Honda VT600CD Shadow VLX Manuals

Manuals and User Guides for Honda VT600CD Shadow VLX. We have 1 Honda VT600CD Shadow VLX manual available for free PDF download: Service Manual

Honda VT600CD Shadow VLX Service Manual (288 pages)

Brand: Honda | Category: Motorcycle | Size: 9.59 MB

Safety Notice
2
How to Use the Manual
3
Table of Contents
3
General Information
5
General Safety
5
Service Rules
5
Model Identification
6
Specifications
7
Torque Values
9
Tools
12
Valve Seat Cutters
13
Cable & Harness Routing
14
Cable & Harness Routing - '88-'89; '91
15
Cable & Harness Routing - '94
16
Cable & Harness Routing - '99-'89, '91
17
Cable & Harness Routing - '94, after '94
18
Cable & Harness Routing - '88-'89, '91-'93
19
Cable & Harness Routing - '94 and after '94
20
Cable & Harness Routing - after '93
23
Evaporative Emission Control System (California Model Only)
24
Emission Control Systems
25
Evaporative Emission Control System
26
Noise Emission Control System
26
Emission Control Information Labels
26
Vacuum Hose Routing Diagram Label (California Model Only)
27
Lubrication Diagram - '88, '89
28
Lubrication Diagram - after '89
29
Lubrication
30
Engine Oil Specifications
30
Oil Pump Specifications
30
Lubrication: Troubleshooting
31
Lubrication: Tools Needed
31
Engine Oil Level
32
Engine Oil Change
32
Oil Capacity
32
Recommended Oil
32
Oil Filter Change
33
Oil Pressure Check
33
Oil Pump
34
Pressure Relief Valve Removal
34
Pressure Relief Valve Disassembly and Inspection
34
Oil Pump Removal/Disassembly
34
Oil Pump Inspection
35
Oil Pump Assembly
36
Oil Pump Installation
39
Control Cable Lubrication
40
Lubrication Points
40
Maintenance
41
Ignition Timing
41
Spark Plug Gap
41
Chassis Maintenance
42
Tires Maintenance
42
Maintenance Schedule '88
43
Maintenance Schedule '89, '91-'93;
44
Maintenance Schedule '93;
45
Fuel Filter
46
Throttle Operation
46
Carburetor Choke
47
Air Cleaner
47
Crankcase Breather
48
Spark Plugs
48
Valve Clearance
48
Carburetor Synchronization
50
Carburetor Idle Speed
51
Radiator Coolant
51
Cooling System
52
Cylinder Compression
52
Evaporative Emission Control System Maintenance
53
Drive Chain Maintenance
53
Chain Slack Inspection
53
Chain Adjustment
53
Lubrication and Cleaning
54
Chain Replacement
54
Brake Fluid
55
Brake Shoe/Pad Wear
56
Brake System
56
Brake Pedal Height
56
Brake Pedal Free Play
57
Brake Light Switch
57
Headlight Aim
58
Clutch System
58
Side Stand
59
Suspension
59
Nuts, Bolts, Fasteners
60
Steering Head Bearings
61
Fuel System Diagram
62
Fuel System
63
Fuel System Specifications
63
Fuel System: Tools Needed
64
Fuel System Troubleshooting
64
Fuel Tank Removal
65
Fuel Tank Installation
65
Air Cleaner Housing Removal
66
Air Claaner Installation
66
Sub-Air Cleaner Element
66
Air Cleaner Chamber Removal/Installation
67
Carburetor Removal
68
Carburetor Disassembly
68
Vacuum Chamber
68
Float Chamber, Floats and Jets
69
Pilot Screw
70
Air Cut off Valve
71
Carburetor Assembly
72
Pilot Screw Installation
73
Float Chamber, Float and Jets Installation
73
Vacuum Chamber Installation
74
Carburetor Separation
75
Carburetor Installation
77
Pilot Screw Adjustment
77
High Altitude Adjustment (USA Only)
78
Evaporative Emission Purge Control Valve Inspection (California Model Only)
78
Evaporative Emission Carburetor Air Vent Control Valve Inspection
79
Cooling System Diagram
82
Cooling System Service Information
83
Cooling System Specifications
83
Cooling System Troubleshooting
83
Cooling System Testing
84
Coolant Mixture
84
Radiator Cap
84
Cooling System Pressure Test
84
Thermostat Removal
85
Coolant Replacement
85
Thermostat Inspection
86
Thermostat Installation
86
Radiator/Cooling Fan Removal
87
Radiator/Cooling Fan Disassembly
88
Radiator/Cooling Fan Assembly
89
Water Pump - Mechanical Inspection
89
Water Pump Installation
90
Coolant/Reserve Tank Removal/Installation
91
Engine Removal/Installation
92
Engine:service Information
94
Engine Removal/Installation: Specifications
94
Engine: Torque Values
94
Engine Removal
95
Engine Installation
97
Clutch/Gearshift Linkage Diagram
98
Clutch/Gearshift Linkage - Service Information
99
Clutch/Gearshift Linkage Specifications
99
Clutch/Gearshift Linkage Torque Values
99
Clutch/Gearshift Linkage: Tools Needed
99
Clutch/Gearshift Linkage Troubleshooting
100
Right Crankcase Cover Removal
101
Clutch Lifter Shaft
101
Clutch Removal
102
Clutch Inspection
104
Gearshift Linkage Removal
106
Gearshift Linkage Inspection
107
Gearshift Linkage Installation
108
Primary Drive Gear Removal
109
Primary Drive Gear Installation
109
Clutch Installation
110
Right Crankcase Cover Installation
112
Alternator/Starter Clutch Diagram
114
Alternator/Starter Clutch - Service Information
115
Alternator/Starter Clutch - Specifications
115
Left Crankcse Cover Removal
116
Stator Replacement
116
Flywheel Removal
117
Starter Clutch Disassembly
118
Starter Clutch Inspection
118
Starter Clutch Assembly
119
Flywheel Installation
119
Left Crankcase Cover Installation
120
Cylinder Head/Valve Diagram
122
Cylinder Head/Valve - Service Information
123
Cylinder Head/Valve Specifications
123
Cylinder Head/Valve Torque Values
124
Cylinder Head/Valve - Tools Neded
124
Cylinder Head/Valve Troubleshooting
124
Cylinder Head Cover Removal
125
Camshaft Removal
126
Camshaft Inspection
128
Cylinder Head Removal
130
Cylinder Head Disassembly/Inspection
131
Valve Guide Replacement
133
Valve Guide Projection Height
134
Valve Seat Inspection/Refacing
134
Valve Seat Refacing
135
Cylinder Head IV Alve
136
Cylinder Head Installation
138
Camshaft Installation
140
Cylinder Head Cover Installation
143
Cylinder/Piston Diagram
146
Cylinder/Piston - Service Information
147
Cylinder/Piston Specifications
147
Cylinder/Piston Troubleshooting
147
Cylinder Removal
148
Cylinder Inspection
148
Piston Removal
149
Piston Inspection
149
Piston Ring Installation
151
Piston Installation
151
Cylinder Installation
152
Crankshaft/Transmission Diagram
154
Crankshaft/Transmission - Service Information
155
Cylinder/Piston
155
Crankshaft/Transmission - Specifications
156
Crankshaft/Transmission Torque Values
156
Crankshaft/Transmission - Tools Needed
156
Crankshaft/Transmission Troubleshooting
157
Crankcase Separation
158
Crankshaft/Connecting Rod
159
Crankshaft Removal
159
Crankshaft Side Clearance Inspection
159
Connecting Rod Assembly
160
Crankshaft Runout Inspection
160
Connecting Rod Bearing Inspection
160
Connecting Rod Bearing Selection
161
Main Bearing Inspection
162
Main Bearing Selection
162
Main Bearing Replacement
163
Connecting Rod/Crankshaft Selection
164
Crankshaft Installation
164
Transmission Removal
165
Transmission Disassembly/Inspection
165
Crankcase Bearing Replacement
167
Crankcase Inspection
169
Transmission Assembly/Installation
171
Crankcase Assembly
173
Front Wheel/Suspension/Steering Diagram
176
Front Wheel/Suspension/Steering - Service Information
177
Front Wheel/Suspension/Steering Specifications
177
Front Wheel/Suspension/Steering Torque Values
177
Front Wheel/Suspension/Steering - Tools Needed
178
Front Wheel/Suspension/Steering Troubleshooting
178
Habdlebar Grip Replacement
179
Handlebar Removal
179
Handlebar Installation
181
Front Wheel Removal
183
Front Wheel Inspection
184
Front Wheel Bearing Replacement
185
Front Wheel Assembly
186
To Replace the Front Wheel
187
Front Wheel Installation
188
Front Fork Removal
189
Front Fork Disassembly
190
Front Fork Inspection
191
Front Fork Assembly
192
Front Fork Installation
194
Steering Stem Removal
196
Steering Stem: Bearing Replacement
197
Steering Stem Installation
199
Steering Head Bearing Preload
200
Rear Wheel/Brakes/Suspension Diagram
202
Rear Wheel/Brakes/Suspension - Service Information
203
Rear Wheel/Brakes/Suspension Specifications
203
Rear Wheel/Brakes/Suspension Torque Values
203
Rear Wheel/Brakes/Suspension - Tools Needed
204
Rear Wheel/Brakes/Suspension Troubleshooting
204
Rear Wheel Removal
205
Rear Wheel Inspection
205
Sprocket/Drive Flange Disassembly/Inspection
206
Rear Wheel Bearing Replacement
206
Rear Wheel Assembly
207
Rear Wheel Installation
209
Rear Brake Inspection
209
Rear Brake Disassembly
210
Rear Brake Assembly
210
Brake Pedal Removal
212
Brake Pedal Installation
212
Rear Shock Absorber Removal
213
Rear Shock Absorber Disassembly
213
Rear Shock Absorber: Spring Free Length
214
Shock Absorber Disposal
214
Rear Shock Absorber Installation
215
Swingarm Removal
216
Swingarm Disassembly
216
Swingarm Inspection
217
Pivot Bearing Replacement
217
Swingarm Assembly/Installation
219
Seat/Rear Fender/Sub-Frame Removal/Installation
220
Hydraulic Disc Brake Diagrams
222
Hydraulic Disc Brake
223
Hydraulic Disc Brake - Service Information
224
Hydraulic Disc Brake Specifications
224
Hydraulic Disc Brake Torque Values
224
Hydraulic Disc Brake Troubleshooting
225
Brake Fluid Replacement/Air Bleeding
226
Brake Fluid Draining
226
Brake Fluid Filling/Air Bleeding
226
Brake Pad/Disc
227
Front Brake Pad Replacement
227
Master Cylinder Removal
230
Master Cylinder Disassembly
230
Disc Thickness
230
Brake Disc Warpage
230
Master Cylinder Inspection
231
Master Cylinder Assembly
231
Master Cylinder Installation
232
Brake Caliper Removal
233
Brake Caliper Disassembly
233
Brake Caliper Assembly
234
Battery/Charging System Diagrams
236
Battery/Charging System - Service Information
238
Battery/Charging System Specifications
238
Battery/Charging System - Tools Needed
238
Battery/Charging System Troubleshooting
239
Battery Removal
240
Battery Installation
240
Voltage Inspection
241
Battery Testing
241
Battery Charging
242
Charging System
243
Leakage Inspection
243
Regulated Voltage Inspection
244
Regulator/Rectifier Inspection
244
Altarnator Inspection
245
Ignition System Diagram
246
Ignition System - Service Information
248
Ignition System Specifications
248
Ignition System - Tools Needed
248
Ignition System Troubleshooting
249
Ignition Control Module Inspection
250
Ignition Coil Inspection
250
Ignition Coil Replacement
251
Ignition Pulse Generator Inspection
252
Side Stand Switch Inspection
252
Side Stand Switch Removal/Installation
253
Electric Starter Diagram
256
Electric Starter - Service Information
257
Electric Starter Troubleshooting
257
Electric Starter Specification
257
Starter Motor Removal
259
Starter Motor Disassembly
259
Starter Motor Inspection
259
Electric Starter Assembly
261
Electric Starter Installation
262
Starter Relay Switch Inspection
262
Continuity Inspection
263
Clutch Diode Removal
263
Clutch Diode Inspection
263
Lights/Meter/Switches - Service Information
265
Lights/Meter/Switches Specifications
265
Lights/Meter/Switches Troubleshooting
266
Lights/Meter/Switches Removal/Installation
267
Bulb Replacement
268
Speedometer Removal
268
Speedometer Installation
269
Indicator Panel Bulb Replacement
270
Ignition Switch Inspection
270
Ignition Switch Replacement
270
Handlebar Switches
271
Thermostatic Switch Inspection
272
Coolant Temperature Indicator
272
Thermo Sensor Inspection
273
Fuel Pump Relay
273
Fuel Pump - System Inspection
274
Oil Pressure Switch
274
Neutral Switch Inspection
275
Brake Light Switch Inspection
275
Clutch Switch Inspection
275
Turn Signal Relay
276
Horn
276
Wiring Diagram
277
Wiring Diagram
278
Wiring Diagram -'92, '93
279
Wiring Diagram - after '93
280
Troubleshooting
281
Engine Does Not Start or Is Hard to Start
281
Engine Lacks Power
282
Poor Performance at Low and Idle Speeds
283
Poor Performance at High Speed
284
Index
285

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Honda VT600CD Shadow VLX Service Manual (288 pages)

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