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VTX1800C (2002-2004)
Инструкция по эксплуатации Страница: 382

Honda VTX1800C (2002-2004) [382/466] Assembly

Содержание

Charging system alternator 2
Clutch gearshift linkage 2
Contents 2
Cooling system 2
Crankshaft transmission 2
Cylinder head valves 2
Cylinder piston 2
Electric starter starter clutch 2
Engine removal installation 2
Final drive 2
Frame body panels exhaust system 2
Front wheel suspension steering 2
Fuel system programmed fuel injection 2
General information 2
How to use this manual 2
Hydraulic brake 2
Ignition system 2
Lights meters switches 2
Lubrication system 2
Maintenance 2
Rear wheel suspension 2
Troubleshooting 2
Wiring diagram 2
Symbols 3
General information 4
Model identification 4
Service rules 4
General information 5
General 6
General information 6
Specifications 6
General information 7
Fuel system programmed fuel injection 8
General information 8
R cooling systfm 8
R lubrication system 8
Cylinde 9
General information 9
Head vai vfs 9
General information 10
Crankshaft transmission 11
General information 11
Front wheel suspension steering 12
General information 12
Rear wheel suspension 12
General information 13
R battery charging system 13
R hydraulic brake 13
Electric starter 14
General information 14
Lights meters switches 14
R ignition system 14
General nfdrma7 om 15
Torque values 15
Engine cont d 16
General information 16
General information 17
N frame 17
Frame cont d 18
General information 18
Frame cont d 19
General information 19
General information 20
General information 21
General information 22
Lubrication seal points 22
Engine cont d ___________________________ _ 23
General information 23
General information 24
General information 25
Cable harness routing 26
General information 26
General information 29
General information 30
General information 31
General information 32
General information 33
California type 35
General information 35
Crankcase emission control system 36
Emission control systems 36
General information 36
Source of emissions 36
Exhaust emission control system secondary air supply system 37
General information 37
Evaporative emission control system california type only 38
General information 38
Noise emission control system 38
An emission control information label is located on the front of the rear fender as shown the seat must be removed to read it it gives base tune up specifications 39
Emission control information labels u s a only 39
General information 39
The vacuum hose routing diagram label is on the front of the rear fender as shown the seat must be removed to read it 39
Vacuum hose routing diagram label california type only 39
Frame body panels exhaust system 40
Service information 40
Troubleshooting 40
Align the seat hook with the fuel tank rear bracket and install the seat 41
Frame body panels exhaust system 41
Install and tighten the socket bolts securely install the washer and tighten the cap nut securely 41
Installation 41
Installation is in the reverse order of removal 41
Left crankcase rear cover 41
Release the side cover bosses from the grommets and remove the side cover 41
Removal 41
Removal installation 41
Remove the cap nut washer and socket bolts 41
Remove the socket bolts and left crankcase rear cover 41
Side cover 41
Slide the seat back and then off 41
Frame body panels exhaust system 42
Muffler exhaust pipe 42
Rear fender 42
Removal 42
Frame body panels exhaust system 43
Frame body panels exhaust system 44
Installation 44
Disassembly assembly 45
Frame body panels exhaust system 45
Frame body panels exhaust system 46
Maintenance 47
Service information 47
Maintenance 48
Specifications 48
Torque values 48
Iihinn 49
Maintenance schedule 49
Fuel line 50
Maintenance 50
Throttle operation 50
Air cleaner 51
Maintenance 51
Crankcase breather 52
Disconnect the spark plug cap from the spark plug bases 52
Inspect or replace as described in the maintenance schedule 52
Maintenance 52
Removal 52
Remove the crankcase breather hose from the air cleaner housing and drain deposits into a suitable container then install the hose securely 52
Remove the socket bolts and spark plug cap cover 52
Remove the spark plug using the equipped spark plug wrench or an equivalent tool 52
Spark plug 52
Check the following and replace if necessary recom mended spark plug page 3 2 insulator for damage electrodes for wear burning condition coloration 53
Check the gap between the center and side electrodes with a wire type feeler gauge 53
If the electrodes are contaminated with accumulated objects or dirt replace the spark plug 53
If the gauge can be inserted into the gap replace the plug with a new one 53
If using a new plug install as follows install and hand tighten the new spark plug then tighten it about 1 2 of a turn after the sealing washer contacts the seat of the plug hole 53
Inspection 53
Maintenance 53
Make sure that the 1 mm 0 4 in diameter plug gauge does not insert between the gap 53
Reinstall the spark plug in the cylinder head and hand tighten then torque to specification 53
Replace the plug if the center electrode is rounded as shown in the illustration 53
Specified spark plug ngk ifr6l11 denso vk20prz11 53
Torque 18 n m 1 kgf m 13 lbf ft 53
Inspection 54
Maintenance 54
Valve clearance 54
Maintenance 55
Adjustment 56
Maintenance 56
Maintenance 57
Engine oil oil filter 58
Maintenance 58
Oil level inspection 58
Engine oil filter change 59
Maintenance 59
Maintenance 60
Cooling system 61
Engine idle speed 61
Maintenance 61
Radiator coolant 61
Maintenance 62
Secondary air supply system 62
Evaporative emission control system california type only 63
Final drive oil 63
Level check 63
Maintenance 63
Avoid spilling fluid on painted plastic or rubber parts place a rag over these parts whenever the system is serviced 64
Brake fluid 64
Do not allow foreign material to enter the system when filling the reservoir 64
Do not mix different types of fluid as they are not compatible with each other 64
Front brake 64
Maintenance 64
Notice 64
Oil change 64
Brake pad wear 65
Brake system 65
Front brake pads 65
Inspection 65
Maintenance 65
Rear brake 65
Rear brake pads 65
Brake light switch 66
Headlight aim 66
Maintenance 66
Clutch fluid 67
Clutch system 67
Maintenance 67
Notice 67
Side stand 67
Front suspension inspection 68
Maintenance 68
Nuts bolts fasteners 68
Rear suspension inspection 68
Suspension 68
Maintenance 69
Steering head bearings 69
Wheels tires 69
Caution 71
Lubrication system 71
Service information 71
Service information 4 1 oil pressure check 4 3 71
Troubleshooting 4 2 oil pump oil strainer 4 3 71
Lubrication system 72
Troubleshooting 72
Lubrication system 73
Oil pressure check 73
Oil pump strainer 73
Removal 73
Lubrication system 74
Lubrication system 75
Oil pipe 75
Relief valve check 75
Disassembly 76
Lubrication system 76
Inspection 77
Lubrication system 77
Assembly 78
Lubrication system 78
Installation 79
Lubrication system 79
Lubrication system 80
Fuel system 82
Fuel system programmed fuel injection 82
Service information 82
Fuel system programmed fuel injection 83
Specifications 83
Torque values 83
Fuel system programmed fuel injection 84
Troubleshooting 84
Fuel system programmed fuel injection 85
System location 85
Fuel system programmed fuel injection 86
Fuel system programmed fuel injection 87
If the malfunction indicator lamp mil does not light or blink the system has no memory of problem data if the mil blinks note how many times the malfunc tion indicator blinks and determine the cause of the problem page 5 10 through 5 45 87
If you wish to read the pgm fi memory for trouble data perform the following 87
Pgm fi programmed fuel injec tion system 87
Place the motorcycle on its side stand start the engine and let it idle 87
Remove the seat page 2 2 87
Self diagnostic procedure 87
Short the pgm fi system service check connector ter minals using a jumper wire 87
Turn the ignition switch to off 87
Fuel system programmed fuel injection 88
Self diagnosis reset procedure 88
Fuel system programmed fuel injection 89
Peak voltage inspection proce dure 89
Test harness connection 89
Fuel system programmed fuel injection 90
Test harness terminal layout 90
Pgm fi self diagnosis malfunction indicator failure codes 91
Fuel system programmed fuel injection 92
Fuel system programmed fuel injection 94
Fuel system programmed fuel injection 96
Fuel system programmed fuel injection 98
Fuel system programmed fuel injection 102
Fuel system programmed fuel injection 104
_______ i_______ 104
Fuel system programmed fuel injection 106
Fuel system programmed fuel injection 108
Fuel system programmed fuel injection 110
_______ i_______ 110
Fuel system programmed fuel injection 111
_______ i_______ 111
Fuel system programmed fuel injection 113
Fuel system programmed fuel injection 118
Fuel system programmed fuel injection 120
Fuel system programmed fuel injection 121
Pgm fi mil 23 blinks o2 sensor heater california type only 121
Fuel system programmed fuel injection 123
Fuel system programmed fuel injection 124
Fuel system programmed fuel injection 126
Fuel line inspection 127
Fuel pressure inspection 127
Fuel system programmed fuel injection 127
Fuel system programmed fuel injection 128
Fuel flow inspection 129
Fuel pump 129
Fuel system programmed fuel injection 129
Inspection 129
Fuel filter replacement 130
Fuel system programmed fuel injection 130
Installation 130
Removal 130
Fuel cut off relay 131
Fuel system programmed fuel injection 131
Fuel tank 131
Installation 131
Notice 131
Removal 131
Air cleaner housing 132
Fuel system programmed fuel injection 132
Installation 132
Removal 132
Fuel system programmed fuel injection 133
Throttle body 133
Throttle body removal 133
Do not damage the throttle body it may cause incorrect throttle and idle valve synchronization the throttle body is factory pre set do not disassemble in a way other than shown in this manual do not loosen or tighten the white painted bolts and screws of the throttle body loosening or tightening them can cause throttle and idle valve synchronization failure 134
Fuel system programmed fuel injection 134
Loosen the band screw and disconnect the water hose 134
Loosen the lock nuts and disconnect the throttle cables from the throttle drum 134
N m 0 5 kgf m 2 lbf ft 134
Notice 134
Fuel system programmed fuel injection 135
Intake manifold removal 135
Fuel system programmed fuel injection 136
Fuel system programmed fuel injection 137
Intake manifold installation 137
Fuel system programmed fuel injection 138
Fuel system programmed fuel injection 139
Throttle body installation 139
Fuel system programmed fuel injection 140
Fuel system programmed fuel injection 141
Injectors 141
Inspection 141
Removal 141
Fuel system programmed fuel injection 142
Fuel system programmed fuel injection 143
Installation 143
Fuel system programmed fuel injection 144
Disassembly 145
Fuel system programmed fuel injection 145
Starter valve 145
Assembly 146
Fuel system programmed fuel injection 146
Air screw synchronization 147
Fuel system programmed fuel injection 147
Baro map sensor 148
Baro sensor removal installation 148
Fuel system programmed fuel injection 148
Map sensor removal installation 148
Output voltage inspection 148
Ect sensor 149
Fuel system programmed fuel injection 149
Iat sensor 149
Removal installation 149
Cam pulse generator 150
Fuel system programmed fuel injection 150
Inspection 150
Installation 150
Removal installation 150
Tp sensor 150
Fuel system programmed fuel injection 151
Bank angle sensor 152
Fuel system programmed fuel injection 152
Engine stop relay 153
Fuel system programmed fuel injection 153
Inspection 153
Removal installation 153
Ecm engine control module 154
Fuel system programmed fuel injection 154
Intake duct control solenoid valve 154
Power ground une inspection 154
Removal installation 154
Fuel system programmed fuel injection 155
Inspection 155
Fuel system programmed fuel injection 156
One way valve 156
Pair solenoid valve 156
Removal installation 156
Fuel system programmed fuel injection 157
Inspection 157
Pair check reed valve 157
Removal installation 157
Evap purge control valve cali fornia type only 158
Fuel system programmed fuel injection 158
Inspection 158
Removal 158
Fuel system programmed fuel injection 159
Notice 159
O2 sensor california type only 159
Removal 159
Caution 161
Coolant replacement 6 4 water pump 6 12 161
Cooling system 161
I notice 161
Service information 161
Service information 6 1 radiator cooling fan 6 6 161
System testing 6 3 thermostat 6 9 161
Troubleshooting 6 2 radiator reserve tank 6 9 161
Cooling system 162
Troubleshooting 162
Coolant hydrometer test 163
Cooling system 163
System testing 163
Coolant replacement 164
Cooling system 164
I notice 164
Radiator cap system pressure inspection 164
Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or block age of radiator passages using tap water may cause engine damage 164
Cooling system 165
Replacement air bleeding 165
Cooling system 166
Radiator cooling fan 166
Removal 166
Cooling system 167
Disassembly 167
Assembly 168
Cooling system 168
Cooling system 169
Installation 169
Radiator reserve tank 169
Removal 169
Removal installation 169
Thermostat 169
Cooling system 170
84 c 176 183 f 171
Cooling system 171
Heat a container of water with an electric heating ele ment for 5 minutes suspend the thermostat in the heated water to check its operation 171
Inspection 171
Install the new o ring on the thermostat housing cover 171
Install the thermostat into the housing with its hole facing upright align the thermostat flange with the groove in the housing upper surface make sure the thermostat is securely installed 171
Installation 171
Mm 0 in minimum at 95 c 203 f 171
Replace the thermostat if the valve responds at tem peratures other than specified 171
Thermostat 171
Thermostat begins to open 171
Valve lift 171
Visually inspect the thermostat for damage replace the thermostat if the valve stays open at room temperature 171
Cooling system 172
Mechanical seal inspection 172
Removal 172
Water pump 172
Cooling system 173
Installation 173
Cooling system 174
Engine removal installation 175
Engine removal installation 176
Service information 176
________7 engine removal installation 176
Engine removal installation 177
Specification 177
Torque values 177
Engine removal 178
Engine removal installation 178
Engine removal installation 179
Engine removal installation 180
Engine removal installation 181
Engine removal installation 182
Eng ne remo val installation 183
Engine installation 184
Engine removal installation 184
Engine removal installation 185
Engine removal installation 186
Engine removal installation 187
Engine removal installation 188
Engine removal installation 189
Engine removal installation 190
Cylinder head valves 192
Service information 192
Cylinder head valves 193
Torque values 193
Troubleshooting 193
Cylinder compression 194
Cylinder head cover removal 194
Cylinder head valves 194
Camshaft removal 195
Cylinder head valves 195
Cylinder head valves 196
Cylinder head valves 197
Camshaft holder disassembly 198
Cylinder head valves 198
Inspection 198
Cylinder head valves 199
Cylinder head removal 200
Cylinder head valves 200
Cylinder head disassembly 201
Cylinder head valves 201
Check the cylinder head for warpage with a straight edge and feeler gauge 202
Cylinder head check the spark plug holes and valve areas for cracks 202
Cylinder head valves 202
Do not reuse a removed stem seal 202
Inspection 202
Remove the carbon deposits from the combustion chamber to avoid damaging the gasket and valve seat surfaces and clean the head gasket surfaces 202
Remove the stem seals and spring seats 202
Remove the valve spring compressor then remove the retainer spring and valve spring valve 202
Retainer 202
Service limit 0 0 mm 0 04 in 202
Cylinder head valves 203
Cylinder head valves 204
Notice 204
Using a torch to heat the cylinder head may cause warpage 204
Valve guide replacement 204
Cylinder head valves 205
Inspection 205
Valve seat inspection refacing 205
Cylinder head valves 206
Valve seat refacing 206
Cylinder head valves 207
Laritie 207
Cylinder head assembly 208
Cylinder head valves 208
Compress the valve springs with the valve spring compressor and install the valve cotters 209
Cylinder head valves 209
Insert the valves into the valve guides to avoid damaging the stem seal turn the valve slow ly when inserting install the valve springs install the spring retainers 209
Install the spring seats and new stem seals 209
Retainer 209
Tap the valve stems gently with a soft hammer to firmly seat the cotters 209
Tool valve spring compressor 07757 0010000 209
Cylinder head installation 210
Cylinder head valves 210
Camshaft holder assembly 211
Camshaft installation 211
Cylinder head valves 211
Camshaft installation 212
Cylinder head valves 212
Cylinder head valves 213
Front cylinder 213
Cylinder head valves 214
Cylinder head valves 215
Rear cylinder 215
Cylinder head cover installa tion 216
Cylinder head valves 216
Cylinder piston 218
Service information 218
Cylinder piston 219
Troubleshooting 219
Cylinder piston 220
Cylinder removal 220
Cylinder piston 221
Inspection 221
Calculate the cylinder for taper and out of round at three levels in the x and y axes take the maximum reading to determine the taper and out of round 222
Check the oil jet for clogs 222
Cylinder piston 222
Inspect the cylinder bore for scratches or wear measure the cylinder i d at three levels in the x and y axes take the maximum reading to determine the cylinder wear 222
Out of round 0 0 mm 0 04 in 222
Piston removal 222
Remove the o ring from the oil jet 222
Remove the oil jet from the crankcase 222
Remove the piston pin and remove the piston 222
Remove the piston pin clip using a pair of pliers 222
Service limit 101 5 mm 3 78 in 222
Service limits 222
Taper 0 0 mm 0 04 in 222
Calculate the cylinder to piston clearance cylinder i d see previous page 223
Clean carbon deposits from the piston ring grooves 223
Cylinder piston 223
Inspect the piston for wear or damage 223
Inspect the piston rings for smooth movement by rotating the rings the rings should be able to move in their grooves without catching 223
Measure and record the piston pin hole i d in the x and y axes take the maximum reading to determine the i d 223
Measure the diameter of the piston at 18 mm 0 in from the bottom and 90 degrees to the piston pin hole 223
Piston 223
Piston piston ring inspection 223
Service limit 0 2 mm 0 26 in 223
Service limit 100 1 mm 3 73 in 223
Service limit 24 18 mm 0 456 in 223
Spread each piston ring and remove it by lifting it up at a point just opposite the gap 223
Cylinder piston 224
Cylinder piston 225
Cylinder stud bolt replacement 225
Piston ring installation 225
Apply engine oil to new o rings and install it onto the oil jet 226
Apply engine oil to the piston pin outer surface set the piston over the connecting rod with the piston direction and position properly as noted during removal 226
Clean the gasket surface of the crankcase thoroughly being careful not to damage it and careful not to allow gasket material into the crankcase 226
Cylinder piston 226
Install new piston pin clips 226
Install the oil jet into the crankcase properly as shown jet hole side facing toward the connecting rod side 226
Piston installation 226
Cylinder installation 227
Cylinder piston 227
Coat a new o ring with coolant and install it in the water hose joint groove of the rear cylinder 228
Coat new o rings with coolant and install them into the end grooves in the water joint pipe and into the cylinders 228
Cylinder piston 228
Install and tighten the bolts securely 228
Install the cylinder head page 8 19 228
Slide the water joint pipe in position between the cylinders install the joint clips in the joint grooves 228
Clutch gearshift linkage 230
Clutch gearshift linkage 231
General 231
Service information 231
Specification 231
Torque values 231
Clutch gearshift linkage 232
Troubleshooting 232
Check the fluid level often while bleeding the clutch to prevent air from being pumped into the system 233
Close the bleed valve and operate the clutch lever if it is still spongy bleed the system again 233
Clutch fluid draining 233
Clutch fluid filling air bleeding 233
Clutch fluid replacement air bleeding 233
Clutch gearshift linkage 233
Connect the bleed hose to the bleed valve loosen the bleed valve and pump the clutch lever until fluid stops flowing out of the bleed valve 233
Fill the reservoir with dot 4 brake fluid from a sealed container connect a commercially available brake bleeder to the bleed valve pump the brake bleeder and loosen the bleed valve adding fluid when the fluid level in the reservoir is low 233
Remove the screws reservoir cap set plate diaphragm and float 233
Repeat the previous procedures until air bubbles do not appear in the plastic hose 233
Turn the handlebar to the right until the reservoir is parallel to the ground before removing the reservoir cap 233
When using a brake bleeding tool follow the man ufacturer s operating instructions 233
Clutch gearshift linkage 234
Clutch gearshift linkage 235
Clutch master cylinder 235
Disassembly 235
Removal 235
Clutch gearshift linkage 236
Assembly 237
Clutch gearshift linkage 237
Inspection 237
Clutch gearshift linkage 238
Clutch gearshift linkage 239
Installation 239
Torque 34 n m 3 kgf m 25 lbf ft 239
Clutch gearshift linkage 240
Clutch slave cylinder 240
Removal 240
Assembly 241
Clutch gearshift linkage 241
Disassembly 241
Inspection 241
Installation 241
Clutch gearshift linkage 242
Removal 242
Right crankcase cover 242
Clutch gearshift linkage 243
Installation 243
Clutch 244
Clutch gearshift linkage 244
Removal 244
Clutch gearshift linkage 245
Clutch gearshift linkage 246
Clutch gearshift linkage 247
Inspection 247
Clutch gearshift linkage 248
Clutch gearshift linkage 249
Clutch gearshift linkage 250
Installation 250
Clutch gearshift linkage 251
Clutch gearshift linkage 252
Clutch gearshift linkage 253
Primary drive gear 253
Removal 253
Clutch gearshift linkage 254
Primary driven gears 254
Removal 254
Clutch gearshift linkage 255
Inspection 255
Installation 255
Clutch gearshift linkage 256
Clutch gearshift linkage 257
Gearshift linkage 257
Removal 257
Clutch gearshift linkage 258
Inspection 258
Installation 258
Clutch gearshift linkage 259
Crankshaft transmission 261
Service information 261
Crankshaft transmission 262
Specification 262
Torque values 262
Crankshaft transmission 263
Troubleshooting 263
Crankcase separation 264
Crankshaft transmission 264
Crankshaft transmission 265
Inspection 265
Primary shaft 265
Removal installation 265
Before removing the connecting rods check the big end side clearance measure the clearance by inserting the feeler gauge between the crankshaft and connecting rod big end 266
Connecting rod removal 266
Crankshaft connecting rod 266
Crankshaft removal 266
Crankshaft transmission 266
Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in the crankcase page 11 25 266
Remove the connecting bearing cap bolts and the bearing caps bearing caps 266
Remove the crankshaft from the left crankcase 266
Separate the crankshaft page 11 4 266
Service limit 0 8 mm 0 11 in 266
Turn the inner race of each bearing with your finger the bearings should turn smoothly and quietly also check that the bearing outer race fits tightly in the crankcase 266
Connecting rod bearing inspection 267
Crankshaft inspection 267
Crankshaft transmission 267
Oil clearance inspection 267
Connecting rod bearing selection 268
Crankshaft transmission 268
Crankshaft transmission 269
Main bearing inspection 269
Connecting rod installation 270
Connecting rod selection 270
Crankshaft transmission 270
Crankshaft transmission 271
Removal 271
Transmission 271
Crankshaft transmission 272
Disassembly 272
Crankshaft transmission 273
Inspection 273
Crankshaft transmission 274
Assembly 275
Crankshaft transmission 275
Crankshaft transmission 276
Installation 276
Crankcase assembly 277
Crankshaft transmission 277
Crankshaft transmission 278
Crankshaft transmission 279
Output gear 279
Removal 279
Backlash inspection gear tooth contact pattern check 280
Crankshaft transmission 280
Crankshaft transmission 281
Crankshaft transmission 282
Crankshaft transmission 283
Case bearing replacement 284
Crankshaft transmission 284
Installation 284
Crankcase bearing replacement 285
Crankshaft transmission 285
Left crankcase bearing 285
Crankshaft transmission 286
Crankshaft transmission 287
Right crankcase bearings 287
Crankshaft transmission 288
Final drive 290
Final drive removal 12 3 290
Service information 290
Service information 12 1 final drive gear 12 5 290
Troubleshooting 12 2 final drive installation 12 18 290
Final drive 291
Troubleshooting 291
Drive shaft removal disassembly 292
Final drive 292
Final drive removal 292
Removal 292
Universal joint removal 292
Backlash inspection 293
Final drive 293
Final drive inspection 293
Final drive gear 294
Ring gear removal shim replacement 294
Final drive 295
Oil seal 295
Remove the oil seal from the ring gear 295
Remove the ring gear bearing using the commercial ly available bearing puller 295
Remove the ring gear from the gear case 295
Replace the ring gear shim 295
Final drive 296
Ring gear installation 296
Final drive 297
Case cover warpage can occur if the cover is not heat ed properly 298
Final drive 298
Notice 298
Final drive 299
Gear tooth contact pattern check 299
Final drive 300
Pinion gear removal shim replacement 300
Final drive 301
Final drive 302
Pinion gear installation 302
Final drive 303
Final drive 304
Case bearing replacement 305
Final drive 305
Breather hole cleaning 306
Final drive 306
Gear case assembly 306
Drive shaft assembly installa tion 307
Final drive 307
Final drive installation 307
Front wheel suspension steering 309
Handlebar 13 3 steering stem 13 33 309
Service information 309
Service information 13 1 front wheel 13 8 309
Troubleshooting 13 2 fork 13 14 309
Front wheel suspension steering 310
Torque values 310
Troubleshooting 310
Disconnect the clutch switch connectors remove the bolts master cylinder holder and clutch master cylinder from the handlebar 311
Front wheel suspension steering 311
Handlebar 311
Left handlebar switch housing 311
Release the wire bands 311
Removal 311
Remove the attaching screws and the left handlebar switch housing from the handlebar screws 311
Front wheel suspension steering 312
Front wheel suspension steering 313
Installation 313
Front wheel suspension steering 314
Front wheel suspension steering 315
Front wheel 316
Front wheel suspension steering 316
Removal 316
Front wheel suspension steering 317
Loosen the left axle pinch bolts pull the front axle out and remove the front wheel 317
Loosen the right axle pinch bolts loosen the axle bolt 317
Raise the front wheel off the ground by supporting the frame securely 317
Remove the axle bolt 317
Remove the bolt caps from the right and left axle pinch bolts 317
Remove the side collar from the left side of the wheel 317
Remove the side collar from the right side of the wheel 317
Disassembly 318
Front wheel suspension steering 318
Inspection 318
Assembly 319
Front wheel suspension steering 319
Front wheel suspension steering 320
Front wheel suspension steering 321
Installation 321
Front wheel suspension steering 322
Removal 322
Front wheel suspension steering 323
Right fork disassembly 323
Front wheel suspension steering 324
Hold the damper rod lock nut with a spanner then loosen and remove the fork cap from the damper rod 324
Loosen the lock nut as shown while pushing down the spring collar remove the spring seat stopper 324
Pour out the fork fluid by pumping the fork pipe up and down several times 324
Pour out the remaining fork fluid by pumping the fork damper rod up and down several times 324
Remove the fork spring 324
Remove the spring collar 324
Front wheel suspension steering 325
Hold the fork pipe in a vise with soft jaws or shop towel 325
Remove the dust seal 325
Remove the fork damper and centering plate fork damper centering plate 325
Remove the fork socket bolt and sealing washer with a hex wrench 325
Remove the stopper ring 325
Socket bolt sealing washer 325
Front wheel suspension steering 326
Left fork disassembly 326
Front wheel suspension steering 327
Hold the rod lock nut with a spanner then loosen and remove the fork cap from the rod remove the rubber stopper from the rod 327
Pull down the outer pipe so the inner fork bolt is visi ble remove the inner fork bolt 327
Remove the fork cap from the outer pipe slide outer pipe down onto the axle holder 327
Rubber stopper pull down the rubber stopper 327
Tool lock nut wrench 36 x 44 mm 07vma mz0010a 327
Front wheel suspension steering 328
Front wheel suspension steering 329
Inspection 329
Front wheel suspension steering 330
Front wheel suspension steering 331
Front wheel suspension steering 332
Right fork assembly 332
Front wheel suspension steering 333
Front wheel suspension steering 334
Front wheel suspension steering 335
Front wheel suspension steering 336
Left fork assembly 336
Front wheel suspension steering 337
Front wheel suspension steering 338
Front wheel suspension steering 339
Front wheel suspension steering 340
Installation 340
Front wheel suspension steering 341
Removal 341
Steering stem 341
Front wheel suspension steering 342
Bearing replacement 343
Front wheel suspension steering 343
Front wheel suspension steering 344
Installation 344
Front wheel suspension steering 345
Front wheel suspension steering 346
Front wheel suspension steering 347
Front wheel suspension steering 348
Steering head bearing pre load 348
Rear wheel suspension 349
Rear wheel 14 3 350
Rear wheel suspension 350
Service information 350
Service information 14 1 shock absorber 14 11 350
Troubleshooting 14 2 swingarm 14 12 350
Rear wheel suspension 351
Troubleshooting 351
Loosen and remove the rear axle nut remove the rear caliper stopper pin bolt 352
Move the rear wheel to the right to separate it from the final gear case and remove the rear wheel 352
Pull out the rear axle then remove the rear caliper from the brake disc 352
Raise the rear wheel off the ground and support the motorcycle firmly 352
Rear wheel 352
Rear wheel suspension 352
Removal 352
Remove the bolts and license plate bracket 352
Remove the exhaust system page 2 3 352
Inspection 353
Rear wheel suspension 353
Disassembly 354
Rear wheel suspension 354
Rear wheel suspension 355
Assembly 356
Rear wheel suspension 356
Rear wheel suspension 357
Rear wheel suspension 358
Installation 359
Rear wheel suspension 359
Inspection 360
Rear wheel suspension 360
Removal 360
Shock absorber 360
Installation 361
Rear wheel suspension 361
Removal 361
Swingarm 361
Inspection 362
Rear wheel suspension 362
Installation 363
Pivot bearing outer race replacement 363
Rear wheel suspension 363
Rear wheel suspension 364
Rear wheel suspension 365
Rear wheel suspension 366
Hydraulic brake 368
Caution 369
General 369
Hydraulic brake 369
Service information 369
Specification 369
Hydraulic brake 370
Torque values 370
Troubleshooting 370
Brake fluid draining 371
Brake fluid replacement air bleeding 371
Connect a bleed hose to the front caliper lower bleed valve 371
Connect a bleed hose to the upper bleed valve 371
Front turn the handlebar to the left until the reservoir is level remove the screws reservoir cap diaphragm plate diaphragm and float 371
Hydraulic brake 371
Install the bolt remove the reservoir cap diaphragm plate and diaphragm 371
Loosen the front caliper lower bleed valve and pump the brake lever stop operating the brake when fluid stops flowing out of the front caliper lower bleed valve 371
Loosen the upper bleed valve and pump the brake lever stop operating the brake when fluid stops flowing out of the upper bleed valve 371
Make sure the master cylinder is parallel to the ground before removing the reservoir cover 371
Once the hydraulic system has been opened or if the brake feels spongy the system must be bled when using a commercially available brake bleeder follow the manufacturer s operating instructions 371
Rear linked remove bolt and the reservoir cover 371
Tighten the front caliper lower bleed valve securely 371
Brake fluid filling air bleeding 372
Hydraulic brake 372
Hydraulic brake 373
Hydraulic brake 374
Hydraulic brake 375
Hydraulic brake 376
Brake pad disc 377
Brake pad replacement 377
Hydraulic brake 377
Hydraulic brake 378
Brake disc inspection 379
Front master cylinder 379
Hydraulic brake 379
Removal 379
Disassembly 380
Hydraulic brake 380
Hydraulic brake 381
Inspection 381
Assembly 382
Hydraulic brake 382
Hydraulic brake 383
Installation 383
Front caliper 384
Hydraulic brake 384
Removal 384
Disassembly 385
Hydraulic brake 385
Assembly 386
Hydraulic brake 386
Inspection 386
Hydraulic brake 387
Installation 387
Hydraulic brake 388
Rear master cylinder 388
Removal 388
Disassembly 389
Hydraulic brake 389
Assembly 390
Hydraulic brake 390
Inspection 390
Coat the master piston and piston cups with clean dot 4 brake fluid install the spring onto the primary piston cup install the spring primary piston cup into the master cylinder 391
Hydraulic brake 391
If the pushrod is reinstalled adjust the pushrod length so that the distance from the center of the master cylinder rear mounting bolt hole to the center of the joint pin hole is 65 mm 2 in after adjustment tighten the lock nut to the specified torque 391
Install the piston boot to the groove on the rear mas ter cylinder body 391
Install the pushrod piston into the master cylinder install the snap ring using the special tool 391
Snap ring pliers 07914 sa50001 391
Torque 18 n m 1 kgf m 13 ibf ft 391
Hydraulic brake 392
Installation 392
Hydraulic brake 393
Rear master cylinder reservoir 393
Disassembly 394
Hydraulic brake 394
Rear caliper 394
Removal 394
Hydraulic brake 395
Inspection 395
Assembly 396
Hydraulic brake 396
Brake pedal 397
Hydraulic brake 397
Installation 397
Removal 397
Hydraulic brake 398
Installation 398
Pcv proportional control valve 398
Removal installation 398
Caution 400
Charging system alternator 400
Service information 400
Charging system alternator 401
Specification 401
Torque values 401
Troubleshooting 402
Battery 403
Battery testing 403
Charging system alternator 403
Installation 403
Removal 403
Voltage inspection 403
Battery charging 404
Charging system alternator 404
Charging system alternator 405
Charging system inspection 405
Current leakage test 405
Battery case 406
Charging system alternator 406
Charging voltage inspection 406
Removal installation 406
Charging system alternator 407
Regulator rectifier 407
Removal installation 407
Wire harness inspection 407
Alternator 408
Charging system alternator 408
Inspection 408
Left crankcase cover removal 408
Charging system alternator 409
Charging system alternator 410
Left crankcase cover installation 410
Stator removal installation 410
Charging system alternator 411
Charging system alternator 412
Ignition system 413
Ignition system 414
Ignition system inspection 17 3 414
Service information 414
Service information 17 1 ignition coil 17 5 414
Troubleshooting 17 2 ignition timing 17 5 414
Ignition system 415
No spark at spark plugs 415
Troubleshooting 415
Ignition coil primary peak voltage 416
Ignition system 416
Ignition system inspection 416
Ignition pulse generator peak voltage 417
Ignition system 417
Front ignition coil 418
Ignition coil 418
Ignition system 418
Ignition timing 418
Rear ignition coil 418
Ignition system 419
Electric starter starter clutch 421
Service information 421
Electric starter starter clutch 422
Starter motor will not turn 422
Troubleshooting 422
Electric starter starter clutch 423
Starter motor turns when the transmission is in neutral but does not turn with the transmission in any position except neutral with the side stand up and the clutch lever pulled in 423
Disassembly 424
Electric starter starter clutch 424
Rear cover 424
Release the rubber cap and remove the terminal nut to disconnect the starter motor cable 424
Removal 424
Remove the bolts and starter motor 424
Remove the o ring from the starter motor 424
Remove the starter drive gear page 18 12 424
Remove the starter motor case bolts and rear cover 424
Starter motor 424
Electric starter starter clutch 425
Inspection 425
Electric starter starter clutch 426
Electric starter starter clutch 427
Assembly 428
Electric starter starter clutch 428
Install the following o ring insulators washer nut 428
Set the collar on the brush terminal set the brush terminal on the brush holder install the brush holder onto the motor case 428
Align the index lines on the front cover and motor case 429
Apply grease to the oil seal lips and bearing and install the front cover by aligning its lugs with the lock washer tab 429
Assemble the motor case and rear cover aligning the brush holder boss with the groove in the rear cover 429
Electric starter starter clutch 429
Install and tighten the starter motor case bolt to the specified torque 429
Install the armature in the motor case 429
Install the insulated washer and lock washer on the armature shaft 429
Install the seal ring onto the motor case install the shims on the armature shaft 429
Install the shims on the armature shaft 429
Rear cover 429
Seal ring insulated front 429
Shims lock washer armature 429
Shims seal ring 429
Torque 5 n m 0 kgf m 3 ibf ft 429
Electric starter starter clutch 430
Inspection 430
Installation 430
Starter relay switch 430
Electric starter starter clutch 431
Operation check 431
Removal installation 431
Electric starter starter clutch 432
Flywheel starter clutch 432
Left crankcase cover bearing replacement 432
Starter driven gear torque lim iter removal 432
Electric starter starter clutch 433
Left crankcase bearing replace ment 433
Starter drive gear inspection 433
Electric starter starter clutch 434
Flywheel removal 434
Starter torque limiter inspec tion 434
Electric starter starter clutch 435
Starter clutch removal 435
Electric starter starter clutch 436
Starter clutch inspection 436
Starter clutch installation 436
Electric starter starter clutch 437
Flywheel installation 437
Balancer weight 438
Electric starter starter clutch 438
Removal 438
Starter driven gear torque lim iter installation 438
Electric starter starter clutch 439
Installation 439
Lights meters switches 441
Service information 441
Lights meters switches 442
Specification 442
Torque values 442
Lights meters switches 443
Troubleshooting 443
Vehicle speed sensor speedometer 443
Avoid touching halogen headlight bulb fingerprints can create hoy spots that will cause the bulb to break 444
Bulb replacement 444
Headlight 444
Lights meters switches 444
Notice 444
Bulb replacement 445
Front turn signal assembly removal installation 445
Headlight case removal instal lation 445
Lights meters switches 445
Turn signals 445
Bulb replacement 446
License light 446
Lights meters switches 446
Tail brake light 446
Disassembly assembly 447
Indicator box 447
Lights meters switches 447
Removal installation 447
Lights meters switches 448
Removal installation 448
Speedometer 448
Lights meters switches 449
Output signal inspection 449
Vehicle speed sensor 449
Voltage inspection 449
Lights meters switches 450
Removal installation 450
Front brake light switch 451
Inspection 451
Lights meters switches 451
Neutral switch 451
Rear brake light switch 451
Removal installation 451
Clutch switch 452
Ignition switch 452
Inspection 452
Lights meters switches 452
Removal installation 452
Handlebar switch 453
Left handlebar switch 453
Lights meters switches 453
Fan motor switch 454
Inspection 454
Lights meters switches 454
Right handlebar switch 454
Coolant temperature indicator 455
Lights meters switches 455
Removal installation 455
Ect thermo sensor unit inspec tion 456
Inspection 456
Lights meters switches 456
Side stand switch 456
Inspection 457
Installation 457
Lights meters switches 457
Oil pressure indicator 457
Removal 457
Inspection 458
Lights meters switches 458
Oil pressure switch removal installation 458
Fuel reserve sensor 459
Inspection 459
Lights meters switches 459
Removal installation 459
Turn signal relay 459
Wiring diagram 460
Troubleshooting 461
Engine lacks power 462
Troubleshooting 462
Poor handling 464
Poor performance at high speed 464

Honda VTX1800C (2002-2004) [382/466] Assembly

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