Honda 86 VT700C Shadow Manuals

Manuals and User Guides for Honda 86 VT700C Shadow. We have 1 Honda 86 VT700C Shadow manual available for free PDF download: Service Manual

Honda 86 VT700C Shadow Service Manual (287 pages)

Brand: Honda | Category: Motorcycle | Size: 45.18 MB

Contents
3
How to Use this Manual
3
General Information
4
General Safety
4
Service Rules
4
Model Identification
5
Specifications
6
Torque Values - Engine
8
Torque Values - Frame
9
Standard Torque Values
10
Tools - Special
11
Tools - Common
12
Cable & Harness Routing
13
Emission Control Systems
18
Exhaust Emission Control System
18
Crankcase Emission Control System
19
Evaporative Emission Control System (California Model Only)
19
Noise Emission Control System
20
Emission Control Information Labels
20
Lubrication - Service Information
22
Lubrication Specifications
22
Oil Pump Service Data
22
Lubrication - Torque Values
23
Lubrication Troubleshooting
23
Engine Oil Level
24
Engine Oil & Filter Change
24
Oil Pressure Check
24
Oil Strainer & Oil Pump Removal
25
Relief Valve Check
26
Oil Pump Disassembly
26
Oil Pump Assembly
27
Oil Pump Installation
28
Final Drive Oil Check
29
Final Drive Oil Change
30
Control Cable Lubrication
30
Lubrication Points
31
Maintenance - Service Information
32
Maintenance - Specifications
32
Maintenance Schedule
34
Fuel Lines
35
Fuel Filter
35
Throttle Operation
36
Carburetor Choke
37
Air Cleaner
38
Spark Plugs
38
Carburetor Synchronization
39
Carburetor Idle Speed
39
Radiator Coolant Check
40
Cooling System Check
40
Cylinder Compression Check
40
Secondary Air Supply System (California Model Only) Check
41
Evaporative Emission Control System (California Model Only) Check
41
Battery Check
42
Brake Fluid Check
42
Brake Pad Wear Check
43
Brake Shoe Inspection
43
Brake System Check
43
Brake Pedal Height
43
Brake Pedal Free Play
44
Brake Light Switch Adjustment
44
Headlight Adjustment
44
Clutch Check
45
Side Stand Inspection
45
Suspension Check
46
Nuts, Bolts, Fasteners Check
46
Wheels/Tires Inspection
46
Tire Pressure Check
46
Recommended Tire Pressure and Tire Sizes
47
Steering Head Bearings Check
47
Fuel System Exploded View
48
Fuel System Service Information
49
Fuel System Specifications
49
Fuel System: Tools
50
Fuel System Troubleshooting
50
Carburetor Removal
51
Vacuum Chamber Removal
52
Vacuum Chamber Installation
53
Float Chamber Removal
53
Float Level Measurement
53
Float and Jets
54
Float Chamber Assembly
54
Pilot Screw Removal
55
Pilot Screw Installation
56
Pilot Screw Adjustment
56
Idle Drop Procedure (USA Only)
56
Air Cut off Valve Removal
57
Air Cut off Valve Inspection
57
Air Cut off Valve Installation
57
Carburetor Separation
58
Carburetor Cleaning
58
Carburetor Assembly
59
Carburetor Installation
60
Fuel Tank
60
Air Cleaner Case
61
High Altitude Adjustment (USA Only)
61
Purge Control Valve Inspection (California Model)
62
Air Vent Control Valve Inspection (California Model)
63
Secondary Air Supply System (California Model) Inspection
64
Reed Valve Inspection
65
Engine Removal/Installation
66
Engine Exploded View
66
Engine Removal/Installation - Service Information
68
Engine Specifications
68
Engine Torque Values
68
Engine Removal
69
Engine Installation
70
Cooling System
71
Cooling System - Service Information
72
Cooling System Specifications
72
Cooling System Troubleshooting
72
Cooling System Testing
73
Coolant
73
Radiator Cap/Cooling System Inspection
73
Coolant Replacement
74
Thermostat Removal
74
Thermostat Inspection
75
Radiator/Cooling Fan Removal
76
Radiator Disassembly
77
Radiator Inspection
77
Radiator Assembly/Installation
77
Water Pump
78
Mechanical Seal Inspection
78
Water Pump Removal
78
Water Pump Installation
79
Clutch System Exploded View
80
Clutch System Service Information
82
Clutch System Specifications
82
Clutch System Torque Values
82
Clutch System: Tools Needed
82
Clutch System Troubleshooting
83
Clutch Fluid Replacement/Air Bleeding
84
Clutch Fluid Draining
84
Clutch Fluid Filling/Air Bleeding
84
Clutch Master Cylinder Disassembly
85
Clutch Master Cylinder Inspection
86
Clutch Master Cylinder Assembly
87
Clutch Master Cylinder Installation
87
Clutch Slave Cylinder Disassembly
88
Piston O.D. Inspection
88
Cylinder I.D. Inspection
89
Clutch Slave Cylinder Assembly
89
Clutch Disassembly
90
Clutch Inspection
92
Clutch Outer Removal
94
Clutch Outer Inspection
95
Clutch Outer Installation
95
Clutch Assembly
97
Primary Drive Gear Removal
102
Primary Drive Gear Installation
102
Alternator/Starter Clutch Exploded View
103
Alternator/Starter Clutch Service Information
104
Alternator/Starter Clutch Specifications
104
Alternator/Starter Clutch Torque Values
104
Alternator/Starter Clutch: Tools Needed
104
Stator Removal
105
Flywheel Removal
106
Starter Clutch Disassembly
106
Starter Drive and Reduction Gear Inspection
107
Starter Clutch Inspection
107
Starter Clutch Assembly
108
Flywheel Installation
109
Stator Installation
109
Gearshift Linkage Exploded View
111
Gearshift Linkage Service Information
112
Gearshift Linkage Troubleshooting
112
Gearshift Linkage Specifications
112
Gearshift Linkage Removal
113
Gearshift Linkage Inspection
114
Gearshift Linkage Installation
115
Cylinder Head/Valve
118
Cylinder Head/Valve Service Information
119
Cylinder Head/Valve Specifications
119
Cylinder Head/Valve Torque Values
120
Cylinder Head/Valve Troubleshooting
120
Cylinder Head Cover Removal
121
Camshaft Removal
121
Camshaft Inspection
122
Cylinder Head Cover Disassembly
124
Cylinder Head Cover Inspection
125
Hydraulic Tappets Inspection
125
Cylinder Head Removal
126
Cylinder Head Disassembly
126
Cylinder Head Inspection
127
Valve Guide Replacement
128
Valve Seat Inspection/Refacing
129
Valve Seat Cutters
130
Valve Seat Refacing
130
Cylinder Head Assembly
131
Cylinder Head Installation
132
Camshaft Installation
133
Front Cylinder
133
Rear Cylinder
135
Cylinder Head Cover Assembly
136
Hydraulic Tappet Adjustment
136
Cylinder Head Cover Installation
137
Cylinder/Piston Exploded View
140
Cylinder/Piston Service Information
141
Cylinder/Piston Specifications
141
Cylinder/Piston Troubleshooting
141
Cylinder Removal
142
Cylinder Inspection
142
Piston Removal
143
Piston/Piston Ring Inspection
144
Piston Ring Installation
145
Piston Installation
146
Cylinder Installation
146
Crankcase Exploded View
147
Crankcase Service Information
148
Crankcase Torque Values
148
Crankcase Separation
149
Crankcase Assembly
150
Crankshaft/Transmission Exploded View
152
Crankshaft/Transmission Service Information
154
Crankshaft/Transmission Specifications
154
Crankshaft/Transmission Torque Values
155
Crankshaft/Transmission: Tools Needed
155
Crankshaft/Transmission Troubleshooting
156
Crankshaft/Connecting Rod
157
Crankshaft Removal
157
Crankshaft Inspection
157
Connecting Rod Removal
157
Inspection of Crankshaft
158
Connecting Rod Bearing Inspection
158
Connecting Rod Bearing Selection
159
Main Bearing Inspection
159
Main Bearing Replacement
161
Connecting Rod Selection
161
Connecting Rod Installation
162
Crankshaft Installation
162
Transmission
163
Transmission Disassembly
163
Transmission Inspection
163
Gearshift Drum Inspection
164
Shift Fork Disassembly
165
Gearshift Fork and Shaft Inspection
165
Gearshift Drum and Fork Shaft Bearing Inspection
166
Shift Fork Assembly
166
Transmission Assembly
167
Countershaft
168
Transmission Installation
169
Output Gear Removal
170
Output Gear Inspection
171
Damper Spring Inspection
172
Backlash Inspection
172
Output Drive Shaft Bearing Replacement
173
Output Driven Gear Bearing Replacement
176
Output Driven Gear Case Bearing Replacement
180
Gear Tooth Contact Pattern Check
181
Output Drive Shaft Installation
182
Crankcase Bearings Replacement
183
Left Crankcase Bearing
183
Right Crankcase Bearing
184
Final Drive Exploded View
185
Final Drive Service Information
186
Final Drive Specifications
186
Final Drive Torque Values
186
Final Drive: Tools Needed
187
Final Drive Troubleshooting
187
Final Drive Removal
188
Drive Shaft Removal
188
Drive Shaft Disassembly/Assembly
188
Universal Joint Removal/Installation
188
Final Drive Gear
189
Ring Gear Removal
189
Ring Gear Bearing/O-Ring Guide Removal
190
Case Cover Oil Seal Replacement
190
Pinion Gear Removal
190
Pinion Bearing Removal
191
Pinion Retainer Oil Seal Replacement
192
Case Bearing and Oil Seal Replacement
192
Breather Hole Cleaning
193
Pinion Gear Assembly
193
Ring Gear Assembly
194
Gear Tooth Contact Pattern Checking
196
Inspection of the Backlash
197
Pinion Joint Installation
198
Final Drive Installation
199
Front Wheel/Suspension Exploded View
201
Front Wheel/Suspension Service Information
202
Front Wheel/Suspension Specifications
202
Front Wheel/Suspension Torque Values
202
Front Wheel/Suspension: Tools Needed
203
Handlebar Removal
204
Handlebar Installation
205
Front Wheel Removal
208
Front Wheel Disassembly
208
Front Wheel Inspection
209
Front Wheel Bearing Replacement
210
Front Wheel Assembly
211
Front Wheel Installation
212
Front Fork Removal
213
Front Fork Disassembly
214
Front Fork Inspection
216
Front Fork Assembly
217
Front Fork Installation
219
Steering Stem Removal
219
Bearing Race Replacement
220
Bearing Installation
222
Steering Head Bearing Preload
223
Rear Wheel/Suspension/Brake Exploded View
224
Rear Wheel/Suspension/Brake Service Information
225
Rear Wheel/Suspension/Brake Specifications
225
Rear Wheel/Suspension/Brake Torque Values
225
Rear Wheel/Suspension/Brake: Tools Needed
226
Rear Wheel/Suspension/Brake Troubleshooting
226
Rear Wheel Removal
227
Rear Wheel Inspection
227
Rear Wheel Rim Runout
228
Rear Wheel Balance
228
Rear Wheel Bearings
228
Rear Wheel Disassembly
229
Rear Wheel Assembly
229
Rear Wheel Installation
230
Rear Brake Inspection
231
Rear Brake Disassembly
231
Rear Brake Assembly
232
Shock Absorber Removal
233
Shock Absorber Disassembly
233
Spring Free Length
234
Rear Shock Absorber Assembly
234
Rear Shock Absorber Installation
234
Swingarm Removal
235
Pivot Bearing Replacement
236
Pivot Bearing Installation
237
Hydraulic Brakes Exploded View
239
Hydraulic Brakes Service Information
240
Hydraulic Brakes Specifications
240
Hydraulic Brakes Torque Values
240
Hydraulic Brakes: Tool Needed
240
Hydraulic Brakes Troubleshooting
241
Brake Fluid Replacement/Bleeding
242
Brake Fluid Draining
242
Brake Fluid Filling/Bleeding
242
Brake Pad/Disc
243
Brape Pad Replacement
243
Disc Thickness
245
Disc Warpage
245
Master Cylinder Removal
245
Master Cylinder Disassembly
246
Master Cylinder Inspection
246
Master Cylinder Assembly
247
Master Cylinder Installation
247
Brake Caliper Removal
247
Brake Caliper Disassembly
248
Brake Caliper Inspection
248
Brake Caliper Assembly
249
Brake Caliper Installation
249
Battery/Charging System Exploded View and Schematic Diagram
250
Battery/Charging System Service Information
251
Battery/Charging System Specifications
251
Battery/Charging System Troubleshooting
251
Battery Removal
252
Battery Inspection
252
Specific Gravity
252
Battery Voltage
252
Battery Charging
253
Charging System
253
Leakage Inspection
253
Charging Output Inspection
253
Alternator
254
Stator Inspection
254
Voltage Regulator/Rectifier
254
Ignition System Diagram
256
Ignition System Service Information
257
Ignition System Troubleshooting
257
Ignition Coil Removal
258
Circuit Check
258
Continuity Check
258
Transistorized Ignition System (Pulse Generator, Spark Unit)
259
Pulse Generator Continuity Test
259
Pulse Generator Replacement
259
Spark Unit
259
Electric Starter Diagram
260
Electric Starter Service Information
261
Electric Starter Troubleshooting
261
Starter Motor Removal
262
Starter Motor Inspection
262
Commutator Bars View
263
Starter Motor Assembly/Installation
263
Starter Relay Switch Inspection
264
Clutch Diode Removal
265
Clutch Diode Inspection
265
Switches Service Information
266
Oil Pressure Switch
267
Neutral Switch
267
Overdrive Switch
267
Rear Brake Light Switch
267
Front Brake Light Switch
268
Clutch Switch
268
Handlebar Switch
268
Left Handlebar Switch
269
Right Handlebar Switch
269
Ignition Switch Inspection
270
Ignition Switch Removal
270
Ignition Switch Disassembly/Assembly
270
Instruments Removal
271
Instruments Installation
271
Bulb Replacement
271
Indicator Panel Bulb Replacement
272
Headlight Bulb Replacement
273
Headlight Case Removal
273
Thermostatic Switch
274
Temperature Sensor
274
Temperature Gauge
275
Fuel Sensor Inspection
275
Horn
275
Fuel Pump
276
Pilot Lamp Checker
276
Brake/Taillight Sensor ('86 Only)
277
Wiring Diagrams
278
Troubleshooting
280
Engine Does Not Start or Is Hard to Start
280
Engine Lacks Power
281
Poor Performance at Low and Idle Speeds
282
Poor Performance at High Speed
282
Poor Handling
283
Hydraulic Tapped - Noisy
283
Index
285

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Honda 86 VT700C Shadow Manuals

Honda 86 VT700C Shadow Service Manual (287 pages)

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