Honda 2002 VT750C3 Manuals

Manuals and User Guides for Honda 2002 VT750C3. We have 1 Honda 2002 VT750C3 manual available for free PDF download: Service Manual

Honda 2002 VT750C3 Service Manual

Honda 2002 VT750C3 Service Manual (428 pages)

Brand: Honda | Category: Motorcycle | Size: 152.86 MB

Table of Contents

How to Use this Manual
2
Contents
2
Symbols
3
General Information
4
General Safety
4
Service Rules
5
Model Identification
6
Specifications
7
Lubrication System
9
Fuel System
9
Cooling System
9
Clutch System
10
Alternator/Starter Clutch
10
Cylinder Head/Valves
10
Cylinder/Piston
11
Crankshaft/Transmission
12
Front Wheel/Suspension/Steering
13
Rear Wheel/Brake/Suspension
13
Ignition System
14
Battery/Charging System
14
Hydraulic Brake
14
Electric Starter
15
Lights/Meters/Switches
15
Torque Values
16
Engine
16
Frame
18
Tools
20
Lubrication & Seal Points
22
Cable & Harness Routing
25
Vt750C
25
Vt750Cd/Cd2 ('98-2000)
25
VT750CD/CD2 (after 2000)
26
Vt750C3/Cd3
26
Evaporative Emission Control System (California Type Only)
36
Exhaust Emission Control System
37
Crankcase Emission Control System
37
Source of Emissions
37
Emission Control Systems
37
Noise Emission Control System
38
Emission Control Information Labels
39
Vehicle Emission Control Information Update Label
39
Vacuum Hose Routing Diagram Label (California Type Only)
39
Frame/Body Panels/Exhaust System
40
Service Information
40
Troubleshooting
40
Seat
41
Steering Cover
42
Side Cover
43
Fuel Tank
43
Rear Fender
45
Grab Rail
45
Exhaust Pipe/Muffler
46
Table of Contents
50
Maintenance
50
Maintenance Schedule
52
Fuel Line
53
Fuel Filter
53
Throttle Operation
53
Starting Enrichment (SE) Valve
54
Carburetor Choke
54
Air Cleaner
55
Crankcase Breather
56
Spark Plug
56
- Replacing a Spark Plug
  57
- Reusing a Spark Plug
  57
Valve Clearance
58
Oil Level Inspection
60
Engine Oil/Oil Filter
60
- Engine Oil Change
  61
- Oil Filter Change
  62
Carburetor Synchronization
63
Engine Idle Speed
64
Level Check
65
Radiator Coolant
65
Cooling System
65
Evaporative Emission Control
66
System (California Type Only)
66
Drive Chain Slack Inspection
67
Drive Chain
67
- Cleaning, Inspection and Lubrication
  68
- Sprockets Inspection
  68
Brake Fluid
71
- Front Brake Pads
  72
- Rear Brake Pads
  72
Brake Shoe/Pad Wear
72
Brake System
72
- Brake Pedal Height
  73
- Brake Pedal Free Play
  73
Brake Light Switch
74
Headlight Aim
74
Clutch System
75
Side Stand
75
- Front
  76
- Rear
  76
Suspension
76
Nuts, Bolts, Fasteners
76
- Lubrication System
  78
- Oil Pressure Check
  80
- Oil Pump
  81
- Oil Pump Disassembly
  82
- Body Clearance
  83
- Pressure Relief Valve Check
  83
- Tip Clearance
  83
- Assembly
  84
- Side Clearance
  84
- Fuel System
  88
- Troubleshooting
  90
- Air Cleaner Housing
  91
- Sub-Air Cleaner Element
  92
- Air Cleaner Chamber
  93
- Carburetor Removal
  95
- Carburetor Disassembly/Assembly
  97
- Vacuum Chamber
  98
- Float Chamber
  100
  - Jets
    102
  - Pilot Screw
    102
  - Valve Seat/Filter
    102
  - Float Level
    103
- Air Cut-Off Valve
  104
- Carburetor Body Cleaning
  104
- Carburetor Separation
  105
- Carburetor Reassembly
  106
- Carburetor Installation
  108
- Idle Drop Procedure
  109
- Pilot Screw Adjustment
  109
- Fuel Pump
  111
  - System Inspection
    111
  - Discharge Volume Inspection
    112
- Fuel Filter
  114
- High Altitude Adjustment (U.S.A. Only)
  114
- Evaporative Emission Purge Control Valve Inspection (California Type Only)
  115
- Evaporative Emission Carburetor Air Vent Control Valve Inspection (California Type Only)
  117
  - System Flow Pattern
    119
  - Cooling System
    120
  - Coolant (Hydrometer Test)
    122
  - Coolant Gravity Chart
    122
  - System Testing
    122
  - Coolant
    123
  - Radiator Cap/System Pressure Inspection
    123
  - Replacement/Air Bleeding
    124
  - Thermostat
    125
  - Radiator/Cooling Fan
    128
  - Mechanical Seal Inspection
    134
  - Water Pump
    134
  - Installation
    135
  - Radiator Reserve Tank
    137
  - Engine Removal/Installation
    139
  - Drive Sprocket Removal
    142
  - Engine Removal
    143
  - Engine Installation
    147
  - Drive Sprocket Installation
    151
  - Clutch/Gearshift Linkage
    154
  - Right Crankcase Cover Removal
    156
  - Clutch Removal
    157
  - Clutch Disc
    160
  - Clutch Spring
    160
  - Lifter Plate Bearing
    160
  - Clutch Center
    161
  - Clutch Outer
    161
  - Clutch Outer Guide
    161
  - Clutch Plate
    161
  - Clutch Outer Needle Bearing Replacement
    162
  - Judder Spring, Spring Seat
    162
  - Mainshaft
    162
  - Oil Pump Drive Sprocket
    162
  - Primary Drive Gear
    163
  - Gearshaft Linkage
    165
  - Clutch Installation
    170
  - Right Crankcase Cover Installation
    174
  - Alternator/Starter Clutch
    178
  - Stator Removal
    179
  - Flywheel Removal
    180
  - Flywheel, Starter Clutch
    180
  - Starter Driven Gear, Starter, Clutch Removal
    181
  - Clutch Housing
    182
  - Needle Bearing
    182
  - One-Way Clutch
    182
  - Starter Clutch Inspection
    182
  - Starter Driven Gear, Starter Clutch Installation
    183
  - Flywheel Installation
    184
  - Stator Installation
    186
  - Cylinder Head/Valves
    190
- Troubleshooting
  192
- Cylinder Compression
  193
Cylinder Head Cover Removal
194
- Camshaft Removal
  197
  - Camshaft Holder Disassembly
    200
  - Camshaft Runout
    200
  - Cam Lobe Height
    201
  - Camshaft Journal
    201
  - Camshaft Oil Clearance
    201
- Cylinder Head Removal
  203
- Cylinder Head Disassembly
  204
  - Cylinder Head
    205
  - Valve Spring
    205
  - Valve Stem, Valve Guide
    205
  - Cam Chain Guide
    206
  - Cam Chain Tensioner
    207
- Valve Guide Replacement
  207
- Valve Seat Inspection/Refacing
  209
- Valve Seat Refacing
  209
- Cylinder Head Assembly
  211
- Cylinder Head Installation
  213
- Camshaft Holder Assembly
  215
- Camshaft Installation
  215
- Cylinder Head Cover Installation
  221
  - Cylinder/Piston
    228
  - Cylinder Removal
    230
  - Piston Removal
    232
  - Crankcase Stud Bolt Inspection
    235
  - Piston Installation
    235
  - Cylinder Installation
    237
  - Crankshaft/Transmission
    240
- Service Information
  241
- Troubleshooting
  242
- Crankcase Separation
  243
- Crankshaft/Connecting Rod
  245
  - Connecting Rod Bearing Inspection
    246
  - Crankpin Oil Clearance
    246
  - Connecting Rod Bearing Selection
    247
  - Connecting Rod/Crankshaft Selection
    248
  - Crankshaft/Crankcase Selection
    248
  - Main Bearing Inspection
    249
- Transmission
  251
  - Shift Drum/Shift Drum Bearing
    253
  - Shift Drum Journal, Shift Fork Shaft Journal
    255
  - Shift Fork, Shift Fork Shaft
    255
  - Mainshaft
    256
  - Countershaft
    257
- Crankcase Bearing Replacement
  259
  - Left Crankcase Bearing Replacement
    259
  - Right Crankcase Bearing Replacement
    260
  - Crankcase Assembly
    261
  - Front Wheel/Suspension/Steering
    266
- Front Wheel/Suspension/Steering
  267
- Troubleshooting
  269
- Grip Replacement
  270
- Handlebar
  270
- Front Wheel
  278
- Vt750C3/Cd3
  278
- VT750CD/CD2 (after 2000)
  278
  - Axle
    279
  - Wheel Bearing
    280
  - Wheel Rim
    280
  - Wheel Balance
    283
- Fork
  287
  - Fork Spring
    292
  - Fork Tube/Slider/Fork Piston
    292
  - Fork Tube Bushing
    293
- Steering Stem
  299
  - Steering Bearing Replacement
    303
  - Steering Bearing Preload
    309
- Nom (2.3 Kgfom, 17 Ibfoft)
  311
  - Rear Wheel/Brake/Suspension
    312
  - Rear Wheel
    314
  - Driven Sprocket
    315
  - Wheel
    315
  - Wheel Bearing
    315
  - Driven Flange Bearing Removal
    316
  - Wheel Bearing Removal
    317
  - Driven Flange Bearing Installation
    318
  - Wheel Bearing Installation
    318
  - Rear Brake
    322
  - Brake Pedal
    326
  - Shock Absorber
    329
  - Swingarm
    330
  - Pivot Bearing Replacement
    333
  - Hydraulic Brake
    340
  - Brake Fluid Draining
    342
  - Brake Fluid Filling/Bleeding
    342
  - Brake Fluid Replacement/Air Bleeding
    342
  - Brake Pad Replacement
    344
  - Brake Pad/Disc
    344
  - Brake Disc Inspection
    345
  - Master Cylinder
    346
  - Brake Caliper
    352
  - System Diagram
    357
  - Battery/Charging System
    358
  - Troubleshooting
    360
  - Battery
    362
  - Battery Charging
    363
  - Charging System Inspection
    364
  - Regulated Voltage Inspection
    364
  - Current Leakage Test
    365
  - Battery Line
    366
  - Charging Line
    366
  - Regulator/Rectifier
    366
  - Wire Harness Inspection
    366
  - Ignition System
    370
  - Ignition Primary Voltage Inspection
    373
  - Ignition System Inspection
    373
  - Ignition Pulse Generator Peak Voltage Inspection
    375
  - Ignition Coil
    376
  - Ignition Control Module (ICM)
    376
  - Ignition Timing
    377
  - System Diagram
    379
  - Electric Starter
    380
  - Starter Motor
    383
  - Brush Holder Disassembly
    385
  - Ground Line
    392
  - Operation Check
    392
  - Starter Relay Switch
    392
  - Starter Relay Voltage
    392
  - Clutch Diode
    393
  - Lights/Meters/Switches
    396
  - Speed Sensor/Speedometer
    399
- Troubleshooting (VT750CD/CD2 (after 2000), VT750C3/CD3)
  399
- Bulb Replacement
  402
  - Headlight
    402
  - License Light
    403
  - Tail/Brake Light
    403
  - Turn Signal Light
    403
  - Indicator Light
    404
  - Speedometer Light
    404
- Speedometer
  405
- Speed Sensor (VT750CD/CD2 (after 2000), VT750C3/CD3)
  408
- Oil Pressure Switch
  409
- Wire Harness Inspection
  409
- Neutral Switch
  410
- Front Brake Light Switch
  411
- Rear Brake Light Switch
  411
- Clutch Switch
  412
- Handlebar Switch
  412
- Right Handlebar Switch
  412
- Ignition Switch
  413
- Left Handlebar Switch
  413
- Fan Motor Switch
  414
- Coolant Temperature
  415
  - Coolant Temperture, Thermo Switch
    415
  - Thermo Switch Inspection
    416
- Horn
  417
- Side Stand Switch
  418
- Turn Signal Relay
  418
- Performance Test
  418
- Wiring Diagram
  420
- Troubleshooting
  422
- Engine Does Not Start or Is Hard to Start
  422
- Engine Lacks Power
  423
- Poor Performance at Low and Idle Speed
  424
- Poor Performance at High Speed
  425
- Poor Handling
  425
- Index
  426

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