Motorcycle engine repair Honda VTX1800C (2001-2008)

Service information of engine removal
General Do not support the engine using the oil filter. A floor jack or other adjustable support is required to support and maneuver the engine. It is recommended to use two steel poles to help remove and install the engine. These poles will go...

Engine removal
Refer to General Service Information on page 7-1 before removing or installing the engine. Especially note the areas to tape on the frame. Drain the engine oil ( page 3-13 ) and coolant ( page 6-4 ). Support the motorcycle securely. Remove the...

Engine installation
Note the direction of the hanger plate bolts. Use a floor jack or another adjustable support to carefully maneuver the engine into place. Support the rear portion of the frame under the swingarm pivot to raise the rear wheel. This will allow you to...

Service information of cylinder head and valves
General This section covers service of the cylinder head, valves, camshafts and rocker arms. To service these parts, the engine must be removed from the frame. When disassembling, mark and store the disassembled parts to ensure that they are...

Troubleshooting of cylinder head and valves
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. (See page 8-3 engine compression testing.) Compression too low, hard starting or...

Cylinder compression
Warm up the engine to normal operating temperature. Open and support the front end of the fuel tank ( page 3-4 ). Disconnect the fuel pump 3P black connector. Stop the engine, disconnect the spark plug caps and remove one spark plug at a time. Shift...

Cylinder head cover removal
Remove the engine from the frame ( section 7 ). Remove the PAIR check reed valves ( page 5-76 ). Remove the valve adjusting covers. The front cylinder head cover can be removed with the engine in the frame. Remove the 8 mm bolts and 10 mm bolts....

Camshaft removal
Remove the socket bolts, timing cover and the crankshaft hole cap. Remove the spark plugs ( page 3-6 ). Remove the spark plug sleeve on the cam chain side using the holder attachment. Tool: Holder attachment 07930-KA50100. Front cylinder: Remove the...

Camshaft holder disassembly
Remove the exhaust rocker arm shaft and exhaust rocker arm from the camshaft holder. Remove the intake rocker arm shaft and intake rocker arm from the camshaft holder.

Camshaft inspection
Camshaft journal Inspect the camshaft journal surfaces for scoring or evidence of insufficient lubrication. Inspect the camshaft journal surfaces for scoring or evidence of insufficient lubrication. Measure the O.D. of each camshaft journal using a...

Cylinder head removal
Remove the camshaft ( page 8-4 ). Remove the cam chain tensioner bolts, sealing washers and cam chain tensioner. Loosen the cylinder head nuts in a crisscross pattern in two or three steps, and remove them. Remove the washers Remove the cylinder...

Cylinder head disassembly
Remove the cylinder head ( page 8-9 ). Remove the cam pulse generator (front cylinder head only, page 5-69 ). Remove the valve spring cotters using the valve spring compressor. Tool: Valve spring compressor 07757-0010000. Compressing the valve...

Cylinder head inspection
Check the spark plug holes and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service limit: 0.10 mm (0.004 in). Valve spring Measure the free length of the valve springs. Service limits: IN: 41.9...

Valve guide replacement
Chill the valve guides in a freezer for approximately 1 hour. Heat the cylinder head to 130-140°C (275-290°F) with a hot plate or oven. Do not heat the cylinder head beyond 150°C (300°F). Use temperature indicator sticks, available from welding...

Valve seat inspection and refacing
Inspection Clean all intake and exhaust valves thoroughly to remove the carbon deposits. Apply a light coat of Prussian Blue to each valve face. Tap the valve against the valve seat several times using a hand-lapping tool, without rotating the...

Cylinder head assembly
Blow out all oil passages in the cylinder head with compressed air. Lubricate each valve stem with molybdenum oil solution. Install the spring seats and new stem seals. Insert the valves into the valve guides. To avoid damaging the stem seal, turn...

Cylinder head installation
Clean any gasket material from the cylinder mating surfaces. Make sure the cam chain guide bosses are in the grooves of the cylinder. Install the dowel pins and new gasket. The cylinder head has the following identification mark: "F": Front cylinder...

Camshaft installation
Camshaft holder assembly Clean the oil passages before assembling the cylinder head and camshaft holder. Lubricate each rocker arm shaft outer sliding surfaces with molybdenum oil solution. The intake rocker arm shaft is longer than the exhaust...

Cylinder head cover installation
Clean any sealant material from the cylinder head cover mating surfaces. Apply liquid sealant to the mating surfaces of the cylinder head cover. Install the new O-ring. Install the dowel pins to the cylinder head. Install the cylinder head cover....

Service information of cylinder and piston
General This section covers service of the cylinder and piston. To service these parts, the engine must be removed from the frame. Take care not to damage the cylinder wall and piston. Be careful not to damage the mating surfaces when removing the...

Troubleshooting of cylinder and piston
Compression too low, hard starting or poor performance at low speed Leaking cylinder head gasket Worn, stuck or broken piston ring Worn or damaged cylinder and piston Compression too high, overheating or knocking Excessive carbon built-up on piston...

Cylinder removal
Remove the cylinder head ( page 8-9 ). Remove the bolt and water hose joint. Rear cylinder only. Remove the О-ring from the hose joint. Remove the joint clips from the water joint pipe. While removing the cylinder, remove the water joint pipe....

Cylinder inspection
Reed valve Check the reed valve for damage or fatigue. Replace if necessary. Replace the reed valve if the rubber seat is cracked, deteriorated or damaged, or if there is clearance between the reed and seat. Cylinder Check the cylinder for warpage...

Piston removal
Remove the piston pin clip using a pair of pliers. Remove the piston pin and remove the piston. Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase. If you plan to reuse the piston, mark the piston with...

Piston/piston ring inspection
Inspect the piston for wear or damage. Measure the diameter of the piston at 18 mm (0.7 in) from the bottom and 90 degrees to the piston pin hole. Service limit: 100.91 mm (3.973 in). Calculate the cylinder-to-piston clearance (cylinder I.D.: see...

Cylinder stud bolt replacement
If you will replace the stud bolts, remove them from the crankcase. Apply engine oil to the stud bolt threads. Install the stud bolts. After installation, be sure to measure the distance from the top of each stud to the crankcase surface as shown.

Piston ring installation
Clean the piston head, ring lands and skirts. Carefully install the piston rings onto the piston with the marks facing up. Note: Do not confuse the top and second rings: the top ring is chrome-coated and the second ring is not coated (black). Be...

Piston installation
Clean the gasket surface of the crankcase thoroughly, being careful not to damage it, and careful not to allow gasket material into the crankcase. Apply engine oil to new О-rings and install it onto the oil jet. Install the oil jet into the...

Cylinder installation
Install the reed valve into the crankcase securely as shown. Install a new gasket and the dowel pins. The cylinders have the following identification marks: "F": Front cylinder "R": Rear cylinder Apply engine oil to the cylinder wall, piston and...