1997-2002 Honda VT1100 VT1100C3 Shadow Aero Service & Repair Manual

HOW TO USE THIS MANUAL This service manual describes the service procedures for the VT11 DOC and VT11 DOT. Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency and California Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/ installation of components that may be required to perform service described in the following sections. Sections 4 through 19 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections have an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you do not know the source of the trouble, go to section 21, Troubleshooting. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR A TVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: March, 1997 © Honda Motor Co., Ltd. z < a: 1- w > C2 c c z < w z (.!) z w en U5 en < :::c (.) ...J < (.) C2 ~ w ...J w CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVE CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE CRANKSHAFT /TRANSMISSION FINAL DRIVE FRONT WHEEL/SUSPENSION/ STEERING REAR WHEEL/BRAKE/SUSPENSION HYDRAULIC DISC BRAKE CHARGING SYSTEM/ ALTERNATOR IGNITION SYSTEM ELECTRIC STARTER/STARTER CLUTCH LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. ~-, lllllijllll Replace the part(s) with new one(s) before assembly. , Use recommended engine oil, unless otherwise specified. 71 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 :1 ). - ~ Use multi-purpose grease (lithium based multi-purpose grease NLGI # 2 or equivalent). Use molybdenum disulfide grease (containing more than 3 % molybdenum disulfide, NLGI # 2 or ~ equivalent). Example: Molykote® BR-2 plus manufactured by Dow Corning, U.S. A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40 % molybdenum disulfide, NLGI # 2 or equivalent). ~ Example: Molykote® G-n paste, manufactured by Dow Corning, U. S. A. Honda Moly 60 (U. S. A. only) Rocol ASP manufactured by Rocol Limited, U. K. Rocol Paste manufactured by Sumico Lubricant, Japan ~ Use silicone grease. ca Apply a locking agent. Use a medium strength locking agent unless otherwise specified . .(limru Apply sealant. I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified . .. Use fork or suspension fluid.

1. GENERAL INFORMATION GENERAL SAFETY 1-1 SERVICE RULES 1-2 MODEL IDENTIFICATION 1-3 SPECIFICATIONS 1-5 TORQUE VALUES (VT1100C) 1-17 TORQUE VALUES (VT1100T) 1-21 TOOLS 1-25 LUBRICATION & SEAL POINTS (VT1100Cl 1-27 GENERAL SAFETY CARBON MONOXIDE If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. ,, ,,,.,.,*'"" The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacua- tion system in an enclosed area. GASOLINE Work in a well vent ilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored. Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. LUBRICATION & SEAL POINTS (VT1100T) 1-31 CABLE & HARNESS ROUTING (VT1100C) 1-35 CABLE & HARNESS ROUTING (VT1100T) 1-52 EMISSION CONTROL SYSTEMS 1-68 EMISSION CONTROL INFORMATION LABELS 1-70 USED ENGINE/TRANSMISSION OIL c, m,,;mog Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. BRAKE DUST Never use an air hose or dry brush to clean brake assem- blies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to min imize the hazard caused by airborne asbestos fibers . '""'*'"" Inhaled asbestos fibers have been found to cause respiratory disease and cancer. BRAKE FLUID CAUTION : Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. • 1-1

GENERAL INFORMATION COOLANT Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible . If the ethylene glycol does ignite, you will not see any flame, but you can be burned. IMN@Ori •Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame. • Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN. • Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. • Keep hands and clothing away from the cooling fan, as it starts automatically. CAUTION : Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. SERVICE RULES BATTERY HYDROGEN GAS & ELECTROLYTE 1¥2"@0@ • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protec- tive clothing and a face shield. - If electrolyte gets on your skin, flush with water. - If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. • Electrolyte is poisonous. - If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN. 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, 0-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown on pages 1-35 through 1-67, Cable & Harness routing. 1-2

GENERAL INFORMATION MODEL IDENTIFICATION VT1100C: VT1100T: 1-3

GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number (VIN) is attached on the left side of the steering head. ENGINE SERIAL NUMBER The engine serial number is stamped on the right crankcase below the rear cylinder. COLOR LABEL The color label is attached to the tool pocket under the right side cover. 1-4 FRAME SERIAL NUMBER The frame serial number is stamped on the right side of the steering head. CARBURETOR IDENTIFICATION NUMBER The carburetor identification number is stamped on the carburetor body intake side.

SPECIFICATIONS - GENERAL VT1100C ITEM DIMENSIONS FRAME ENGINE Overall length Overall width Overall height Wheelbase Seat height Ground clearance Dry weight (49 state/Canada type) (California type) Curb weight (49 state/Canada type) (California type) Maximum weight capacity (49 state/ California type) (Canada type) Frame type Front suspension Front wheel travel Rear suspension Rear wheel travel Front tire size Rear tire size Tire brand (Dunlop) Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Front/Rear Intake valve opens at 1 mm lift Intake valve closes at 1 mm lift Exhaust valve opens at 1 mm lift Exhaust valve closes at 1 mm lift Lubrication system Oil pump type Cooling system Air filtration Engine weight Firing order Cylinder number GENERAL INFORMATION 2,380 mm (93.7 in) 880 mm (34.6 in) 1,220 mm (48.0 in) 1,650 mm (65.0 in) 730 mm (28.7 in) 140 mm (5.5 in) 251 kg (553 lbs) 252 kg (556 lbs) 270 kg (595 lbs) 271 kg (597 lbs) 164 kg (362 lbs) 168 kQ (370 lbs) Double cradle Telescopic fork 135 mm (5.3 in) Swingarm 100 mm (3.9 in) 110/90- 19 62H 170/80- 15 M/C 77H F24 I K555 Hydraulic single disc SPECIFICATIONS Mechanical leading/trailing shoe 32°40' 152 mm (6.0 in) 15.8 Q (4 . 17 US gal, 3.48 Imp gal) 2.2 Q (0.58 US Qal , 0.48 Imp Qal) 2 cylinder 45° V transverse 87.5 x 91.4 mm (3.44 x 3.60 in) 1,099 cm 3 (67 .0 cu-in) 8.0: 1 Silent multi-link chain driven OHC with rocker arms Front: 5° BTDC Rear: 2° BTDC 30° ABDC 33° ABDC 30° BBDC 37° BBDC 5° ATDC - 2° ATDC Forced pressure and wet sump Trochoid Liquid cooled Viscous paper element 96 kg (212 lbs) Front - 495 °- Rear - 225°- Front - Front: # 2, Rear: # 1 1-5

GENERAL INFORMATION - GENERAL VT1100C ( 'd) cont ITEM SPECIFICATIONS CARBURETOR Carburetor type Constant Venturi Throttle bore 36 mm (1 .4 in) DRIVE TRAIN Clutch system Multi -plate, wet Clutch operation system Cable operating Transmission 5 speeds Primary reduction 1.692 (66/39) Secondary reduction 0.806 (29/36) Third reduction (Output drive reduction) 1.059 (18/ 17) Final reduct ion 3.091 (34/ 11) Gear ratio 1st 2.375 (38/ 16) Gear ratio 2nd 1.391 (32/ 23) Gear ratio 3rd 1.037 (28/ 27) Gear ratio 4th 0.888 (32/36) Gear ratio 5th 0.766 (23/30) Gearshift pattern Left foot operated return system 1- N- 2- 3- 4- 5 ELECTRICAL Ignition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator/ rectifier SCR shorted/ triple phase full-wave rectification Liqhtinq system Battery 1-6

- GENERAL VT1100T ITEM DIMENSIONS FRAME ENGINE Overall length Overall width Overall height Wheelbase Seat height Ground clearance Dry weight (49 state/Canada type) (California type) Curb weight (49 state/Canada type) (California type) Maximum weight capacity (49 state/ California type) (Canada type) Frame type Front suspension Front wheel travel Rear suspension Rear wheel travel Front tire size Rear tire size Tire brand (Dunlop) Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Front/Rear Intake valve opens at 1 mm lift Intake valve closes at 1 mm lift Exhaust valve opens at 1 mm lift Exhaust valve closes at 1 mm lift Lubrication system Oil pump type Cooling system Air filtration Engine weight Firing order Cylinder number GENERAL INFORMATION 2,480 mm (97 .6 in) 965 mm (38.0 in) 1.430 mm (56.3 in) 1,655 mm (65.2 in) 730 mm (28.7 in) 150 mm (5 .9 in) 284 kg (626 lbs) 285 kg (628 lbs) 296 kg (653 lbs) 297 kg (655 lbs) 173 kg (381 lbs) 177 kg (390 lbs) Double cradle Telescopic fork 124 mm (4 .9 in) Swingarm 100 mm (3.9 i n) 130/80R18 66H 170/70R 16 75H D206F I D206A Hydraulic single disc Hydraulic single disc 32°15' 149 mm (5.9 in) SPECIFICATIONS 15.8 Q (4. 17 US gal, 3.48 Imp gal) 2.2 Q (0.58 US gal , 0.48 Imp gal) 2 cylinder 45° V transverse 87 .5 X 91 .4 mm (3 .44 X 3.60 in) 1,099 cm 3 (67 .0 cu-in) 8.0 : 1 Silent multi-link chain driven OHC with rocker arms Front: 5° BTDC Rear: 2° BTDC 30° ABDC 33° ABDC 30° BBDC 37° BBDC 5° ATDC - 2° ATDC Forced pressure and wet sump Trochoid Liquid cooled Viscous paper element 96 kg (212 lbs) Front - 495°- Rear- 225°- Front - Front: # 2, Rear: # 1 1-7

1997-2002 Honda VT1100 VT1100C3 Shadow Aero Service & Repair Manual

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