Honda VTX1800 Series Repair Manual 2002-2008

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Item # M230  ISBN: 9781599692319




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This repair and service manual covers Honda VTX1800 Series, 2002, 2003, 2004, 2005, 2006, 2007, and 2008, including:

• VTX1800C 2002-2007
• VTX1800R 2002-2007
• VTX1800S 2002-2006
• VTX1800N 2004-2008
• VTX1800F 2005-2008
• VTX1800T 2007-2008

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers and information labels | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING
Starting the engine | Engine will not start | Poor engine performance | Fuel system | Engine | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Electrical testing | Final drive | Front suspension and steering | Brake system

CHAPTER THREE: PERIODIC LUBRICATION, MAINTENANCE and TUNE-UP
Tune-up | Cylinder identification and firing order | Engine rotation | Air filter | Crankcase breather inspection | Engine compression test | Spark plugs | Ignition timing | Valve clearance | Idle speed adjustment | Air screw synchronization | Fuel hose inspection | Throttle cable | Clutch | Engine oil and filter | Engine oil pressure check | Cooling system | Secondary air supply system inspection | Evaporative emission control system inspection (California models) | Battery | Final drive | Wheels and tires | Steering assembly inspection | Front suspension inspection | Rear suspension inspection | Brake system | Headlight aim | Sidestand and ignition cut-off switch test | Front fork oil change | Fastener inspection | Specifications

CHAPTER FOUR: ENGINE TOP END
Cylinder head covers | Camshafts | Cam chain tensioner and cam chain | Cylinder head | Valves and valve components | Cylinder | Pistons and piston rings | Cylinder stud replacement | Specifications

CHAPTER FIVE: ENGINE LOWER END
Servicing engine in frame | Engine | Crankcase | Crankcase seal and bearing replacement | Crankshaft | Connecting rods | Balancer shaft | Oil pump | Output gear | Engine break-in | Specifications

CHAPTER SIX: CLUTCH and EXTERNAL SHIFT MECHANISM
Clutch bleeding | Clutch fluid flushing and draining | Clutch master cylinder | Clutch slave cylinder | Right crankcase cover | Clutch | Primary drive and driven gears | External shift mechanism | Specifications

CHAPTER SEVEN: TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission | Internal shift mechanism | Specifications

CHAPTER EIGHT: FUEL INJECTION and EMISSION CONTROL SYSTEMS
Fuel system precautions | Fuel tank | Depressurizing the fuel system | Fuel pressure test | Fuel flow test | Fuel pump | Air filter housing | Throttle body | Intake manifold | Fuel injectors and fuel rails | Starter valve | BARO and MAP sensors | Throttle position (TP) sensor | Intake air temperature (IAT) sensor | Engine coolant temperature (ECT) sensor | Crankshaft position (CKP) sensor | Camshaft position (CMP) sensor | Bank angle sensor | Oxygen (O2) sensors (California models) | Engine control models (ECM) | Intake duct control solenoid assembly | Throttle cable replacement | Emission control system labels | Secondary air supply system | Evaporative emission control system (California models only) | Fuel injection system identification | Malfunction indicator lamp (MIL) | DTC troubleshooting | Specifications

CHAPTER NINE: ELECTRICAL SYSTEM
Electrical component replacement | Electrical connectors | Battery | Battery box | Charging system | Stator coil, crankcase position (CKP) sensor and left crankcase cover | Flywheel, starter clutch and starter drive gears | Ignition system testing | Ignition coils | Crankshaft position (CKP) sensor | Engine control module (ECM) | Ignition system testing | Starter | Starter relay | Lighting system | Meter assembly | Vehicle speed sensor (VSS) | Coolant temperature indicator and engine coolant temperature (ECT) sensor | Coolant temperature sensor | Fan motor switch | Oil pressure indicator and oil pressure switch | Neutral indicator and neutral switch | Fuel reserve indicator and fuel reserve sensor | Sidestand switch | Clutch switch | Front brake light switch | Rear brake light switch | Ignition switch | Handlebar switch | Switch continuity test | Turn signal relay | Turn signal-position relay | Horn | Engine stop relay | Fuel cut-off relay | Clutch diode | Fuses | Wiring diagrams | Specifications

CHAPTER TEN: COOLING SYSTEM
Temperature warning system | Cooling system inspection | Radiator | Cooling fan | Coolant reserve tank | Thermostat | Thermostat housing | Coolant pipe | Water pump | Specifications

CHAPTER ELEVEN: WHEELS and TIRES
Motorcycle lift | Front wheel | Rear wheel | Front and rear hubs | Driven flange | Wheel service (cast wheels) | Wheel service (laced wheels) | Tire safety | Tire changing | Wheel balance | Specifications

CHAPTER TWELVE: FRONT SUSPENSION AND STEERING
Handlebar | Handlebar grips | Front fork | Steering assembly | Steering bearing preload | Steering head bearing race replacement | Steering stem bearing replacement | Specification

CHAPTER THIRTEEN: REAR SUSPENSION and FINAL DRIVE
Shock absorber | Swing arm | Final drive unit and drive shaft | Final drive unit overhaul | Ring and pinion gear | Specifications

CHAPTER FOURTEEN: BRAKES
Linked braking system (LBS) | Brake service | Brake bleeding | Brake fluid draining | Brake pads | Brake caliper removal-installation | Brake caliper overhaul | Front master cylinder | Rear master cylinder | Proportional control valve | Brake hose and brake line replacement | Brake disc | Rear brake pedal | Specifications

CHAPTER FIFTEEN: BODY and EXHAUST SYSTEM
Seat | side covers | Left crankcase rear cover | Front fender | Rear fender | Rider footrests | Sidestand | Windshield | Saddlebags | Exhaust system | Specifications

COLOR WIRING DIAGRAMS

Honda VTX1800 Series Repair Manual 2002-2008