilot screw seat will occur if
the pilot screw is tightened againstthe seat.
R e m o v et h e p i l o t s c r e w sa n d i n s p e ctth e m .R e p l a c e
them if they areworn or damaged.
P I L O TS C R E W
INSTALLATION
I n s t a l lt h e p i l o t s c r e w sa n d r e t u r n t h e m t o t h e i r
o r i g i n a pl o s i t i o na sn o t e dd u r i n gr e m o v a l .
Perform pilot screwadjustmentif new pilot screws
a r ei n s t a l l e d( p a g e4 - 1 6 ) .
NOTE
' Do not installnew plugsuntil afteradjust.
ment hasbeenmade.
made.
' l f y o u r e p l a c et h e p i l o t s c r e wi n o n e c a r -
buretor,you must replacethe pilot screws
in the other carburetorsfor proper pilot
screwadjustment.
SEPARATION
CARBIJRETOR AIRCHAMBER
R e m o v et h e s c r e w sa t t a c h i n g
t h e a i r c h a m b etro t h e
carburetorsand seoaratethe chamberand carbu-
retors.
SCREWS
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 4-9
ITONTf,DA
FUEL SYSTEM V45 INTERCEPTOR
S N DR O D S
C H O K EL E V E R A
Removethe nuts, and removethe choke leversand
rods.
Removethe cotter pins and washers,and remove
the chokerod.
C H O K ER O D
SYNCHRONIZATION
No.1
S P RI N G S CARBURETOR
Carefully separatethe No. 1 carburetorfrom the
assembly.Then separatethe No. 2 carburetor.
CAUTION
Separate the carburetors horizontally to pre-
vent damageto the joint pipes.
t
No.2
I AIRJOINT No.4
C A R B U R E T O RS P RI N G S PIPES CARBURETOR
T H R O T T LL
EI N K
Disconnectthe throttle link from the No.3 and 4
caburetorsby removingthe cotter pins.
Dateof lssue:January,1983
4-10^ O H O N D AM O T O RC O . ,L T D .
EIONTXDA
V45 INTERCEPTOR FUEL SYSTEM
F U E LJ O I N TP I P E N o . 4C A R B U R E T O R
'\--
Carefullyseparatethe No. 3 and No. 4 carburetors. t :
I
No.3 CARBURETOR
NUT
C H O K EV A L V E
Checkthe chokevalveand springfor nicks.grooves,
or other damage.
SPRING
Dateof lssue:January,1983
O H O N D A M O T O RC O . ,L T D . 4-11
ITONTXDA
FUEL SYSTEM V45 INTER,CEPTOR
CARBURETOR
ASSEMBLY S P R I N GC O L L A R
NUT
F U E LJ O I N TP I P E
C o a t t h e n e w O - r i n g sw i t h o i l a n d i n s t a l tl h e m o n
the fuel joint pipefor No. 3 and No. 4 carburetors.
I n s t a l tl h e f u e l j o i n t p i p e t o t h e N o . 3 a n d N o . 4
carburetors.
O.RINGS
T H R O T T L EL I N K
R e c o n n e ctth e t h r o t t l e l i n k a g eb e t w e e nt h e N o . 3
and No.4 carburetors, usingnew cotter pins.
Pr',":,:l:
wr:iffin:{iffi
N o . 4 C A R B U R E T O C O T T E RP I N S No.3CARBURETOR
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
4- 12 O H O N D AM O T O RC O . ,L T D .
IIONTI'A
V45 INTER,CEPTOR, FUEL SYSTEM
F U E LJ OI N T P I P E
Coat new O-ringswith oil and installthem on the I
I
f u e l a n da i r j o i n t p i p e s . I
I
Put the No. 1 and No. 2 carburetorstogetherwith I
the joint pipes.
A I R J O I N TP I P E S
THRUST
No,4CARBURETOR SPRING No.2CARBURETOR
Loosenthe synchronizationadjustingscrewsu n t i l
there is no tension.
I n s t a ltl h e s y n c h r o n i z a t i osnp r i n g s .
Installthe thrust springsbetweenthe throttle v a l v e
shafts.
I Z A T I O NS P R I N G
N o . 1 C A R B U R E T O RT H R U S TS P R I N G 3 C A R B U R E T O R
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 4- 13
IIONTXDA
FU ELS Y S T EM V45 INIER,CEPTOR
CHOKERODSAND LEVERS
Installthe choke rods and levers,usingthe nuts and
new cotter pins.
C H O K ER O D
FUNNEL GROMMETS
M a k e s u r et h e a i r c h a m b e rf u n n e l s ,g r o m m e t sa n d
dowel pinsare in place.
D O W E LP I N S
P l a c et h e a i r c h a m b e o
r v e rt h e c a r b u r e t o rasl i g n i n g
the dowel pinswith the carburetorholes.
Attach the air chamberto the carburetorswith the
eightscrews.
Dateof lssue:January,1983
4- 14 O H O N D A M O T O RC O . ,L T D .
IIONTIDA
V45 INTERCEPTOR FUEL SYSTEM
B Y . P A S SH O L E
\-/ Turn the throttle stop screw to align the No. 4
throttle valvewith the edgeof the by-passhole.
T H R O T T L ES T O PS C R E W
No.2 ADJUSTING
SCREW
Align eachthrottle valvewith the by-passholeedge
by turningthe synchronization adlustingscrews.
Inspectthrottle operationasdescribedbelow:
. Openthe throttle slightlyby pressing the throttle
l i n k a g eT. h e nr e l e a steh e t h r o t t l e .
t Makesurethat it returnssmoothly.
\r . Make sure that there is no drag when opening
and closingthe throttle.
C l o s et h e c h o k ev a l v eb y t u r n i n gt h e c h o k el i n k a g e .
Releasethe choke linkage and make sure that it
returnssmoothly.
II{STATIATIOl{
CARBURETOR
lnstallationis essentially
the reverse
of removal.
NOTE
Routethe throttle and choke cablesproperly
( p a g e1 - 1 0 t o 1 - 1 2 1 .
Dateof lssue:January,1983
O H O N D AM O T O RC O . ,L T D . 4- 15
IIONTDA
VT7OOI750INTERCEPTOR
FUEL SYSTEM
PILOT AOII|STMEI{T
SCRTtt P I L O TS C R E W
I D L ED R O PP R O C E D U R( U
E . S . AO. N L Y )
NOTE
' The pilot screwsare factory pre'setand no
adjustment is necessaryunlessthe pilot
screwsarereplaced(page4-8).
. Use a tachometerwith graduationsof 50
rom or smallerthat will accuratelyindicate
a 50 rpm change.
CAUTION
Damage to the pilot screw seat will occur
if the pilot screw is tightened against the
seat.
Dateof lssue:
June,1984
4- 16 @AmericanHondaMotor Co., Inc. 1984 - All RightsReserved
IIONTXDA
V45 INTERCEPTOR,
SYSTEM
Tl|TtTAI{l(
C h e c kt h e v e n t h o l e o f t h e f i l l e r c a p f o r b l o c k a g e .
Checkthat fuel is flowing out of the fuel valve
f r e eyl .
M a k es u r et h a t t h e r ea r en o f u e l l e a k s .
'@
@:e.
AIRCtTAl{ER
CASE/CHAMBER
Checkthe air cleanercasesealrubbersfor deteriora-
tion.
C R A NK C A S EV E N T L
I A T I O NS Y S T E M
C h e c kt h a t t h e b r e a t h etru b e i s n o t r e s t r i c t e d .
A I R C L E A N E RC O V E R
R ELEMENT
S E A LR U B B E R I
&
@ BREATHER
BREATHER
HOSE SEPARATOR
S E A LR U B B E R
q S E A LR U B B E R
Iu
fl
U
?
&
I N L E TA I R
DUCTS A I R C L E A N E RC A S E
D a t eo f l s s u eJ: a n u a r v 1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 4- 17
ITOilTf,DA
FUEL SYSTEM
VF7OOI750INTERCEPTOR
FUEL
PUMP F U E L P U M PC O U P L E R
F U E LP U M PM O U N T I N B
GO L T S
Turn the fuel valveoff .
Removethe breatherseparator.
C l i p t h e f u e l i n l e tl i n e ,t h e nd i s c o n n e ct h
t e fuelinlet
a n do u t l e tl i n e sf r o m t h e f u e l p u m p .
Remove the fuel pump mounting bolts and fuel
pump.
Installthe fuel pump in the reverse orderof removal.
ADII|STMEI{T
ALTITUDT
1|IO}|
(USA
only)
B R E A T H ESRE P A R A T O R
When the vehicle is to be operatedcontinuously
above2,000 m (6,500 feet) the carburetormust be
readjustedas follows to improve driveability and
exhaustemissions.
decrease
NOTE
T h i s a d l u s t m e n tm u s t b e m a d ea t h i g h a l t i -
t u d e t o e n s u r ep r o p e rh i g ha l t i t u d eo p e r a t i o n .
Dateof lssue:June,1984
4- 1A HondaMotorCo.,Inc.1984- All RightsReserved
@American
ITONTXDA
V45 INTERCEPTOR FUEL SYSTEM
PURGE
C O N T R OVLA L V E
PURGE
CO]{TROI I}ISPECTION
VALI|E
(Galifornia
model)
TO CHARCOAL
NOTE: CANISTER
The purgecontrol valveshouldbe inspectedif \
hot restartis diff icult.
TO 3.W VACUUM PUMP
C h e c k a l l f u e l t a n k , P u r g eC o n t r o l V a l v e ( P C V ) , JOINT (U.S.A.
ST-AH-260-MC7 only)
and charcoalcanisterhosesto be surethey are not
kinkedand are securelyconnected.
Replaceany hose that shows signsof damageor
deterioration.
NOTE:
The PCV is located under the instrument
assembly.
D i s c o n n e ct th e P C Vh o s e sf r o mt h e 3 - w a yj o i n t ,t h e
N o . 2 c a r b u r e t o ra, n d t h e r i g h t c h a r c o a cl a n i s t e r .
R e m o v et h e P C Vf r o m i t s m o u n t .R e f e rt o t h e r o u t -
i n g l a b e la t t a c h e dt o t h e f u e l t an k b e l o wt h e s e a tf o r
h o s ec o n n e c t i o n s .
Connecta vacuumpump to the 8 mm LD. hosethat T OC A R B U R E T O R
goesto the 3-wayjoint. Apply the specifiedvacuum BODY
to the PCV. V A C U U MP U M P
SPECIFIED V A C U U M : 2 5 0 m m ( 9 . 8i n ) H g S T - A H - 2 6 0 - M C( 7U . S . A o
. nlv)
The specified vacuumshouldbe maintained.
Replacethe PCV if vacuumis not maintained.
Removethe vacuum pump and connect it to the
hosethat goesto the carburetorbody.
Apply the specifiedvacuumto the PCV.
V A C U U M : 2 5 0 m m { 9 . 8i n } H g
SPECIFIED
The specified vacuumshouldbe maintained.
Replacethe PCV if vacuumis not maintained.
R e v i s e dJ:u l y , 1 9 8 4
@American
MSV 7227 8407
HondaMotorCo.,Inc.1984- All RightsReserved 4- 19
ITOilIXDA
V45 INTERCEPTOR
FUELSYSTEM
CAUTION:
To preventdanageto thepurgecontrolvalve,
do not use high air pressuresources.Usea
handoperatedair PumPonlY.
NOTE: ROTJTINGDIAGRAM
VACIJUMFTCSE
.
G8
"lr',inI o71110{
Be careful not to bend, twist or kink the !lll!1"[lf
tubeswhen installing. uilt0nill IililclI
. Slidethe end of eachtube completelyonto
itsf ittingand securewith the hoseclamps.
' Secure with the hose clamps whenev-er
specified.
. Check that the hosesare not contacting
sharpedgesor corners.
R e v i s e dJ: u l Y ,1 9 8 4
HondaMotorCo.,Inc.1984- All RightsReserved
4-20, @American
MSV 7227 8401
If;IOIS.E)A
VII5 INTERCEPTOR
FUEL SYST.EM
I
MEMO
L.
Dateof lssue;October,1983
O HONDA MOTORCO., LTD. +21
DIONTI)A
V45 INTERCEPTOR
E N GI N E R E M O V A L / I N S T A L L A T I O N
45-55 N.m
(4.5-5.5 ks-m,33-40 ft-lb)
24-30 N.m
(2.4-3.Oks-m,17-22 ft-lbl
@W
r50-54 N.m
(5.0-5.4kg-m,
36-39 ft-rb)
.N%^-b
W,*
\-
35-45 N.m
(3.5-4.5 ks-m,25-33 ft-tb)
35-45 N'm
(3.5-4.5ks-m,25-33 ft-lbl
Dateof lssue:January,1983
5-O @ H O N D AM O T O RC O . ,L T D .
IiIONITDA
VF7OOI750
INTERCEPTOR
5. ENGINE
BEMOVAL
INSTALLATION
SERVICEINFORMATION 5-1
E N G I N ER E M O V A L 5-2
ENGINEINSTALLATION 5-6
INFORMATION
SERVICE
GENERAL
Clutch Alternator
Gearshiftlinkage Starter motor
Front cylinderhead Carburetors
SPECIFICATIONS
Enginedry weight 8 1. 5 k g ( 1 8 0 l b )
'83-'84:
Oil capacity 3 . 0 l i t e r s( 3 . 2 U . S .q t z )
'84:
After 2 . 7 l i t e r s( 2 . 9 U , S .q t , 2 . 4 l m p q t )
TOROUE
VALUES
Drive sprocket bolt 50-54 N.m(5.0-5.4 kg-m,36-39 ft-lb)
Enginerear hanger bolts 45-55 N.m(4.5-5.5 kg-m,33-40 ft-lb)
Enginecenter hanger bolts 24-30 N.m(2.4-3.0 ks-m,17-22 tt-tbl
Enginefront hanger bolts 35-45 N.m(3.5-4.5 kg-m,25-33 ft-lb)
Sub-framebolts 35-45 N.m(3.5-4.5 kg-m,25-33 ft-lb)
Rtltl0VAt
El{Gl]{E C L U T C HS L A V EC Y L I N D E R
NOTE
Do not operatethe clutch leverafter removing
t h e c l u t c h s l a v ec y l i n d e r ;l t w i l l c a u s ed i f -
ficulty when reinstallingthe slave cylinder
G E A R S H I FA
TR M
A L T E R N A T O RW I R EC O U P L E R
Disconnectthe neutral switch wire connectorand
alternatorwire coupler.
N E U T R A LS W I T C HW I R EC O N N E C T O R
D R I V ES P R O C K EC
TOVER
Removethe drivesprocketcover.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
5-2 @ H O N D AM O T O RC O . .L T D .
EIOlVXDA
V45 INTER,GEPTOR, E N G I N ER E M O V A L / I N S T A L L A T I O N
D R I V ES P R O C K E B
TO L T
Remove the drive sprocket bolt' Then remove
the drivesprocketwith the drivechain.
D R I V EC H A I N
A I R C L E A N E RC A S E
Remove the air cleanercaseand the carburetors
(page4-3).
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 5-3
ITONTT)A
E N G I N ER E M O V A L / I N S T A L L A T I O N V45 INTER.CEPTOR
BOLT
R E A RE X H A U S TP I P E BOLT
C L A M PB O L T S
S T A R T E RM O T O RC A B L E
Disconnectthe startermotor cablefrom the starter
motor.
D a t eo f l s s u eJ: a n u a r y 1, 9 8 3
5-4 O H O N D AM O T O RC O . ,L T D .
IIONIIDA
V45 INTER,CEPTOR E N G I N ER E M O V A L / I N S T A L L A T I O N
W IR E C O U P L E R
P U L S EG E N E R A T O R
Disconnectthe pulsegeneratorwire coupler.
HOUSING
THERMOSTAT
F r e et h e s t a r t e rm o t o r c a b l ef r o m t h e c l a m p .
NOTE
The jack heightmust be continuouslyadjust-
ed to relievestressfrom bolts that are being
removed.
R e m o v et h e e n g i n e h a n g e rb o l t s f r o m t h e r i g h t s i d e .
\--
Remove the f rame-to-sub-iramebolt.
D a t eo f l s s u eJ: a n u a r y 1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 5-5
IIONTXDA
V45 INTERCEPTOR
E N G I N ER E M O V A L / I N S T A L L A T I O N
S U B . FR A M E
Disconnect the crankcase breatherhose.
R e m o v et h e e n g i n eh a n g e rb o l t sa n d n u t sf r o m t h e
left side.
Removethe sub-framebolts.
CRANKCASE
B R E A T H E RH O S E
E1{0t]{E
|ilSTALTAT|0N SUB-FRAME
BOLTS C E N T E RH A N G E RB O L T S
C h e c kt h e e n g i n em o u n t r u b b e r sf o r d a m a g ea n d
replaceif necessary.
I n s t a ltl h e e n g i n em o u n tr u b b e r s .
E n g i n e i n s t a l l a t i o ni s e s s e n t i a l l yt h e r e v e r s eo f
removal.
U s e a f l o o r j a c k o r o t h e r a d j u s t a b l es u p p o r tto
c a r e f u l l ym a n u e v et rh e e n g i n ei n t o p l a c e .
CAUTION
Carefully align mounting points with the iack
to prevent damnge to mounting bolt threads
and wire harnessand cables.
NOTE F R O N TH A N G E R R E A RH A N G E R S U B . FR A M E
' Routethe wiresand cablesproperly(pages BOLTS BOLTS BOLTS
1 - 1 0t h r u 1- 12 ) .
. F i l l t h e c r a n k c a steo t h e p r o p e rl e v e lw i t h
t h e r e c o m m e n d eodi l ( P a g e 2-1).
. F i l l t h e c o o l i n gs y s t e m( P a g e5 - 3 ) .
. P e r f o r mt h e f o l l o w i n gi n s p e c t i o na n d a d -
justments:
T h r o t t l eo p e r a t i o n( P a g e3 - 5 ) .
C l u t c h( P a s e3 - 1 8 ) .
D a t eo f l s s u eO
: ctober1
, 983
5-6 O H O N D AM O T O RC O . ,L T D .
ffithffrrcrA
rl!1ffilEPtoR
$4$ ENGINE REMOVAil/MSTALLAT.IOfiI
MEMO
Dateof lssue:.l*nuary,1983
O HONDAMOTOREO..LTD. &S. -*
IIONTf,'A
V45 INTER,CEPTOR
COOLINGSYSTEM
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
6-O O H O N D A M O T O RC O . ,L T D .
ITONTf,DA
V45 INTERCEPTOR, SYSTEM
6. COOLING
S E R V I C EI N F O R M A T I O N 6-1 THERMOSTAT 6-4
TROUBLESHOOTING 6-1 R A D I A T O R / C O O L I NFAN
G 6-5
S Y S T E MT E S T I N G 6-2 W A T E RP U M P 6-9
C O O L A N TR E P L A C E M E N T 6-3
\- INTORtrtATION
SERtlICE
GENERAL
result.
Do not remoye the radiator cap when the engine is hot. The coolant is under pressureond severescoldingcould
The enginemust be cool before servicingthe cooling system.
. d r m a x i m u mc o r r o -
U s eo n l v d i s t i l l e dw a t e r a n d e t h y l e n eg l y c o li n t h e c o o l i n gs y s t e mA. 5 0 - 5 0 m i x t u r ei s r e c o m m e n d ef o
s i o np r o t e c t i o nD. o n o t u s ea l c o h o l - b a s a endtifreeze.
a A d d c o o l a n ta t t h e r e s e r vtea n k .D o n o t r e m o v et h e r a d i a t o cr a pe x c e p t o r e f i l lo r d r a i nt h e i y s t e m .
o A l l c o o l i n gs y s t e ms e r v i c cea nb e d o n ew i t h t h e e n g i n ei n t h e f r a m e .
o A v o i d s p i l l i n gc o o l a n to n p a i n t e ds u r f a c e s .
o A f t e r s e r v i c i ntgh e s y s t e mc, h e c kf o r l e a k sw i t h a c o o l i n gs y s t e mt e s t e r .
o R e f e rt o S e c t i o n2 0 f o r f a n m o t o r t h e r m o s t a t iscw i t c ha n dt e m p e r a t u rsee n s oirn s p e c t i o n s .
S P E C I IFC A T I O N S
R a d i a t ocr a pr e l i e fP r e s s u r e 7 5 - 1 0 5 k P a( 0 . 7 5 - 1 . 0 5k s / c m ' , 1 0 , 7 - 1 4 . 9p s i )
5 5 %D i s t i l l e dw a t e r+ 4 5 %e t h y l e n eg l y c o l :- 3 2 o C ( - 2 5 ' F )
g o i n t ( H y d r o m e t etre s t ):
Freezinp 5 0 %D i s t i l l e dw a t e r+ 5 0 %e t h y l e n eg l y c o l :- 3 7 o C ( - 3 4 " F )
4 5 %D i s t i l l e dw a t e r+ 5 5 %e t h v l e n eg l y c o l : - 4 4 . 5 " C ( - 4 8 ' F )
Coolantcapacity:
R a d i a t o ra n d e n g i n e 2 . 5 l i t e r s( 2 . 6 5U S q t )
R e s e r v et a n k 0.4 liters(0.42 US qt)
Total system 2.9 liters(3.07 US qt)
B e g i n st o o p e n :8 0 o t o 8 4 o c ( 1 7 6 o- t o 1 8 3 " F )
Thermostat V a l v el i f t : M i n i m u mo f 8 m m a t 9 5 ' C ( 0 . 3 1 5i n a t 2 0 3 o F )
Fl
: 107.7"C 1226"
Unpressurized
B o i l i n gp o i n t( w i t h5 0 - 5 0 m i x t u r e ) : (258'F)
Capon,pressurized:
125.6"C
TROUBTESHOOTIl{G
Enginetemperaturetoo high Enginetemperaturetoo,low
1 . F a u l t yt e m p e r a t u rgea u g eo r g a u g es e n s o r 1 . F a u l t yt e m p e r a t u rgea u g eo r g a u g es e n s o r
2. Thermostatstuckclosed 2. Thermostatstuckopen
3 . F a u l t yr a d i a t o cr a p
4 . I n s uf i c i e n tc o o l a n t Coolantleaks
5 . P a s s a gbelso c k e di n r a d i a t o rh, o s e so, r w a t e rj a c k e t 1 . F a u l t yp u m pm e c h a n i csael a l
6 . F a nb l a d e sb e n t 2 . D e t e r i o r a t eOd - r i n g s
7 . F a u l t yf a n m o t o r
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 6-1
IIONTTDA
COOLINGSYSTEM
V45 INTERGEPTOR,
SYSTE1||
TESTIilIO A N T I F R E E ZTEE S T E R
COOLANT
T e s t t h e c o o l a n t m i x t u r e w i t h a n a n t i f r e e z et e s r e r .
For maximum corrosion protection, a 50-50%
solution of ethylene glycol and distilled water ts
recommended.
RADIATOR
C A PI N S P E C T I O N
P r e s s u rtee s t t h e r a d i a t o rc a p . R e p l a c et h e r a d i a t o r
c a p i f i t d o e sn o t h o l d p r e s s u r eo,r i f r e l i e fp r e s s u r e C O O L I N GS Y S T E MTESTE R
is too high or too low. lt must hold specified ( C O M M E R C I A L LAYV A I L A B L E )
pressure for at leastsix seconds.
NOTE
B e f o r ei n s t a l l i n gt h e c a p o n t h e t e s t e r ,a p p l y
waterto sealingsurfaces.
R A D I A T O RC A PR E L I E FP R E S S U R E :
7 5 - 1 0 5 k P a( 0 . 7 5 - 1 . 0 5k g / c m 2 , 1 0 . 7 - 1 4 . 9p s i l
RADIATOR CAi'
Pressurize t h e r a d i a t o r ,e n g i n ea n d h o s e s ,a n d c h e c k
for leaks.
C O O L I N GS Y S T E MT E S T E R
CAUTION
Excessive pressure can damage the radistor.
Do not exceed1.05 kglcm2 (14.9 psi)
R e p a i r o r r e p l a c ec o m p o n e n t si f t h e s y s t e mw i l l n o r
hold specified pressurefor at least six seconds.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
6-2 O H O N D AM O T O RC O . ,L T D .
DIONTf,DA
V45 INTER,CEPTOR
COOLINGSYSTEM
COOtAilT
RTPTACT]|IENT CAP
RADIATOR
CAUTION
The engine must be cool before servicing the
cooling system, or severescalding may result.
R e m o v et h e r a d i a t o cr a p .
t
\
\
D R A I NP L U G
W A T E RP U M PC O V E R
Drain the coolantfrom the engineby removingthe
drain bolts at the water pump cover and cylinder
heads.
R e p l a c teh e d r a i np l u ga n d b o l t s .
F i l l t h e s y s t e mw i t h a 5 0 - 5 0 m i x t u r e o f d i s t i l l e d
w a t e ra n de t h y l e n eg l y c o l .
B l e e da i r f r o m t h e r a d i a t o r .
. S t a r t t h e e n g i n ea n d r u n u n t i l t h e r e a r e n o a i r
b u b b l e si n t h e c o o l a n t .a n d t h e l e v e ls t a b i l i z e s .
o S t o pt h e e n g i n ea n d a d dc o o l a n tu p t o t h e p r o p e r
levelif necessary.
o R e i n s t a tl lh e r a d i a t o cr a p .
o Checkthe levelof coolantin the reserve tank and
fill to the correctlevelif the levelis low.
o Installthe lower radiatorcowl.
D R A I NB O L T D R A I NB O L T
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . .L T D . 6-3
I'IONTf,DA
V45 INTERCEPTOR
C O O L I N GS Y S T E M
T1|ERil|OSTAT W I R EC O N N E C T O R
REMOVAL
T u r n t h e f u e l v a l v eO F F .
Removethe seat,frame side coversand fuel tank.
D r a i nt h e c o o l a n t( p a g e6 - 3 ) .
Disconnectthe temperaturesensorwire connector
from the sensor.
T E M P E R A T U RS
EE N S O B
T H ER M O S T A TH O U S I N GC O V ER
Removethe thermostathousingcover by removing
two bolts.
HOUSING
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
6-4 O H O N D AM O T O RC O . ,L T D .
IIONTf,DA
V45 INTERCEPTOR.
C O O L I N GS Y S T E M
INSPECTION
Inspectthermostatvisuallyfor damage.
Suspendthe thermostatin heatedwaterto checkits THERMOSTAT
operation.
NOTE
lf the thermostator thermometertouchesthe THERMOMETER
pan,you'll get a falsereading.
TechnicalData
Start to open g o ot o B 4 o c( 1 7 6 ' - 1 8 3 ' F )
8 m m m i n i m u m( 0 . 3 1i n )
Valvelift when heatedto gSoC(203"F)
f o r f i v em i n u t e s .
INSTALLATION
Installthe thermostatinto the housing.
Install the thermostathousingcover with a new
O-ring.
Connect the temperaturesensorwire connector.
Install the fuel tank, frame side coversand seat.
\- Fill the coolingsystem(page6-3).
RAoTAT0R/C00U1{G
FAl{ U P P E RH O S E
REMOVAL
Removethe lower radiatorcowl and radiatordrain
p l u ga n dd r a i nt h e c o o l a n t .
. U P P E RR A D I A T O R
Loosenthe upper hoseclamp and disconnectthe
upperhose.
H O S EC L A M P
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 6-5
XIONTDA
V45 INTER,CEPIOR
COOLINGSYSTEM
R A D I A T O RG R I L L E
Removethe radiatorgrilleand sidecovers.
RI D EC O V E R S
R A D I A T OS
R A D I A T OO
R V E R F L OT
WU B E
Disconnect the radiatoroverflowtube.
Loosen the joint hose clamp and disconnectthe
joint hosefrom the upperradiator.
,: :1'
HOSECLAMP
MOUNTBOLTS
Dateof lssue:October,1983
6-6 O H O N D AM O T O RC O . .L T D .
IilONTTDA
V45 INTERCEPTOR,
COOLINGSYSTEM
J O I N TH O S E
. L O W E RR A D I A T O R
Loosenthe joint hoseclamp and disconnect the
joint hosefrom the lower radiator.
Loosenthe lower hose clamp and disconnect the
lowerhose.
THERMOSTATIC
SWITCH
D I S A S S E MLBY
Removethe fan shroudswith the fansand motors.
D a t eo f l s s u eJ: a n u a r v1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 6 -7
IIONTEDA
COOLINGSYSTEM
V45 INTERCEPTOR
NUT
FANMOTOR
Removethe fan motor from the shroudby remov-
ing the threescrews.
F A NS H R O U D
R A D I A T O RI N S P E C T I O N
Inspectthe radiatorsolderedjoints and seamsfor
leaks.
Blow dirt out from betweencore fins with com-
pressedair. lf insects,etc.,arecloggingthe radiator,
washthem off with low pressure water.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
6-8 O H O N D AM O T O RC O . ,L T D .
IIOTTTf,DA
V45 INTERCEPTOR C O O L I N GS Y S T E M
ASSEMBLY/ INSTALLATION
Assembleand install the radiatorsin the reverse
o r d e ro f r e m o v a l .
A f t e r i n s t a l l a t i o nf i,l l t h e c o o l i n gs y s t e m( p a g e6 ' 3 ) .
tryATER
PU]I|P W A T E RP U M P
M E C H A N I C ASLE A LI N S P E C T I O N
Inspectthe telltalehole for signsof mechanical
seal
coolantleakage.
Replacethe water pump as an assemblyif the
\ mechanicalsealis leaking.
T E L L T A L EH O L E
C L U T C HS L A V EC Y L I N D E R
REMOVAL
D r a i nt h e c o o l a n t( p a g e6 - 3 ) .
R e m o v et h e c l u t c hs l a v ec y l i n d e r . ryq
NOTE
Do not operate the clutch lever after removing
t h e c l u t c h s l a v ec y l i n d e r . T o d o s o w i l l c a u s e
d i f f i c u l t y i n r e i n s t a l l i n gt h e s l a v e c y l i n d e r .
#4
Remove the gearshift arm from the shift shaft. ;qis: I
Removethe drivesprocketcover.
L-
G E A R S H I FA
TR M D R I V ES P R O C K E T
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 6-9
ITOTVXDA
COOLINGSYSTEM
V45 INTERCEPTOR
COVERBOLTS WATERPUMPCOVER
Disconnectthe water hose from the water pump
cover.
Removethe water pump cover bolts and cover.
W A T E RH O S E D R A I NB O L T
P I P EC L A M P HOSEBANDS
R e m o v et h e w a t e rp i p ec l a m pb o l t .
Loosenthe waterhosebands.
Pull off the water pump from the crankcase.
Remove the water pipe from the water pump.
W A T E RP I P E WATERPUMP
Dateof lssue:October,1983
6-10 O H O N D A M O T O RC O . ,L T D .
IIONIf,DA
V45 INTERCEPTOR C O O L I N GS Y S T E M
GROOVE O I L P U M PS H A F T
INSTALLATION
Apply a coat of clean engineoil to a new O-ring
a n d i n s t a l li t i n t h e w a t e r p u m p g r o o v e .
Align the water pump shaft groove with the oil
p u m p s h a ft a n d i n s e r t t h e w a t e r p u m p i n t h e
c r an k c a s e .
O.RING
W A T E RP I P EC A P O-RING
I n s e r ta n e w O - r i n go v e rt h e e n d o f t h e w a t e rp i p e .
C o n n e c t h e w a t e rp i p et o t h e p u m p h o s ea n dw a t e r
p i p ec a p .
W A T E RP I P E
'\- I n s t a l lt h e d o w e l p i n s a n d i n s t a l la n e w O - r i n gi n
the grooveof the water pump cover.
I n s t a l lt h e w a t e r p u m p c o v e ra n d t o r q u et h e b o l t s .
Connectthe water inlet hose.
lnstall the drive sprocketcover, gearshiftarm and
c l u t c hs l a v ec Y l i n d e r '
F i l l t h e c o o l i n gs y s t e m( p a g e6 - 3 ) .
O.RING W A T E RP U M PC O V E R
D a t eo f l s s u eJ: a n u a r V1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 6-11
ITOilTDA
CLUTCHSYSTEM
V45 INTERCEPTOR.
V @,*6@@(W@6
dw %g
4-7 N'm
(40-70 kg-cm,
3 5 - 6 1 i n -t b )
% op
k D a t eo f l s s u eJ: a n u a r y1, 9 8 3
7-O O H O N D AM O T O RC O , ,L T D
ITONTXDA
V45 INTERCEPTOR I. CTUTC]|
SYSTTIU
S E R V I C EI N F O R M A T I O N 7-2 C L U T C HC O V E R R E M O V A L 7_1O
TROUBLESHOOTING 7-3 STARTERCLUTCH DISASSEMBLY 7_1O
C L U T C HF L U I D R E P L A C E M E N T / CLUTCH DISASSEMBLY 7_12
AIR BLEEDING 74 CLUTCH ASSEMBLY 7-17
C L U T C HM A S T E RC Y L I N D E R 7-5 STARTERCLUTCHASSEMBLY 7_20
C L U T C HS L A V E C Y L I N D E R 7-8 CLUTCHCOVER INSTALLATION 7-22
62-68 N'm
(6.2-6.8ks'm,
45-49 ft-lb)
p%
"&
d"
19-22 ttlbl
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 7-1
DIOIVEDA
CLUTCHSYSTEM V45 INTER,CEPIOR,
SERI|ICE
INTORMATIO1{
GENERAL
o This sectioncoversremovaland installationof the clutch hydraulicsystem,clutch and starterclutch.
o DOT-4 brakefluid is usedfor the hydraulicclutch and is referredto as clutch fluid in the section.Do not useother types
o f f l u i d a st h e y a r en o t c o m p a t i b l e .
o Clutchmaintenance can be donewith the enginein the frame.
SPECIFICATIONS
STANDARD S E R V I C EL I M I T
C l u t c hm a s t e cr y l i n d e r C y l i n d e lr. D . mm (0,5512-0.5524
14.000-14.043 in) 14.06mm 0.553in)
P i s t o nO . D . 13.957-13.984
mm 0.5495-0.5506in) 1 3 . 9 4m m 0.549in)
C l u t c hs l a v ec y l i n d e r C y l i n d e lr, D . 38.100-38.162
mm 1.5000-1.5024inl 3 8 . 1 8m m 1 . 5 0 3i n )
P i s t o nO . D . 38.036-38.075
mm 1 . 4 9 7 5 - 1 . 4 9 9 0i n ) 38.02mm 1 . 4 9 7i n )
Clutch O u t e rg u i d el . D . 24.995-25.O12
mm 0,9841-0.9847
in) 25.08mm (0.987in)
Springfree height 4 . 1 m m ( 0 . 1 6i n ) 3 . 9m m ( 0 . 1 5i n )
C l u t c hc e n t e rB l . D . 74.414-7 4.440mm Q.9297-2.9307 inl 74.47mm (2.932inl
Oneway clutch
i n n e rO . D . 57.71O-57 .840 mm 12.272O-2.277 2 inl 57.60mm (2.268inl
Discthickness 3 . 7 2 - 3 . 8 8m m { 0 . 1 4 7 - 0 . 1 5 3i n ) 3 . 1m m ( 0 . 1 2i n )
Platewarpage 0.30mm (0.012in)
P u l s ec o i l a i r g a p 0.35-0.85mm (0.014-0.033
in)
Starterclutch D r i v e ng e a rO . D . 47.175-47.200mm (1.8573-1.8583in) 4 7 . 1 6m m ( 1. 8 5 7i n )
T O R O U EV A L U E S
Primarydrivegear 8 0 - 1 0 0 N . m ( 8 . 0 - 1 0 . 0k s - m ,5 8 - 7 2 f t - l b )
Clutch lock nut 62-68 N'm (6.2-6.8 kg-m,45-49 ft-lb)
Starterclutch 26-30 N.m (2.6-3,0 kg-m,19-22 ft-lb)
TOOLS
Special
S n a pr i n gp l i e r s 07924-MC7OOO2 or modif ied 07024-MC70001 or O7924-MC70000
Gearholder or 07924-41 50000
Common
Extension 07716-0020500---l
L o c k n u t w r e n c h ,1 7 x 2 7 m m 07716-0020399--J- or equivalent
in U.S.A.
Driver 07749-0010000
Attachment,37 x 40 mm 07746-0010200
P i l o t , 3 5m m 07746-0040800
Universalholder 07725-0030000
Dateof lssue:January,1983
7-2 O H O N D A M O T O RC O . ,L T D .
IilOTtTDA
V45 INIERGEPTOR, CLUTCHSYSTEM
TROUBTESl|OOTIl{G
Glutch leversoft or spongy Motocyclecreepswith clutch disengaged
1 . A i r b u b b l e si n h y d r a u l i cs y s t e m 1 . A i r b u b b l e si n h y d r a u l i cs y s t e m
2. Low fluid level 2. Low fluid level
3. Hydraulicsystemleaking 3 . H y d r a u l i cs y s t e ml e a k i n g
4 . H y d r a u l i cs y s t e ms t i c k i n g
Clutch levertoo hard 5. Plateswarped
1 . S t i c k i n gp i s t o n ( s )
2. Cloggedhydraulicsystem Excessive leverpressure
1 . H y d r a u l i cs y s t e ms t i c k i n g
'clutch 2. Lifter mechanism damaged
slips
1 . H y d r a u l i cs y s t e ms t i c k i n g
2. Discsworn Clutch operationfeelsrough
3. Springsweak 1 . O u t e rd r u m s l o t sr o u g h
2 . S t i c k i n gp i s t o n ( s )
Clutchwill not disengage
1. A i r b u b b l e si n h y d r a u l i cs y s t e m
2. Low fluid level
3 . H y d r a u l i cs y s t e ml e a k i n g
4 , H y d r a u l i cs y s t e ms t i c k i n g
5. Plateswarped
Dateof lssue:January)1983
O H O N D AM O T O RC O . ,L T D . 7-3
, l
I'iIOTVf,DA
V45 INTERCEPTOR
CLUTCHSYSTEM
TTUID
CTUTCI| REPLAGEMEIIT/
AIRBLEtDIl{G
C h e c k t h e f l u i d l e v e lw i t h t h e f l u i d r e s e r v o i rp a r a l l e l
to the ground.
CAUTION
. I n s t a l tl h e d i a p h r a g m o n t h e r e s e r v owirhen
o p e r a t i n gt h e c l u t c hl e v e r .F a i l u r et o d o s o
w i l l a l l o w c l u t c hf l u i d t o s q u i r to u t o f t h e
r e s e r v od i ru r i n gc l u t c ho p e r a t i o n .
. A v o i d s p i l l i n gf l u i d o n p a i n t e ds u r f a c e s .
P l a c ea r a g o v e r t h e f u e l t a n k w h e n e v e r
t h e s y s t e mi s s e r v i c e d .
L O W E RL E V E L
B L E E DH O S E B L E E DV A L V E
CLUTCH
F L U I DD R A I N I N G
C o n n e c t a b l e e d h o s et o t h e b l e e d v a l v e .
L o o s e n t h e s l a v ec y l i n d e r b l e e d v a l v e a n d p u m p t h e
clutch lever.
S t o p o p e r a t i n gt h e l e v e r w h e n n o f l u i d f l o w s o u t o f
t h e b l e e dv a l v e .
CLUTCH
F L U I DF I L L I N G
NOTE
D o n o t m i x d i f f e r e n t t y p e s o f f l u i d s i n c et h e v
may not be compatible.
C l o s e t h e b l e e d v a l v e , f i l l t h e r e s e r v o i r .a n d i n s t a l l
thediaphragm.
T o p r e v e n t p i s t o n o v e r t r a v e la n d c l u t c h f l u i d s e e -
page, keep a 20 mm l3l4 inl spacer between the
h a n d l e b a rg r i p a n d l e v e r w h e n b l e e d i n g t h e c l u t c h
s y s t e m .P u m p u p t h e s y s t e mp r e s s u r ew i t h t h e l e v e r
20 mm SPACER
until there are no air bubbles in the fluid flowing
o u t o f t h e r e s e r v o i rs m a l l h o l e a n d l e v e rr e s i s t a n c ei s
f e l t . T h e n b l e e dt h e s y s t e m .
A I RB L E E D I N G
I\OTE
' C h e c k t h e f l u i d l e v e lo f t e n w h i l e b l e e d i n g
the clutch to prevent air from being
pumped into the system.
' Use only DOT 4 brake fluid from a sealed
c o n t aIn e r .
' Do not mix brake fluid types and never
r e u s et h e f l u i d w h i c h h a s b e e n p u m p e d o u t
d u r i n g b l e e d i n g ,o r t h e e f f i c i e n c y o f t h e
c l u t c h s y s t e mw i l l b e i m p a i r e d .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
7-4 O H O N D AM O T O RC O . ,L T D .
IIONIXDA
V45 INTERCEPTOR, CLUTCHSYSTEM
B L E E DH O S E B L E E DV A L V E
1 ) S q u e e z et h e c l u t c h l e v e r , o p e n t h e b l e e d v a l v e
l 1 2 t u r n t h e n c l o s et h e v a l v e .
NOTE
D o n o t r e l e a s et h e c l u t c h l e v e ru n t i l t h e
b l e e dv a l v eh a sb e e nc l o s e da g a i n .
2 ) R e l e a s et h e c l u t c h l e v e r s l o w l y a n d w a i t s e v e r a l
secondsafter it reachesthe end of its travel.
R e p e a tt h e a b o v es t e p su n t i l b u b b l e sc e a s et o a p p e a r
in the f luid at the end of the hose.
Tighten the bleed valve,
to theupperlevel.
Fillthefluidreservoir
BOLT
]||ASTER
CLUTCH CYLINOER
DISASSEMBLY
Drain clutch fluid from the hydraulic system.
R e m o v et h e r e a r v i e w m i r r o r a n d c l u t c h l e v e r .
Disconnect the clutch switch wires and remove
. the clutch hose.
cAUTtOr{
Avoid spilling clutch fluid on painted surfaces.
Place a rag over the fuel tank whenever the
clutch system is serviced.
NOTE
W h e nr e m o v i n gt h e o i l b o l t , c o v e rt h e e n d o f CLUTCHHOSE
t h e h o s et o o r e v e n ct o n t a m i n a t i oann ds e c u r e
thehose.
R e m o v et h e m a s t e cr y l i n d e r .
S N A PR I N GP L I E R S
07914-3230001 0 R EOU|VALENT
Dateof lssue:October,1983
O H O N D A M O T O RC O . ,L T D . 7-5
IIONTf,DA
CLUTCHSYSTEM V45 INTERCEPTOR
R e m o v et h e f o l l o w i n g :
- pistonand secondary cup.
- primarycup and spring.
- clutch switch,if necessary.
L U T C HM A S T E R
CYLINDER
CLUTCH i P R I M A R YC U P
*-w
SWITCH SPRING /
I / sEcoN D AR Y
N / /cup
w "@^/
^l /
_,, PlsToN
MASTER
CYLINDER
I . D .I N S P E C T I O N
M e a s u rteh e m a s t e cr v l i n d e rl . D .
C h e c k t h e m a s t e r c y l i n d e r f o r s c o r e s ,s c r a t c n e s
or nicks.
S E R V I C EL I M I T : 1 4 . 0 6m m ( 0 . 5 5 3i n )
M A S T E R P I S T O NO . D . I N S P E C T I O N
M e a s u rteh e m a s t e o
r i s t o nO . D .
S E R V I C EL I M I T : 1 3 . 9 4m m ( 0 . 5 4 9i n )
C h e c kt h e p r i m a r ya n d s e c o n d a rcyu p sf o r d a m a g e
b e f o r ea s s e m b l v .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
7-6 @ H O N D AM O T O RC O . .L T D .
IIONTf,DA
V45 INTERCEPTOR CLUTCHSYSTEM
R E S E R V O IC
RO V E R
ASSEMBLY
CAUTloltl DIAPHRAGM
CAUTION
Wheninstalling the cups, do rnt allow the lips
@ C L U T C HL E V E R
l/+
to turn inside out. MASTE v P I V O TB O L T
#F
CYLINDER
Install the snapring makingsure it is seatedfirmly S P RI N G
P R I M A R YC U P
in the grooveT . h e n i n s t a l tl h e b o o t a n d p u s hr o d .
I n s t a ltl h e c l u t c hs w i t c h .i f i t w a sr e m o v e d .
l
CLUTCH
S N A PR I N G
SWITCH
P U S HR O D E N D P I E C E
P U N C HM A R K OILBOLT
P l a c et h e m a s t e rc y l i n d e r o n t h e h a n d l e b a a r nd
" U P " m a r kf a c i n gu p a n d
i n s t a l tl h e h o l d e rw i t h t h e
the two mountingbolts.
Align the mark of the holder with the handlebar
p u n c hm a r k .
Tighten the top bolt first, then the bottom bolt.
I n s t a l tl h e o i l h o s ew i t h t h e b o l t a n d i t s t w o s e a l i n g
washers.
Installthe push rod end pieceinto the clutch lever
holeand installthe clutch lever.
Connect the clutch switch wires to the switch
terminals.
Fill the reservoir and bleed the clutch system
(pase7 -4t..
Dateof lssue:October,1983
O H O N D AM O T O RC O . ,L T D . 7-7
IIONTf,'A
V45 INTERCEPTOR,
CLUTCHSYSTEM
CLUTC||
SLAI|E
CYLINDER S L A V EC Y L I N D E R OIL BOLT
DISASSEMB
LY
P l a c e a c o n t a i n e r u n d e r t h e s l a v ec y l i n d e r , r e m o v e
t h e o i l b o l t a n d d i s c o n n e c tt h e c l u t c h h o s e .
NOTE
A v o i d s p i l l i n gc l u t c h f l u i d o n p a i n t e ds u r -
faces.
R e m o v et h e s l a v ec y l i n d e r .
A p p l y c o m p r e s s eadi r t o t h e f l u i d i n l e t t o r e m o v e
t h e p i s t o n .U s et h e a i r i n s h o r ts p u r t s .
AIR NOZZLE
SPRING
R e m o v et h e s p r i n gf r o m t h e s l a v ec y l i n d e r .
R e m o v et h e o i l a n d p i s t o ns e a l s .
C l e a nt h e p i s t o ng r o o v ew i t h c l u t c hf l u i d .
Check the piston spring for weaknessor damage.
O I LS E A L PISTN
OSEAL
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
7-8. O H O N D AM O T O RC O . ,L T D .
DIOTTTTDA
V45 INTERCEPTOR CLUTCHSYSTEM
O . D .I N S P E C T I O N
PISTON
Check the piston for scoring or scratches.
M e a s u r et h e o u t s i d e d i a m e t e r o f t h e p i s t o n w i t h a
m icrometer.
S E R V I C E L I M I T : 3 8 . 0 2 m m ( 1 . 4 9 7i n )
CYLINDER
I . D .I N S P E C T I O N
C h e c kt h e s l a v ec y l i n d e rf o r s c o r i n go r s c r a t c h e s .
M e a s u r et h e i n s i d ed i a m e t e ro f t h e c y l i n d e rb o r e .
S E R V I C EL I M I T :3 8 . 1 8m m ( 1 . 5 0 3i n l
ASSEMBLY OILSEAL
P I S T O NS E A L
A s s e m b l et h e s l a v ec y l i n d e ri n t h e r e v e r s o
e r d e ro f S L A V EC Y L I N D E
d i s a s s e m b l yT.h e o i l s e a l sm u s t b e r e p l a c e dw i t h BODY
new oneswheneverthev havebeenremoved.
L u b r i c a t et h e p i s t o na n d p i s t o ns e aw
l ith a medium
g r a d e o f H i - T e m p e r a t u rsei l i c o n eg r e a s eo r b r a k e
f l u i d b e f o r ea s s e m b l y .
k
GREASE
D a t eo f l s s u eO
: c t o b e r 1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 7-9
XTONTDA
CLUTCHSYSTEM
V45 INTERCEPTOR
I n s t a ltl h e i n s u l a t oar n ds l a v ec y l i n d e r .
Connectthe clutch hose with the oil bolt and the
two sealingwashers.
CLUTC]|
COI'ER
REil|Ot'AL CLUTCH
COVER
D r a i nt h e e n g i n o
eil.
Removethe clutchcover,gasketand dowel pins.
STARTER DISASSEMBTY
CLUTCI| A R T E RI D L E RG E
Dateof lssue:January,1983
7-10 @ H O N D AM O T O RC O . ,L T D .
ITONTTDA
V45 INTERCEPTOR CLUTCHSYSTEM
G E A R H O L D E R0 7 9 2 4 - M C 7 O O Oo 2r m o d i f i e d
07 924 -MC7 O001 o r 07 924 -MC7 O000 o r 07 924 4 1SOOOO
Hold the primary gear with the gear holder and
removethe bolt.
Removethe starterclutch.
P R I M A R YG E A R
D R I V E NS U BG E A R
PRIMARY D R I V EG E A R
PRIMARY
S h i f t t h e p r i m a r y d r i v e n s u b g e a rw i t h a s c r e w -
driver to take preload off the primary drive gear
a n d r e m o v et h e p r i m a r yd r i v eg e a r .
d
d
s p d
S T A R T E RC L U T C HC O V E R
of lssue:
January,
1983
,,;;Eate
O HONDAMOTORCO.,LTD. 7-11
IIONTf,DA
V45 INTER.CEPTOR
CLUTCHSYSTEM
STARTER
D R I V E NG E A RI N S P E C T I O N
Inspect the driven gear for damage or excessive
wear.
M e a s u r et h e d r i v e n g e a rO . D .
S E R V I C E L I M I T : 4 7 . 1 6 m m ( 1 . 8 5 7i n )
DISASSE1||BLY
CLUTC1| C L U T C HL I F T E RP L A T E L I F T E RG U I D E
S N A PR I N G BEAR I NG
S P R I N GS E TP L A T E
Shift the transmissioninto 5th gearand apply the
rearbrake.
NOTE
lf the engine is not in the frame, shift the
transmissioninto gear and use the universal
holder (07725-0030000) to hold the drive
sprocket.
L O C KN U T W R E N C H1, 7 x 2 7 m m EXTENSION
07716-00203000 R EOUIVALENT I N U . S . A .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
7-12 O H O N D AM O T O RC O . .L T D .
ITO1\TXDA
V45 INIER.CEPTOR. CLUTCHSYSTEM
D I S C SA N D P L A T E S C L U T C HP R E S S U RP
EL A T E
Removethe clutch pressure
Plate,
T C H C E N T E RB
Removeclutch centerB and the one-wayclutch as f
an assembly.
O N EW A Y C
rI
C L U T C HC E N T E RA
, Removeclutch centerA and washer.
h
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
@ H O N D AM O T O RC O . ,L T D . 7-13
IIOl\tTDA
CLUTCHSYSTEM V45 INTERCEPTOR
C L U T C HO U T E R
Removethe clutch outer and outer guide.
C L U T C HO U T E RG U I D E
INSPECTION
. C L U T C HS P R I N G
. C L U T C HD I S C
R e p l a c et h e c l u t c h d i s c s i f t h e y s h o w s i g n so f
s c o r i n go r d i s c o l o r a t i o n .
M e a s u rteh e t h i c k n e sos f e a c hd i s c .
S E R V I C EL I M I T :3 . 1 m m ( 0 . 1 2i n )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
7-14 O H O N D AM O T O RC O . ,L T D .
IIONTXDA
V45 INTER,CEPTOR. CLUTCHSYSTEM
O C L U T C HP L A T E
. O N EW A Y C I I J T C HI N S P E C T I O N
wear.
Checkthe rollersfor excessive
M e a s u rteh e l . D . o f c l u t c hc e n t e rB .
S E R V I C EL I M I T : 7 4 . 4 7m m ( 2 . 9 3 2i n )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 7-15
IilOTVf,DA
CLUTCHSYSTEM V45 INTERCEPTOR
M e a s u rteh e O . D .o f t h e o n e w a y c l u t c hi n n e r .
SERVfCE LIMIT: 57.60 mm 12.268inl
SLOT N E E D L EB E A R I N G
INSPECTION
. CLUTCH OUTER
C h e c k t h e s l o t s i n t h e c l u t c h o u t e r f o r n i c k s ,c u t s
o r i n d e n t a t i o n sm a d e b y t h e f r i c t i o n d i s c s .
Check the cltrtch outer needlebearingfor damage
o r e x c e s s i vpel a y .
l f t h e n e e d l eb e a r i n gi sd i f f i c u l t o r e m o v e
fromtne
c l u t c hh o u s i n gu, s et h e f o l l o w i n gt o o l s :
D r i v e r :0 7 7 4 9 - 0 0 1 0 0 0 0
Attachment,37 x 40 mm: O7746-0010200
Pilot,35 mm : O7746-0040800
O C L U T C HO U T E R G U I D E
M e a s u r et h e l . D . o f t h e c l u t c ho u t e r g u i d e .
S E R V T C EL I M I T : 2 5 . 0 8 m m ( 0 . 9 8 7i n )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
7-16 O H O N D AM O T O RC O . .L T D .
ITONIXDA
V45 INTERCEPTOR CLUTCHSYSTEM
ASSEMBLY
GTllTG]| O I L P U M PD R I V ES P R O C K E T
I n s t a l lt h e c l u t c h o u t e r g u i d eo v e r t h e m a i n s h a f t .
I n s t a l tl h e n e e d l eb e a r i n gi n t o t h e c l u t c ho u t e r .
A l i g n t h e h o l e si n t h e c l u t c ho u t e r w i t h t h e p i n s
o n t h e o i l p u m p d r i v e s p r o c k e ta n d i n s t a l l t h e
clutchouter overthe guide.
C L U T C HO U T E R C L U T C HO U T E RG U I D E
C L U T C HC E N T E RA WASHER
lnstallclutchcenterA and the washer'
GROOVES CLUTCH N T E RB
Place the clutch center B with the groovedside
\- facingdown.
Installthe one-wayclutch into the clutch center B
with its flangedcagefacinguP.
Installthe clutch inner into the one-wayclutch with
its groovesfacing up. Turn it counterclockwise as
you installit.
O N E - W A YC L U T C H C L U T C HI N N E R
Dateof lssue:January,1983
O H O N D AM O T O RC O . ,L T D . 7 -1 7
ITONTEDA
CLUTCHSYSTEM
V45 INTER,CEPTOR,
CLUTCHCENTERB (Turnsclockwise)
lnstallthe one-wayclutch/clutchcenterB assembly
overthe mainshaft,
NOTE
Make sure the one way clutch assemblyis
installed correctly by turning the clutch
centerB. The clutch centershouldturn clock-
wise freely and should not turn counter-
clockwise.
CLUTCH
ONE-WAY
C L U T C HP R E S S U R E
PLATE
lnstallthe clutch pressure
plate.
Dateof lssue:January,1983
7-14 O H O N D AM O T O RC O . ,L T D .
IIONf,DA
V45 INTERCEPTOR
CLUTCHSYSTEM
r
R I N GS E TP L A T E
lnstallthe clutch springsetplate,clutch spring,and
washers.
I
f
NOTE
Installthe clutch springwith the dishedface
towardsthe inside.
h.
CLUTCH
L O C KW A S H E R
lnstallthe lock washerwith its dishedfacetowards
the inside.
in 5th gear.
Placethe transmission
NOTE
. lf servicingthe clutch with the engineout
of the frame,shift the transmission into gear
and hold the drive sprocket with the
H O L D E R0 7 7 2 5 - 0 0 3 0 0 0 0 .
TOROUE:
62-68 N.m{6.2-6.8ks-m,45-49ft-lb}
L O C KN U T W R 17x27 mm
o 7 7 1 6 - 0 0 2 0 3 0 00 R E O U T V A L E N Tt N U . S . A .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 7-19
ITONTIDA
V45 INTERCEPTOR
CLUTCHSYSTEM
L I F T E RR O D
lnstallthe clutch lifted rod.
L I F T E RP L A T E B E A R I N G L I F T E RG U I D E
lnstallthe snaPring.
S N A PR I N G
STARTER ASSTMBLY
CTUTCI| P R I M A R YD R I V EG E A R
T H R U S TW A S H E R
D a t eo f l s s u eJ: a n u a r v1, 9 8 3
7-2o. O H O N D AM O T O RC O . .L T D .
ITONIf,DA
V45 INTER,CEPTOR
CLUTCHSYSTEM
ROLLER PLUNGER D O W E LP I N
I n s t a l lt h e s p r i n g s ,p l u n g e r sa n d r o l l e r si n t o t h e
starterclutch.
I n s t a ltl h e d o w e lp i n .
I n s t a l lt h e s t a r t e rc l u t c h c o v e ra l i g n i n gt h e d o w e l
p i n h o l e w i t h t h e d o w e l p i n a n d t i g h t e nt h e b o l t s .
TOROUE: 26-30 N.m (2.6-3.0 kg-m,19-22 ft-lbl
NOTE
Apply a locking agent to the bolt threads.
C L U T C HC O V E R
S T A R T E RD R I V E RG E A R
Installthe starterdrivengearby turning it clockwise.
P U N C HM A R K S
A l i g n t h e p u n c h m a r k s o n t h e s t a r t e rc l u t c h a n d
crankshaftand installthe starterclutch.
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
@ H O N D AM O T O RC O . ,L T D . 7-21
ITOilTXDA
CLUTCHSYSTEM
V45 INTERCEPTOR
G E A R H O L D E R0 7 9 2 4 - M C 7 0 O Oo2r m o d i f i e d
07924-MC7 O001 o r 07924-MC7 0000 o r 07924-41 5O0O0
Hold the primary gearwith the gearholder 107924-
MC70002)and tightenthe primarygearbolt.
TORQUE:
80-100 N.m (8.0-10.0 ks-m,58-72 ft-lb)
* *
"-$ij
S T A R T E RC L U T C H
I D L E RG E A RS H A F T
Installthe starteridler gearand shaft.
$
S T A R T E RI D L E RG E A R
CTUTC]|
COI|ER
IIISTALIATIOl{
I n s t a ltl h e d o w e lp i n sa n d a n e wg a s k e t .
D O W E LP I N S
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
7-22 O H O N D A M O T O RC O . ,L T D .
IIONIf,DA
V45 INTER.CEPTOR CLUTCHSYSTEM
U T C HC O V E R
I n s t a lI t h e c l u t c h c o v e r .
F i l l t h e c r a n k c a sw e i t h o i l ( p a g e2 - 3 ) .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 7-23
IIOilTf,DA
V45 INTERCEPTOR,
G E A R S H I F TL I N K A G E
wnw{"W
%@
nP*r
*wb
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
8-O O H O N D AM O T O RC O . .L T D .
TIONTf,DA
V45 INTER,CEPTOR 8. GEARS1IIFT
IIN](AG[
S E R V I C EI N F O R M A T I O N 8-1
TROUBLESHOOTING 8-1
G E A R S H I F TL I N K A G E R E M O V A L 8-2
G E A R S H I F TL I N K A G E I N S T A L L A T I O N 8-4
SERt|ICT
I1{FORMATION
GENERAL
o The gearshiftspindleand stopperarmscan be servicedwith the enginein the frame.
o lf the shift forks,drum and transmission removethe engineand separate
requireservicing, the crankcase.
TRoUBt
tSH0oTtl{C
Hardto shift
1 . A i r b u b b l e si n t h e c l u t c hh y d r a u l i cs y s t e m
2. Shift forks bent
3. Shift clawbent
4. Shift drum cam groovesdamaged
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . .L T D . 8-1
V45 INTERCEPTOR
G E A R S H I F TL I N K A G E
tII{I(AGT
OTARS}|ITT RE]||O['AT
Drain the engine oil {page2-3).
Remove the gearshift arm from the shift shaft.
Remove the clutch cover and clutch assembly
(Section 7).
G E A R S H I FA
TR M S H I F TS H A F T
O I L P U M PD RI V E R I V ES P R O C K E T
R e m o v et h e o i l p u m pd r i v e ns p r o c k ebt o l t .
R e m o v et h e o i l p u m p d r i v ec h a i n ,d r i v ea n d d r i v e n
sorockets.
O I L P U M PD R I V E NS P R O C K E TB O L
D R U MS T O P P E A
RR M
Removethe drum stopperarm nut, washer,spring,
c o l l a r ,a n da r m .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
8-2 O H O N D AM O T O RC O . .L T D .
IIONTXDA
V45 INTER,CEPTOR,
G E A R S H I F TL I N K A G E
R e m o v et h e t a b w a s h e r .
TAB WASHER
P u l l t h e g e a r s h i fst p i n d l ea s s e m b loyu t o f t h e c r a n k -
case.
WW
G E A R S H I FS
TP I N D L E
N E U T R A LS T O P P EA
RR M
Remove the neutral stopper a r m b o l t , a r m a n d
s p r i n ga n d w a s h e r .
ARM BOLT
D a t eo f l s s u eJ: a n u a r V1, 9 8 3
O H O N D AM O T O RC O . .L T D . 8-3
ITONTDA
G E A R S H I F TL I N K A G E
V45 INTERCEPTOR
S H I F TD R U MC A M P L A T E
Removethe shift drum cam platebolt and cam
plate.
OEARS]|ITT
LII{I(AGT
II{STALIATION D O W E LP I N
I n s t a ltl h e d o w e lp i n i n t h e h o l eo f t h e s h i f td r u m .
I n s e r t h e f i v e p i n si n t [ e h o l e so f t h e c a m p l a t e .
A l i g n t h e c a m p l a t eh o l ew i t h t h e d o w e lp i n o n t h e
s h i f td r u m a n d i n s t a ltl h e c a mp l a t e .
T i g h t e nt h e b o l t s e c u r e l y .
C A MP L A T E HOLE
N E U T R A LS T O P P EA
RR M
Installthe washer,neutral stopperarm, springand
a r mb o l t .
Tightenthe arm bolt securely.
R E T U R NS P R I N G G E A R S H I FST P I N D L E
TABWASHER
ARM
D R U MS T O P P E R
Installthe drum stopperarm, collar,spring,washer
and nut overthe arm bolt.
Tightenthe nut securely.
Rotate the gearshiftspindleand checkthe linkage
for smoothoperation.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 8-5
IIONTEDA
LINKAGE
GEARSHIFT
V45 INTERCEPIOR,
O I L P U M PD R I V E
I n s t a l l t h e o i l p u m p d r i v e a n d d r i v e n sprockets
w i t h d r i v e c h a i n a n d t i g h t e n t h e d r i v e n sprocket
bolt securely.
NOTE:
T h e d r i v e n s p r o c k e th a s a n " l N " m a r k t h a t
mustfacethe crankcase.
D RI V E NS P R O C K E T B O L T
G E A R S H I FA
TR M S HI F T S H A F T
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
8-6 O H O N D AM O T O RC O . ,L T D .
TflCTTTf,DA
V45 INTERCEPTOR G E A R S H I F TL I N K A G E
MEMO
\-
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 8-7
IIONTf,DA
V45 INTER,CEPTOR
ALTERNATOR
80-100N.m \
(8.0-10.0ks-m,
58-72 ft-tb)
Dateof lssue:January,1983
9-O O H O N D AM O T O RC O . ,L T D .
ITONTTDA
V45 INTER,CEPTOR, g. A|.IERNATO
S E R V I C EI N F O R M A T I O N 9- 1
F L Y W H E E LR E M O V A L 9-2
F L Y W H E E LI N S T A L L A T I O N 9-3
I1{TORMAIIOl{
SERYICE
GENERAL
o This sectioncoversremovaland installationof the alternator.
and inspectionof the alternator.
Referto section17 for troubleshooting
T O R O U EV A L U E
Alternatorrotor/Flywheelbolt 8 0 - 1 0 0 N . m ( 8 , 0 - 1 0 . 0k g - m , 5 8 - 7 2f t - l b )
TOOLS
Common
Flywheelholder 07725-0040000
Rotor puller or 07933-3290001
07733-0020001
\-_
\-
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 9-1
IIONTfDA
V45 INTERCEPTOR
ALTERNATOR
FLYW||EEL
RTMOI'AT ALTERNATOC
ROVER
Removethe alternatorcover.
FLYWHEEB
L OLT
Hold the flywheel with the flywheel holder and
removethe flywheelbolt.
R O T O RP U L L E R
07733-00200010R
Removethe flywheelwith the rotor puller.
Removethe woodruff keVfrom the crankshaft.
FLYWHEEH L OLDER
07725-0040000
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
9-2 O H O N D AM O T O RC O . .L T D .
IIONTDA
V45 INTER,CEPTOR. ALTERNATOR
RE]||OI'AL
STATOR
Remove the frame left side cover.
Disconnect the alternator wire coupler and free the
a l t e r n a t o rw i r e f r o m t h e c l a m p .
A L T E R N A T O RW IR E C O U P L E R
STATOR W I R EC L A M P
R e m o v et h e s t a t o rb y r e m o v i n gt h e b o l t sa n d w i r e
ctamo.
STATOR
I]{STALIATIOl{
I n s t a ltl h e s t a t o ra n dw i r e c l a m P .
\- Route the alternatorwire properly,secureit with
clamp and connectthe alternatorwire coupler to
t h e m a i nh a r n e s s .
lnstallthe f rameleft sidecover.
TLY[|J]|ETL N
I]{STATLATIO
Installthe woodruff key into the crankshaft.
l n s t a l lt h e f l y w h e e lb y a l i g n i n gi t s k e y w a yw i t h t h e
key in the crankshaft.
Hold the flywheel with the flywheel holder and
torquethe flywheelbolt.
TOROUE:80-100 N.m
(8.0-10.0 ks-m,58-72 ft-lb)
lnstallthe alternatorcover.
(page
Check engineoil level and add if necessary
2-3t.
07725-0040000
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 9-3
IIOIITTDA
V45 INTER,CEPTOR
C Y L I N D E RH E A D / V A L V E
8-12 N.m
16\
* (d,
u&* 6Y@
9w
% x
-@ 1 0 - 1 4N . m
(1.0- 1.4 kg-m,7- 10 ft-lb)
2 1 - 2 5N . m
( 2 . 1 - 2 . 5k g - m ,
t
45-50 N.m
\ r h
he flf'*
ru,-
- f u ffi
\\
/#r\
J
llrF
18-20 N.m
hp
( 1 . 8 - 2 . 0 k g - m ,1 3 - 1 4 f t - l b )
g
5 u%
38-42 N.m w
(3.8-4.2 kg-m,27-30 ft-lb)
stRt|tcE
t1{t0RiltATlo1{
GENERAL
o The front cylinderheadcan be removedwith the enginein the frame.
o The rear cylinder head cannot be removedwith the enginein the frame;howeverits camshaftsand rocker aims can be
servicedwith the enginein the frame.
o lf the cam sprocketsof eitherfront or rearcylinderare removed,the valvetiming of both cylindersmust be checkedduring
reinstalIation.
o C a m s h a f t l u b r i c a t i n gi sofi e
l d t h r o u g h t h e e x t e r noai l l i n e s . B e s u r e t h e ol i ln e s a r e n o t c l o g g e d .
o D u r i n ga s s e m b l ya,p p l ym o l y b d e n u m d i s u l f i d et o t h e c a m s h a fht o l d e rs u r f a c etso p r o v i d ei n i t i a ll u b r i c a t i o n .
o T h e c y l i n d e rn u m b e r i n g
i s g i v e nb e l o w :
FRONT c o
o o
+
LEFT
SPECIFICATIONS
STANDARD S E R V I C EL I M I T
C o m p r e s s i opnr e s s u r e 1.300t 200kPa
,184 ! 28 Psi)
113x 2 kglcm2
Camshaft Cam height IN 3 5 . 3 3 5 - 3 5 . 4 9 5m m ( 1. 3 9 11 - 1 ' 3 9 7 4i n ) 3 5 . 3m m ( 1 . 3 9i n )
EX 1-1 .3974in)
mm (1.391
35,335-35.495 3 5 . 3m m ( 1 . 3 9i n )
Runout 0.10mm (0.004in)
End clearance 0.05-0.25mm (0.002-0.010 in) 0.30mm {0.012in}
Oil clearance Center 0.131-0.191 mm (0.0052-0'0075 in) 0.20mm (0.008in)
Both ends 0.020-0.081 mm (0.0008-0.0032 in) 0.10mm (0.004in)
R o c k e ra r m R o c k e ar r m l . D . 12.000-12.018 mm @.4724-O.4731 inl 12.05mm 1O.474 in
S h a f tO . D . 11 . 9 6 6 - 1 . 9 8 4m m ( 0 . 4 711- 0 . 4 7 1 8
in) 1 1 . 9 3m m ( 0 . 4 7 0
in
Valve V a l v es t e mO . D . IN 5 . 4 7 5 - 5 . 4 9 0m m ( 0 . 2 1 5 6 - 0 . 2 1 6 1i n ) 5 . 4 7m m ( 0 . 2 1 5i n
EX 5.455-5.470 mm 1O.2148-O.2154inl 5 . 4 5m m ( O . 2 1 4i n
V a l v eg u i d e l . D . 5 . 5 0 0 - 5 . 5 1 5m m ( 0 . 2 1 6 5 - 0 . 2 1 7 1i n ) 5 . 5 5m m ( 0 . 2 1 9i n
Stem-to-guide clearance IN mm
0.010-0.040 (0.0004-0.0016
inl 0.08mm (0.003in
EX mm
0,030-0.060 (0.0012-0.0024
in) 0.10mm (0.004in
V a l v es t e mr u n o u t 0.05mm (0.002in
Valve length IN 8 9 . 5 5m m ( 3 . 5 2 6i n ) 89.05mm (3.506in
EX 8 9 . 3 5m m ( 3 . 5 1 8i n ) 8 8 , 8 5m m { 3 . 4 9 8i n
V a l v e s e a tw i d t h 0.99-1.27mm (0.039-0.050
in) 1 . 5m m ( 0 . 0 6i n )
Dateof lssue:October,1983
O H O N D A M O T O RC O . ,L T D . 10-1
I'iIONTf,DA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
V a l v es p r i n g Free length In n e r 4 1 . 6m m ( 1. 6 4i n ) 4 0 . 2 5m m ( 1 . 5 8i n )
Outer 4 3 . 7m m ( 1 . 7 2 i n \ 4 2 . 2 3m m ( 1 . 6 6i n )
Preload/length Inner 7 .42-8.72 ks/34.2mm ( 16.36-l 9.22 7 . 1 1k g l 3 4 . 2m m
l b / 1 . 3 5i n ) ( 1 5 . 6 7l b / 1 . 3 5i n )
Outer .t mm (28.44-33.29
12.9-15.1 ks137 12.29kg/37.7 mm
lb/1.48
in) l 2 7 . O gl b / 1 . 4 8i n )
C y l i n d e rh e a d Warpage 0.1mm (0.004in)
T O R O U EV A L U E S
TOOLS
Special
Vaiveguidereamer,5.5 mm 07984-2000000
Common
V a l v es p r i n gc o m p r e s s o r 07757-0010000
V a l v eg u i d er e m o v e r5, . 5 m m 07742-0010100
TROUBTESl|OOIIl{G
E n g i n et o p - e n dp r o b l e m su s u a l l ya f f e c t e n g i n eperformance. These can be diagnosed by a compression test. or by tracing
noiseswith a soundingrod or stethoscope.
RTt|OI,AT
CAMS]|ATT F R O N TC Y L I N D E RH E A DC O V E R
NOTE
The camshaftscan be removed with the
enginein the frame.
R E A RC Y L I N D E RH E A DC O V E R
Removethe seat,frame side coversand fuel tank.
Removethe rearcylinderheadcover.
C A M C H A I NG U I D E
Removethe oil line and cam chain guiderhounting
bolts,and the cam chainguide.
Removethe alternatorcover and rotate the crank-
shaft counterclockwiseuntil the cam chain hasfree
play.
Removethe alternatorcover.
Dateof lssue:October,1983
O H O N D A M O T O RC O . ,L T D . 10-3
IIONTDA
V45 INTER,CEPTOR
C Y L I N D E RH E A D / V A L V E
T 1 . 3M A R K R E A RM A T I N GS U R F A C E
C A M S H A F TH O L D E R S
I N T A K EC A M S H A F T D O W E LP I N S
Remove the camshaft holder dowel pins and the
-
i n t a k e a n d e x h a u s tc a m s h a f t .
D O W E LP I N S E X H A U S TC A M S H A F T
C A M S H A F TH O L D E R
C A M S H A F T / C AH
MO L D E R
INSPECTION
Inspect the camshaft and holder journal surfaces
f o r s c o r i n g s c r a c h e s ,o r e v i d e n c e o f i n s u f f i c i e n t
lubrication.
C A M S H A FR
TU N O U T
C h e c k c a m s h a f tr u n o u t w i t h a d i a l i n d i c a t o r .
S u p p o r t b o t h e n d s o f t h e c a m s h a f tw i t h V - b l o c k s .
U s e 1 1 2 o f t h e t o t a l i n d i c a t o r r e a d i n gt o d e t e r m i n e
r un o u t .
S E R V I C E L I M I T : 0 . 1 0 m m ( 0 . 0 0 4i n )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 10-5
ITONTIDA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
CAM INSPECTION
Usinga micrometer,measure
eachcam lobe.
S E R V I C EL I M I T S :l N , E X : 3 5 . 3m m ( 1 . 3 9i n l
W i p ea n y o i l f r o m t h e j o u r n a l s .
Lay a strip of plastigauge lengthwise on top of each
c a m s h a fj to u r n a l .
PLASTIGAUGE
B
I n s t a l l t h e c a m s h a f th o l d e r s a n d t i g h t e n i n a
ffi
crisscross pattern.
NOTE
Do not rotate the camshaft when using
plastigauge.The camshaftholderbolts in each
corner of the cylinder head are longerthan
the others.
TOROUE:
A: 6mm BOLT: 10-14 N'm
( 1 . 0 - 1 . 4k g - m ,7 - 1 0 f t - l b )
B: 8 mm BOLT: 21-25 N.m
( 2 . 1 - 2 5 k g - m ,1 5 - 1 8 f t - l b l
C : 9 m m B O L T : 38-42 N.m
|.3.8-4.2 ks-m, 27-30 ft-lb)
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
10-6 O H O N D AM O T O RC O . ,L T D .
IIONTXDA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
R e m o v et h e c a m s h a f th o l d e r s a n d m e a s u r et h e
Width of each strip of plastigauge. The widest
thicknessdetermines the oil clearance.
S E R V I C EL I M I T :
CENTER: 0 . 2 0m m ( 0 . 0 0 8i n l
B O T HE N D S : 0 . 1 0m m { 0 . 0 0 4i n )
W h e n t h e s e r v i c el i m i t s a r e e x c e e d e d ,r e p l a c e
the camshaftand recheckthe oil clearance.
R e p l a c et h e c y l i n d e r h e a d a n d c a m s h a f th o l d e r s
i f t h e c l e a r a n cset i l le x c e e dsse r v i c e
limits.
I|TAD
CYLII{DER RE]||OI,AL W A T E RH O S E
NOTE
The front cylinderheadcan be removedwith
the engineinstalled.But to removethe rear
cylinder head,you must removethe engine.
Loosenthe waterhoseclamps.
Removethe waterpipesand hoses.
Removethe waterpipeO-rings.
BASE
C A M C H A I NT E N S I O N E R
R e m o v et h e f r o n t a n d r e a r c a m c h a i n t e ns i o n e r
b a s em o u n t i n gb o l t s .
P u l lt h e c a mc h a i nt e n s i o n ebr a s eu o .
D a t eo f l s s u eJ: a n u a r V1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 1o'-7
ITONTXDA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
T E N S I O N ES
RL I P P E R CL I P PIN
Removethe slipperclip, washerand pin and remove
the tensionerbase.
WASHER BASE
TENSIONER
F l e m o vteh e c y l i n d e rh e a db o l t s
R e m o v et h e c y l i n d e r h e a d su s i n ga s c r e wd r i v e r
at the pry points.
PRY POINT
GASKET
Removethe front and reai cylinder head gaskets
anddowel pins.
D O W E LP I N S
: c t o b e r 1. 9 8 3
D a t eo f l s s u eO
10-a O H O N D A M O T O RC O . .L T D .
II(oNTf,DA
V45 INIERCEPTOR, C Y L I N D E RH E A D / V A L V E
F R O N TC Y L I N D E RC A M R E A RC Y L I N D E RC A M
C H A I N S L I P P E RB A S E C H A I NG U I D E
#
Removethe front cylinder cam chain slipperbase,
and removethe rear cylinder cam chain guide by
ry
removingthe cliP and washer. {b
Removethe front cylinder cam chain guide bolts
a n dg u i d e .
NOTE
Do not drop the clip, washerand bolts into
the crankcase.
F R O N TC Y L I N D E R
C A MC H A I NG U I D E
T E N S I O N EG
RU I D E T E N S I O N ES
RL I P P E R
C A MC H A I NG U I D EA N DC A M
C H A I NT E N S I O N EIR
NSPECTION
Lq
Inspect the cam chain guide and tensioner for
%.*
d a m a g eo r e x c e s s i v w
e ear.
I n s p e c t t h e c a m c h a i n t e n s i o n e rs l i p p e r f o r d a m a g e
or excesslvewear.
Inspect the spring for good tension, replace if
necessary.
4 f
/
I
T E N S I O N ES
RP R I N G
R O C K E RA R M
R O C K E RA R M S H A F TB O L T
l|[ADDISASSEMBLY
CYLINDTR
Removethe rockerarm shaftand rockerarms'
R O C K E RA R M
S H A F TB O L T
HW
SPRING O.RtNG
Dateof lssue:October,1983
O H O N D A M O T O RC O . ,L T D . 10-9
IIONTf,DA
C Y L ! N D E RH E A D / V A L V E V45 INTERCEPTOR
cAuTtol{
To prevent a lossof tension,do not compress
the valve springs more than neceswry to
remove the cotters.
NOTE
partsto ensurecorrect
Mark all disassembled
reassembly.
Removethe valvestemseals.
V A L V E S P RI N G C O M P R E S S O R
07757-0010000
NOTE
Gaskets will come off easier if soaked in
solvent.
CAUTION
Do not damagethe gasket surfaces.
CYLINDER
H E A DI N S P E C T I O N
C h e c k t h e s p a r k p l u g h o l e a n d v a l v ea r e a sf o r
cracks.
C h e c k t h e c y l i n d e r h e a d f o r w a r p a g ew i t h a
s t r a i g het d g ea n d f e e l e rg a u g e .
S E R V I C EL I M I T : 0 . 1 m m ( 0 . 0 0 4i n l
A R MI N S P E C T I O N
ROCKER
l n s p e c t t h e r o c k e r a r m s f o r w e a r o r d a m a g et o
the camshaft contact surface or for a cloggedoil
hole.
M e a s u r et h e l . D . o f e a c h r o c k e r a r m .
S E R V I C E L I M I T : 1 2 . 0 5m m ( 0 . 4 7 4i n l
, , i
R R MS H A F TA N DS P R I N G
R O C K EA
INSPECTION
M e a s u r ee a c h r o c k e r a r m s h a f t O . D .
S E R V I C E L I M I T : 1 1 . 9 3m m ( 0 . 4 7 0i n )
I n s p e c t t h e s h a f t f o r w e a r o r d a m a g ea n d c a l c u l a t e
t h e s h a f tt o r o c k e r a r m c l e a r a n c e .
S E R V I C E L I M I T : 0 . 1 2 m m ( 0 . 0 0 5i n )
V A L V ES P RNI G I N S P E C T I O N
M e a s u r teh e f r e e l e n g t ho f t h e i n n e ra n d o u t e rv a l v e
springs.
S E R V I C EL I M I T :
I N N E R( l N , E X ) : 4 0 . 2 5m m ( 1 . 5 8i n )
O U T E R ( l N , E X ) : 4 2 ' 2 3 m m ( 1 . 6 6i n )
D a t eo f l s s u eO
: ctober.1983
O H O N D AM O T O RC O . ,L T D . 10-11
ITONf,DA
C Y L I N D E RH E A D / V A L V E V45 INTERCEPTOR,
V A L V ES T E M - T O - G U I D E
CLEARANCE
I n s p e c t e a c h v a l v e f o r b e n d i n g , burning, scratches
o r a b n o r m a ls t e m w e a r .
Check valve movement in the g u i d e a n d m e a s u r e
and record each valve stem O.D.
S E R V I C EL I M I T S : l N : 5 . 4 7m m ( 0 . 2 1 5i n l
E X : 5 . 4 5 m m ( 0 . 2 1 4i n )
V A L V EG U I D ER E A M E R
07984-2000000
NOTE
R e a mt h e g u i d e st o r e m o v ea n y c a r b o nb u i l d .
u p b e f o r ec h e c k i n g
clearances.
M e a s u r ea n d r e c o r de a c h v a l v eg u i d e L D . u s i n ga
b a l lg a u g eo r i n s i d em i c r o m e t e r .
S E R V I C EL I M I T : 5 . 5 5m m ( 0 . 2 1 9i n )
NOTE
l f t h e s t e m - t o - g u i dcel e a r a n c e x c e e d st h e
s e r v i c el i m i t s ,d e t e r m i n ei f a n e wg u i d ew o u l d
bring the clearance w i t h i n t o l e r a n c e l.f s o ,
replaceany guidesas necessary and ream to
fit.
l f t h e s t e m - t o - g u i d ec l e a r a n c ee x c e e d st h e s e r v i c e
l i m i t s w i t h n e w g u i d e s ,r e p l a c et h e v a l v e s .
NOTE
Reface the valve seats whenever the valve
g u i d e sa r e r e p l a c e d( p a g e1 0 - 1 3 ) .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 0 .1 2 O H O N D AM O T O RC O . ,L T D .
IIONTf,DA
V45 INTER,CEPTOR, C Y L I N D E RH E A D / V A L V E
V A L V EG U I D ER E M O V E R , 5 .m5 m
I|ALI|E REPLACT]I|ENT
GUIDE 07742-0010100
CAUTION
. Do not use a torch to heat the cylinder;
it may causewarping.
. To avoid burns, wear heavy gloves when
handling the heated cylinder hmd.
S u p p o r tt h e c y l i n d e rh e a d a n d d r i v e o u t t h e o l d
g u i d e sf r o m t h e c o m b u s t i o nc h a m b e rs i d eo f t h e
c v l i n d e rh e a d .
V A L V EG U I D ER E M O V E R , 5 .m
5m
o7742-0010100
D r i v e n e w g u i d e sin from the rocker arm side of
t h e c v l i n d e rh e a d .
NOTE
Cylinder head heat should still be at 100"C
( 2 1 2 - F l f o r i n s t a l l a t i o no f t h e n e w g u i d e s .
"*i
,
V A L V EG U I D ER E A M E R
07984-2000000
Let the cylinder head cool to room temperature
and reamthe new valveguides.
NOTE
. U s e c u t t i n g o i l o n t h e r e a m e rd u r i n gt h i s
operation.
. Rotate the reamer in the samedirection
w h e ni n s e r t i n agn dr e m o v i n g .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . .L T D . 1 0 -1 3
ITONITDA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
II{SPECTION/
SEAT
I|AL'JE
REFACING
C l e a na l l i n t a k ea n d e x h a u s tv a l v e st h o r o u g h l yt o
removecarbondeposits
A p p l y a l i g h t c o a t i n go f v a l v eP r u s s i abnl u et o e a c h
valveface. Lap each valveand seat usinga rubber
h o s eo r o t h e rh a n d - l a p p i nt og o l .
R e m o v et h e v a l v ea n d i n s p e c tt h e f a c e .
CAUTION
The valves cannot be ground. If the valve
face is rough, worn unevenly, or contacts the
seat improperly, the valvemust be replaced.
S E A TW I D T H :
lnsoectthe valveseat. 0 . 9 9 - 1 . 2m
7m
(0.039-0.050 in)
, r h a sl o w s p o t s ,
l f t h e s e a ti s t o o w i d e ,t o o n a r r o w o
the seatmust be ground.
SERVICE LIMIT:
NOTE 1 . 5m m ( 0 . 0 6i n )
operating
Follow the refacermanufacturer's
in s t r u c t i o n s .
28mm
lN: CUTTER 3 0m m
l N .E X : C U T T E R l N : C U T T E R2 9 m m
EX:CUTTER2 5m m E X : C U T T E R2 4 . 5m m
0 . 9 9 - 1 . 2 7m m
O L D S E A TW I D T H ( 0 . 0 3 9 - 0 . 0 5 0i n )
O L D S E A TW I D T H
Dateof lssue:October,1983
10 -14 O H O N D AM O T O RC O . ,L T D .
IIONTfDA
V45 INTER.CEPTOR C Y L I N D E RH E A D / V A L V E
CYLIIIDER
}|EAD
ASSEI||BLY V A L V E S T E MS E A L
NOTE
I n s t a l ln e w v a l v es t e ms e a l sw h e n a s s e m b l i n g .
/ f-r'.
il
VALVE COTTERS
'if-"1
x INE R
I n s t a ltl h e v a l v ec o t t e r s ,
cAuTtot{.
V A L V ES P RN
I GC O M P R E S S O R
07757-0010000
NOTE
S u p p o r t t h e c y l i n d e rh e a d a b o v et h e w o r k
bench surface to prevent possible valve
damage.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . .L T D . 1 0 -1 5
IIONTDA
C Y L I N D E RH E A D / V A L V E
V45 INTERCEPTOR
ROCKER ARM
R O C K E RA R M S H A F TB O L T
Install the O-ring and spring onto the rocker arm
s ha f t .
A p p l y e n g i n eo i l t o t h e r o c k e r a r m s h a f t a n d i n s t a l l
the rockerarm.
I n s t a l la n d t i g h t e n t h e r o c k e r a r m s h a f t b o l t .
TORQUE: 45-50 N.m
\f
(4.5-5.0 ks-m, 33-36 ft-lb)
CYLII{DER
|IEAD
I]{STATLATION
C l e a n t h e c y l i n d e r h e a d s u r f a c eo f a n y g a s k e t
material.
R E A RC Y L I N D E R F R O N TC Y L I N D E RC A M
BASE
C H A I NS L I P P E R
I n s t a l lt h e r e a rc y l i n d e rc a m c h a i n g u i d ew i t h t h e
w a s h ear n dc l i p .
I n s t a ltl h e f r o n t c y l i n d e rc a mc h a i ng u i d e .
I n s t a l lt h e f r o n t c y l i n d e rc a m c h a i n s l i p p e rb a s e .
NOTE
Be careful not to drop the washer, clip or
bolts into the crankcase.
F R O N TC Y L I N D E R
C A MC H A I NG U I D E
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 0 -1 6 O H O N D AM O T O RC O . ,L T D .
IIONTXDA
vrs rnrEnGpron C Y L I N D E RH E A D / V A L V E
GASKET
I n s t a ltl h e d o w e lp i n sa n d n e w h e a dg a s k e t s .
D O W E LP I N S
BASE
TENSIONER
W i t h t h e c a m c h a i n t e n s i o n e rr a i s e di n t h e d i r e c t i o n
M
of the arrow, inserta pin or pieceof wire through
t h e h o l e i n t h e t e n s i o n e rb a s ea n d t e n s i o n e r .
"",.F%
TENSIONER
T E N S 1 O N ESRL I P P E R C L I P PIN
P l a c et h e c V l i n d e rh e a do n t h e c y l i n d e r .
P a s st h e c a m c h a i n t h r o u g h t h e c a m c h a i n t e n s i o n e r
a n d i n s t a l lt h e t e n s i o n e rs l i p p e ra s s h o w n .
NOTE
Check that the lower end o{
i n t h e s l i p p e rb a s ec o r r e c t l Y .
BASE
TENSIONER
D a t eo f l s s u eO
: c t o b e r1
. 983
O H O N D AM O T O RC O . ,L T D . 1 0 '1 7
IIONIDA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
C Y L I N D E RH E A D B O L T S
Looselytightenthe cylinderheadbolts.
NOTE
Tighten the cylinder head bolts to the speci-
fied torque after all cylinder head bolts are
i n s t alle d .
il1
I n s t a l lt h e e x t e r i o r o i l p i p e w i t h w a s h e r so n t o t h e
c y l i n d e ra n d c y l i n d e rh e a d .
O I LP I P E
W A T E RH O S E S
I n s t a l lt h e w a t e r p i p e s a n d h o s e sa n d tighten the
h o s ec l a m p ss e c u r e l y .
W A T E RP I
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 0 -1 8 @ H O N D AM O T O RC O . .L T D .
IiIONIf,DA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
I1{STALLATION
CAMSHATT
CAUTION
I N D E XM A R K
. Follow this procedure from beginning to
end, even if you are only servicing one
cylinder head.
' Check the camshaft marks so that you
install eachcamshaft in its conect location.
' The marks on the camshaftmean:
EX RR, ER: Rear cylinder exhaust
IN RR, IR: Rear cylinder intake
EX FR, EF: Front cylinder exhaust
IN FR, IF: Front cylinder intake
. The camshaftsprocketsare interchangeable,
M A T I N GS U R F A C E
R E A RC R A N K C A S E
. Rear Cylinder Camshafts
until the T1-3
Turn the crankshaftcouterclockwise
mark on the flywheel rotor alignswith the rear
crankcasematingsurfaces.
CAUTION
When tuming the crankshaft, make sure
the cam chains don't jam at the cam chain
tensionersor at the crankshaft.
D a t eo f l s s u eO
: ctober,1983
O H O N D AM O T O RC O . ,L T D . 10-19
EIOIUTDA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
C A M S H A F TM A R K S
Install the intake and exhaust camshaftsand
sprocketsthrough the rear cylinder cam chain as
shown.
Turn the camshaftsso the camshaftmarksface up.
NOTE
lf the front cylinder camshaftswere not
removed,checkthat the front camshaftmarks
face up. lf not, turn the crankshaftcounter-
clockwise360 degrees(oneturn). 2 '\
lf a valve clearanceadjusterkeepsthe camshaft
from seatingfully in the cylinder head, back the
adjusterout all the way.
CAUTION
NOTE
The camshaftholder bolts in each cornerof
the cylinder head are longerthan the others.
Dateof lssue:October,
1983
10-20 @ HONDAMOTORCO.,LTD.
ii..1::,;;,
rilt{du,, , ,'rit::l;,'llt:'
I,IOI|TXDA
V45 INTERCEPTOR C Y L I N D E RH E A D / V A L V E
BOLTS
SPROCKET
Slide the sprocketsonto the camshaftflanges,and
install the sprocket bolts in the exposed holes.
Check that tfre sprocketindex lines align at T1-3.
Unlockthe cam chaintensioner.
I N D E XL I
Dateof lssue:October,1983
O H O N D A M O T O RC O . ,L T D . 1o.21
TIONTIDA
V45 INTER,CEPTOR
C Y L I N D E RH E A D / V A L V E
o Front CylinderCamshafts
zt7-"t/t 0t"",4,- offK'{;l ^
NOTE
Install the rear cVlinder head camshafts
before you install the front camshafts.
CAUTION
lilhen turning the uankshaft, makesure the
cam chain doesn't jam at the cam chain
tensioneror at the crankshaft.
T2.4MARK
Dateof lssue:October,1983
1o,-22 iri
O H O N D AM O T O RC O . .L T D .
IIONTDA
V45 INTER.CEPTOR C Y L I N D E RH E A D / V A L V E
A l i g n t h e p e r m a n e n ti n d e x d o t s o r n e w i n d e x m d r k
on the front cylinder cam sprockets with the top of
t h e c y l i n d e r h e a d ( v i e w e df r o m t h e l e f t s i d e o f t h e 46 PINS
e n g in e ) .
NOTE
There should be a total of 46 pins between
t h e i n d e x m a r k s o n t h e i n t a k ea n d e x h a u s t
cam sorocketsasshown.
o ValveTimingInspection
Checkthe front-to-rearcylindercamshafttiming as
follows.
o W h e nt h e T 1 - 3 m a r k a l i g n sw i t h t h e r e a rc r a n k -
c a s em a t i n gs u r f a c et,h e i n d e x l i n e so n a l l c a m
sprockets should align with the top of the
c y l i n d e rh e a d s .
o A l l c a m s h a fm t a r k sw i l l e i t h e rf a c eu p o r d o w n .
TENSIONER
B A S EB O L T S
Tightenthe tensionerbaseboltssecurely.
D a t eo f l s s u eO
: ctober,1983 I
O H O N D AM O T O RC O . ,L T D . 1o.23 "l
1
;:., J
IIOTVXDA
V45 INTERCEPTOR
C Y L I N D E RH E A D / V A L V E
NOTE
Cleanthe gasketbeforeapplyingsealant.
Tightenthe cylinderheadcoverbolts.
TOROUE:8-12 N.m (0.S-1.2 kg-m,6-9 ft-lbl
8mm
21-25 N' m
( 2 . 1 - 2 . 5kg-m,1 5 -118 f t - t b )
qq
I t
\
B\
o> @
,J
@b
6mm
10-14N'm
( 1 . 0 - 1 . 4k s - m ,7 - 1 0 f t - l b )
bt -\g qb
6mm
h\ b bb
7 bbb
10-14N.m
\b
(1.0-1.4 ks-m,7-10 ft-tb)
9mm
30-34 N. m
(3.0-3.4ks-m,22-25 ft
\h
Dateof lssue:January,1983
11-O O H O N D AM O T O RC O . ,L T D .
IIONTTDA
V45 INTER,CEPTOR 11. CRANI(CAS
S E R V I C EI N F O R M A T I O N 11 - 1
CRANKCASEDISASSEMBLY 11-2
CRANKCASEASSEMBLY 11-3
INFI|RMATItlN
SERVICE
RAL
GENE
o To servicethe pistons,crankshaft,connectingrodsand transmission, halvesmust be separated.
the crankcase
r The followingpartsmust be removedbeforedisassembling the crankcase.
' Oilpan R e f e rt o s e c t i o n2
. O i lp u m p Referto section2
. w a t e rp u m p Referto section6
. Clutch/starterclutch Referto section7
' G e a r s h i flti n k a g e R e f e rt o s e c t i o n8
' Alternator Referto section9
. C y l i n d e rh e a d s R e f e rt o s e c t i o n1 0
. Startermotor Referto section19
T O R O U EV A L U E S
TOOLS
Special
Driver 07949-3710000
Common
A t t a c h m e n t , 5 2x 5 5 m m 07746-001
0400
Dateof lssue:October,1983
@ H O N D AM O T O RC O . ,L T D . 11-1
IilONTXDA
CRANKCASE V45 INTERCEPTOR
CRAIII(CAST
OISASSEil|BLY N E U T R A LS W I T C HC O V E R
R e f e r t o S e r v i c eI n f o r m a t i o n( p a g e1 1 - 1 ) f o r r e -
moval of necessaryparts before disassembling
crankcase.
Removethe countershaftbearingcover.
Removethe neutral switch cover and the switch
(pase20-3).
nl@miii i j ! i ! ii i i i ; . : i , f : r i i i
C O U N T E R S H A FBTE A R I N GC O V E R
M A I N S H A F IB E A RI N G H O L D ER
Removethe mainshaftbearingholder by removing
the screwand bolts.
Removethe uppercrankcase
bolts.
Dateof lssue:October,1983
1 1-2 @ H O N D AM O T O RC O . ,L T D .
IIONTTDA
V45 INTER,CEPTOR CRANKCASE
T u r n t h e e n g i n e o v e r a n d r e m o v et h e l o w e r c r a n k
casebolts.
NOTE:
Removethe bolts in two or more stepsand
in a crisscrosspattern to preventdistorting
the crankcase.
D r i v e t h e c o u n t e r s h a f tb e a r i n go u t o f t h e c a s e .
C O U N T E R S H A FBTE A RI N G
ASSEMBTY
CRANKCASE A T T A C H M E N T5, 2 x 5 5 m m
07746-0010400
Drive the countershaftbearinginto the crankcase.
DRIVER
07949-37 10000
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
O H O N D AM O T O RC O . .L T D . 11-3
ITONTf,DA
CRANKCASE
V45 INTERCEPTOR
I n s t a ltl h e f o l l o w i n gp a r t s :
. S h i f t f o r k a n ds h i f td r u m ( S e c t i o n1 3 ) .
. T r a n s m i s s i o( nS e c t i o n1 3 ) .
o C r a n k s h a f(tS e c t i o n1 2 ) .
o P i s t o na n dc o n n e c t i nrgo d s( S e c t i o n1 2 )
M 2 l 3G E A R
A p p l y m o l y b d e n u md i s u l f i d eg r e a s et o t h e s h i f t
fork groovesof the M213,C4 and Cb gears.
C 5G E A R C4GEAR
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
11-4 O H O N D AM O T O RC O . .L T D .
IIONTf,DA
V45 INTERCEPTOR,
CRANKCASE
CAUTION
Do not apply sealant to the area near the
main bearings.
DO NOT COATTHIS
AREA.
I n s t a ltlh e d o w e lp i n i n t o t h e l o w e rc r a n k c a s e .
A s s e m b l et h e c r a n k c a s h
ea l v e sa
, l i g n i n gt h e s h i f t
forks with the gears.
Tighten the bolts to the specifiedtorque valuesin
the sequence shown.
T O R O U EV A L U E S :
9 mm bolt: 30-34 N.m mm BOLT
(3.0-3.4 kg-m, 22-25 ft-lbl
8 mm bolt:21-25 N.m
12.1-2.5ks-m,14*18 ft-lbl
6 mm bolt: 10-14 N.m
( 1 . 0 - 1 . 4k s - m ,7 - 1 0 f t - l b )
patternand in 2-3
Tightenthe bolts in a crisscross
steps.
D a t eo f l s s u eO
: ctober.1983
@ H O N D AM O T O RC O . ,L T D . 11-5
IIONTTDA
V45 INTERCEPTOR
CRANKCASE
6 mm BOLT
Tighten the upper crankcasebolts to the specified
patternand in 2-3 steps.
torquein a crisscross
T O R O U E :I m m : 2 1 - 2 5 N . m
( 2 . 1 - 2 . 5 k s - m ,1 5 - 1 8 f t - l b )
6 mm: 10-14 N.m
( 1 . 0 - 1 . 4k g - m ,7 - 1 0 f t - l b )
NOTE
Make sure that the plain washersare under
the 8 mm bolt headsand the battery ground
cable is under the 6 mm bolt headas shown.
M A IN S H A F TB E A RI N G H O L D E R
I n s t a l lt h e m a i n s h a fbt e a r i n gh o l d e ra n d t i g h t e nt h e
screwand bolts.
N E U T R A LS W I T C HC O V E R
Install the neutral switch and cover (page20-3).
D O W E LP I N S
Dateof lssue:October,1983
11-6 O H O N D AM O T O RC O . ,L T D .
IIONTDA
V45 INTER,CEPTOR
CRANKCASE
C O U N T E R S H A FBTE A R I N GC O V E R
Apply greaseto the countershaftoil seallip in the
countershaft bearingcover, then install it being
carefulnot to damagethe oil seallip.
OILSEAL
Dateof lssue:October,1983
O H O N D AM O T O RC O . ,L T D . 1 1-7
IIOilTEDA
s
V45 INTER,CEPTOR.
CRANKSHAFT/PISTON
ffi\ @
@^\@
@b
4ffi')[-'22-2sr"b,
%@b
(r FRoNr
=
.@D ffiPr
\u
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
12-O O H O N D AM O T O RC O . .L T D .
rtolvxtA
V45 INTERCEPTOR. 12.CRA N
PISTO
Nl(S1|ATT
S E R V I C EI N F O R M A T I O N 12-1 B E A R I N GI N S P E C T I O N 12_8
TROUBLESHOOTING 12- 2 B E A R I N GS E L E C T I O N 12_10
CONNECTING ROD REMOVAL 12-3 CRANKSHAFTINSTALLATION 12_12
PISTONREMOVAL 124 PISTONAND ROD INSTALLATION 12_12
C R A N K S H A F TR E M O V A L 12- 7
SERI|ICE
I1{FOR]||ATIOl{
GENERAL
o All bearinginsertsare selectfit and are identifiedby color code.Selectreplacement bearings from the codetables.After
installingnew bearings. recheckthem with plastigauge to verify clearance.
o Applymolybdenum d i s u l f i d eg r e a steo t h e m a i nj o u r n a l sa n dc r a n k p i nds u r i n ga s s e m b l y .
o Beforeremovingthe pistonand connectingrod assemblies, cleanthe top of the cylinderof any carbondeposits.
o Forservicingthepiston,connectingrodandcrankshaft,thecrankcaseassemblymustbeseparated(Sectionll).
SPECIFICATIONS
TOROUE:
30-34N.m(3.0-3.4ks-m,22-25
Crankpin: tt-lbl
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 12- 1
CRANKSHAFT/PISTON
TROUBTES}|OOIIIIO
Excessive
noise
1. Crankshaft
o Worn main bearing
a
a Worn rod bearing
2. Pistonand ConnectingRod
o W o r np i s t o no r c y l i n d e r
o W o r np i s t o np i n o r p i n h o l e
. Worn rod smallend
Excessivg smoke
1 . W o r nc y l i n d e rp, i s t o no r p i s t o nr i n g s
2 . l m p r o p e r l yi n s t a l l e p
d i s t o nr i n g s
3 , D a m a g e pd i s t o no r c y l i n d e r
Overheating
1. Excessivecarbonbuild-upon pistonhead
2. Blockedor restrictedflow of coolant
3. Stickingthermostat
Knockingor abnormalnoise
1 . W o r np i s t o n sa n dc y l i n d e r s
2. Excessive carbonbuild-upon pistonhead.
Dateof lssue:January,1983
12-2 @ H O N D AM O T O RC O . .L T D .
IIONIf,DA
V45 INTERGEPTOR,
CRANKSHAFT/PISTON
c0r{ilEcTr]{0
RoDRE|||0I,AL
S e p a r a t e t h e c r a n k c a s e a s s e m b l y ( S e c t i o n 1 1) .
C h e c k t h e c o n n e c t i n gr o d s i d ec l e a r a n c e .
S E R V I C E L I M I T : 0 . 4 0 m m ( 0 . 0 1 6i n l
BEARI
Removethe connectingrod bearingcapsand note
t h e i rl o c a t i o n s .
CAUTION
D a t eo f l s s u eO
: c t o b e r1
, 983
O H O N D AM O T O RC O . .L T D . 12-3
ITONTXDA
V45 INTER,CEPTOR,
CRANKSHAFT/PISTON
M a r k t h e r o d s , p i s t o n s ,b e a r i n g sa n d c a p sa s y o u
r e m o v et h e m t o i n d i c a t et h e c o r r e c tc y l i n d e ra n d
p o s i t i o no n t h e c r a n k p i n s .
PISTOl{
REMOI/AL PISTON
P I NC L I P
R e m o v et h e p i s t o n p i n c l i p s .P u s ht h e p i s t o n p i n
out and removethe piston.
M a r k t h e p i s t o n p i n s t o i n d i c a t et h e i r c o r r e c t
p i s t o np o s i t i o n .
*%i
P I S T O N / P I S T O NR I N G I N S P E C T I O N
M e a s u rteh e p i s t o nr i n g - t o - g r o o cv lee a r a n c e .
S E R V I C EL I M I T :0 , 1 0m m ( 0 . 0 0 4i n )
(TOP/SECOND)
R e m o v et h e p i s t o nr i n g sa n d m a r kt h e mt o i n d i c a t e
t h e c o r r e c ct y l i n d e ra n d p i s t o np o s i t i o n
D a t eo f l s s u eJ: a n u a r v1, 9 8 3
12-4 O H O N D AM O T O RC O . ,L T D .
IIONTf,DA
V45 INTERCEPTOR CRANKSHAFT/PISTON
M e a s u rteh e p i s t o nO . D .
NOTE:
T a k e m e a s u r e m e n1t s0 m m ( 0 . 4 i n ) f r o m t h e
b o t t o m ,a n d9 0 " t o t h e p i s t o np i n h o l e .
S E R V I C EL I M I T :6 9 . 8 5m m ( 2 . 7 5 0i n )
I n s p e c tt h e c y l i n d e r b o r e s f o r w e a r o r d a m a g e .
M e a s u r teh e c y l i n d e rl . D . a t t h r e el e v e l si n X a n dY
a xt s ,
: - f'
f E L I M I T :7 0 . 1 0m m 1 2 . 7 6 i n l
S E R VC
O v e r s i zpei s t o n sa r e a v a i l a b l ien t h e f o l l o w i n gs i z e s :
0 . 2 5 ,0 . 5 0 ,0 . 7 5a n d 1 . 0 0m m
$+:
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 12-5
IIOIVTDA
V45 INTER,CEPTOR,
CRANKSHAFT/PISTON
M e a s u reea c hp i s t o np i n h o l eL D .
S E R V I C EL I M I T : 1 8 . 0 6m m ( 0 . 7 1i n )
M e a s u reea c hp i s t o np i n O . D .
S E R V I C EL I M I T : 1 7 . 9 8m m ( 0 . 7 0i n )
M e a s u r et h e c o n n e c t i n g r o d s m a l l e n d l . D . l f t h e
r e a d i n ge x c e e d st h e s e r v i c el i m i t , r e p l a c et h e r o d .
S E R V I C E L I M I T : 1 8 . 0 8 m m ( 0 . 7 1 2i n )
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
12-6 O H O N D AM O T O RC O . ,L T D .
IIONTf,DA
V45 INTER.CEPTOR, CRANKSHAFT/PISTON
C A MC H A I N
REMOI|AL
CRAN1(S]|AFT ( R E A RC Y L I N D E R ) CRANKSHAFT
@-l
C A MC H A I N
{ F R O N TC Y L I N D E R )
C R A N K S H A FI T
NSPECTION
A c t u a l r u n o u t i s 1 1 2o f t h e t o t a l i n d i c a t o r e a d i n g .
S E R V I C EL I M I T : 0 . 0 3m m ( 0 . 0 0 1i n )
NOTE
The liidex lines should be parallelto each
other.
I N D E XL I N E S
Replacethe cam chainif it is longerthan the service
limit.
Dateof lssue:October,1983
O H O N D A M O T O RC O . ,L T D . 12-7
ITONITDA
CRANKSHAFT/PISTON V45 INTERCEPTOR
BEARTl{G
tl{SPtCTt0l{
MAIN BEARING
NOTE
Do not put the plastigauge over the oil hole
in the main bearingjournal of the crankshaft.
PLASTIGAUGE
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
12-8 O H O N D AM O T O RC O . ,L T D .
IIONTXDA
V45 INTER,CEPTOR CRANKSHAFT/PISTON
CRANKSHAFT/PISTON
Inspect the bearing inserts for unusual wear or
damage.
Wipe all oil from the bearinginsertsand crankpins.
Put a pieceof plastigaugeon eachcrankpin.
NOTE
' Do not put the plastigauge overthe oil hole
i n t h ec r a n k p i n .
' The bearingtabs should face toward the
exhaust ports. Rememberthe front and
rear cylinder exhaustports face opposite
directions.
I n s t a l l t h e b e a r i n gc a p s a n d r o d s o n t h e c o r r e c t
c r a n k p i n sa,n dt i g h t e nt h e me v e n l y .
TOROUE: 30-34 N.m (3.0-3.4 kg'm, 22'25 +llbl
NOTE
Do not rotate the cranksha{tduring inspec-
tion.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
@ H O N D AM O T O RC O . .L T D . 12-9
IIOTVXDA
CRANKSHAFT/PISTON
BEARIl{G
STLECTIOl{
CONNECTING
R O DB E A R I N G
lf rod bearingclearanceis beyondtolerance,setect
replacementbearingsasfollows:
T h e c o d en u m b e r s( 1, 2 , o r 3 ) s t a m p e d
o n e a c hc o n -
necting rod identifies its inside diameter fl.D.).
1\
\
t . D .c o D EN U M B E R
O . D .C O D EL E T T E R S
B E A R I N GI N S E R TT H I C K N E S S :
A ( B l u e ) : 1 . 5 0 2 - 1 . 5 0 6m m ( 0 . 0 5 9 1 - 0 . 0 5 9 3 in)
B (Bfack): 1.498-1.5O2mm (0.0590-0.0b91in)
C (Brown): 1.494-1.498mm (0.0588-0.0590in)
D ( G r e e n ) : 1 . 4 9 0 - 1 . 4 9 4m m ( 0 . 0 5 8 7 - 0 . 0 5 8 i8n )
E ( Y e l l o w ) : 1 . 4 8 6 - 1 . 4 9 0m m ( 0 . 0 5 8 5 - 0 . 0 5 8 i7n )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 2 -1 0 O H O N D AM O T O RC O . .L T D .
II(oNTTDA
CRANKSHAFT/PISTON
M A I NB E A R I N G
The code letters(A, B, or C) stampedon the rear
portion of the upper crankcase identifiesthe inside
d i a m e t e r( 1 . D . )o f e a c hm a i n b e a r i n gj o u r n a l ,f r o m
left-to-right.In this example,the l.D. code for the
r i g h tm a i nj o u r n a li s " A " .
I . D .C O D EL E T T E R S
NA B L E ( E N G I N EN o .- R C l 5 E2 0 0 1 5 8 6 )
S E L E C T I OT
Unit : mm {in}
\ M A I NJ o U R N A L 1 2 3
\ o.D. coDE
\ N U M B E R 35.992-36.000 35.984-35.992 35.976-35.984
cnse t5---\ \ 1. 4 1 7 0 - \1.4167" 1 1. 4 1 6 4 -
C O D EL E T T E R S \ 1 .41731 1 .4170) 1.41671
39.000-39.O08
( 1.s354-1.53571 D (Green) c ( Brown) B (Black)
39.008-39.016
C (Brown) B (Black) A (Bluel
( 1.5357-1.5361)
O . D .C O D EN U M B E R S
39.016-39.024
c B (Black) A (Blu€) A {Blue)
( 1. 5 3 6 1 . .15 3 6 4 )
- )
NA B L E ( E N G I N EN O . R C l 5 E2 0 0 1 5 8 7
S E L E C T I OT
Unit: mm (inl
IiIAIN JOURNA 1 2 3
39.000-39.008
( 1.5354-1.5357) E {Y€llow) D {Green) C { Brown)
39.008-39.016
D {Green) C { Brown) B ( Black)
{ 1.5357-l.5361)
39.016-39.024
c ( 1.s361-1.s364)
C (Brownl B ( Black) A {Blue)
M A I N B E A R I N GI N S E R TT H I C K N E S S :
A ( B l u e ) : 1 . 5 0 6 - 1 . 5 1 0m m ( 0 . 0 5 9 3 - 0 . 0 5 9 4 in)
B ( B l a c k ) : 1 . 5 0 2 - 1 . 5 0 6m m ( 0 . 0 5 9 1 - 0 . 0 5 9 3
in)
C ( B r o w n l : 1 . 4 9 8 - 1 . 5 0 2m m ( 0 . 0 5 9 0 - 0 . 0 5 9 1
in)
D ( G r e e n ) : 1 . 4 9 4 - 1 . 4 9 8m m ( 0 . 0 5 8 8 - 0 . 0 5 9 0
in) C O L O RC O D E
E (Yeffow): 1.490-1.494mm (0.0587-0.0588in)
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . .L T D . 12-11
IIONTDA
V45 INTER,CEPTOR,
CRANKSHAFT/PISTON
CRAl{l(S|{AFT
I1{STALLATION
I n s t a l l t h e m a i n b e a r i n g si n t o t h e u p p e r c r a n k c a s e .
A p p l y m o l y b d e n u m d i s u l f i d e g r e a s et o t h e u p p e r
and lower main bearings.
Install the crankshaft with the cam chains.
NOTE:
' lt is not necessary to perform the weight
selectionbetweenthe No. 1 and 3, or No.
2 and4 connectingrods.
' The "o" mark in the table indicatesthat
the matching is possiblein the crossed
codes.
' The cylindersare arrangedin the order of
N o . 1 , 2 , 3 , 4 f r o m t h e a l t e r n a t osr i d e . \
WEIGHC T ODE
( A L P H A B E T I CC
AOL DE)
SELECTION
TABLE
B o B o o
c o o c ^
D o D o o
E E
Dateof lssue:October,1983
1 2 -1 2 O H O N D AM O T O RC O . .L T D .
IIONTEDA
V}7OOI750INTERCEPTOR CRANKSHAFT/PISTON
A}rD
PrsT0r{ RoD
tltsTAt
tATt0il
C l e a nt h e p i s t o nd o m e s r, i n gl a n d sa, n d s k i r t s .
C a r e f u l l yi n s t a l tl h e p i s t o nr i n g so n t o t h e p i s t o n .
Staggerthe ring end gapsasshown.
NOTE:
' Be careful not to damagethe piston and
pistonringsduringassembly. TOP
'All r i n g s s h o u l d b e i n s t a l l e dw i t h t h e
SECOND
m a r k i n g fsa c i n gu p .
. A f t e r i n s t a l l i ntgh e r i n g st h e y s h o u l dr o t a t e
S I D ER A I L
f r e e l y ,w i t h o u t s t i c k i n g .
SPACER
S I D ER A I L
GAP
"IN" MARK
R E A RC Y L I N D E R I D E N T I F I C A T I OM
NARK
Dateof lssue:June,1984
@American Honda Motor Co., Inc. 1984 - All Rights Reserved 12- 13
IilONTXDA
VT7OOI750INTERCEPIOR
CRANKSHAFT/PISTON
F r o n tc y l i n d e r s : F R O N TCYLI ND ER IDENTIFICATIO
MNARK
Note that the front cylinder connectingrods are
marked "MBO-R" or "MB2-F" for the VF750F. VF75OF
a n d" M 8 1 - R " f o r t h e V F 7 0 0 . shown.
Install the pistons on the front rods so that the VFTOOF:
i n t a k e" l N " m a r k i s f a c i n gt h e s a m ed i r e c t i o na st h e MB1.R
o i l h o l ei n t h e r o d .
NOTE:
' Do not interchangethe pistons, piston
p i n s o r c o n n e c t i n gr o d s .
' Make sure that the piston pin clips are
properlyseated.
A l i g n t h e h o l e i n t h e c o n n e c t i n gr o d b e a r i n g i n s e r t
w i t h t h e h o l e i n t h e c o n n e c t i n gr o d a n d i n s t a l l t h e
in s e r t .
OILHOLE
I n s t a l tl h e c o n n e c t i n rgo d c a pb e a r i n gi n s e r t .
Apply molybdenumdisulfidegreaseto the connect-
ing rod bearings.
CONNECTING
R O DB E A R I N G
,,IN"MARKS
Coat the cylinders,piston rings/groovesand piston
with oil. To preventdamagingthe crankshaft,slip
short sectionsof rubber hose over the rod bolts
beforeinstallation.
Install the rod and piston assembliesinto the
cylindersfrom the top of the crankcase.Be sure
eachassemblyis returnedto its originalpositionas
n o t e dd u r i n g . r e m o v a l .
NOTE
"lN"
The piston intake marks should be
f a c i n ge a c h o t h e r a s s h o w n .
P I S T O NR I N GC O M P R E S S O R
( C o m m e r c i a l l ya v a i l a b l e )
C o m p r e s st h e p i s t o n r i n g sw i t h a r i n g c o m p r e s s o r
a n d i n s e r t h e p i s t o na n d r o d i n t o t h e c y l i n d e ru n t i l
the rod seatson the crankpin.
NOTE
Be carefulnot to damagethe pistonsor rings
d u r i n ga s s e m b l y .
NOTE
. B e s u r e t h e b e a r i n gc a p sa r e i n s t a l l e di n
t h e i r c o r r e c t l o c a t i o na s m a r k e d d u r i n g
removal.
' T i g h t e nt h e n u t s i n t w o o r m o r es t e p s .
. A f t e r t i g h t e n i n gt h e b o l t s ,c h e c kt h a t t h e
rodsmovefreelywithout binding.
A s s e m b l et h e c r a n k c a s e( S e ep a g e 1 1 - 3 ) .
Dateof lssue:October,1983
O H O N D A M O T O RC O . ,L T D . 1 2 -1 5
EIOIVDA
TRANSMISSION V45 INTER,CEPTOR
21-25 N.m
( 2 . 1 - 2 . 5 k s - m ,1 5 - 1 8 f t . t b )
16-20N.m
(1.6-2.0ks-m,12-14ft-lb)
Y@
rr,$t
\/,q
IF
b
g
lh&m
d/
a
)A
D a t eo f l s s u eJ: a n u a r v1, 9 8 3
13-O O H O N D AM O T O RC O . ,L T D .
13.TRAiltSil|tSSt0
S E R V I C EI N F O R M A T I O N 13-1
TROUBLESHOOTING 13-2
DISASSEMBLY
TRANSMISSION 13-3
S H I F T F O R KA N D S H I F TD R U M 13-6
TRANSMISSION
ASSEMBLY 13-9
lllt0Ril|AT|0l{
stRt|lcE
GENERAL
o The gearshiftlinkagecan be servicedwith the enginein the frame (Section8).
o For internaltransmission
repairs.the crankcase must be separated (Section11).
SPECIFICATIONS
STANDARD S E R V I C EL I M I T
Transmission Backlash 1st 0.047-0.142mm (0.0019-0.0056 in) 0.20mm (0.008in)
2nd 0.064-0.128mm (0.0025-0.0050 in) 0 . 1 7m m ( 0 . 0 0 7i n )
3rd,4th, sth 0.068-0.136mm (0.0027-0.0054 in) 0 . 1 8 m m ( 0 . 0 0 7i n )
G e a rl . D . M4, M5 gear 2 1m ( 1 . 1 0 2 4 - 10. 3
2 8 , 0 0 0 - 2 8 . 0m 1 2i n ) 2 8 . 0 4m m { 1 . 1 0 4
in)
C1gear mm ( 1.0236-1.0244inl
26.000-26.021 26.04mm {1.025in}
C2, C3 gear mm (1.2205-1.2215
31.000-31.025 inl inl
31.04mm 11.222
Gearbushing M4, M5 gear 2 7. 9 5 9 - 2 7 . 9 8 0m m ( 1 . 1 0 0 7 - 1. 1 0 1 6i n ) 2 7 . 9 4 m m( 1 . 1 0 0i n )
o.D. Cl gear mm 113220-1.O228inl
25.959-25.980 2 5 . 9 4m m ( 1 . 0 2 1i n )
C2, C3 gear 3 0 . 9 5 0 - 3 0 . 9 7 5m m ( 1 . 2 1 8 5 - 1 . 2 91 5 i n ) 3 0 . 9 3m m ( 1 . 2 1 8
in)
G e a rb u s h i n g M4 6 mm (0.9840-0.9849
24.995-25.01 in) 25.04mm (0.986 in)
t.D. (0.8669-0.8678
in) 22.06mm (0.869 in)
c1 22.020-22041mm
MainshaftO.D at M4) 24.977 -24.990 mm (0.9833-0,9839in) 24.92mm(0.981in)
f t. D .( a t C 1 )
C o u n t e r s h aO 21.979-22.000 mm {0.8653-0.8661in) 21.96mm (0.865in)
Gear-to- M4,M5 0.020-0.062mm (0.0008-0.0024
in) 0.10mm (0.004in)
bushing (0.0008-0.0024
in) 0.10mm (0.004n )
c1 0.020-0.062mm
clearance
c2 ,c3 0.025-0.075mm (0.0010-0.0030
in) 0 . 1 1m m ( 0 . 0 0 4n )
Bushing-to- M4 0.005-0.047mm (0.0002-0.0019
in) 0.06mm (0.002n )
shaftclearance c 1 0.020-0.062mm (0.0008-0.0024
in) 0.10mm (0.004n l
Shift fork Clawthickness 6.43-6.50 mm (0.253-0.256in) 6 . 1 m m ( 0 . 2 4i n )
t.D. Left and right mm (0.551
14.000-14.021 2-0.5520in) 1 4 . 0 4m m ( 0 . 5 5 3i n )
Fork shaft o.D. mm (0.5498-0.5505
13.966-13.984 in) 13.90mm (0.547in)
Dateof lssue:January.1983
@ H O N D AM O T O RC O . ,L T D . 1 3 -1
ITONTI)A
TRANSMISSION V45 INTERGEPTOR
T O R O U EV A L UE S
Countershaft bearingholder 2 1 - 2 5 N ' m ( 2 . 1 - 2 . 5k g - m ,1 5 - 1 8 f t - l b )
Shift fork center 16-20 N.m ( 1.6-2.0 kg-m, 12-14 ft-lbl
TOOLS
Common
\''
Driver 07746-0030100---
oriver 07945-371o2o0
Attachment, 25 mm 07746-00,0200--For
TROUBTES1|OOIIl{G
Hard to shift
1. Clutchslavecylindersticking
2. Shift fork bent
3. Shift shaftbent
4. Shift claw bent
5. Shift drum cam groovesdamaged
Dateof lssue:January,1983
13-2 O HONDA MOTORCO., LTD.
E|IONTf,DA
TRANSMISSION
TRAl{S1||ISS
IO1{DISASSE]I|BLY
Separatethe crankcase (Section11).
Removethe dowel pinsfrom the crankcase.
Inspectthe backlashof eachgear.
S E R V I C EL I M I T :
lst: 0.20 mm {0.008inl
2nd: 0.17 mm (0.007in)
3 r d , 4 t h , S t h : 0 . 1 8 m m ( 0 . 0 0 7i n )
MAINSHAFT
Removethe mainshaft.
C O U N T E R S H A FBTE A R I N GH O L D E R
Removethe countershaftbearingholderbolts.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 13-3
IIOTVf,DA
V45 INTERCEPTOR
TRANSMISSION
C3GEAR C4GEAR
Pull the countershaftout of the crankcasewhile
removingCl , C4, C2, C3, and the splinewashers
and bushings.
C2 GEAR
I S S I O NI N S P E C T I O N
TRANSM
Check gear dogs, dog holes and gear teeth for ex-
cessiveor abnormalwear,or evidenceof insufficient
lubrication.
Dateof lssue:January,1983
13-4 O H O N D AM O T O RC O . ,L T D .
IIONIfDA
V45 INTERCEPTOR,
TRANSMISSION
the clearance
Calculate betweenthe bushingand
shaft.
SERVICE LIMIT:
0.06mm (0.002in)
M4 bushing-to*haft:
0.10mm (0.004in)
C1bushing-toshaft:
Dateof lssue:January,1983
O H O N D AM O T O RC O . ,L T D . 13-5
IIONTf,DA
TRANSMISSION
V45 INTERCEPTOR
FORI(
S1|ITT A1{D DRU],|
S]|ITT R I G H TF O R K C E N T E RF O R K LEFTFORK
REMOVAL
F O R KS H A F T L O C KW A S H E R
S H I F TD R U M
Removethe bearingstopperplates.
ffi
BEARING PLATES
STOPPER
G E A RS H I F TD R U MA N DS H I F T
F O R KI N S P E C T I O N
Dateof lssue:January,1983
13-6 O H O N D AM O T O RC O . .L T D .
IIONTID.A.
V45 INIER,CEPTOR. TRANSMISSION
Dateof lssue:January,1983
O H O N D AM O T O RC O . ,L T D . 13-7
rrorvxDA
TRANSMISSION V45 INTERCEPTOR
, 8 3O N L Y
INSTALLATION
lnstallthe shift drum.
Apply a locking agent to the screw threadsand
installthe bearingstopperplates.
PLATES
B E A R I N GS T O P P E R
S H I F TF O R KS H A F T OILHOLE
lnstall the shift fork shaft so that the oil hole egrd
is towardthe right.
D a t eo f l s s u eO
: c t o b e r 1, 9 8 3
13-8 O H O N D AM O T O RC O . .L T D .
I{ONTDA
V45 INTERCEPTOR TRANSIVIISSION
DRIVER
ASSEil|BLY
TRANSMISSION 0200
00 0R 07945-371
07746-00301
MAINSHAFT
A T T A C H M E N T ,m
2 5m l . D .
07746-0030200
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
@ H O N D AM O T O RC O . ,L T D . 13-9
IIONTEDA
TRANSMISSION V45 INTERCEPTOR
COUNTERSHAFT
Before installingthe countershaftin the crankcase,
installthe C5 gearand snapring.
"7w;,
I n s t a ltl h e C 3 g e a ra n d s p l i n ec o l l a r .
I n s t a l lt h e s t o p p e rw a s h e wr h i l e a l i g n i n gt h e t a b o f
the stopper washerwith the groovein the spline
collar.
8!i,r:lxr::rij nffi:e
S P L I N EC O L L A R WASHER
STOPPER
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
1 3 -1 0 O H O N D AM O T O RC O . .L T D .
IIOTVf,DA
V45 INTERCEPTOR TRANSMISSION
C O U N T E R S H A FBTE A R I N GH O L D E R
Install the countershaftbearingholder bolts and
tightenthem.
TOROUE:21-25 N.m (2.1-2.5 kg-m,15-18 ft-lb)
MAINSHAFT
Installthe mainshaft,then reassemble
the upperand
lowercrankcase (seeSection11).
Dateof lssue:October,1983
O H O N D AM O T O RC O . ,L T D . 13-11
ITONTf,DA
V45 INTER,CEPTOR
FRONTWHEEL/SUSPENSION
90-120 N.m
( 9 . 0 - 1 2 . 0k g - m ,
65-87 ft-lb)
30-40 N.m
(3.0-4.0kg-m,
22-29' t'tlbl
22-29 ft-tbl
Seepage
14-35 --'-'
..1
9-13 N.m
(0.9-1.3ks'm,
.
+
7-10 ft-lbl
45-55 N'm
(4.5-5.5kg-m,
-%
33-40 ft-rb)
30-40 N.m
(3.0-4.0kg'm,
22-29 tt-lbl
55-65 N.m (g
(5.5-6.5ks-m, a
40-47 ft-rb)
/
18-25N'm
(1.8-2.5kg-m,13-18ft-lbl e 20-25 N.m
GD
a (2.0-2.5ks-m,
14-18ft-lbl
Dateof lssue:October,1983
14-O O H O N D AM O T O RC O . ,L T D .
IIOilTEDA
INTERCEPTOR
VF7OOI750 14.FRONT
WHEET/SUSPENSIO
SERVICEINFORMATION 14-1 tGNtTtONSWTTCH 14-6
TROUBLESHOOTING 14_2 HANDLEBARS 14-7
HEADLIGHT 14_3 FRONTWHEEL 14-11
INSTRUMENTS 14_3 F R O N TF O R K S 14-18
FUSEHOLDERREPLACEMENT 14_5 STEERING STEM 14-31
INFORMATION
SERVICE
GENERAL
A jack or other support is requiredto supportthe front of the motorcyclewhen your are working on the front wheel or
fork.
SPECIFICATIONS
STANDARD LIMIT
SERVICE
Axleshaftrunout 0.2 mm (0.0,l in)
Front wheel rim runout Radial 2.0 mm (0.08 in)
Axial 2 , 0 m m ( 0 . 0 8i n )
Fork spring free length 4 7 9 . 3 m m ( 1 8 . 8 7i n ) 4 7 0 m m ( 1 8 . 5i n )
Forktube runout 0 . 2 m m ( O . 0 1i n )
Front fork fluid capacity VF7SOF:
360 cc ozl,VFTOOF; 350 cc (11.9oz)
Right '84112.2
VF7OOF: 350 cc (11.9 oz)
After
VALUES
TOROUE
Steeringstem nut 9O-120 N'm (9.0-12.0kg-m,65-87 ft-lb)
'83: 1O-12 N.m(1.O-1.2 kg-m,7-9 ft-lb)
Steeringbearingadjustmentnut
After'83: 1 9 - 2 3 N . m( 1 . 9 - 2 . 3k g - m ,1 4 - 1 7 f t - l b )
Fork bridgepinch bolt 30-40 N'm (3.0-4.0 kg-m,22-29 ft-lbl
Front axle holder 18-25 N.m(1.8-2.5 ks-m,13-18 ft-lb)
Front axle nut 55-65 N.m(5.5-6.5 kg-m,40-47 ft-lb)
Forktop pinch bolts 9-13 N.m(0.9-1.3 kg-m,7-10 ft-lb)
Fork bottom pinch bolts 45-55 N.m(4.5-5.5 kg-m,33--40 ft-lb)
Handlebarpinch bolts 30-40 N.m (3.0-4.0 kg-m,22-29ft-tbl
Front brake calipermount bolts 30-40 N.m(3.O--4.0ks-m.22-29 ft-tbl
Anti-divepiston pin bolt 20-25 N.m(2.0-2.5 kg-m,14-18 ft-lb)
Front brake disc 35-40 N.m(3.5--4.0kg-m,25-29 ft-lb)
IiIONITDA
V45 INTERCEPTOR
F R O N TW H E E L / S U S P E N S I O N
TOOLS
Special
H e x .w r n e c h 6 , mm 07917-3230000 or equivalent
S n a pr i n gp l i e r s 07914*3230001or equivalentin U.S.A.
Fork sealdriver 07947-4630100
Steeringstemsocket 0 7 9 16 - 3 7 10 r 0 0
Bearingraceremover 07946-3710500
Ball raceremover 07953-4250002
Steeringstemdriver 07946-M 800000or-- Steering stemd river07946-37 10601
L Attachment07964-MB00200
Common
Driver 07749-0010000
Attachment,42 x 47 mn 07746-0010300
P i l o t ,1 5 m m 07746-0040300
Lock nut wrench,30 x 32 mm 0 7 7 1 6 - 0 0 2 0 4 0 0o r e q u i v a l e ni nt U.S.A.
Extension 07716-0020500or equivalentin U.S.A.
Attachment,52 x 55 mm 07746-0010400
Bearingremovershaft 0 7 7 4 6 - 0 0 5 0 1 0 0o r e q u i v a l e ni n
t U.S.A.
Bearing r e m o v ehr e a d ,1 5 m m 0 7 7 4 6 - 0 0 5 0 4 0 0o r e q u i v a l e ni tn U . S . A .
TROUBLES1|OOTI
NG
Hardsteering
1. S t e e r i n b gearing a d j u s t m e nnt u t t o o t i g h t
2 . F a u l t ys t e e r i n sgt e mb e a r i n g s
3. Damagedsteeringstembearings
4 . I n s u fifc i e n t i r e o r e s s u r e
Front wheelwobbling
1 . B e n tr i m
2 . W o r nf r o n t w h e e lb e a r i n g s
3 . F a u l t yt i r e
4 . A x l e n u t t i g h t e n e di m p r o p e r l y
Soft suspension
1. W e a kf o r k s p r i n g s
2 . I n s u f f i c i e nf lt u i d i n f o r k s
3. Fork air pressure incorrect
Hardsuspension
1 . I n c o r r e cftl u i d w e i g h ti n f o r k s
2 . F o r k a i r p r e s s u rien c o r r e c t
3 . B e n tf o r k t u b e s
4. Cloggedf luid passage
5 . C l o g g ea dn t i - d i v e
o r i fi c e
: c t o b e r1
D a t eo f l s s u eO , 983
14-2 O H O N D AM O T O RC O . ,L T D .
IIONTTDA
V45 INTERCEPTOR
F R O N TW H E E L / S U S P E N S I O N
1|EADLIO1|T
RE M O V A L / I N S T A L L A T I O N
Removethe fairing.
FAIRING
HEADLIGHT
Removethe headlightrim and headlightby remov-
ing the threescrews.
the headlightcoupler.
Disconnect
orderof removal.
Installthe headlightin the reverse
HEADLIGHT
RIM
INSTRUMEIITS
REMOVAL
Removethe fairing.
Removethe headlightwith its bracketby removing
the mount bolt and nuts.
'l
Dateof lssue:October, 983
@ H O N D A M O T O RC O . ,L T D . 14-3
IIONTf,DA
V45 INTERCEPTOR
F R O N TW H E E L / S U S P E N S I O N
S P E E D O M E T ECRA B L E I N S T R U M E NW
TI R E
COUPLER
DISASSEMBLY
Removethe odometerresetknob.
KNOB
O D O M E T ERRE S E T
I N S T R U M E NP
TO D
Removethe instrumentpod from the instrument
panel.
Removethe instrumentbulb sockets,
Replaceany burnt bulbs.
lf the bulb doesnot light, inspectthe wiringfor an
openor shortcircuit.
I N S T R U M E NP
TA N E L
Dateof lssue:January,1983 .
14-4 @ H O N D AM O T O RC O . ,L T D .
IIONTTDA l
l
VF7OOI750
INTERCEPTOR PENSIO
FRONT WHEEL,/SUS N
INSTRUMENTASSEMBLY,/
INSTALLATION
Assemble andinstalltheinstruments
inthereverse
orderof disassembly andremoval.
REPLAGEMENT
FUSEHOLDER
Removethe headlightbracket(page14-3).
Disconnectthe fuse holderwire coupler.
Removethe fuse holdercover.
NOTE
F U S EH O L D E R
sulllcl|
tGl{lTl01{ I G N I T I O NS W I T C H v
REMOVAL/INSTALLATION
(page
Remove the headlight and the instruments
14-3).
Remove the fuse holder cover'
Disconnectthe ignition switch wire coupler'
and
Remove the ignition switch mounting bolts,
remove the ignition switch.
of
Install the ignition switch in the reverseorder
removal.
M O U N T I N GB O L T S
D I S A S S E MLBY / A S S E M B L Y
Pry openthe retainer'
partway
I n s e r tt h e i g n i t i o nk e y a n d t u r n i t s o i t i s
betweenthe ON and OFF detent positions'
D a t eo f l s s u eJ: a n u a r Y1. 9 8 3
14-6, O H O N D AM O T O RC O . ,L T D .
ITONTIDA
V45 INTERGEPTOR
FRONT WHEEL/SUSPENSION
SLOTS
Push in the lugs,that are lockedin the slots,then
pull the contactbasefrom the switch.
Assemblethe ignition switch in the reverseorder of
disassembly.
LUGS
l{AI{DtEBARS F R O N TB R A K EM A S T E R
CYLINDER
REMOVAL
Disconnect
the front brakeswitchwires.
Removethe front brakemastercylinder.
R I G H TH A N D L E B A RS W I T C H
Removethe right handlebarswitch.
Dateof lssue:January,1983
O H O N D AM O T O RC O . ,L T D . 14-7
I{OTTTTDA
V45 INTERCEPTOR
F R O N TW H E E L / S U S P E N S I O N
C L U T C HM A S T E RC Y L I N D E R
the clutch switchwires.
Disconnect
Removethe clutch mastercylinder.
L E F T H A N D L E B A RS W I T C H
Removethe left handlebarswitch.
C H O K EL E V E R
Disconnectthe choke cable from the choke lever.
C H O K EC A B L E
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
14-A O H O N D AM O T O RC O . .L T D .
ITONTf,DA
V45 INTER.CEPTOR.
F R O N TW H E E L / S U S P E N S I O N
RING
STOPPER
R e m o v e t h e l e f t a n d r i g h t h a n d l e b a rr e t a i n e r r i n g s .
Loosen the left and right handlebarpinch bolts.
Remove the handlebarsfrom the fork tubes.
Remove the throttle grip from the right handlebar.
P I N C HB O L T
HANDLEBAR
INSTALLATION
{pply greaseto the throttle grip slidingsurfaceand
s l i d et h e t h r o t t l eg r i po v e rt h e h a n d l e b a r .
RETAINERING
lnstall the handlebarsonto the fork tubes and on
the handlebarspacers.aligning the pin on the
bottom of the handlebarwith the hole in the spacer.
I n s t a ltl h e h a n d l e b arre t a i n er i n g s .
SPACER P I N C HB O L T
D a t eo f l s s u eO
: c t o b e r 1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 14-9
rrorrrxDA
FRONT WHEEL/SUSPENSION
V45 INTERCEPTOR
HOLE
Align the right handlebarswitch locatingpin with
the hole in the handlebarand install the right
handlebarswitch.
Installthe top portion of the switch and tightenits
screws,
Tighten the forward screw first, then tighten the
rearscrew.
L O C A T I N GP I N
F R O N TB R A K EM A S T E RC Y L I N D E R , , U P "M A R K
Placethe front brakemastercylinderon the handle-
bar and install the mastercylinderholderwith the
"UP"
mark facingup.
Align the index mark on the holderwith the punch
mark on the handlebar,and tighten the upper bolt
first then tightenthe lower bolt.
P U N C HM A R K I N D E XM A R K HOLDER
HOLE
Connectthe chokecableto the chokelever.
L O C A T I N GP I N
Dateof lssue:January,1983
1 4 -1 0 O H O N D AM O T O RC O . .L T D .
IIONIXDA
V45 INTER,CEPTOR FRONT WHEEL/SUSPENSION
, , U P "M A R K C L U T C HM A S T E RC Y L I N D E R
\_ Placethe clutch mastercylinder on the handlebar
and installthe mastercylinderholderwith the "UP"
mark facingup.
Align the index mark bn the holderwith the punch
mark on the handlebar,and tighten the upper bolt
I N D E XM A R K P U N C HM A R K
IT]|EET
TROl{T
REMOVAL
Removethe right front brakecaliperfrom the fork
leg.Removethe right axle holder.
NOTE
lf you squeezethe froht brake lever after the
caliper is removed,the caliper piston will
moveout and makereassembly difficult.
R I G H TF R O N TC A L I P E R AXLEHOLDER
L E F T F R O N TC A L I P E R
Remove the speedometercable set screwand dis-
connectthe speedometer cable.
Remove the left front caliper from the fork leg
and anti-divepistoncase.
AXLEHOLDER S P E E D O M E T ECRA B L E
Dateof lssue:JanuarY,1983
O H O N D AM O T O RC O . ,L T D .
14-11
IIOIITf,DA
F R O N TW H E E L / S U S P E N S I O N V45 INTER,CEPTOR
DISASSEMBLY
Removethe front axle nut and axle.
SPACER S P E E D O M E T EGRE A RB O X
Removethe spacerfrom the right side.
Removethe speedometer gearbox from the left side.
B R A K ED I S C
Removethe left and right brakedisc mountingbolts
a n dd i s c s .
Dateof lssue:January,1983
1 4 -1 2 O H O N D AM O T O RC O . .L T D .
IIONTf,DA
V45 INTERCEPTOR. FRONT WHEEL/SUSPENSION
INSPECTION
W H E E LB E A R I N G
..-
Check wheel bearing play by placing the wheel in
a truing stand and spinning the wheel by hand.
PLAY
Replacethe bearingswith new ones if they are noisy
or have excessiveplay.
W H E E LI N S P E C T I O N
Check the rim runout by placing the wheel in a
truing stand. Spin the wheel slowly and read the
r u n o u tu s i n ga d i a l i n d i c a t o r .
S E R V I C EL I M I T S :
R A D I A L R U N O U T :2 . 0 m m ( 0 . 0 8i n )
A X I A L R U N O U T : 2 . 0 m m ( 0 . 0 8i n )
NOTE
The wheel cannot be repairedand must be
replacedwith a new one if the servicelimits
areexceeded.
AXLE INSPECTION
Set the axle in V blocks and measurethe runout.
S E R V I C EL I M I T : 0 . 2 m m ( 0 . 0 1i n )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
@ H O N D AM O T O RC O . ,L T D . 1 4 -1 3
IIONIDA
F R O N TW H E E L / S U S P E N S I O N
V45 INTERCEPTOR
B E A R I N GR E M O V E R
SHAFT
07746-0050100
W H E E LB E A R I N GR E M O V A L
lf the bearingneed replacement,
removethe bear-
ingsand distancecollar.
NOTE
N e v e rr e i n s t a lol l d b e a r i n g so;n c et h e b e a r i n g s
are removed,they must be replacedwith new
ones.
B E A R I N GR E M O V E R
HEAD
07746-0050400
ASSEMBLY
NOTE
' The castwheelhasno rim band.
' The front wheel usesa tubelesstire. For
tubelesstire repair, refer to the Honda
T u b e l e sTsi r e M a n u a l .
1 4 -1 4 Dateof lssue:October,1983
O H O N D AM O T O RC O . .L T D .
IIONTf,DA
V45 INTER,CEPTOR F R O N TW HE E L / S U S P E N S I O N
DRIVER
0000
07749-001
Packall bearingcavitieswith grease.
Drive in the right bearingfirst. sealedside facing
out, then pressthe distancecollarinto place.
NOTE
Be certain the distancecollar is in position
beforeinstallingthe left bearing.
ATTACHMENT,42 x 47 mm07746-0010300
PILOT,15 mm 07746-0040300
S P E E D O M E T EGRE A R R E T A I N E R
Installthe speedometer gearretainerin the left side
of the wheel hub, aligningits tangswith the slotsin
thehub.
Align
B R A K ED I S C
lnstallthe left dust seal.
\- Place new gasketson the disc mounting flange,
"L" mark facing
then install the left disc with its
out.
Tightenthe discmountingbolts.
TOROUE35-40 N'm (3.5-4.0 ks-m,25-29 ft-lb)
D U S TS E A L
Dateof lssue:Januarv.1983
O H O N D AM O T O RC O . ,L T D . 1 4 -1 5
IilONTTDA
F R O N TW H E E L / S U S P E N S I O N V45 INTERCEPTOR
Installthe spacer.
D U S TS E A L
S P E E D O M E T EGRE A R
D R I V EG E A R BOX
Fill the speedometer gearboxwith greaseand install
t h e p l a i nw a s h ear n dd r i v eg e a r .
TANGS SLOTS
AXLE NUT
I n s t a l tl h e f r o n t a x l ea n d a x l e n u t . T i g h t e nt h e a x l e
nut.
TOROUE: 55-65 N.m (5.5-6.5 ks-m,40-47 ft-lb)
ffi
NOTE
There are flats on the oppositeend of the
a x l e ,s o y o u c a n h o l d t h e a x l e w h i l et o r q u i n g
t h e a x l en u t .
Dateof lssue:January,1983
1 4 -1 6 O H O N D AM O T O RC O . .L T D .
II( TVDA.
V45 INTERGEPTOR
F R O N TW H E E L / S U S P E N S I O N
TANG
INSTALLATION
Positionthe wheelbetweenthe fork legs.
Lower the engineso the fork legsreston the top of
theaxle.
A R R O WM A R K
C A L I P E RM O U N TB O L T C A L I P E RM O U N TB O L T
Installthe right front caliperand tightenthe mount
bolts.
TOROUE:30=40 N.m (3.0-4.0 kg-m,22-29 ft'lb)
T i g h t e nt h e c a l i p e rm o u n tb o l t .
TOROUE:30-40 N.m (3.0-4.0 ks-m,22-29 ft'lb)
ANTI.DIVP
E I V O TB O L T
cableand secureit with
Connectthe speedometer
the set screw.
B R A K ED I S C
D a t eo f l s s u eO
: c t o b e r1
, 983
O H O N D A M O T O RC O . ,L T D . 1 4 -1 7
T
I EIONTTDA
V45 INTER,CEPTOR
FRONT WHEEL/SUSPENSION
FROIIT
TORI(S
REMOVAL
Removethe followingparts:
- fairing.
- headlight.
- instruments.
- handlebars.
- front wheel.
- handlebarspacers.
H A N D L E B A RS P A C E R S
F R O KB R A C E
Removethe front fenderand fork brace.
F R O N TF E N D E R
U P P E RP I N C HB O L T S
Loosenthe fork upperand lowerpinch bolts.
L O W E RP I N C HB O L T S
Dateof lssue:January,1983
1 4 -1 A O H O N D AM O T O RC O . ,L T D .
Itorvf,DA
V45 INTERCEPTOR,
F R O N TW H E E L / S U S P E N S I O N
NOTE
Because of the friction causedby the air joint
O-rings,you'll have to turn the tubes while
p u l l i n gd o w n .
F O R KS T O PR I N G
Dateof lssue:January,1983
O H O N D A M O T O RC O . ,L T D . 1 4 -1 9
IIONTXDA
FRONT WHEEL/SUSPENSION
V45 INTER,CEPTOR
F O R KC A P
DISASSEMBLY
Hold the fork tube in a vise,witli soft jawsor a shop
towel and removethe fork tube cap.
CAUTlOltl
Do not damage the sliding surface.
SPRING SPACER
Removethe fork spring,spacerand washer.
D r a i nt h e f o r k f l u i d b y p u m p i n gt h e f o r k u p a n d
down several times.
WASHER
HEXWRENCH (6 mm)07917-3230000
O RE O U I V A L E N T
Hold the fork slider in a vise with soft jaws or a
shoptowel.
Removethe socketbolt with a hex wrench.
NOTE
Temporarily install the spring and fork cap
if difficulty is encounteredin removingthe
socketbolt.
'83-'84:
Removethe dust seal, foam seal and plastic PLASTICWASHER FOAM SEAL D U S TS E A L
washer.
D i s c a r dt h e f o a m s e a l a n d p l a s t i cw a s h e r .D o n o t
I
I
reuse or replace.
\
After'84:
R e m o v et h e d u s t s e a l .
bl
'83-'84 Shown
R e m o v et h e s n a p r i n g . S N A PR I N GP L I E R S0 7 9 1 4 - 3 2 3 0 0 0 1
O R E Q U I V A L E NITN U . S . A .
\
*
S N A PR I N G
P u l l t h e f o r k t u b e o u t u n t i l r e s i s t a n c ef r o m t h e
slider bushingis felt. Then move it in and out,
t a p p i n gt h e b u s h i n g l i g h t l y u n t i l t h e f o r k t u b e
s e p a r a t e sf r o m t h e s l i d e r .T h e s l i d e rb u s h i n gw i l l
b e f o r c e do u t b y t h e f o r k t u b e b u s h i n g .
R e m o v et h e o i l l o c kp i e c ef r o m i n s i d et h e s l i d e r .
F O R KT U E E F O R KS L I D E R
F O R KT U B EB U S H I N G
C I R C L I P O I L L O C KV A L V E SPRING
INSPECTION
FORKSPRINGFREELENGTH
Measurethe forkspringfree length.
SERVICELIMIT:47Omm (18.5in)
F O R KT U B E / F O R S
K L ID E R / P I S T O N
Check the fork tube, fork slider and piston for P I S T O NR I N G
score marks, scratches,or excessiveor abnormal
wear. Replaceany componentswhich are worn or
\ ronr ruee SLIDER
PISTON
damaged.
Checkthe fork pistonring for wearor damage.
Check the rebound spring for fatigueor damage.
\
I
REBOUND
SPRING
F O R KT U B E
Set the fork tube in V blocksand checkits runout.
S E R V I C EL I M I T : 0 . 2 0m m ( 0 . 0 0 8i n )
B U S H I N G / B A C K .R
UIPN G
BUSHING B A C K . U PR I N G
Visually inspectthe sliderand fork tube bushings.
scoringor
Replacethe bushingsif there is excessive
scratching,or if the teflon is worn so that the
copper surface appearson more than 3/4 of the
entire surface.
Dateof lssue:January,1983
O H O N D AM O T O RC O . ,L T D . 74-23
IIONIf,DA
INTERCEPTOR
VT7OOI750
FRONT WHEEL,/SUSPENSION
After'84:
R e m o v et h e p i s t o na n d s p r i n g .
R e m o v et h e b o o t , p i v o t b o l t c o l l a r a n d r u b b e r
bushing.
%& Wa
\:/%
Date of lssue: October,1984
14-24 @rAmerican HondaMotor Co.,Inc. 1984 - All RightsReserved
ITONTXDA
V}7OOI750INTERCEPTOR FRONTWHEEL,/SUSPENSION
,P is
Removethe checkvalvesettingscrew,valvespring
and check ball.
After'84: SIDE
Removethe screwattachingthe anti-driveadjuster WASHER
knob, knob and orifice.
Removethe check ball screw, spring and ball.
Check the orifice for clogging,scoring,excessive
wear or damage.
Replaceif necessary.
RING
STOPPER
C H E C KB A L L
NOTE
BOOTHOLDER
'83-' 84 After'84:
Checkthe operationof the collar and piston.
ffil
bry %
l#
ASSEMBLY
OILSEAL
S N A PR I N G
BACK.UP F O R KB R A C E
RING
ss
a S L ID ER
BUSHING
9/3
li li ul S L ID ER
a
ll €= F O RK
ANTr-DtvE
CASE
lg SPRI NG
'%.
!g d g
g
F 8
| 0@@
n
€ p
s F
CJ
iln
H A g
g
/\D € €
g
e After'84:
g €
l l ( @ , /
t4
U PISTON
g
F O R KT U B E
BUSHING(S)
SPRI NG N O T E :O n l y
o n e b u s h i n gi s
O**,pffu
*ry/ @**
'84 s4 @o
used after
NOTE
VALVE SPRING
P l a c et h e f o r k s l i d e r i n a v i s e w i t h s o f t j a w s o r a
shop towel.
Apply a lockingagentto the socketbolt and thread
i t i n t ot h e p i s t o n T
. i g h t e nw i t h a 6 m m h e xw r e n c h .
NOTE
T e m p o r a r i l yi n s t a l lt h e f o r k s p r i n g a n d f o r k
cap bolt to tighten the socketbolt.
TOROUE: CUTOUT
1 5 - 2 5 N . m ( 1. 5 - 2 . 5 k s - m , 1 1 - 1 8 f t - l b l
P l a c et h e s l i d e rb u s h i n go v e rt h e f o r kt u b ea n d r e s t F O R KS E A LD R I V E R
i t o n t h e s l i d e r .P u t t h e b a c k - u pr i n g a n d a n o l d 07947-4630100
b u s h i n go r e q u i v a l e ntto o l o n t o p .
D r i v e t h e b u s h i n gi n t o p l a c ew i t h t h e s e a l d r i v e r
a n d r e m o v et h e o l d b u s h i n go r e q u i v a l e ntto o l
Coat a new oil seal with ATF and installit with
t h e s e a l m a r k i n g sf a c i n gu p . D r i v et h e s e a l i n w i t h
t h e s e a ld r i v e r .
P'18iil
I n s t a l lt h e s n a p r i n g w i t h i t s r a d i u s e de d g ef a c i n g S N A PR I N GP L I E R S
d o w n a n d i n s t a l lt h e d u s t s e a l . 07914-3230001 D U S TS E A L
NOTE
'83 '84
On and do not install the plastic S N A PR I N G
w a s h e ro r f o a m s e a l .
O I LS E A L
B A C K - U PR I N G
S L I D E RB U S H I N G
P o u r t h e s p e c i f i e da m o u n t o f A T F i n t o t h e f o r k
tube.
'85 VF700F:
Right 35Occ (11.9oz)
Left 375 cc (12.7ozl
I n s t a l tl h e f o r ks p r i n g s. p r i n gs e a ta n d s p a c e ri n t h e
fork tube.
NOTE
Notethe spring direction;the closelywound
coils must face down in the tube.
-** €
BOTTOM TOP
Bevised;February.1986
14-28, @American HondaMotor Co.,Inc. 1986 - All RightsReserved
MSV98418602 '83 _ '85 VF700/750F
IIONTI'A
V45 INTERCEPTOR F R O N TW H E E L / S U S P E N S I O N
INSTALLATION
F O R KS T O PR I N G
T O PP I N C HB O L T S
Tightenthe bottom pinch bolts.
TOROUE45-55 N.m (4.5-5.5 kg-m,33-40 ft-lb)
B O T T O MP I N C HB O L T S
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 14-29
IIONTTDA
V45 INTERCEPTOR
F R O N TW H E E L / S U S P E N S I O N
F R O N TF O R KB R A C E
Looselyinstallthe fork brace.
Install the removedparts in the reverseorder of
removal.
- front fender.
- handlebarspacers.
- handlebars,
- front wheel.
- headlight.
- instruments.
- fairing.
F R O N TF E N D E R
F i l l t h e f o r k t u b e sw i t h a i r .
R E C O M M E N D EP
RR E S S U R E :
0-40 kPa (0-0.4 kg/cm2,0-6 psi)
CAUTION
. Useonly a hand-operated air pump to fiil
the fork tubes.Do not usecompressed air.
' Maximumpressureis 300 kPa(3 kglcm2,
43 psi). Do not exceedthis or fork tube
componentdamagemay occur.
STE]I|
STEERING
REMOVAL
Removethe followingcomponents.
- f ai r i n g .
- headlight.
instrument.
- - handlebars.
- front wheel.
- ignitionswitch.
- brakehose3-waYjoint,
B R A K EH O S E3 . W A YJ O I N T
L O C KN U T W R E N C H3, 0 x 3 2 m m
07716-0020400or EOUIVALENT I N U.S.A.
Loosenand removethe steeringstemnut.
Removethe forks,
EXTENStON 07716-0020500
O R E O U I V A L E NUT. S . A .
T O PB R I D G E
Loosenthe top bridgepinch bolt and removethe
top bridgewith the fork air joint.
: c t o b e r 1, 9 8 3
D a t eo f l s s u eO
O H O N D A M O T O RC O . ,L T D . 14-31
IIONTf,DA
V45 INTERCEPTOR
F R O N TW H E E L / S U S P E N S I O N
L O C KW A S H E R L O C KN U T
Straighten the lock washer tabs and remove the
lock nut and lock washer.
S T E E R I NSGT E MS O C K E T
07916-3710100
L o o s e n t h e b e a r i n ga d j u s t m e n tn u t a n d r e m o v e
the steeringstem. I
ti.,. I
I
'83 shown
Check the steeringstem bearingsfor damageor'
wear.
REPLACEMENT
BEARING
NOTE
Replacethe bearing and bearing race as a set.
Removethe greaseretainer.
Removethe bearinginner race and dust sealfrom
the steeringstem.
D U S TS E A L BEAR I NG
Dateof lssue:October,1983
14-32 O H O N D AM O T O RC O . ,L T D .
IIONIXDA
VJ7OOI750INTERCEPTOR FRONTWHEEL,/SUSPENSION
BALL RACEREMOVER
Removethe lower bearing race with the special 07953-4250002
tool.
NOTE
BEARINGRACEREMOVER
07946-3710500
'83: After'83:
LocKNUr - GD
*r
S.TLOCK WASHER
@g.oRrNG ADJUsTMEN€
NUT ;t'7r
(e\ \ oust senl
I@*UPPER
/\V
B E A R I N GI N N E R / 6 1 q
fu RAcE ',fft. 'UPPER
EuppeR BEARING
B E A R T NoG
urER/s
e*. RACE
-GREASE --/re
RETAINER
/S., tS.\
\J< r oO
L wWF FE B
R FEAARR
l R O
6 1U
T INNGG l 1Tp E
p .R
2 \' - i
@ RACE
EARI NG I NNER+€
@*LOWER BEARING
\- S-toyEff_B
\i::;":,.^, -s
Date of lssue: October, 1984
o AmericanHondaMotor Co.,Inc. 1984 - All RightsReserved 14-33
I
ITONTTDA
FRONTWHEEL,/SUSPENSION VF7OOI750
INTERCEPTOR
DRIVER ATTACHMENT,52 x 55 mm
Drivethe upperbearingouter raceinto the steering 07749-0010000 07749-0010400
head
ATTACHMENT. 42 x 47 mm DRTVER
07749-0010000
07746-001 0300
STEERINGSTEMDRIVER
Installa dust seal onto the steeringstem and press 07946-MBOOOOO OR
the lower bearing inner race over the stem with 07946-3710601AND07964-M800200
the specialtool.
'83 SHOWN
INSTALLATION U P P E RB E A R I N G /
,83
I N N E RR A C E SHOWN
Packthe bearingcavitieswith bearinggrease.
'83:
l n s t a l l t h e g r e a s e r e t a i n e ro n t h e s t e e r i n g
stem,then insertthe steeringstemintothe steering
head. Install the bearing relainer and upper
bearing,/innerrace.
A f t e r ' 8 3 : I n s t a l l t h e l o w e r b e a r i n ga n d g r e a s e
r e t a i n e ro n t o t h e s t e e i n g s t e m , t h e n i n s e r t t h e
steering stem into the steering head. Install the
upper bearingand inner race.
l n s t a l la n e w b e a r i n ga d j u s t m e nnt u t l o c k w a s h e r
a l i g n i n gt h e t a b sw i t h t h e g r o o v e si n t h e n u t . B e n d
two oppositetabsdown into the grooves.
NOTE L O C KN U T
D O N O T i n s t a l la u s e d b e a r i n ga d j u s t m e n t
nut lock washer.
H a n dt i g h t e nt h e l o c k n u t .
H o l d t h e a d j u s t m e n tn u t a n d f u r t h e r t i g h t e nt h e
l o c k n u t o n l y e n o u g ht o a l i g ni t s g r o o v e sw i t h t h e
lock washertabs.
NOTE
l f t h e l o c k n u t g r o o v e sc a n n o t b e e a s i l y
alignedwith the lock washertabs,removethe
n u t , t u r n i t o v e ra n d r e i n s t a lilt .
D a t eo f l s s u eO
: c t o b e r1
, 983
O H O N D AM O T O RC O . .L T D . 14-35
ITONTDA
V45 INTER,CEPTOR,
F R O N TW H E E L / S U S P E N S I O N
EXTENSION
O 7 7 1 6 - 0 0 2 0 5 0o0r E O U I V A L E N Tl N U . S . A .
I n s t a ltl h e t o p b r i d g ew i t h t h e f o r k a i r j o i n t .
Instaflthe front forks (page14-291.
I n s t a lal n dt i g h t e nt h e s t e e r i n sgt e mn u t .
T O R Q U E :9 0 - 1 2 0 N . m ( 9 . 0 - 1 2 . 0k s - m ,
drl
65-87 ft-lb)
PE
L O C KN U TW R E N C H , 3 x0 3 2 m m
07716-0020400
o r E O U I V A L E Nl N
T U.S.A,
S T E E R I NH
GE A DB E A R I N G
PRELOAD
lnstallthe front wheel(pale 14-17],.
P l a c ea s t a n du n d e rt h e e n g i n ea n d r a i s et h e f r o n t
w h e e lo f f t h e g r o u n d . S P RN I GSCALE
P o s i t i o nt h e s t e e r i n gs t e m t o t h e straight ahead ( c o m m e r c i a la
l Vv a i l a b l e )
position.
H o o k a s p r i n g s c a l et o t h e f o r k t u b e a n d m e a s u r e
t h e s t e e r i n gh e a d b e a r i n gp r e l o a d .
NOTE
M a k e s u r e t h a t t h e r e i s n o c a b l ea n d w i r e
h a r n e sisn t e r f e r e n c e .
Dateof lssue:October,1983
14-36 O H O N D AM O T O RC O . .L T D .
rtoilrxDA
V45 INTER,CEPTOR, FRONT WHEEL/SUSPENSION
MEMO
L
I
Dateof lssue:January,1983
O H O N D AM O T O RC O , .L T D . 14-37
REAR WHEEL/SUSPENSION @Hs..ily-?*+
@o
40-50 N'm
(4.0-5.0ks-m,29-36 ft-lb)
%
85-105N.m
(8.5-10.5kg-m, 30-40 N.m
61-76 ft-tb) (3.0-4.0ks-m,
40-50 N.m
(4.0-5.0 kg-m,
29-36 ft-rb)
1 8 - 2 5N . m
(1.8-2.5kg-m,
13-18ft-lb)
80-100N.m
(8.0-10.0ks-m,
40-50 N.m 58-72 ft-rb)
(4.0-5.0ks-m,
29-36 ft-tb) @
20-30 N.m
(2.0-3.0kg-m,
14-22 ft-lbl
85-105 N.m
( 8 . 5 - 1 0 . 5k g - m ,6 1 - 7 6 f t - l b )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
15-O O HoNDA MoToR cO., LTD.
IilONTf,DA
V45 INTERCEPTOR
15.REAR
II|IiIEI/SUSPENSI0
S E R V I C EI N F O R M A T I O N 15-1
TROUBLESHOOTING 15-2
REARWHEEL 15-3
S H O C KA B S O R B E R 15-8
SWINGARM 15-13
SERI|ICE
INFORMATIO}I
GENERAL
o The rearwheelusesa tubelesstire. F o r t u b e l e stsi r e r e p a i r sr,e f e rt o t h e T U B EL E S ST I R E M A N U A L .
SPECIFICATIONS
T O R O U EV A L U E S
Shockarm-to-frame bolts 40-50 N.m(4.0-5.0ks-m,29-36ft-lb)
Shocklink-to-shock arm bolt 40-50 N.m(4.0-5.0ks-m,29-36ft-lb)
Rearshockabsorbermount bolts 40-50 N.m(4.0-5.0ks-m,29-36ft-lb)
Swingarmpinch bolt 20-30 N,m(2.0-3.0kg-m,14*22t:d-|bl
Swingarmpivot bolts 8 5 - 1 0 5N . m( 8 . 5 - 1 0 . k5s - m , 6 1 - 7f6t - l b )
Rearbraketorque rod 8mm 1 8 - 2 5N . m( 1 . 8 - 2 . 5k s - m1, 3 - 1 8 f t - l b )
1 0m m 30-40 N.m(3.0-4.0kg-m,22-29 ft-lbl
F i n a ld r i v e ns p r o c k e t 80-100N.m(8.0-10.0ks-m,58-72ft-lb)
R e a rb r a k ed i s c 35-40 N.m(3.5-4.0kg-m,25-29ft-lb)
R e a ra x l en u t 8 5 - 1 0 5N . m( 8 . 5 - 1 0 .k5g - m6, 1 - 7 6f t - l b )
TOOLS
Special
N e e d l eb e a r i n gr e m o v e r 07931-MA70000
O i l s e ad
l r i v e ra t t a c h m e n t 07965-MC70100
O i l s e ad
l r i v e ra t t a c h m e nrti n g 07965-ME70100
O i l s e ad
l river 07965-M800100
Common
Attachment,32 x 35 mm 07746-0010100
A t t a c h m e n t , 3 Tx 4 0 m m 07746-0010200
A t t a c h m e n t , 5 2x 5 5 m m 07746-0010400
Attachment,62 x 68 mm 07746-0010500
P i l o t ,1 7 m m 07746-0040400
P i l o t , 2 0m m 07746-0040500
P i l o t ,2 5 m m 07746-0040600
Driver 07749-0010000
Bearingremovershaft 07746-0050100 in U.S.A.
or equivalent
B e a r i n gr e m o v ehr e a d , 2 0m m 07746-0050600 in U.S.A.
or equivalent
Dateof lssue:October,1983
O H O N D A M O T O RC O . .L T D . 1 5 -1
IIONIIDA
'v45 INIERGEPTOR
REAR WHEEL/SUSPENSION
TROUBTES||OOTIl{G
Oscillation
1 . B e n tr i m
2. Loosewheelbearings
3. Faultytire
4. Looseaxle
5. Tire pressure incorrect
6. Swingarmbearings worn
7. Worntires
Soft suspension
1 . W e a ks p r i n g
2. Insufficientf luid in shockabsorber
3. Shockabsorberair pressure incorrect
Hard suspension
1. Incorrectfluid weightin shockabsorber
2. Bent shockabsorber
3. Shockabsorberair pressure incorrect
Sucpenrionnoise
1 . S h o c kc a s eb i n d i n g
2. Loosefasteners
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
15-2 O H O N D AM O T O RC O . ,L T D .
IIOTVDA
V45 INTERCEPTOR
REAR WHEEL/SUSPENSION
REAR
l|l]|ETL L O C KN U T ALXE NUT
REMOVAL
R e m o v et h e a x l en u t a n da x l e .
NOTE
lf you depressthe brake pedal after the
rear wheel is removed,the caliperpiston will
moveout and makereassembly difficult. D R I V EC H A I NA D J U S T I N GB O L T AXLb
R E A RB R A K ED I S C
D I S A S S E MLBY
Removethe rearbrakedisc.
R e m o v et h e d u s ts e a l .
D U S TS E A L
F I N A LD R I V E NS P R O C K E T
R e m o v et h e f i n a l d r i v e nsprocketand drivenflange
together.
NOTE
Do not separatethe driven sprocket and
f lange, unless replacementof the driven
sprocketor flangeis necessary.
D U S TS E A L F I N A LD R I V E NF L A N G E
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
@ H O N D AM O T O RC O . .L T D . 15-3
IIONTXDA
V45 INTERCEPTOR
REAR WHEEL/SUSPENSION
INSPECTION
AXLE
Set the axle in V blocks and readthe axle runout
with a dial indicator.
S E R V I C EL I M I T : 0 . 2 m m ( 0 . 0 1i n )
R E A RW H E E L
BEARING
Checkthe wheelbearingplay by rotatingthe wheel
by hand.Replacethe bearingswith new onesif they PLAY
are noisyor haveexcessive
play.
R E A RW H E E LR I M R U N O U T
Checkthe rim for runout by placingthe wheelt n a
truing stand.Spin the wheel slowly, and read the
runout usinga dial indicator.
S E R V I C EL I M I T S :
R A D I A L R U N O U T : 2 . 0 m m ( 0 . 0 8i n )
A X I A L R U N O U T : 2 . 0 m m ( 0 . 0 8i n )
NOTE
The wheel cannot be servicedand must be
replacedif the abovelimitsareexceeded.
Dateof lssue:January.1983
15-4 @ H O N D AM O T O RC O . .L T D .
IIONTTDA
V45 INTER,CEPTOR, REAR WHEEL/SUSPENSION
F I N A LD R I V E NS P R O C K E T
Check the condition of the final driven sprocket
teeth. Replace the sprocket if worn or distorted.
ry
ment, inspect the drive chain and drive
sprocket.
D A M P E RR U B B E R
RUBBERS
DAMPER
Replacethe damPerrubbers if thev are damaged
or deteriorated.
B E A R I N GR E M O V E R
SHAFT
07746-0050100
B E A R I N GR E P L A C E M E N T
Removethe wheelbearings.
D r i v et h e d r i v e nf l a n g es i d eb e a r i n go u t ,
NOTE
N e v e rr e i n s t a lol l d b e a r i n g so;n c et h e b e a r i n g s
are removed,they must be replacedwith new
ones.
H E A D .2 0 m m
B E A R I N GR E M O V E R
07746-0050600
Dateof lssue:October,1983
@ H O N D AM O T O RC O . ,L T D . 15-5
ITONTIDA
REAR WHEEL/SUSPENSION V45 INTER,CEPIOR,
DRIVER
Packall bearingcavitieswith grease.
Pressdistancecollar into placefrom the left side.
Drivethedrivenflangebearing
in with thefollowing
tools.
DRTVER 07749-0010000
ATTACHMENT,62
x 68 mm 07746-0010500
PlLOT,25mm 07746-0040600
CAUTION
A T T A C H M E N T& P I L O T
Dive the bearingsin squarely with the sealed
end facing out, making sure they are fully
seated.
ASSEMBLY
NOTE
The rear wheel usesa tubelesstire. For tube-
less tire repairs,refer to the TubelessTire
Manual.
35-40N.m(3.5-4.0ks-T,
- 6{
25-29 ft-tb)
F I N A LD R I V E NF L A N G E
80-100N ' m
(8.0-10
.0 kg-m, 58-72 ft-lb)
h t
N\I
Wb
@ @
@ @ @
DAMPER
RUBBER
w% F I N A LD R I V E N
SPROCKET
Dateof lssue:January,1983
15-6 O H O N D AM O T O RC O . ,L T D .
IiIONTDA
V45 INTER,CEPTOR REAR WHEEL/SUSPENSION
D R I V E NF L A N G E D R I V E NS P R O C K E T
Installthe rear axle sleeve,final driven flangeand
drivensprocket.
l n s t a l tl h e d u s ts e a l .
D U S TS E A L
R E A RB R A K ED I S C
thebolts.
thebrakediscandtighten
Install
TOROUE:35-40 N'm (3.5-4'0kg-m'
25-29fb-lbl
thedustseal.
lnstall
D U S TS E A L
L E F TS I D ES P A C E R R I G H TS I D ES P A C E R
lnstallthe left and right sidespacers.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . .L T D . 15-7
WHEEL/SUSPENSION
INSTALLATION
Install the rear wheel in the reverseorder of re-
moval.
NOTE
' When installingthe wheel,carefullyfit the
brakediscbetweenthe brakepads.
' After installingthe wheel,apply the brake
severaltimes. Then check that the wheel
rotates freely. Recheckwheel installation
if the brakedragsor if the wheeldoesnot
rotatefreely.
A d j s u tt h e d r i v ec h a i ns l a c k( p a g e3 - 1 3 ) .
B R E A T H E RS E P A R A T O R
ABSORBER
Sl|OCl(
REMOVAL
Placethe motorcycleon its centerstand.
E L E C T RI C P A N E L
U P P E RM O U N T I N GB O L T
Removethe shockabsorberlowermountingbolt.
Removerthe shock absorberupper mountingbolt,
tilt the shock absorberrearwardand removeit
f r o m t h e f r a m eb y p u l l i n gi t u p .
L O W E RM O U N T I N GB O L T
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
15-8 O H O N D AM O T O RC O . .L T D .
IIONIf,DA
V45 INTERCEPTOR, REAR WHEEL/SUSPENSION
BOOT
O I L S E A LR E P L A C E M E N T
Removethe shockcaseboot.
P r e s st h e b a c k - u pr i n g 1 . 0 - 2 . 0 m m ( 0 . 0 4 - 0 . 0 8i n ) ATTACHMENT
in with the Oil SealDriverand attachment. 07965-MC70100
CAUTION
Do not press in the back-up ring excessively, S T O PR I N G
since it can cause the guid.e bushing to iam
ACK-UP
into the shock case, making guide bushing
RING
removal difficult.
OILSEAL
Removethe stopring.
G U I D EB U S H I N G
S T O PR I N G
: c t o b e r 1, 9 8 3
D a t eo f l s s u eO
O H O N D A M O T O RC O . .L T D . 15-9
IICDTVXDA
REAR WHEEL/SUSPENSION
V45 INTERGEPTOR
D A M P E RO I L
( A T FO R E O U I V A L E N T )
Turn the shock absorberupsidedown as soon as
all the ATF hasdrainedfrom the outer case.
O I LS E A L
Installthe guidebushinginto the dampercase.
CAUTION
Be careful not to ddmagethe oil sealduring
installation. J
TAPE
O I L S E A LD R I V E R
Pressthe oil seal into the shock absorberwith a
07965-MB00100
hydraulicpressuntil the oil sealdriver stopsat the ATTACHMENT
edgeof the outer ca$€. 00
07965-MC701
T T A C H M E N TR I N G
07965-ME70100
OILSEAL
GUIDE
BUSHING
iii-irfi !:trl,,,j1i.iijll:t|lL
ATTACHMENT
07965-MC70100
GROOVE
B A C K - U PR I N G
BOOT
lnstallthe boot.
Install the boot clip with the edge facing down.
INSTALLATION U P P E RM O U N T I N GB O L T
Apply pastegrease(containingmore than 45% of
molybdenum)to the uppermountingbushings.
NOTE
Use paste grease(containingmore than 45o/o
of molybdenum)asfollows:
*MOLYKOTE G-n PASTE manufactured
by Dow Corning,U.S.A.
*
Locol Paste manufactured by Sumico
Lubricant,Japan.
*
Other lubricantsof equivalentquality.
Dateof lssue:October,1983
O H O N D AM O T O RC O . ,L T D . 15-11
ITOI|IEDA
vi700t750 TNTERGEPToR
R E A RW H E E L / S U S P E N S I O N
NOTE
SWINGARM S H O C KL I N K S H O C KA B S O R B E R
SHOCK ABSORBER LINKAGE
P I N C HB O L T SHAFT LOWERMOUNTINGBOLT
REMOVAL
R e m o v et h e s h o c k l i n k b y r e m o v i n g t h e s h o c k
absorberlower mounting bolt, shock link-to-shock
arm bolt, swingarm pinch bolt, and shock link
shaft.
S H O C KL I N K L I N K - T O - A R M S H O C KA R M
BOLT
LINKAGE PIVOTINSPECTION
,83
SHOWN:
C h e c kt h e l i n k a g en e e d l eb e a r i n g s( b u s h i n g sf o r
'83)
and collarsfor wear or damage.
Inspectthe dust sealsfor damage.
Replaceparts as necessary.
I n s t a l l t h em u f f l e r s .
S H O C KL I N K L I N K - S H O C KA R M - T O .
ARM BOLT F R A M EB O L T
Slt|NGARlY| S H O C KL I N K P I N C HB O L T S H O C KL I N K S H A F T
REMOVAL
Removethe rearwheel(page15-3).
Removethe right muff ler.
R e m o v et h e s h o c k l i n k p i n c h b o l t a n d s h o c kl i n k
shaft.
L E F T P I V O TB O L T R I G H TP I V O TB O L T
Remove the left and right swingarmpivot bolts.
Dateof lssue:October,1983
O H O N D A M O T O RC O . .L T D . 1 5 -1 3
IIONTfDA
V45 INTERCEPTOR,
REAR WHEEL/SUSPENSION
L O C KP I N T O R O U ER O DB O L T
D R I V EC H A I NS L I D E R
D U S TS E A L
*'il
P I V O TB E A R I N GR E P L A C E M E N T
Removethe pivot collar from the swingarm'sright
pivot. Removethe dust seal.
Removethe snapring and drive out the right pivot
bearings.
**w
P I V O TC O L L A R S N A PR I N G
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 5 -1 4 O H O N D AM O T O RC O . ,L T D .
IIONTTDA
V45 INTER,CEPTOR,
REAR WHEEL/SUSPENSION
N E E D L EB E A R I N GRE M O V ER
07931-M47000 N O T A V A IL A B L E I N U . S . A .
R e m o v e t h e d u s t seal from the swingarm'sleft
pivot.
R e m o v e t h e l e f t p i v o t n e e d l eb e a r i n gw i t h t h e
s p e c i a tl o o l . ffi %
DRIVER WOODEN
07749-0010000 BLoc K
D r i v ea n e w n e e d l ebearinginto the swingarmleft
pivot.
CAUTION
To prevent swingarm damage, support the
swingarmas shown.
A T T A C H M E N T , 3 x2 3 5 m m 0 7 7 4 6 - 0 0 1 0 1 0 0
P I L O T .2 0 m m 0 7 7 4 6 - 0 0 4 0 5 0 0
D R I V ER
07749-0010000
Drive new ball bearings into the swingarm right
pivot.
A T T A C H M E N T , 3 Tx 4 0 m m 0 7 7 4 6 - 0 0 1 0 2 0 0
P I L O T ,1 7 m m 0 7 7 4 6 - 0 0 4 0 4 0 0
D a t eo f l s s u eO
: c t o b e r 1, 9 8 3
O H O N D AM O T O RC O . .L T D . 1 5 -1 5
IIOTVDA
V45 INTERCEPTOR
REAR WHEEL/SUSPENSION
S N A PR I N G P I V O TC O L L A R
D R I V EC H A I NS L I D E R
INSTALLATION
I n s t a ltl h e d r i v ec h a i ns l i d e r .
in theframe.
I n s t a ltl h e s w i n g a r m
L O C KP I N
Make sure that the rear braketorque rod's flanged
washeris installedin the swingarmpivot'
Connectthe rear braketorque rod to the swingarm
and tightenthe Pivotbolt'
TOROUE: 18-25 N'm (1.8-2.5 kg'm, 13-18 ft'lb)
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 5 -1 6 O H O N D AM O T O RC O . ,L T D .
IIONIf,DA
V45 INTER,CEPTOR
REAR WHEEL/SUSPENSION
S H O C KL I N K P I N C HB O L T S H O C KL I N K S H A F T
Connect the swingarmand shock link and install
the shock link shaft and shocklink pinch bolt.
T i g h t e nt h e s h o c kl i n k p i n c hb o l t .
TOROUE:20-30 N'm (2.0-3.0 ks-m, 14-22 ft-lb)
l n s t a l tl h e r i g h tm u f f l e r .
I n s t a ltlh e r e a rw h e e l( p a g e1 5 - 8 ) .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 1 5 -1 7
IIONIfDA
V45 INTERCEPTOR
H Y D R A U L I CB R A K E
B ^ \
\i
\ q
% w@ *,g,^ e\
30-40 N'm
(3.0-4.0kg'm,
\\--,=t
\%) NPo ilt#iir,,$h**"^
22-29it-lbl
W ffi@rz-zs,"6t
# ff
25-40N.m
flt Ngwh#-_
(2.5-4.0kg-m.
18-2eft-rb)
/,,*,i/a\
N#
W * 4 , s *t r
t dgwl?1;r'1i3;'
**@
'li:lirn;'ru=<r
% g
v
"kp
20-25 N'm
I
tu
(2.0-2.5kg-m,
14-18ft-lb)
20-25 N.m
(2.0-2.5ks-m,
14-18ft-lb)
,r%tr
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
16-0 @ H O N D AM O T O RC O . .L T D .
IilONITDA
V45 INTERCEPTOR BRA]{ES
10.}|YDRAULIC
S E R V I C EI N F O R M A T I O N 16- 1
TROUBLESHOOTING 16- 2
B R A K E F L U I D R E P L A C E M E N T / AB
I RL E E D I N G 16- 3
BRAKE PAD/DISC 16- 5
F R O N T M A S T E RC Y L I N D E R 16- 8
B R A K EC A L I P E R S 16-10
R E A R M A S T E RC Y L I N D E R 16-14
l1{t0R]I|AT|0ll
SERI,TCE
GENERAL
o The brakecaliperscan be removedwithout disconnecting the hydraulicsystem.
. or if the brakefeelsspongy.
Bleedthe hydraulicsystemif it is disassembled
o Do not allow foreignmaterialto enterthe systemwhen filling the reservoir.
o Avoid spillingbrakefluid on paintedsurfaces
or instrumentlenses, asseveredamagecan result.
o Alwayscheckbrakeoperationbeforeridingthe motorcycle.
S P E C IIFC A T I O N S
ITEM STANDARD S E R V I C EL I M I T
F r o n t d i s ct h i c k n e s s 4.5-5.2 mm (0,177-0.205 inl 4 . 0m m ( 0 . 1 5 7
in)
F r o n td i s cr u n o u t 0 . 3 0m m ( 0 . 0 1 2
in)
F r o n t m a s t ecr y l i n d e rl . D . 15 . 8 7 0 - 15 . 9 1 3m m ( 0 . 6 2 4 8 - 0 . 6 2 6 5
in) 15.925mm (0.6270n
F r o n tm a s t ep r i s t o nO . D . -
15.827 15.854 mm 1O.6231 -0.6242 inl 1 5 . 8 1 5m m ( 0 . 6 2 2 6n
F r o n tc a l i p e rp i s t o nO . D . 8 m ( 1 . 2 5 7 8 - 1 . 2 5 9i8n )
3 1 . 9 4 8 - 3 1 . 9 9m 3 1 . 9 4 0m m ( 1 . 2 5 7 5i n
F r o n tc a l i p e cr y l i n d e rL D . mm ( 1.261
32.030-32.080 0-1.2630in 0 m ( 1 . 2 6 3i4n
3 2 . 0 9m
R e a rm a s t e cr y l i n d e rL D . mm (0.551
14.000-14.043 2-0.5529in 14.055 mm (0.5533n
R e a rm a s t e pr i s t o nO . D . mm (0.5495*0.5506
13.957-13.984 in 13.945 mm (0.5490n
R e a rc a l i p ecr y l i n d e lr. D . mm ( 1.0630-1
27.OOO-27.O50 .0650in 27.060mm (1.0654n
R e a rc a l i p e rp i s t o nO . D . 26.918-26.968mm ( 1.0598-1.0617 in 2 6 . 9 1 0m m ( 1 . 0 5 9 4n
R e a rd i s ct h i c k n e s s 6.5-7.2 mm (0.256-0.283
in) 6.0mm (0.236in)
R e a rd i s cr u n o u t 0 . 3 0m m ( 0 . 0 1 2
in)
T O R O U EV A L U E S
, Front brakecaliperbracketmount bolt (Right) 30-40 N.m (3.0-4.0 kg-m,22-29 ftlbl
\- Front brakecaliperbracketmount bolt ( Left-upper) 30-40 N.m (3.0-4.0 kl-m, 22-29 ft-lbl
(Left-lower) 2 0 - 2 5 N . m ( 2 . 0 - 2 . 5 k g - m ,1 4 - 1 8 f t - l b )
B r a k ec a l i p e rm o u n tb o l t 2 0 - 2 5 N . m ( 2 . 0 - 2 . 5 k g - m ,1 4 - 1 8 f t - l b )
B r a k ec a l i p e rp i v o t b o l t 2 5 - 3 0 N ' m ( 2 . 5 - 3 . 0 k g - m ,1 8 - 2 2 f t - l b )
Brakehoseoil bolt 25-40 N'm (2.5-4.0 kg-m,18-29 ft-lb)
R e a rb r a k ea c t u a t i nagr m 1 0 - 1 5 N ' m ( 1 . 0 - 1 . 5k g - m , 7 - 1 1 f t - l b )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 1 6 -I
IIOTVXDA
H Y D R A U L I CB R A K E
V45 INTER,CEPTOR
TOOL
Special
Snapring pliers 07914-3230001or equivalentin U.S.A.
TROUBTTSHOOTIIIG
Brakelever/pedalsoft or spongy Brakesgrab
1 . A i r b u b b l e si n h y d r a u l i cs y s t e m 1 . P a d sc o n t a m i n a t e d
2. Low fluid level 2 . D i s co r w h e e lm i s a l i g n e d
3 . H y d r a u l i cs y s t e ml e a k i n g
Dateof lssue:January,1983
16-2 O H O N D AM O T O RC O . ,L T D .
IIONIIDA
V45 INTER,CEPTOR H Y D R A U L I CB R A K E
BRAI(E REPLACE1V|EI{T/F R O N T
TLUID U P P E BL E V E L U P P E RL E V E L
AIRBTEEDING
l i t h t h e f l u i d r e s e r v o ipra r a l l e l
C h e c kt h e f l u i d l e v e w
to the ground.
CAUTION
Install the cover on the reservoir whenever
operating the brake lever or pedal. Failure
to do so will allow brakefluid to squirt out
of the reservoirduring brake operation.
Avoid spilling fluid on painted surfaces.
Place clean shop towels over the fuel tank
wheneverthe system is being serviced.
L O W E RL E V E L ERLEVEL
FRONT REAR
B R A K EF L U I DD R A I N I N G
B R A K EF L U I DF I L L I N G
NOTE
Do not mix differenttypesof fluid sincethey
may not be compatible.
D a t eo f l s s u eO
: c t o b e r1
. 983
O H O N D AM O T O RC O . .L T D . 16-3
ITONTfDA
H Y D R A U L l CB R A K E INTERCEPTOR,
MITYVAC
B R A K EB L E E D E R
w
A I RB L E E D I N G FRONT
NOTE
. Check the fluid leveloften while bleeding
the brakesto preventair from beingpump-
ed into the system.
' When using the Mityvac Brake Bleeder,
follow the manufacturer'sinstructions.
cauflol{
' Useonly DOT4 broke
fluid from a sealed
container.
' Do not mix brakefluid typesand neverre-
use the contaminated fluid whichhasbeen
pumpedout duringbrakebleeding,because
this will impair the efftciencyof the brake
system
R U B B E RH O S E B L E E D E RV A L V E
Pump the brake lever or pedalto bring the caliper
padsin contactwith the disc.
Remove the master cylinder cap and fill the re- M I T Y V A CB R A K EB L E E D E R
r
s e r v o itro n e a rf u l l . REA * 6 S 6 G C o m m e r c i a lAl yv a i l a b l ei n U . S . A .
Connectthe MityvacBrakeBleederor equivalentto
the bleedervalve.
Pumpthe brakebleederand loosenthe bleedervalve,
Add fluid when the fluid levelin the mastercylinder
reservoiris low.
Repeataboveproceduresuntil air bubblesdo not
appearin the plastichose.
NOTE
lf air is enteringthe bleederfrom aroundthe
bleedervalve threads,seal the threadswith
teflon tape.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
16-4 O H O N D A M O T O RC O . .L T D .
ITONIf,DA
V45 INTERCEPTOR H Y D R A U L I CB R A K E
PAD/DISC
BRAKE L E F TC A L I P E R
F R O N TP A DR E P L A C E M E N T
NOTE
Always replacethe brake pads in pairs to
assureevendisc pressure.
P A DP I N S
Removethe pad pin retainerand pull the pad prns
out of the caliper.
Removethe brakepads.
P A DS P R I N G
Positionthe padspringin the caliperasshown.
Pushthe caliperpistonsin all the way.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 16-5
IIONTf,DA
H Y D R A U L I CB R A K E V45 INTERCEPTOR
P A DP I N
Installthe new padsin the caliper.
Installthe pad pins, one pad pin first, then install
the other pin by pushingthe padsagainstthe caliper
to depress the padspring.
PADS
RETAINER
Placethe pad Siinretainerover the pad pins. Push
the retainerdown to securethe pins.
R I G H TC A L I P E R L E F TC A L I P E R
Installthe pad pin retainerbolt.
Install the caliper to the bracket so the disc is
positionedbetweenthe pads,beingcareful not to
damagethe pads.
Right caliper: Tighten the caliper bolt and pivot
bolt.
Left caliper: Tighten the caliper pivot bolt and
anti-divelink bolt.
Dateof lssue:January,1983
16-6 O HoNDAMoToRco., LTD.
ITONTTDA
V45 INTERCEPTOR H Y D R A U L I CB R A K E
R E A RB R A K EP A DR E P L A C E M E N T
Loosen the caliper bolt and remove it from the
c a l i p e rb r a c k e t .
Pivotthe caliperup out of the waY.
Replacethe rear brake padsusingthe samemethod
asusedfor front brakepad replacement.
C A L I P E RB O L T
D I S CT H I C K N E S S
the thicknessof eachdisc.
Measure
S E R V I C EL I M I T :
F R O N T : 4 . 0 m m ( 0 . 1 6i n )
R E A R : 6 . 0 m m { 0 . 2 4i n )
B R A K ED I S CW A R P A G E
Measure brakediscfor warpage.
S E R V I C EL I M I T : 0 . 3 0 m m ( 0 . 0 1 2i n )
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . .L T D . 16-7
ITONTf,DA
H Y D R A U L I CB R A K E V45 INTERCEPTOR
]I|ASTER
TROl{T CYLII{DER
DISASSEMBLY
Drain brake fluid from the hydraulic system.
Removethe brake leverand rear view mirror from
the mastercylinder.Disconnectthe brakehose.
CAUTION
Avoid spilling brake fluid on painted surfacel
Plqce u rag over the fuel tank whenever the
brake system is being serviced.
NOTE
When removingthe fluid hosebolt, coverthe
end of the hose to prevent contamination.
Securethe hoseto preventfluid from leaking
out.
Disconnect
the front brakeswitchwires.
Removethe front brakemastercylinder.
S N A PR I N GP L I E R So r E O U I V A L E N Tl N U . S . A .
07914-3230001
w a
E
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
16-8 O H O N D A M O T O RC O . ,L T D .
IIOI|Tf,DA
V45 INTERCEPTOR, H Y D R A U L I CB R A K E
INSPECTION
M e a s u rteh e m a s t e cr y l i n d e rl . D .
Check the mastercylinder for scores,scratchesor
nicks.
S E R V I C EL I M I T : 1 5 . 5 2 5m m ( 0 . 6 2 7 0i n )
M e a s u rteh e m a s t e o
r i s t o nO . D .
S E R V I C EL I M I T : 1 5 . 8 1 5m m ( 0 . 6 2 2 6i n )
A S S E M LBY
CAUTION
Keep the master cylinder piston, cylinder
and spring as a set; don't substitute individual B R A K EF L U I DE
parts. DOT-4 E
D i p t h e p i s t o nc u p i n b r a k ef l u i d b e f o r ea s s e m b l y .
CAUTION
l,lhen installing the cups, do not allow the lips
to turn inside out and be certain the snaping
is firmly seatedin the groove.
I n s t a ltl h e p i s t o na n ds n a pr i n g . L I G H TS W I T C H
l n s t a l tl h e b o o t .
D a t eo f l s s u eO
: ctober.1983
O H O N D AM O T O RC O . .L T D . 16-9
ITONTDA
H Y D R A U L I CB R A K E
V45 INTER,CEPTOR
CATIPERS
BRAI(E R I G H TC A L I P E R L E F TC A L I P E R
REMOVAL
F R O N TB R A K EC A L I P E R
Placea clean containerunder the caliper and dis-
connectthe brakehosefrom the caliper.
cAuTtol{
Avoid spillingbrakefluid on paintedsurfaces.
R i g h t c a l i p e r : R e m o v et h e c a l i p e rp i v o t b o l t a n d
caliperbolt, and removethe caliper.
Left caliper: Remove the caliper pivot bolt and
anti-divelink bolt, and removethe caliper.
REMOVAL
R E A RB R A K EC A L I P E R
Placea clean containerunder the caliperand dis-
connectthe brakehosefrom the caliper.
CAUT!ON
Avoid spilling brake fluid on the painted
wrfaces to prevent paint damage.
D a t eo f l s s u eO
: c t o b e r1
. 983
1 6 -1 0 @ H O N D AM O T O RC O . .L T D .
IIONIf,DA
V45 INTERCEPTOR H Y D R A U L I CB R A K E
DISASSEMBLY
Removethe brakepads(page16-5).
Removethe pad spring.
Removethe caliperpivot collarand boots.
Removethe pistonsfrom the caliper.
P I V O TC O L L A R
CAUTION
Be careful not to damage the piston sliding
surfaces.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 16-11
IIONTTDA
H Y D R A U L I CB R A K E V45 INTERCEPTOR
P I S T O NI N S P E C T I O N
C h e c k t h e p i s t o n s f o r s c o r i n g . s c r a t c h e so r o t h e r
d a m a g e .M e a s u r et h e p i s t o n d i a m e t e r w i t h a m i c r o -
meter.
SERVICELIMIT:
F R O N T : 3 1 . 9 4 0 m m ( 1 . 2 5 7 5i n )
REAR: 26.910 mm (1.0594in)
CYLINDER
INSPECTION
C h e c kt h e c a l i p e rc y l i n d e rf o r s c o r i n gs, c r a t c h eosr
o t h e rd a m a g eM . e a s u rteh e c a l i p e rc y l i n d e rb o r e .
S E R V I C EL I M I T :
F R O N T : 3 2 . 0 9 0m m ( 1 . 2 6 3 4i n )
R E A R : 2 7 . 0 6 0m m ( 1 . 0 6 5 4i n )
t
r'i
P I S T O NS E A L S
A S S E ML
BY
l f t h e c o l l a r b o o t s a r e h a r d e n e do r d e t e r i o r a t e d .
replace t h e mw i t h n e w o n e s .
The piston sealsmust be replacedwith new ones
wheneverthey are removed.Coat the sealswith
s i l i c o n eg r e a s oe r b r a k ef l u i d b e f o r ea s s e m b l y .
Installthe pistonswith the dishedendstoward the
ffire
pads.
A p p l y m i d i u m g r a d e o f H i - T e m p e r a t u r sei l i c o n
g r e a steo t h e c o l l a ra n d i n s i d eo f t h e c o l l a rg r e a s e .
I n s t a l lt h e c o l l a rb o o t sa n d c o l l a rm a k i n gs u r et h a t
the bootsareseatedin the collarand calipergrooves
properly.
-ffi
" l u*w
I n s t a ltl h e p a ds p r i n g .
I n s t a ltl h e p a d s( p a g e1 6 - 5 ) .
COLLAR
I
P A DS P R I N G
D a t eo f l s s u eO
: c t o b e r1
, 983
1 6 ^1- 2 O H O N D AM O T O RC O . ,L T D .
IIONTf,DA
V45 INTERCEPTOR H Y D R A U L I CB R A K E
CALIPER
PIVOTBOOT
F R O N TB R A K EC A L I P E R
INSTALLATION
Make sure that the retainerclip is in position on
the caliperbracket.
Inspect the condition of the caliper pivot boot.
Apply siliconegreaseto the caliperpivot bolt.
R I G H TC A L I P E R L E F TC A L I P E R
Installthe caliperassemblyover the brake disc so
that the disc is positionedbetweenthe pads.
CAUTION
t\- R i S h t c a l i p e r : I n s t a l l t h e c a l i p e rp i v o t b o l t a n d
caliperbolt, and tightenthem securely.
Left caliper: Installthe caliperpivot bolt and anti-
dive link bolt, and tightenthem securely.
C A L I P E RP I V O TB O O T
R E A RB R A K EC A L I P E RI N S T A L L A T I O N
Makesurethat the retainerclip is in positionon the
caliperbracket.
Inspect the condition of the caliper pivot boot.
to the caliperpivot bolt.
Apply siliconegrease
\
CLIP
RETAINER
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . .L T D . 1 6 -1 3
IIONTIDA
H Y D R A U L I CB R A K E
V45 INTER,CEPTOR
S E A L I N GW A S H E R S
]YIASTER
REAR CYTINDER
REMOVAL
Drain the rear brake hydraulicsystem(page16-3).
Remove the brake hose bolt and disconnectthe
brakehose.
R I G H TF O O T P E G
BRACKET
Loosenthe rearmastercylindermount bolts.
Removethe right footpegbracket.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 6 -1 4 O H O N D AM O T O RC O . ,L T D .
IIONTf,DA
V45 INTER,CEPTOR
H Y D R A U L I CB R A K E
M A S T E RC Y L I N D E RH O S E
Removethe hoseconnectorscrew and disconnect
the mastercylinderhose.
A C T U A T I N GA R M B O L T S P RI N G
Unhookthe rearbrakepedalreturnspring.
Removethe rear brake actuatingarm bolt and the
m i d d l ea r m .
C O T T E RP I N
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 1 6 -1 5
IIONTIDA
H Y D R A U L I CB R A K E
V45 INTER.CEPIOR,
S N A PR I N G
DISASSEMBLY
Removethe rubberboot.
I
R e m o v et h e s n a pr i n ga n dp u s hr o d f r o m t h e m a s t e r
c y l i n d e rb o d y .
R e m o v et h e m a s t e rp i s t o n ,p r i m a r yc u p a n ds p r i n g .
I t m a y b e n e c e s s a rt yo a p p l y a s m a l la m o u n to f a i r
pressureto the fluid outlet to removethe master
p i s t o na n d p r i m a r yc u P .
C l e a na l l p a r t sw i t h b r a k ef l u i d .
S N A PR I N GP L I E R So r E O IN U.S.A.
07914-3230001
I . D .I N S P E C T I O N
CYLINDER
Measure t h e i n s i d ed i a m e t e ro f t h e m a s t e rc v l i n d e r
bore.
S E R V I C EL I M I T : 1 4 . 0 5 5m m ( 0 . 5 5 3 3i n )
or nicks.
Checkfor scores,scratches
O . D .I N S P E C T I O N
PISTON
r i s t o nO . D .
M e a s u rteh e m a s t e P
S E R V I C EL I M I T : 3 . 9 4 5m m ( 0 . 5 4 9 0i n )
1
C h e c kt h e p r i m a r yc u p a n d p i s t o nc u p f o r d a m a g e .
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 6 -1 6 O H O N D AM O T O RC O . .L T D .
IIONITDA
V45 INTER,CEPTOR.
H Y D R A U L I CB R A K E
ASSEMBLY
CAUTION
Keep the master cylinder piston, cylinder
and sping as a set; do not substitute indivi-
dual parts.
@,
Assemble the mastercylinder. rg- u / s.,^
Coatall partswith cleanbrakefluid.
lnstallthe rubbercover.
INSTALLATION
Install the master cylinder to the right footpeg
\_ bracket.
MASTE,R
CYLINDER
P U N C HM A R K S R E T U R NS P R I N G
Connectthe rear brake actuatingarm to the master
cylinderpush rod with the joint pin, and securethe
joint pin with the washerand a new cotter pin.
Installthe actuatingarm onto the rear brakepedal
shaft, aligningthe punch marks on the arm and
shaft.
Hook the rear brake pedal ieturn spring to the
actuatingarm.
Tightenthe actuatingarm bolt.
T O R O U E :1 0 - 1 5 N . m ( 1 . 0 - 1 . 5 k g - m , 7 - 1 1 f t - l b )
J O I N TP I N
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 1 6 -1 7
IIOTSXDA
V45 INTERGEPTOR,
H Y D R A U L I CB R A K E
M A S T E RC Y L I N D E RH O S E BRAKE T C HS P R I N G
Connect the master cylinder hose to the master
cylinderwith a new O-ringand screw.
A C T U A T I N GA R M
R I G H T F O O T P E GB R A C K E T
Installthe right footpegbracket.
Tightenthe bracketbolt.
Tightenthe rear brakemastercylindermount bolts.
C Y L I N D E RM O U N TB O L T S
MASTER
F L U I DB O L T
Connectthe rear brake hosewith the fluid bolt and
two sealingwashers.
Fill and bleedthe rearbrakesystem(page16-4).
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1 6 -1 8 @ H O N D AM O T O RC O . ,L T D .
IIONTXDA
V45 INTERCEPTOR BR AKE
HYDRAULIC
'l
MEMO
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 1 6 -1 9
IilONTDA
BATTERY/CHARGING
SYSTEM V45 INTERCEPTOR,
BATTERY
ALTERNATOR
BATTERY/CHARGI NG SYSTEM
RED/WHITE
(r
llJ
F
F
3 cll
o
J
J
UJ
VOLTAGE
SENSOR
ALTERNATOR
REGULATOR/RECTIFIER
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
17-O O H O N D AM O T O RC O . .L T D .
ITONTT'A
BATTE
RY
/ Cl|ARG
INOSYSTTM
S E R V I C EI N F O R M A T I O N 17-1
TROUBLESHOOTING 17-2
BATTERY 17-3
C H A R G I N GS Y S T E M 17-4
sERt|rCt
t1{F0RMAT|01{
GENE
RAL
o B a t t e r yf l u i d l e v e sl h o u l db e c h e c k e dr e g u l a r l yF. i l l w i t h d i s t i l l e dw a t e r w h e nn e c e s s a r y .
o Ouick-charge a batteryonly in an emergency; slow-charging is preferred.
o Removethe battery from the motorcyclefor charging.lf the battery must be chargedon the motorcycle,disconnectthe
battervcables.
Do not smoke or allow flames near a charging battery. The gasproduced by a battery will exptode if flnmes or sparks
are brought near.
SPECIFICATIONS
R e v i s e d J: a n u a r y , 1 9 8 6
o AmericanHondaMotor Co.,Inc.- All RightsReserved
MSV 9675 (8601)- ' 83-' 85 VF700F/VF750F 17-1
rDt IIONIDA
BATTERY/CHARGING v4s TNTERCEPTOR
SYSTEM €l
TR0UBtts]|00Ttl{0
No power- key turned on: Intermittentpower:
1. Deadbattery 1. Loosebatteryconnection
- Low fluid level 2. Loosechargingsystemconnection
- Low specificgravity 3. Loosestartingsystemconnection
- Chargingsystemfailure 4. Looseconnectionor shortcircuit in ignition
2. Disconnected batterycable system
3 . M a i nf u s eb u r n e do u t 5. Looseconnectionor shortcircuit in lighting
4. Faulty ignitionswitch system
Low power- key turnedon: Chargingsystemfailure:
1. Weakbattery 1. Loose,brokenor shortedwire or connection
- Low fluid level 2. Faultyvoltageregulator/rectifier
- Low specificgravity 3 . F a u l t ya l t e r n a t o r
- Chargingsystemfailure
2. Loosebatteryconnection
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
17-2 O H O N D AM O T O RC O . ,L T D .
EIOIITTDA
V45 INTERCEPTOR
BATTERY/CHARG
I NG SYSTEM
BATTERY
REMOVAL
Remove the battery holder bcilt, then swing the
holderout of the way.
Disconnect the negative cable at the battery, then
d i s c o n n e c t h e p o s i t i v ec a b l e .
Disconnect the battery breather hose from the
battery.
R e m o v et h e b a t t e r y .
TESTINGSPECIFICGRAVITY
NOTES 1 31 B A T T E R YI E M P E R A T U R E
VS SPECIFIC
GRAVITY
1 .2 4
e r ( )r r
p o s i t i v e( + )t e r l h i n a l .
Connect the charger negative (-) cable to the
batterynegative(-) terminal.
Chargingcurrent:1.4 amperesmax.
Chargethe battery until specificgravity is 1.27O-
L290 at 20'C {69'F).
uo-u
,,^
\/
. Before charging a battery, remove the cap
from each cell.
, Keep
flames and sparks awoy from a charg-
ing battery,
' Turn power ONIOFF ot the charger, not
at the battery terminols to prevent sparks.
' Discontinue charging if the electrolyte
temperatureexceeds4S"C ( I l3"F).
R e v i s e dJ: a n u a r y 1
, 986
@ AmericanHondaMotor Co.,Inc.- All RightsReserved
MSV 9675 (8601i- ' 83-' 85 vF70OF/VF7iOF
17-3
IIONTIDA
V45 INTERGEPTOR
SYSTEM
BATTERY/CHARGING
CAUTION
' f;AUTr0r{
Quick-chargingshould only be done in an rtnrie *$ $}fitfrfi t(t0r.
emergency; slow'charging h prefened.
, Route the breather tube as shown on the
battew caution label. 8tr1{n
Y
[]$q*s
""*..'
After installingthe battery,coat the terminalswith
m$f
cleangrease. s****_-*
r * t P_-{$ir:ri::
8 TI T { NT
8SItt]rfn
$fi ,"--"-'"
ril$fnT lfit HtrT[a{
$*ril[tt riltI
sfIunIrY,
SYSTEM
CHARGIl{G VOLTMETER
C U R R E NT E S T
NOTE
Make sure the battery is fully charged before
performingthis test.
R E G U L A T E DV O L T A G E : 1 4 . 0 - 1 5 . 0 V
l f v o l t a g ee x c e e d s1 5 V w h e n r a i s i n gt h e e n g i n es p e e d ,
t h e l i k e l i h o o di s :
o Open or short circuit (black wire of the regulator/
rectifier).
o Loose or poorly connected regulator,/rectifier \-.
coupler.
o Faulty regulator,/rectifier.
lf voltage does not increase when raising the engine
speed,the likelihoodis:
r Open or short circuit between the alternator and
regu lator,/rectifier.
o Loose or poorly connected alternator or regulator/
rectifier couplers.
o Open circuit in wire harness (red,/white or green
wires).
. Faulty alternator or regulator/rectifier.
R e v i s e dJ: a n u a r y , 1 9 8 6
17-4 @ AmericanHondaMotor Co.,Inc.'- All RightsReserved
MSV 9675 (8601) -' 83-' 85 VF700F/VF750F
DIOIVf,DA
V45 INTERCEPTOR. BATTERY/CHARG
ING SYSTEM
A L T E R N A T O RC O U P L E R
S T A T O RC O N T I N U I TTYE S T
Removethe left sidecover.
Disconnectthe alternator and regulator/rectifier
coupler.
Check for continuity betweenthe leads,and be-
t w e e nt h e l e a d sa n dg r o u n d .
Replace t h e s t a t o ri f t h e r ei s n o c o n t i n u i t yb e t w e e n
the leads,or if there is continuitybetweenthe leads
a n dg r o u n d .
R E G U L A T O R / R E C T I F I ECRO U P L E R
V O L T A G ER E G UL A T O R / RE C T F
I I ER
TEST
Removethe left sidecover.
Disconnect
the regulator/rectifier
couplers.
NOTE
The test results shown are for a positive
ground ohmmeter and the opposite results
w i l l b e o b t a i n e dw h e na n e g a t i vger o u n do h m -
m e t e ri s u s e d .
N O R M A LD l R E C T I O N
: CONTINU
ITY RED/WHITE
@ probe O probe z
YELLOW GREEN
z F
t_)
tl RED/WHITE YELLOW I.JJ
F E
uJ o
REVERSE
D I R E C T I O NN
: OC O N T I N U I T Y = UJ
o o
E
J J Iu
@ probe O probe
= 6 uJ
GREEN YELLOW
tl YELLOW RED/WHITE z
GREEN
D a t eo f l s s u eO
: c t o b e r1
, 983
O H O N D A M O T O RC O . .L T D . 17-5
IIONTDA
V45 INTERCEPTOR
BATTERY/CHARGING
SYSTEM
V O L T A G ER E G U L A T O R
PERFORMANC TE S T BLACK
Dateof lssue:January,1983
r7-6 O H O N D AM O T O RC O . ,L T D .
ITCDNIf,DA
V45 ]NTERCEPTON
MEMO
Dateof lssue:January,1983
O HONDA MOTOR CO.. LTD. 17-7
\IIONTXDA
I G N I T I O NS Y S T E M
V45 INTERCEPTOR
I G N I T I O NS W I T C H
E N G I N ES T O PS W I T C H
I G N I T I O NC O I L S
S P A R KU N I T S
S P A R KP L U G S
PULSE
GENERATORS BATTERY
I G N I T I O NS Y S T E MD I A GR A M
W H I T EC O U P L E R I G N I T I O NC O I L S P A R KP L U G
1 . 3C Y L I N D E R
S P A R KU N I T
T
I
I BATTERYt\-/
|
J_
P U L S EG E N E R A T O R S
R E DC O U P L E R
2 . 4C Y L I N D E R
S P A R KU N I T
D a t eo f l s s u eJ: a n u a r y1. 9 8 3
18-O O H O N D AM O T O RC O . ,L T D .
IIOISX'A
VJ7OOI750INTERCEPTOR
f8. t01{tTt0N
SYSTEM
S E R V I C EI N F O R M A T I O N 18-1
TROUBLESHOOTING 18-2
I G N I T I O NC O I L 18-3
T R A N S I S T O R I Z EIDG N I T I O NS Y S T E M 18-4
I G N I T I O NT I M I N G 18-5
S[Rt|
|CE|1{t0RilATl0
t{
GENERAL
o A TRANSISTORIZED
I G N I T I O NS Y S T E Mi s u s e da n d n o a d j u s t m e n tcsa nb e m a d e .
S P E C IIFC A T I O N S
ND NGK
S p a r kp l u g Standard X24EPR.U9 DPR8EA.9
F o r c o l d c l i m a t eB e l o w5 0 c ( 4 1 ' F ) X22EPR.U9 DPRTEA-9
F o r e x t e n d e dh i g h s p e e dd r i v i n g X27EPR.U9 DPR9EA.9
S p a r kp l u gg a p 0.8-0.9mm (0.031-0.035
in)
l g n i t i o nt i m i n g At idte- VF750F:1oo.VFToOF:150BTDC
Full advance37"BTDC/3,300rpm
Pulsegeneratorair gaP 0.3-0.9mm (0.012-0.035
in)
TOOL
Special
Timing inspectioncover 07998-M800000
\_
Dateof lssue:
June,1984
@AmericanHondaMotor Co., Inc. 1984 - All RightsReserved 18-1
IIOilIXDA
V45 INTERGEPTOR
I G N I T I O NS Y S T E M
TROUBTTS}|OOTIIIG
T h e i g n i t i o n s y s t e mh a s t w o s u b - s y s t e mosn; e f o r
t h e N o . 1 a n dN o . 3 c y l i n d e rasn do n ef o r t h e N o . 2
a n d N o . 4 c y l i n d e r sD. e t e r m i n w
e h i c h s u b - s y s t e im
s
faulty,then proceedto the detailedtestsbelow.
No sparkat plug
- E n g i n es t o ps w i t c hO F F
- P o o r l yc o n n e c t e db,r o k e no r s h o r t e dw i r e s
Betweenignitionswitchand enginestop switch
B e t w e e ns p a r ku n i t a n de n g i n es t o ps w i t c h
B e t w e e ns p a r ku n i t a n d i g n i t i o nc o i l
B e t w e e ni g n i t i o nc o i l a n d p l u g
B e t w e e ns p a r ku n i t a n d p u l s eg e n e r a t o r
- F a u l t yi g n i t i o nc o i l
- F a u l t yi g n i t i o ns w i t c h
- F a u l t ys p a r ku n i t
- F a u l t yp u l s eg e n e r a t o r
Enginestartsbut runspoorly
- l g n i t i o np r i m a r yc i r c u i t
F a u l t yi g n i t i o nc o i l
\-
L o o s eo r b a r ew i r e
In t e r mi t t e n ts h o r tc i r c u i t
- S e c o n d a rcyi r c u i t
F a u l t yp l u g
F a u l t yh i g ht e n s i o nw i r e
Timingadvanceincorrect
- F a u l t yp u l s eg e n e r a t o r
- F a u l t ys p a r ku n i t
\-.
a
Dateof lssue:January,1983
1A-2 O H O N D AM O T O RC O . ,L T D .
IIONTTDA
V45 INTERCEPTOR I G N I T I O NS Y S T E M
tGNtTt0l{
c0rL
Removethe seatand fuel tank.
I G NI T I O NC O IL T E R M I N A L S
C O N T I N U I T YT E S T
the coilsprimaryleads.
Disconnect
M e a s u rteh e p r i m a r yc o i l r e s i s t a n c e .
R E S I S T A N C E2:. 8 O
Dateof lssue:October.1983
O H O N D A M O T O RC O . ,L T D . 18-3
IIONTDA
I G N I T I O NS Y S T E M
V45 INTER.CEPTOR
TRAl{SISTORIZTD
IGNITIOl{
SYSTE||| P U L S EG E N ER A T O RC O U P L E R
P U L S EG E N E R A T OTRE S T
Removethe right sidecover.
Disconnectthe pulsegeneratorcouplerand measure
the coil resistance.
RESISTANCE:Approximately480 Q
B e t w e e nw h i t e / y e l l o wa n d y e l l o w l e a d s( 1 , 3 c y -
Ii n d e r s )
B e t w e e nw h i t e / b l u e a n d b l u e l e a d s ( 2 , 4 c y -
linders)
2 _ 4 C Y L I N D E RP U L S E
GENERATOR
P UL S EGE N ER A T O RRE P L A C E M E N T
Removethe clutchcover(page7-10).
Removethe pulse generatormounting bolts, and
pulsegenerators.
Installnew pulsegenerators.
Measurethe air gap betweenthe pulse generator
and rotor.
AIR GAP: 0.3-0.9 mm (0.012-0.035in)
F E E L E RG A U G E
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
1A-4 O H O N D AM O T O RC O . .L T D .
ITONTf,DA
V45 INTERGEPTOR
I G N I T I O NS Y S T E M
1 , 3C Y L I N D E R 2 , 4C Y L I N D E R
SPARK UNIT S P A R KU N I T
S P A R KU N I T
lf the pulsegenerators, ignitioncoils and wiringare
good, and the ignitiontiming is not within specifica-
tion; replacethe spark units with new ones and
recheckthe ignitiontiming.
tGNtTr0l{
Tt|||mG F U L L A D V A N C EM A R K
\- NorE
NOTE
The ignition system is transistorizedand
c a n n o t b e a d j u s t e d l.f t h e i g n i t i o nt i m i n g i s
incorrect,check the spark units and pulse
generators.
Replacepartsas required.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . .L T D . 18-5
....-,.1
IIONTT)A
ELECTRIC
STARTER V45 INTER.CEPTOR,
C L U T C HS W I T C H
STARTER STARTER
BUTTON R E L A YS W I T C H
STARTER BATTERY
MOTOR
N E U T R A LS W I T C H
STARTER
S T A R T E RM O T O R R E L A YS W I T C H
GREEN/RED
FUSE T
30A ()
F-
STARTER
BUTTON
3
U)
R E L A YC O I L J CLUTCH
I G N I T I O NS W I T C H SWITCH
r
IJJ
I
N E U T R A LI N D I C A T O R
z
GR E E N
BATTERY
D a t eo f i s s u eJ: a n u a r y1, 9 8 3
19-O O H O N D AM O T O RC O . .L T D .
IIOI\Tf,DA
V45 INTER,CEPTOR
19.ELECTRIC
STARTER
S E R V I C EI N F O R M A T I O N 19-1
TROUBLESHOOTING 19-1
STARTERMOTOR 19-2
S T A R T E RR E L A Y S W I T C H 19-5
C L U T C HD I O D E 19-5
INTOR]I|ATIO]I
SERI,ICE
GENERAL
o T h e s t a r t e rm o t o r c a n b e r e m o v e dw i t h t h e e n g i n ei n t h e f r a m e .
S P E C IIFC A T I O N S
STANDARD SERVICL
EI M I T
Startermotor B r u s hs p r i n gt e n s i o n 680-920s Q4i-325 ozl 545s (19.2ozl
B r u s hl e n g t h 1 2 . 0 - 1 3 . 0m m ( 0 . 4 7 - 0 . 5 1i n ) 6 . 5 m m ( 0 . 2 6i n )
TROUBTES1|OOIINO
Startermotor will not turn: Startermotor turns,but enginedoesnot turn:
1. Batterydischarged. 1 . F a u l t ys t a r t e cr l u t c h .
2. Faulty ignitionswitch. 2. Faulty startermotor gears.
3. Faulty starterswitch. 3. Faulty startermotor or idle gear.
'
4, Faulty neutralswitch.
' Startermotor and engineturns,but enginedoes
5. Faulty starterrelayswitch. /'
not start
6. Looseor disconnected wire or cablel
1 . F a u l t yi g n i t i o ns y s t e m .
7. Clutchdiodeopen. .z-
2. Engineproblems.
Startermotor turnsengineslowlY - Low compression.
1. Low specificgravityin battery. - FouledsparkPlugs.
2. Excessiveresistancein circuit.
3. Bindingin startermotor.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 1 9 -1
IilOTVDA
E L E C T R I CS T A R T E R
V45 INTERCEPTOR,
il|OIOR
STARTTR S T A R T E RC A B L E
REMOVAL
C A S EA N D F I E L DC O I L
ARMATURE
B R U S HH O L D E R
B R U S HS P R I N G
O-RING
REAR C O V E R S HI M S
C A B T ET E R M I N A LA N D B R U S H E S
F R O N TC O V E R
Dateof lssue:October,1983
19-2 O H O N D AM O T O RC O . .L T D .
I1IONTf,DA
V45 INTERCEPTOR E L E C T R I CS T A R T E R
BRUSH
B R U S HI N S P E C T I O N LENGTH
R e m o v et h e s t a r t e rm o t o r c a s es c r e w s .
l n s p e c t h e b r u s h e sa n d m e a s u r et h e b r u s hl e n g t h
M e a s u r eb r u s h s p r i n gt e n s i o nw i t h a s p r i n gs c a l e .
S E R V I C EL I M I T S :
B r u s hl e n g t h : 6 . 5 m m ( 0 . 2 6i n )
B r u s hs p r i n gt e n s i o n : 5 4 5 g ( 1 9 . 2o z )
COMMUTATOR
C O M M U T A T OIR
N S P E CO
T IN
R e m o v et h e s t a r t e rm o t o r c a s e .
NOTE
Record the location and number of shims.
I n s p e ctth e c o m m u t a t obr a r sf o r d i s c o l o r a t i o n .
i n p a i r si n di c a t eg r o u n d e d
B a r sd i s c o l o r e d armature
c o iIs .
NOTE
Do not use emery or sand paperon the com-
mutator.
C O N T I N U I T YB E T W E E N
COMMUTATOR B A R P A I R S :N O R M A L
Checkfor continuity betweenpairsof commutator
oars.
T h e r es h o u l db e c o n t i n u i t y .
A l s o , m a k e a c o n t i n u i t yc h e c kb e t w e e ni n d i v i d u a l
c o m m u t a t o br a r sa n dt h e a r m a t u r es h a f t .
T h e r es h o u l db e n o c o n t i n u i t v .
rrroco rrrrrnruITYBETWEEN
B A R SA N D A R M A T U R ES H A F T :N O R M A L
COMMUTATOR
D a t eo f l s s u eJ: a n u a r yi,9 8 3
O H O N D AM O T O RC O . .L T D . 19-3
ITOTUXDA
E L E C T R I CS T A R T E R V45 INIERCEPTOR.
N OC O N T I N U I TBYE T W E E N
F I E L DC O I LI N S P E C T I O N CABLE T E R M I N AALN DM O T O RC A S EN: O R M A L
B R U S HH O L D E R NOTCH PIN
ASSEM
BL Y / IN S T AL L A T IO N
A s s e m b lteh e s t a r t e rm o t o r .
A l i g n t h e c a s en o t c h w i t h t h e b r u s h h o l d e r p i n .
PIN
I n s t a l lt h e r e a rc o v e ra l i g n i n gi t s s l o t w i t h t h e b r u s h
h o l d e rp i n .
B R U S HH O L D E R R E A RB R A C K E T
Dateof lssue:October,1983
19-4 O H O N D AM O T O RC O . .L T D .
ITONTTDA
V45 INTER.CEPTOR E L E C T R I CS T A R T E R
RTTAY
STARTER SI|JITCI| S T A R T E RR E L A YS W I T C H
I N S P E C TOI N
D e p r e s st h e s t a r t e r s w i t c h b u t t o n w i t h t h e i g n i t i o n
oN.
T h e c o i l i s n o r m a li f t h e s t a r t e r e l a ys w i t c hc l i c k s .
C o n n e c ta n o h m m e t e rt o t h e s t a r t e rr e l a y s w i t c h
t e r mi n a l s .
C o n n e c ta 1 2 Y b a t t e r vt o t h e s w i t c hc a b l et e r m i '
n at s .
T h e s w i t c hi s n o r m a li f t h e r ei s c o n t i n u i t y .
----,/-*----l'
CTUTCI|
DIOOE C L U T C HD I O D E
REMOVAL
R e m o v et h e f u e l t a n k .
R e m o v et h e c l u t c h d i o d e f r o m t h e w i r e h a r n e s s .
D a t eo f l s s u eJ: a n u a r v 1, 9 8 3
O H O N D A M O T O RC O . .L T D . 19-5
InofirtDA
E L E C T R I CS T A R T E R
V45 INTERCEPIOR
N O R M A LD l R E C T I O N
: CONTINUITY
REVERSE D I R E C T I O NN: OC O N T I N U I T Y
lNSPECTION
Checkfor continuitywith an ohmmeter.
\-.
Jfr
Dateof lssue;
October,1983
19'6 O HONDAMOTORCO.,LTD.
IIONTXDA
V45 INTERCEPTOR,
20.stt|lTcHEs
S E R V I C EI N F O R M A T I O N 2O_1 FUEL PUMP RELAY 20_6
OIL PRESSURE
SWITCH 2O_2 FUEL LEVEL SENSOR 20-7
BRAKE LIGHT SWITCH 2O_2 THERMOSTATIC
SWITCH 20-8
N E U T R A LS W I T C H 2O_3 FAN MOTOR RELAY 20-8
CLUTCHSWITCH 2O_3 TEMPERATURESENSOR 20-9
H A N D L E B A RS W I T C H E S 2O-4 TEMPERATURE
GAUGE 20-10
I G N I T I O NS W I T C H 2O_5 TACHOMETER 20-10
FUEL PUMP 20-6 B R A K E A N D T A ! L L I G H T SENSOR 20-10
l1{t0R]I|AT|0l{
SERI|TCE
GENERAL
o Somewires havedifferent coloredbandsaroundthem nearthe connector.Theseare connectedto other wireswhich cor-
respondwith the bandcolor.
o All plasticplugshavelockingtabsthat must be released beforedisconnecting, and must be alignedwhen reconnecting.
t h r o u g h o utth i s s e c t i o na n d o n t h e w i r i n gd i a g r a m .
r T h e f o l l o w i n gc o l o rc o d e su s e da r ei n d i c a t e d
o T o i s o l a t ea n e l e c t r i c af la i l u r e ,c h e c kt h e c o n t i n u i t yo f t h e e l e c t r i c apl a t ht h r o u g ht h e p a r t .A c o n t i n u i t yc h e c kc a nu s u a l l y
be madewithout removingthe part from the motorcycle.Simply disconnectthe wiresand connecta continuity testeror
v o l t - o h m m e t et or t h e t e r m i n a l so r c o n n e c t i o n s .
o A continuitv tester is usefulwhen checkingto find out whetheror not there is an electricalconnectionbetweenthe two
ooints.An ohmmeteris neededto measurethe resistance of a circuit,suchaswhen there is a specificcoil resistance involv-
ed, or when checkingfor high resistance causedby corrodedconnections.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM o T o R c o . . L T D . 20. 1
IIONTDA
V45 INTERCEPTOR
SWITCHES
OItPRESSURE
SITITC]|
Disconnectthe oil pressureswitch leadand remove
the switch.
BRAIfiTIG]|ISltITC]|
Check the rear brake light switch for continuity
with the rearbrakeapplied.
F R O N TB R A K EL I G H TS W I T C H
Check the front brake light switch for continuity
with the front brakeapplied.
D a t eo f l s s u eJ: a n u a r V1, 9 8 3
20.2 O H O N D A M O T O RC O . ,L T D .
IIONTDA
V45 INTERGEPTOR SWITCHES
1{EUTRAt
SI||ITCl| N E U TR A L S W I T C HC O N N E C T O R
\\_
SCREWS
REMOVAL
Removethe neutralswitchcover.
; L INSTALLATION
lnstall the neutral switch in the reverseorder of
removal. Tighten the switch mounting screws'
T O R O U E : 7 - 1 1N . m
(0.7-1.1 ks-m,5-8 ft-lb)
lnstallthe neutralswitchcover.
N E U T R A LS W I T C H
COVER
C L U T C HS W I T C H
CTUTCH
SITITC1|
Checkcontinuity of the clutch lever(safety)switch
with the clutch releasedand applied. Replaceif
necessary.
\_'
C L U T C HA P P L E
I D:CONTINUITY
C L U T C HR E L E A S E DN: O C O N T I N U I T Y
Dateof lssue:October.1983
@ H O N D A M O T O RC O . ,L T D . 20'-3
DIONTf,DA
SWITCHES
V45 INTERCEPTOR
HEADLIGHT
1|A]IDLEBAR
SltITC|lIS HI_LOSWITCH
bar clusterswitchesfollow:
T U R N S I G N A LS W I
T U R NS I G N A LS W I T C H Turn SignalSwitch
H O R NB U T T O N Horn Button
T I
Color code LG WG
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
20.4 O H O N D AM O T O RC O . ,L T D .
IIONTDA
V45 INTERCEPTOR,
SWITCHES
S T A R T E RB U T T O N E N G I N ES T O PS W I T C H
Bl to Y/R with button pushedin.
Bl/R to Bu/W with button out.
Starter Button
IG ST HLl HL2
OUT o- --o
START c- --c
Color code BI Y/R BI/R BUAV
* \_ ENGTNE
sroPswtrcH
RUN: Blto Bl/W
OFF: No continuity STARTER
EngineStop Switch
BAT2 IG
OFF
RUN o-
Color code BI/W BI
IGilITIOl{
SI{ITG||
Removethe fairing and headlight.Disconnectthe
ignitionswitchcoupler.
S W I T C HP O S I T I O N
I G N I T I O NS W I T C H
LOCK: No continuity
\_ OFF: No continuity
ON: R to Bl, BrlW to Br - continuity
PARK: Br to R - continuity
Terminal
PA BATl IG TLr TLz
Position
P }_
ON G. --o {
OFF
LOCK
Color
code
Br R BI Br/W Br
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D A M O T O RC O . ,L T D . 20.5
IIONTTDA
V45 INTER,CEPIOR,
SWITCHES
I G N I T I O NS W I T C HD I S A S S E M B L Y
Insertthe key and turn it so it is part way between
t h e " O N " a n d " O F F " d e t e n tp o s i t i o n s .
Pry openthe wire retainer.
P u s hi n t h e l u g st h a ta r e l o c k e di n t h e s l o t s t, h e np u l l
the contactbase{romthe switch.
Assemblein the reverse orderof removal.
PUltlP
FlJEL \z'':-*
F U E LP U M PR E L A Y
\ z,--.-\
T u r n t h e i g n i t i o ns w i t c ho n a n d l e t f u e l f l o w i n t o
t h e b e a k e rf o r 5 s e c o n d st,h e n t u r n t h e i g n i t i o n \ \ry*I
-\ffiil Il
s w i t c ho f f . M u l t i p l yt h e a m o u n ti n t h e b e a k e b
r y 12
t o d e t e r m i n et h e f u e l p u m p f l o w c a p a c i t yp e r
minute. / \ u
JUMPEW
R IRE
F U E L P U M PF L O WC A P A C I T Y :
660cc(22 US oz, 18.6 lmp ozl t 1O%/minute
NOTE
d a t t e r yo r f a l s er e a d i n g s
U s ea f u l l y c h a r g e b
may result.
Battery voltage should be above 12.5 V.
FUEL
PUMP
RTLAY
Checkfor a burnt sub-fuse.
Check the relay couplerfor impropercontactand F U E LP U M PR E L A Y
looseness. VOLTMETER
Measurethe voltagebetweenthe relay black wire
and a body ground. The battery voltageshould
r e g i s t ewr i t h t h e i g n i t i o ns w i t c hO N .
M a k e s u r e t h a t t h e f u e l p u m p o p e r a t e sw h i l e t h e
r e l a yc o u p l e rb l a c ka n d w h i t e w i r e sa r es h o r t e da n d
the ignitionsiruitch is ON.
l f t h e p u m p d o e sn o t o p e r a t ec, h e c kt h e f u e l p u m p
c o u p l e fr o r i m p r o p e cr o n t a c ta n dt h e f u e l p u m p .
R e v i s e dJ: a n u a r v , 1 9 8 6
20.6 o AmericanHondaMotor Co.,Inc.- All RightsReserved
MSV 9675 (8601)-
'83-'85
VF7OoF/VF75OF
IIONIf,DA
V45 INTER,GEPTOR SWITCHES
FUEL
TEYET
SE]ISOR F U E L L E V E LS E N S O R
REMOVAL
Removethe fuel tank and drainthe fuel.
Remove the fuel level sensorattachingnuts and
fuel levelsensor.
INSPECTION
Measurethe resistance of the fuel levelsensorin the
full and empty float positions.
R E S I S T A N C EF: U L L 3 . 5 - 9 . 5 Q
EMPTY 9O-1OOO
EMPTY
i\
'""'"'^^^'i
rrr.
FULL
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 2o.7
IIONTDA
SWITCHES 50 INTERCEPTOR
VJTOOIT
THERMOSTATIC
THEBMOSTAT
SWITCH THERMOSTATIC
SWITCHLEADS SWITCH
t%
T h e c o o l i n gf a n m o t o rs h o u l ds t a r t r u n n i n g .
lf it does not start, checkfor batteryvoltagefrom
the black lead (positive)to black,/blue(negative)of
t h e f a n m o t o rc o u p l e r .
lf there is no voltage,check for a blown or faulty
fuse, loose terminals or connectors,or an open
c i r c ui t .
lf it starts, inspectthe fan thermostaticswitch as
"-":i..,",
follows:
J U M P E RW I R E
NOTE
M a i n t a i n t h e h i g h t e p e r a t u r ef o r 3 m i n -
utes beforetesting continuity.A sudden
c h a n g ei n t e m p e r a t u r ew i l l c a u s ea n e r r o r
in the reading.
Do not let the themometeror switch touch
t h e p a n a s i t w i l l g i v ea f a l s er e a d i n g .
Soak the switch in coolant uo to its
threads.
(' 83VF750F)
FANM0T0RRELAY
NOTE FAN MOTORRELAY
'83
TheYFTOOF /VF750F after do not have
t h e f a n m o t o rr e l a y .
'83
The w i r i n g d i a g r a mc a l l s t h i s p a r t a
MainRelay.
OHMMETER
SEI{SOR
TTI||PERATURE
Disconnectthe green/bluewire from the tempera-
ture sensor.
Drain the coolant and remove the temperature
sensorfrom the thermostatcase.
g50c TEMPERATURE
SENSOR
60'c 1 1 0 ' C 120"C
Temperature
140"F 1950F 23oo F 24goF
Resistance 104.0s)43.9Q 20.3s) 1 6 . 1 Q
NOTE
. Oil must be usedas the heatedliquid to
checkoperationabove100"C (212" F).
. You'll get false readings if either the THERMOMETER
t hermometer or temperature sensor
touchesthe pan.
Dateof lssue:October,1983
O H O N D AM O T O RC O . ,L T D . 20.9
....
Iil(oNTXDA
SWITCHES
V45 INTER,GEPTOR
TE]I|PERATURT
GAUGT T E M P E R A T U RS
EE N S O R
CAUTION
Do not leave the temperature sensor wire
grounded for longer than a few secondsor the
temperature gauge will be damaged.
TACl|OMETER
lf the tachometerdoes not work properly,replace
the 1-3 sparkunit with a new one and recheckthe TACHOMETER
oPeration.
lf the problem still appears,replacethe sparkunit
with the originalone and tachometerwith a new 4 lllxlooorPm
one.
P U L S EG E N E R A T O R
B R A K EA N D T A I L
ANDTAItLIG]|T
BRAI(T SENSOR L I G H TS E N S O R
T u r n t h e i g n i t i o ns w i t c ho n .
Checkthe sourcevoltageat the black/brownlead.
lf there is no voltage,check and repairthe source
c i r c ui t .
lf there is voltage, measurethe voltage at the
white/yellow (positive)and green/yellow(negative)
wires.
VOLTAGE: 5V
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
2o'-10 O H O N D AM O T O RC O . .L T D .
IIOTVf,DA
VF7OOI750
INTERCEPTOR
'83
\r-
v 4 5 T N T E R C E P T O (RV F 7 5 O F }
i A(ffiAOLtgT)
B (SETER)
c(IUm srillL. FRoilT.
REAR8RAXE.
rcil)
o(FRorlT
POSrlil. rErERLrgT TArL)
uEnRLBT --.j
IHERMo StrrcH
\-
slrq ffrun
ms'm l,
ffii
m l P L
R o
H.Oto 1-\ |
v 4 5 I N T E R C E P T O R{ V F 7 5 O F }
t FUS€ {rln) Il
|@rqT)
('trl
-F gqtL. FMT. R€rR mA(E. ffi)
qr msrlrfl. TETERLr*T utL)
+t
-qr{4
IM gML REUY
r+-t 1l
| r
rtrRMosilTCN
J-J"l I
ilzr
iI
l?w'bot tr)
STF AD TAILLIST
I
I
e
I
E.
P
b I
:_l
I
I S'O Svrfl
I
otL mEsSuRE
strrcH
E uq & WN
YE[fl 0 ffre
o *G u Udr 1[
ffi l{ !ffiffi
R m
IHTE q qft
-tB2- 6700
00302
21-1
I
IIOI|IXDA
V}7OOI750INTERCEPTOR
i I N T E R C E P T O R( V F 7 s O F )
rl
ruqr)
ro)
a wL 5TS L|ST m)
FTIq ilElER LIGHI TIIL)
rQ' fuEL.START'CHARtr)
F U S E( M A l N )
sA
as &x
*r =
-*1 TURflSIilIL R RURTUfr 9il1 l?Wcp(?lr)
THENMO INIT
:
^ msl sroFLGNT SW]TCN
fs'a-'.-
I
i,rbd{ l
Lixefo/ |
rcNrlot colL
lr;ii
L RSn IUm gqll llw&r{llr)
P+
p<q ill
I
P<E
b +P
A
(6ril)
,LjPARX
-
REfuLATOR/NECTIFIER
,*,'lltttt^'o'
0 u q & w i l
Y YELLOI O fire
& aE u uqT*[
e m k uqTqEi
R M P H i l
T THTE O qft
00302-M82-9000
Dateof lssue:October,1984
@AmericanHondaMotorCo.,Inc. 1984- All RightsReserved
W I R I N GD I A G R A M S
AFTER'83
(VF7sOF)
v45 INTERCEPTOR
rDarfi Lrqr cLusti i2v3w xa
R TURNSIOAL IWATfr
EUTRIL IUCITfi
aq s$ rrctctrfi
rilTtd sflrq
rusE&x
I FUSElOA (EAilqT)
TNERMOSWlCH
u'r-loc=-
R MT TR gqIL I ro$Tlil LISI
t?v!?/t.rt?t/t*)
L]GNTSWITCH
tetTtot colL
L FW TW SIilL I rcgTlil LIqI
lIv3z/3co(2!/lr)
ffn
ste s[TcN
roStlld.Tm gqAL.OilMER. ffi SIITS
- srtTcH cflltNufv
qMM€R
ffiffi
stlRtER sflts ffi sre sffq SW]ICH
ffiffi
,All IG TU fL2
a a
r) l' loFrol
21-2
ITONTf,DA
V45 INTERCEPIOR TEATIJRE
22.TEGHl'llCAt
V . 4 E N G I N EF E A T U R E S 22-1
ONE.WAYCLUTCH SYSTEM 22-2
l,.4E]{GII{E
TEATURES
watercooledV'4.
The enginedesignis a DOHC, 16'valve,
apart.
The cylindersarearrangedin two banksof two cylinders,90 degrees
I
The pent-roofcombustionchamberhas four valvesper cylinder (two intakeand two exhaustvalves)ensurehighly-efficient
intakeand exhaustflow.
o Rocker arms
With the rocker arms under the camshafts,
overall weight is reduced and valve float at high
rpm is virtually eliminated.
D a t eo f l s s u eJ: a n u a r v1. 9 8 3
MoroR
oH'NDA &r 22- 1
l'F,Jll,,'-',,-', -4
I{ONIXDA
T E C H N I C A LF E A T U R E S
V45 INTERCEPTOR,
O}IE.I||AY
CLUTC||
SYSTEM
Purpose:
On rapid downshiftingfrom high RPM, the compression brakingforcescreatedby the enginecan exceedthe rear wheel's
traction;the enginebecomesa rearwheelbrake.This cancausemomentarylockupof the rearwheel- until the compression
brakingforce drops below the levelnecessary to makethe reartire breaktraction.lf multipledownshiftsaremade,the result
will be a much longer loss of traction. The one-wayclutch systemhas been specificallydesignedto preventthis lossof
traction.
C L U T C HI N N E R
( h a ss p l i n e s ) o
O N E - W ACYL U T C H
O N E . W A YS P R A G
CLUTCH
( S p l i n e dt o m a i n s h a f t )
INNER
C L U T C HI N N E R
( n o s p l i n e sb u t r e c e i v e s
powervia the one-way
s p r a gc l u t c h )
O U T E RP O R T I O N
Design:
The majordifferencebetweenthis systemand a conventionalclutch is a two-piececlutch inner.In addition,the outer portion
of the clutch inner, that which controls the majority of the clutch platesand discs,is driven by a specialone-waysprag
c lu t c h .
o T h e i n n e rp o r t i o no f t h e c l u t c h i n n e ri s s p l i n e dt o t h e t r a n s m i s s i o nm ' sa i n s h a fat s i s n o r m a l .B u t i t o n l y c o n t r o l sa b o u t
t w o - f i f t h e so f t h e c l u t c hp l a t e sa n d d i s c s T
. h i s p o r t i o no f t h e c l u t c ht r a n s m i t sp o w e ra n dd e c e l e r a t i ofno r c e si n t h e u s u a l
manner.
o T h e o u t e r p o r t i o no f t h e c l u t c h i n n e ri s n o t s p l i n e dt o t h e t r a n s m i s s i o nm' sa i n s h a f tl .t c o n t r o l sa b o u tt h r e e -iff t h e so f t h e
clutch plates and discs.This portion transmitspower when the spragclutch is locked up, such as during normal
a c c e l e r a t i ocnr,u i s i n ga, n dd e c e l e r a t i o n .
Operation:
Whenthe transmission is downshiftedfrom high RPM, it causesa backloadingat the clutch because of the forcesgenerated
by the engine'scompressionbrakingeffect. lf theseforcesapproachthat which will causethe rear wheelto lock up, tne
o n e - w a yc l u t c hw i l l d i s e n g a gt eh e o u t e r p o r t i o na n d a l l o wt h e i n n e rp o r t i o nt o s l i p .l t w i l l d o t h i s t o a d e g r e e
t h a t a l l o w st h e
r e a rw h e e lt o m a i n t a i nt r a c t i o nw h i l e m a i n t a i n i n tgh e h i g h e set f f e c to f e n g i n eb r a k i n g S. o r a t h e rt h a n b e i n ga h a r s hO N o r
O F F m e c h a n i s mt h , e o n e - w a yc l u t c h d e t e r m i n e tsh e c o r r e c ta m o u n t o f s l i p f o r e a c hs i t u a t i o n a . ll the whilemaintainino
maximumpossibleenginebrakingeffect.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
22-2 O H O N D AM O T O RC O . .L T D .
IIONTfDA
V45 INTERCEPTOR
T E C H N I C A LF E A T U R E S
r Operation C L U T C HO U T E R
During acceleration, cruising and deceleration,
power is transmitted through the clutch in the
normalmanner:
Clutch outer * f riction di56+ pl61s--)one-way clutch ONE-WAY
-+ mainshaft.
CLUTCH
OUTER
CLUTCH
CENTER ONE-WAY
CLUTCH
ONE.WAY
CLUTCH
*- INNER
MAINSHAFT
l V h e nt h e r ei s a b a c k l o a d i nogn t h e c l u t c hc a u s e db y
t h e r e a r w h e e ln e a r i n gl o c k - u p t, h e o n e - w a yc l u t c h
( A ) w i l l s l i p j u s t e n o u g ht o p r e v e n t h e w h e e lf r o m
l o c k i n g : w i t h o u t l o s i n gt h e b e n e f i t o f m a x i m u m
e n g i n ec o m p r e s s i obnr a k i n g .
ONE.WAY
CLUTCH
INNER
CLUTCH
CENTER
CLUTCH
OUTER
. P O W E RF L O WD I A G R A M
C L U T C HO U T E R
ONE.WAY
CLUTCH
OUTE
FRICTION
DISC FRICTION
C L U T C HP L A T E
O N E W A Y C L U T C HO U T E R
O N EW A Y C L U T C H
CLUTCH
CENTER INNER
O N EW A YC L U T C H
CLUTCH
OUTTER
M A I NS H A F CLUTCH
COMP.
CENTER
<- o R D I N A R Y P O W E RF L O W
---- B A C KL O A D
Dateof lssue:January,1983
22-3
O H O N D A M O T O RC O . .L T D .
a
ITONTf,DA
T E C H N I C A LF E A T U R E S V45 INTERCEPIOR
MEMO
\-.
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
22-4 O H O N D AM O T O RC O . ,L T D .
IIONTf,DA
V45 INTER,CEPTOR 23.TROUBLES]|OO
E N G I N ED O E SN O TS T A R TO R I S H A R DT O S T A R T 23-1
E N G I N EL A C K SP O W E R 23-2
P O O RP E R F O R M A N CAET L O WA N D I D L ES P E E D S 23-3
P O O RP E R F O R M A N CAET H I G HS P E E D 23-3
P O O RH A N D L I N G 23-3
ENGINE 1{OT
DOES START TOSTART
ORISI|ARD
P O S S I B L EC A U S E
1. Check fuel flow to carburetor NOT REACHING CARBURETOR---=_---+(1) Fuel tank empty
l2l C l o g g e df u e l l i n e o r f u e l f i l t e r
R E A C H I N GC A R B U R E T O R (3) Stickingfloat valve
II (4)
(5)
Faultyf uel pump
Faulty fuel pump relay
I (6) P i n c h e df u e l t a n k v e n t n o s e
I
I
t
Perform a 3-point sparktest WEAK OR NO SPARK+(I) F a u l t y s p a r kp l u g s
2.
(21 Fouled spark plugs
G O O DS P A R K ( 3 ) F a u l t y s p a r ku n i t
I l4l Broken or shorted high tension
II wires
( 5 ) F a u l t y s p a r ku n i t
(6) Broken or shorted ignition coil
l7l Faulty ignition switch
V
I ( 8 ) F a u l t y p u l s eg e n e r a t o r
II AI l m p r o p e r i g n i t i o nt i m i n g
( S p a r k u n i t o r p u l s eg e n e r a t o r )
(5)
I Fuel contaminated
I
V
5. R e m o v e a n d i n s p e c ts p a r k p l u g W E TP L Carburetor flooded
( 2 1 C a r b ur e t o r c h o k e e x c e s s i v e l y
closed.
(3) Cylinder flooded
t4l A i r c l e a n e rd i r t y
D a t eo f l s s u eJ: a n u a r V1, 9 8 3
O H O N D AM O T O RC O . ,L T D . 23- 1
\
IIONTf,DA
TROUBLESHOOTING
V45 INTERCEPTOR
EilGtNE P0IYIR
tACl(S
POSSIBLECAUSE
1 . Raisewheelsoff groundand spinby hand WHEELS
DONOTSPINFREELY.--..-..+(1) Brake dragging
QI Worn or damaged wheel bearings
W H E E LS P I N SF R E E L Y (3) Wheel bearing needs lubrication
I @l Drive chaintoo tight
f {5} R e a r a x l e n u t e x c e s s i v e l yt i g h t
2. Check tire pressure LOW_l
PRESSURE
|.+(11 Puncturedtire
P R E S S U R EN O R M A L (21 Faulty tire valve
t
Accelerate rapidly from low to second E N G I N ES P E E DC H A N G E D Clutch slipping
t
E N G I N ES P E E DL O W E R E D
W H E NC L U T C HI S R E L E A S E D t 2 l Worn clutch disc/plate
( 3 1 Warped clutch disc/plate
WHEN
C L U T C HI S R E L E A S E D \-.
I
V
4 . Accelratelightly E N G I N ES P E E DD O E SN O T I N C R E A S E----->(1) Carburetor choke closed
t2l C l o g g e da i r c l e a n e r
E N I G N ES P E E DI N C B E A S E S (3) Restricted fuel flow
(4) Clogged muffler
(5) Clogged fuel tank vent hole
V
6 . Checkvalveclearance INCORRECT ( 1 ) lmproper valve adj ustment
Q I Worn valve seat \-'
CORRECT
t
7 . Test cylinder compression TOO LOW Valve stuck open
Q I Worn cylinder and piston rings
NORMAL (s) L e a k i n gh e a d g a s k e t
I ( 4 ) lmproper valvetiming
V
Checkcarburetorfor clogging CLOGGED Carburetor not serviced
frequently enough
N O TC L O G G E D
I
Removesparkplug F O U L E DO R D I S C O L O R E D ( 1 ) Plugs not serviced frequently
enough
N O T F O U L E DO R D I S C O L O R E D t 2 l Spark plug with incorrect heat
I range
V
1 0 . Checkoil leveland condition I N C O R FE C T ( 1 ) O i l l e v etl o o h i g h
(21 Oil leveltoo low
CORRECT (3) Contaminated oil
i
1 1 . Remove cylinder head cover and inspecl VALVE TRATNNOT LUBRICATED__-+(1) oit passage
Ctogged
lubrication PROPERLY l2l Clogged oil control orifice
I
V A L V ET R A I N L U B R I C A T E D
(1) Coolant levellow
PROPER LY Ql Fan motor not working
t
1 2 . Checkfo-rengineoverheating OVERHEATING
(fan motor relay faulty)
(3) Thermostat stuck closed
@l Excessivecarbon build-uo
N O TO V E B H E A T I N G in combustion chamber
(5) Useof poor quality fuel
I
V {6) Clutch slipping
1 3 . Accelerateor run at high speed E N I G N EK N O C K S (1) Worn piston and cylinder
(2) Wrong type of fuel
E N G I N ED O E SN O T K N O C K ( 3 ) E x c e s s i v ec a r b o n b u i l d - u p i n
combustion chamber
(41 lgnition timing too advanced
(Faulty spark unit)
D a t eo f l s s u eJ: a n u a r y1, 9 8 3
23-2 O H O N D AM O T O RC O . .L T D .
II(oNTEDA
TROUBLESHOOTING
\ PERTORI'|Al{CE
POOR ATtOI',Al{DIDLE
SPEEDS
P O S S I B L EC A U S E
1 . Checkignitiontimingand valveclearance INCORREC lmproper valve clearance
QI lmproper ignition timing
CORRECT (Faulty sparkunit)
t
2. Check carburetor pilot screw adjustment INCORRECT See Fuel System Section
CORRECT
I
V
3 . Check for leakingintake pipe Deteriorated
insulatorO-ring
t2l Loosecarburetor
NO LEAK
v
I
POOR
PERTORMAI{CE
ATl|IGl|SPTED
NOTE: lgnitionto the No. 2 and No. 4 cylindersis cut'off at 11,300-1 1,800rpm to preventenginedamage.
1. Checkignitiontimingand valveclearance INCORRECT (1) lmproper valveclearance
(21 Faulty spark unit
CORRECT ( 3 1 F a u l t y p u l s eg e n e r a t o r
t
Disconnectfuel line at carburetor F U E L F L O WR E S T R I C T E D (1) F u e lt a n k e m p t y
Ql C l o g g e df u e l l i n e
1 F U E L F L O W SF R E E L Y (31 C l o g g e df u e l t a n k b r e a t h e r h o l e
\ II (4) Clogged fuel valva
I (5) Faulty fuel pump
t
Removecarburetorsand checkfor CLOGGED Clean
cloggediets
NOCLOGGED
JETS
t
4 . Checkvalvetiming INCORRECT Camsprocketnot installed
propeny
CORRECT
f
5 . Checkvalvespringtension WEAK Faultyspring
N O TW E A K E N E D
HAl{DtIl{G
POOR pressures
Checktire and suspensions
1. lf steering Steering stem adiuster nut too
tight
l2l Damaged steering head bearings
D a t eo f l s s u e J: a n u a r y1. 9 8 3
O H O N D A M O T O RC O . .L T D . 23-3
';F,:
ESGDIIIIf,}A
VI5 ]NIERCEPTOR
MEMO .,,e***,rf
r-\
\-'
\-l
* t''\*/
1983
Date:oflssue:JanuarY,
O HONDAMOTORCO.,LTD.