2007-2009 Honda VT750C2 Shadow Spirit Service & Repair Manual

HOW TO USE THIS MANUAL This service manual describes the service procedures for the VT750C2IC2F. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are with the standards set by the U.S. Environmental Protection Agency, California Air Resources Board (CARB) and Transport Canada. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. CONTENTS • GENERAL INFORMATION •. i========== ~T=E=C=H=N=I=CA=L=FE=,;.=:r=U=R=E=========. ===FR=A=M=EIB==O=DY=PA=N=E=L=S=/E=X=H=A=U=S=T=S=Y=S=T=EM===_ r----i==M=A=IN=T=E=N=A=N=C=E===========_ Sections 1 and 4 apply to the whole motorcycle. Section 3 illustrates procedures for removal/installation of components that may be required to perform service described In the following sections. Section 5 through 21 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 start with an assembly or system illustration, service information and trOUbleshooting for the section. The subsequent pages give detailed procedure. If you don't know the source of the trouble, go to section 23 Troubleshooting. Your safely, and the safely of others, is very important. To help you make informed decisions we have provided safely messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safely information in a variely of forms including: • Safely Labels - on the vehicle • Safely Messages - preceded by a safely alert symbol & and one of three signal words, DANGER, WARNING, or CAU- TION. These signal words mean: ~ You WILL be KILLED or SERIOUSLY ~ HURT if you don't follow instructions. ~ You CAN be KILLED or SERIOUSLY ~ HURT if you don't follow instructions. ~ You CAN be HURT if you don't follow ~ instructions. • Instructions - how to service this veh Icle correctly and safely. As you read this manual, you will find information that is preceded by a [NOm:EJ symbol. The purpose of this message is to help prevent damage to your vehicle, other property. or the environment. LUBRICATION SYSTEM ALTERNATOR/STARTER CLUTCH CRANKSHAFTrrRANSMISSION COOLING SYSTEM CYLINDERJPISTON' ENGINE REMOVAL/INSTALLATION CYLINDER HEADNALVE REAR WHEELlBAAKElSUSPENSION IGNITION SYSTEM WIRING DIAGRAMS BATTERY/CHARGING SYSTEM FRONT WHEEL/SUSPENSIONISTEERING CLUTCH/GEARSHIFT LINKAGE FUEL SYSTEM FINAL DRIVE HYDRAULIC BRAKE ELECTRIC STARTER LIGHTSIMETERSISWITCHES z :it 0: ... W > ~ C C z <t w z a z w ....I <t o ~ t; .~ W TROUBLESHOOTING INDEX - Date of Issue: September. 2006 .. .. - ---_.---_.

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. .. ~ IIiiiil' Replace the part (s) with new one (s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1) . """"1 -, .. ..wM 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 (US.A. only) Rocol ASP manufactured by Rocol Limited, UK. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. ,.. ~ ~ ew JI~ Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use Fork or Suspension Fluid. I ..

1. GENERAL INFORMATION B· SERVICE RULES .. ·······································1-2 MODEL IDENTIFICATION· .. ·· .. ·.. ····· .. ·········· 1-2 GENERAL SPECIFICATIONS .... ··· .... ···· .. ····· 1-5 LUBRICATION SYSTEM SPECIFICATIONS······ .... ··· .. ········ ...... ·.... ······ 1-7 FUEL SYSTEM SPECIFICATIONS·· .. ·········· 1-7 COOLING SYSTEM SPECIFICATIONS ······1-7 CYLINDER HEAD/VALVE SPECIFICATIONS· .. ·· .. ·····:· .... ·················... ·· 1-8 CYLINDER/PISTON SPECIFICATIONS ······1-8 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS 1-9 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS·· 1-9 CRANKSHAFT/TRANSMISSION SPECiFiCATIONS···· 1-10 FINAL DRIVE SPECIFICATIONS· .... ·········· 1-10 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ·.. ··············· .. ·········· .. ·····1-11 REAR WHEEUBRAKE/SUSPENSION SPECIFICATIONS 1-11 HYDRAULIC BRAKE SPECIFICATIONS··· 1-11 BATTERY/CHARGING SYSTEM SPECIFICATIONS .. ······· .. ········· .. · .... ··· ...... ·1-12 IGNITION SYSTEM SPECIFICATIONS ····1-12 ELECTRIC STARTER SPECIFICATIONS 1-12 LIGHTS/METERS/SWITCHES SPECIFICATIONS 1-12 STANDARD TORQUE VALUES· .. ····· .. ····· 1-13 ENGINE & FRAME TORQUE VALUES·· .. 1·13 LUBRICATION & SEAL POINTS ··········· .. ·1-19 CABLE & HARNESS ROUTING ···············1·22 EMISSION CONTROL SYSTEMS 1·39 1-1 ------ . - --------- --------

GENERAL INFORMATION SERVICE RULES 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, a-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then 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 in the Cable and Harness Routing (page 1-22). ABBREVIAl"ION Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbrev. tenn Full tenn SE valve Starting Enrichment valve TP sensor Throttle Position sensor EOP switch Engine Oil Pressure switch VS sensor Vehicle Speed sensor ICM Ignition Control Module CAV control valve Carburetor Air Vent control valve PAIR Pulsed Secondary Air Injection EVAP Evaporative Emission ECT sensor Engine Coolant Temperature sensor MODEL IDENTIFICATION 1-2

GENERAL INFORMATION SERIAL NUMBERS The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. The engine serial number is stamped on the right side of the crankcase. The carburetor identification number is stamped on the throttle position sensor side ofthe c'arburetor body. ......... ~ CARBURETOR IDENTIFICATION NUMBER ~ . LABELS The Safety Certification Label is located on the right side of the frame down tube. 1-3

GENERAL INFORMATION The color label is attached to the frame, behind of the left side cover .. When ordering color-coded parts, always specifY the designated color code. The Emission Control Information Label ('07 model) is located on the r-EM-IS-S-I-O-N-C-O-N-T-R-O-L---------.. rear fender and frame cross pipe as shown•. INFORMATION LABEL (Canada type) EMISSION CONTROL INFORMATION LABEL (Except Canada type) The Emission Control Information Label (After '07) is located on the left 1------:&~7)~;::N:=-------__"l side of the frame down tube. z , EMISSION CONTROL "INFORMATION LABEL ~ . (Canada type) , . Revised: May 2007. 2007-2006 Vf750C2 1.-4

GENERAL INFORMATION GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSION Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Curb weight (49 states/Canada type) (California type) Maximum weight capacity (49 states/California type) (Canada type) 2,430 mm (95.7 in) 835 mm (32.9 in) 1,130 mm (44.5 in) 1,655 mm (65.2 in) 655 mm (25.8 in) 283 mm (11.1 in) 130 mm (5.1 in) 243 kg (536 Ibs) 246 kg (542 Ibs) 180 kg (397 Ibs) 184 kg (406 Ibs) FRAME Frame type Front suspension Front axle travel Rear suspension Rear axle travel Front tire size Rear tire size Tire brand Front Rear Front brake Rear brake Caster angle Trail length Fuel tank capacity Double cradle Telescopic fork 115 mm (4.5 in) Swingarm 90 mm (3.5 in) 90/90-21 M/C 54S 160/80-15M/C 74S EXEDRA G701 (BRIDGESTONE) D404F (DUNLOP) EXEDRA G702 (BRIDGESTONE) D404 (DUNLOP) Hydraulic single disc Internal expanding shoe 34° 30' 158 mm (6.2 in) 14 liters (3.7 US gal, 3.1 Imp gal) ENGINE Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Firing order Cylinder number 2 cylinders 52° V transverse 79 x 76 mm (3.1 x 3.0 in) 745 cm 3 (45.4 cu-in) 9.6: 1 Silent cam chain driven, OHC Front: 0° BTDC (at 1 mm lift) Rear: 5° ATDC (at 1 mm lift) 25° ABDC (at 1 mm lift) 35° BBDC (at 1 mm lift) Front: 0° ATDC (at 1 mm lift) Rear: 5° BTDC (at 1 mm lift) Forced pressure and wet sump Trochoid Liquid cooled Viscous paper element 72.3 kg (159.4Ibs) Front - 308° - Rear - 412° - Front Front: #2/Rear: #1 CARBURETOR Type Throttle bore Constant velocity (CV) 34 mm (1.3 in) '-5 -----~ --- ---- ----------- I

GENERAL INFORMATION ITEM SPECIFICATIONS DRIVE TRAII;II Clutch system Clutch operation system Transmission Primary reduction Secondary reduction Third reduction (Output drive reduction) Final reduction Gear ratio 1st 2nd 3rd 4th 5th Gearshift pattern Multi-plate, wet Cable operating Constant mesh, 5-speeds 1.763 (67/38) 0.891 (33/37) 1.058 (18117) 3.091 (34111) 2.400 (36/15) 1.550 (31/20) 1.174 (27/23) 0.960 (24/25) 0.852 (23/27) Left foot operated return system, 1-N-2-3-4-5 ELECTRICAL Ignition system Starting system Charging system Regu'lator/rectifier Lighting system Full transistorized ignition Electric starter motor Triple phase output alternator SCR shortedltriple phase full-wave rectification Battery 1-6.

GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit· mm (in) ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 2.5 liters (2.6 US qt, 2.2 Imp qt) - At oil filter change 2.6 liters (2.7 US qt, 2.3 Imp qt) - At disassembly 3.2 liters (3.4 US qt, 2.8 Imp qt) - Recommended engine oil Pro Honda GN44-stroke oil (U.S.A. and Canada) or equivalent motor oil API service classification: SG or higher - JASO T 903 standard: MA Viscosity: SAE 10W-30 Oil pressure at EOP switch 530 kPa (5.4 kgf/cm 2 , 77 psi) - at 5,000 rpm/(80°C/176°F) Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 - 0.21 (0.006 - 0.008) 0.35 (0.014) Side clearance 0.02 - 0.08 (0.001 - 0.003) 0.10 (0.004) FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Carburetor identification number 49 states/Canada type VE5EA California type VE5ES Main jet Standard #122 High altitude #120 Slow jet #50 Pilot screw Initial/final opening See page 6-25 High altitude adjustment See page 6-26 Float level 18.5 mm (0.73 in) Engine idle speed 1,200 ± 100 rpm Throttle grip freeplay 2 - 6 mm (1/16 -1/4 in) COOLING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1.58 liters (1.67 US qt, 1.39 Imp qt) Reserve tank 0.38 liter (0.40 US qt, 0.33 Imp qt) Radiator cap relief pressure 108 - 137 kPa (1.1 -1.4 kgf/cm 2 , 16 - 20 psi) Thermostat Begin to open 80 - 84°C (176 -183°F) Fully open 95°C (203°F) Valve lift 8 mm (0.3 in) minimum at 95°C (203°F) Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors Standard coolant concentration 1 : 1 (mixture with distilled water) 1-7

2007-2009 Honda VT750C2 Shadow Spirit Service & Repair Manual

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