Honda:
Elements of transmission motorcycle Honda VTX1800C (VTX series, 2001-2008)
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Service information of clutch and gearshift linkage
General This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame. Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some...
General This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame. Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some...
Troubleshooting of clutch and gearshift linkage
Clutch lever soft or spongy Air in hydraulic system Low fluid level Hydraulic system leaking Clutch lever too hard to pull in Sticking master cylinder piston Sticking slave cylinder Clogged hydraulic system Damaged clutch lifter mechanism Faulty...
Clutch lever soft or spongy Air in hydraulic system Low fluid level Hydraulic system leaking Clutch lever too hard to pull in Sticking master cylinder piston Sticking slave cylinder Clogged hydraulic system Damaged clutch lifter mechanism Faulty...
Clutch fluid draining
Turn the handlebar to the right until the reservoir is parallel to the ground, before removing the reservoir cap. Remove the screws, reservoir cap, set plate, diaphragm and float. Do not allow foreign material to enter the system when filling the...
Turn the handlebar to the right until the reservoir is parallel to the ground, before removing the reservoir cap. Remove the screws, reservoir cap, set plate, diaphragm and float. Do not allow foreign material to enter the system when filling the...
Clutch fluid filling and air bleeding
Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed valve. Use only DOT 4 brake fluid from a sealed container. Pump the brake bleeder and loosen the bleed valve, adding fluid...
Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed valve. Use only DOT 4 brake fluid from a sealed container. Pump the brake bleeder and loosen the bleed valve, adding fluid...
Clutch master cylinder — removal and installation
Removal Drain the clutch fluid from the hydraulic system ( page 10-4 ). Remove the left rear view mirror. Disconnect the clutch switch connectors. Remove the clutch hose oil bolt, sealing washers and clutch hose. When removing the oil bolt, cover...
Removal Drain the clutch fluid from the hydraulic system ( page 10-4 ). Remove the left rear view mirror. Disconnect the clutch switch connectors. Remove the clutch hose oil bolt, sealing washers and clutch hose. When removing the oil bolt, cover...
Clutch slave cylinder — removal and installation
Removal Drain the clutch hydraulic system ( page 10-4 ). Remove the clutch hose oil bolt, sealing washers and clutch hose. When removing the oil bolt, cover the end of the hose to prevent contamination. Remove the bolts and clutch slave cylinder...
Removal Drain the clutch hydraulic system ( page 10-4 ). Remove the clutch hose oil bolt, sealing washers and clutch hose. When removing the oil bolt, cover the end of the hose to prevent contamination. Remove the bolts and clutch slave cylinder...
Right crankcase cover — removal and installation
Removal Remove the exhaust system ( page 2-3 ). Drain the engine oil ( page 3-12 ). Remove the bolts and clutch cover. Remove the bolts and timing cover. Remove the rubber damper from the clutch cover. Remove the bolts, ground cable and right...
Removal Remove the exhaust system ( page 2-3 ). Drain the engine oil ( page 3-12 ). Remove the bolts and clutch cover. Remove the bolts and timing cover. Remove the rubber damper from the clutch cover. Remove the bolts, ground cable and right...
Clutch — removal and installation
Removal Remove the right crankcase cover ( page 10-13 ). Loosen the lifter plate bolts in a crisscross pattern in two or three steps, and remove the bolts and clutch springs. Remove the lifter plate. Remove the lifter piece and clutch lifter rod....
Removal Remove the right crankcase cover ( page 10-13 ). Loosen the lifter plate bolts in a crisscross pattern in two or three steps, and remove the bolts and clutch springs. Remove the lifter plate. Remove the lifter piece and clutch lifter rod....
Primary drive gear — removal and installation
Removal Wear groves while working with the primary drive gear. The outer webs of the gear assembly are extremely sharp and should be handled with care. Remove the right crankcase cover ( page 10-13 ). Insert the gear holder as shown. Loosen the...
Removal Wear groves while working with the primary drive gear. The outer webs of the gear assembly are extremely sharp and should be handled with care. Remove the right crankcase cover ( page 10-13 ). Insert the gear holder as shown. Loosen the...
Primary driven gears — removal and installation
Removal Remove the right crankcase cover ( page 10-13 ). Remove the clutch ( page 10-15 ). Unstake the primary driven gear nut. Insert the gear holder as shown. Loosen the primary driven gear nut and remove the nut. TOOL: Gear holder 07724-0010100...
Removal Remove the right crankcase cover ( page 10-13 ). Remove the clutch ( page 10-15 ). Unstake the primary driven gear nut. Insert the gear holder as shown. Loosen the primary driven gear nut and remove the nut. TOOL: Gear holder 07724-0010100...
Gearshift linkage — removal and installation
Removal Shift the transmission into neutral. Remove the right crankcase cover ( page 10-13 ). Remove the clutch ( page 10-15 ). Remove the bolt and gearshift arm from the gearshift spindle. Remove the gearshift spindle and thrust washer. Lift up the...
Removal Shift the transmission into neutral. Remove the right crankcase cover ( page 10-13 ). Remove the clutch ( page 10-15 ). Remove the bolt and gearshift arm from the gearshift spindle. Remove the gearshift spindle and thrust washer. Lift up the...
Service information of crankshaft and transmission
General The crankcase halves must be separated to service the connecting rod, crankshaft and transmission (including the shift fork and shift drum). To service these parts, the engine must be removed from the frame ( section 7 ). The following parts...
General The crankcase halves must be separated to service the connecting rod, crankshaft and transmission (including the shift fork and shift drum). To service these parts, the engine must be removed from the frame ( section 7 ). The following parts...
Troubleshooting of crankshaft and transmission
Excessive noise Worn crankshaft main journal bearings Worn connecting rod bearings Worn connecting rod small end Worn, seized or chipped transmission gear Worn or damaged transmission bearing Hard to shift Bent shift fork Bent shift fork shaft...
Excessive noise Worn crankshaft main journal bearings Worn connecting rod bearings Worn connecting rod small end Worn, seized or chipped transmission gear Worn or damaged transmission bearing Hard to shift Bent shift fork Bent shift fork shaft...
Crankcase separation
Refer to Service Information ( page 11-1 ) for removal of necessary parts before disassembling the crankcase. Remove the cam chains from the drive sprockets. Remove the left crankcase bolt. Loosen the right crankcase bolts and remove them with the...
Refer to Service Information ( page 11-1 ) for removal of necessary parts before disassembling the crankcase. Remove the cam chains from the drive sprockets. Remove the left crankcase bolt. Loosen the right crankcase bolts and remove them with the...
Primary shaft — removal and installation
Removal/installation Separate the crankcase ( page 11-4 ). Remove the primary shaft from the left crankcase. Installation is in the reverse order of removal. Inspection Inspect the primary shaft for wear or damage. Replace the primary shaft if...
Removal/installation Separate the crankcase ( page 11-4 ). Remove the primary shaft from the left crankcase. Installation is in the reverse order of removal. Inspection Inspect the primary shaft for wear or damage. Replace the primary shaft if...
Crankshaft/connecting rod — removal and installation
Crankshaft removal Separate the crankshaft ( page 11-4 ). Remove the crankshaft from the left crankcase. During crankshaft and connecting rod service, be careful not to damage the main journal or connecting rod bearing inserts. Connecting rod...
Crankshaft removal Separate the crankshaft ( page 11-4 ). Remove the crankshaft from the left crankcase. During crankshaft and connecting rod service, be careful not to damage the main journal or connecting rod bearing inserts. Connecting rod...
Transmission — removal and installation
Removal Separate the crankcase ( page 11-4 ). Remove the oil pump ( page 4-3 ). Pull the shift fork shaft up and remove it from the shift forks. Remove the shift drum and shift forks. Remove the washer, C1 gear, C4 gear, collars and needle bearing...
Removal Separate the crankcase ( page 11-4 ). Remove the oil pump ( page 4-3 ). Pull the shift fork shaft up and remove it from the shift forks. Remove the shift drum and shift forks. Remove the washer, C1 gear, C4 gear, collars and needle bearing...
Crankcase assembly
Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Make sure all parts are installed in the left and right crankcase. Apply liquid sealant to the crankcase mating surfaces. Install the crankshaft to the...
Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Make sure all parts are installed in the left and right crankcase. Apply liquid sealant to the crankcase mating surfaces. Install the crankshaft to the...
Output gear — removal and installation
Description of the output gear assembly: Removal Separate the crankcase ( page 11-4 ). Remove the transmission ( page 11-11 ). Remove the bolts and the output gear assembly. Remove the oil orifice and O-rings. Backlash inspection/gear tooth contact...
Description of the output gear assembly: Removal Separate the crankcase ( page 11-4 ). Remove the transmission ( page 11-11 ). Remove the bolts and the output gear assembly. Remove the oil orifice and O-rings. Backlash inspection/gear tooth contact...
Crankcase bearing replacement
Left crankcase bearing Remove the output gear case assembly ( page 11-19 ). Before removing the bearings, heat the crankcase around the bearings to 80°C (176°F). Be careful not to damage the crankcase mating surfaces. Always wear insulated gloves...
Left crankcase bearing Remove the output gear case assembly ( page 11-19 ). Before removing the bearings, heat the crankcase around the bearings to 80°C (176°F). Be careful not to damage the crankcase mating surfaces. Always wear insulated gloves...
Service information of final drive
General The final drive gear assembly and final drive shaft must be removed together. Replace the ring and pinion gears as a set. Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The...
General The final drive gear assembly and final drive shaft must be removed together. Replace the ring and pinion gears as a set. Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The...
Troubleshooting of final drive
Excessive noise Worn or scored ring gear shaft and driven flange Scored driven flange and wheel hub Worn or scored drive pinion and splines Worn pinion and ring gears Excessive backlash between pinion and ring gear Oil level too low Oil leak Clogged...
Excessive noise Worn or scored ring gear shaft and driven flange Scored driven flange and wheel hub Worn or scored drive pinion and splines Worn pinion and ring gears Excessive backlash between pinion and ring gear Oil level too low Oil leak Clogged...
Final drive removal
Removal Drain the final drive oil ( page 3-17 ). Remove the rear wheel ( page 14-3 ). Support the swingarm and remove the left shock absorber lower mounting bolt and release the shock from the gear case. Remove the gear case mounting nuts, then...
Removal Drain the final drive oil ( page 3-17 ). Remove the rear wheel ( page 14-3 ). Support the swingarm and remove the left shock absorber lower mounting bolt and release the shock from the gear case. Remove the gear case mounting nuts, then...
Final drive gear
Ring gear removal/shim replacement Remove the distance collar. Remove the dust guard plate bolt and remove the dust guard plate by turning it counterclockwise. Remove the case cover bolts and gear case cover. Remove the wave washer if it remains in...
Ring gear removal/shim replacement Remove the distance collar. Remove the dust guard plate bolt and remove the dust guard plate by turning it counterclockwise. Remove the case cover bolts and gear case cover. Remove the wave washer if it remains in...
Final drive installation
Check that the final gear case stud bolts are tight. If any are loose, remove them, clean their threads with contact cleaner, then install them using locking agent. After installation, be sure to measure the distance from the top of each stud to the...
Check that the final gear case stud bolts are tight. If any are loose, remove them, clean their threads with contact cleaner, then install them using locking agent. After installation, be sure to measure the distance from the top of each stud to the...
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- Information for owner
- Control devices
- Operation manual
- Maintenance
- Engine and systems
- Engine repair
- Fuel and control system
- Cooling system
- Lube system
- Transmission
- Running gear and frame
- Frame and hinged elements
- Front suspension and handlebar
- Rear suspension
- Brake system
- Electric equipment
- Equipment and devices
- Ignition system
- Starting and charging system
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