Honda Shadow VT1100 - Owner's Manual

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Contents1
Honda Shadow VT1100 View2
About this Manual3
Identification Numbers4
Buying Parts5
General Specifications5
Maintenance Techniques, Tools and Working Facilities7
Maintenance and Minor Repair Tool Kit8
Repair and Overhaul Tool Set11
Care and Maintenance of Tools12
Working Facilities12
Safety First13
Motorcycle Chemicals and Lubricants15
Troubleshooting16
Index25
Common Spark Plug Conditions31
Models Covered by this Manual32
Tune-Up and Routine Maintenance33
Honda Shadow Routine Maintenance Intervals35
Introduction to Tune-Up and Routine Maintenance36
Fluid Levels-Check36
Engine Oil36
Brake Fluid36
Clutch Fluid37
Coolant37
Battery Electrolyte Level/Specific Gravity-Check38
Brake Pads and Shoes-Wear Check38
Brake System-General Check39
Brake Pedal Height and Freeplay (Drum Brake Models)-Check and Adjustment39
Tires/Wheels-General Check39
Throttle Cable and Choke Operation-Check and Adjustment40
Clutch-Check and Adjustment42
Final Drive Oil-Check and Change42
Engine Oil/Filter-Change43
Air Filter Element-Servicing44
Cylinder Compression-Check45
Spark Plugs-Replacement45
Lubrication-General46
Idle Speed-Check and Adjustment47
Carburetor Synchronization-Check and Adjustment47
Cooling System-Check47
Cooling System-Draining, Flushing and Refilling48
Evaporative Emission Control System (California Models Only)-Inspection49
Exhaust System-Check50
Steering Head Bearings-Check, Adjustment and Lubrication50
Fasteners-Check50
Fuel System-Check and Filter Replacement50
Suspension-Check51
Suspension Adjustments51
Engine, Clutch and Transmission53
Torque Specifications59
General Information60
Operations Possible with the Engine in the Frame60
Operations Requiring Engine Removal60
Major Engine Repair-General Note60
Engine-Removal and Installation61
Engine Disassembly and Reassembly-General Information62
Cylinder Head Cover and Rocker Arm Assembly-Removal, Inspection and Installation65
Reassembly68
Bleeding the Hydraulic Tappets68
Adjusting the Hydraulic Tappets68
Valve Adjustment Shim Selection Chart69
Camshaft and Sprocket-Removal, Inspection and Installation70
Front Cylinder Camshaft72
Rear Cylinder Camshaft73
Front or Rear Camshaft73
Cam Chain Tensioner-Removal, Inspection and Installation74
Cylinder Head-Removal and Installation74
Valves/Valve Seats/Valve Guides-Servicing75
Cylinder Head and Valves-Disassembly, Inspection and Reassembly76
Cam Chain Guide-Removal, Inspection and Installation79
Cylinder-Removal, Inspection and Installation79
Pistons and Oil Jets-Removal, Inspection and Installation82
Piston Rings-Installation84
Clutch Release System-Bleeding, Removal and Installation86
Hydraulic System (1985 through 1996 VT1100C Models)86
Bleeding the Hydraulic Release System86
Master Cylinder Overhaul86
Clutch Master Cylinder (Hydraulic Clutch Models)-Exploded View87
Master Cylinder Installation87
Stave Cylinder Removal87
Slave Cylinder Overhaul87
Cable System (VT1100C2, VT1100T and 1997-On VT1100C Models88
Slave Cylinder Installation88
Cable Removal and Installation88
Lifter Arm Removal88
Lifter Arm Inspection89
Clutch-Removal, Inspection and Installation91
1985 Through 1996 VT1100C Models91
VT1100C2, VT1100T and 1997-On VT1100C92
Clutch Disc Details94
Oil Pump Drive Chain and Sprockets-Removal, Inspection and Installation96
Primary Drive Gear-Removal, Inspection and Installation98
Cam Chains and Rear Cam Chain Drive Sprocket-Removal, Inspection and Installation99
Gearshift Linkage-Removal, Inspection and Installation99
Externa, Gearshift Linkage (VT1100C Models)101
Internal Gearshift Mechanism101
Oil Pump-Removal, Inspection and Installation102
Oil Pressure Relief Valve Details103
Oil Pump Details103
Crankcase-Disassembly and Reassembly105
Right Crankcase Bolts105
Crankcase Components-Inspection and Servicing107
Main and Connecting Rod Bearings-General Note107
Connecting Rods and Bearings-Removal, Inspection and Installation107
Connecting Rod Bearing Selection Chart109
Connecting Rod Weight Selection109
Connecting Rod Weight Selection Chart110
Crankshaft and Main Bearings-Removal, Inspection and Installation110
Crankcase Bearing Diameter Selection Chart111
Transmission-Removal, Inspection and Installation112
Shift Drum, Shift Forks and Shift Fork Shaft113
Countershaft and Mainshaft113
The Assembled Mainshaft and Countershaft114
Output Gear Assembly-Removal and Installation115
Initial Start-Up after Overhaul117
Recommended Break-In Procedure117
Cooling System118
Radiator Cap-Check119
Radiator-Removal and Installation119
Cooling Fan and Thermostatic Fan Switch-Check and Replacement120
Fan Motor121
Thermostatic Fan Switch121
Coolant Temperature Warning System-Check and Component Replacement121
Coolant Temperature Sensor122
Thermostat-Removal, Check and Installation122
Thermostat Housing-Removal and Installation123
Coolant Reservoir-Removal and Installation123
Water Pump-Check, Removal and Installation124
Removal, Inspection and O-Ring Replacement124
Fuel and Exhaust Systems128
Fuel Tank-Removal and Installation129
Main Fuel Tank130
Auxiliary Fuel Tank130
Fuel Tank-Cleaning and Repair131
Crankcase Emission Control System-Description, Check and Component Replacement131
Crankcase Breather Separator131
Left Crankcase Cover Breather Pipe Adapter O-Ring131
Breather Hoses132
Evaporative Emission Control System (California Models)-Description, Check and Component Replacement132
Purge Control Valve133
Carburetor Air Vent Control Valve (California Models)133
Purge Control Valve (California Models)134
EVAP Canister134
Air Cleaner Housing-Removal and Installation134
Air Intake Ducts-Removal and Installation135
Sub-Air Cleaner-Removal and Installation135
Fuel Pump System-Check and Component Replacement135
Fuel Pump Discharge Volume Check136
Fuel Pump Relay136
Throttle Cables and Grip-Removal, Installation and Adjustment137
Carburetor Overhaul-General Information137
Carburetors-Removal and Installation138
Carburetors-Disassembly, Inspection, Cleaning and Reassembly140
Float Assembly, Jets and Pilot Screw Assembly143
Vacuum Chamber and Air Cut-Off Diaphragm Assemblies143
Idle Fuel/Air Mixture-Adjustment145
Exhaust System-Removal and Installation145
Ignition System148
Ignition System-Check149
Engine will Not Start149
Engine Starts but Misfires149
Ignition Coils-Check and Replacement150
Ignition Coil Test (1985 through 1986 Models)150
Ignition Pulse Generator(S)-Check and Replacement151
Ignition Pulse Generator Details151
Timing Rotor-Removal and Installation152
Ignition Control Module-Check and Replacement152
Ignition Timing-Check152
Steering, Suspension and Final Drive154
Handlebar-Removal and Installation155
Fork Oil Change156
Forks-Removal and Installation156
Forks-Disassembly, Inspection and Reassembly157
Front Fork Details158
Steering Stem and Bearings-Removal, Inspection and Installation161
Steering Stem/Lower Triple Clamp Details163
Rear Shock Absorbers-Removal, Inspection and Installation164
Swingarm-Removal and Installation165
Swingarm Bearings-Replacement166
Brakes, Wheels, Tires and Final Drive167
Brake Pads-Replacement169
Brake Caliper-Removal, Overhaul and Installation170
Front Brake Caliper Assembly172
Brake Disc-Inspection, Removal and Installation173
Brake Master Cylinder-Removal, Overhaul and Installation174
Master Cylinder Details175
Brake Hose-Inspection and Replacement177
Brake System Bleeding177
Drum Brake-Removal, Overhaul and Installation178
Rear Brake Pedal and Linkage-Removal and Installation180
Wheels-Inspection and Repair182
Rear Wheel-Removal and Installation183
Front Wheel-Removal and Installation184
Left Fork Leg Details184
Wheel Bearings-Inspection and Maintenance185
Front Wheel Bearings185
Rear Wheel Bearings186
Tires-General Information187
Frame and Bodywork189
Frame-Inspection and Repair189
Footpegs-Removal and Installation189
Sidestand-Maintenance190
Sidestand-Removal and Installation190
Seat-Removal and Installation190
Steering Head Covers-Removal and Installation191
Side Covers-Removal and Installation191
Saddlebags (VT1100C2 Models)-Removal and Installation192
Rear Fender-Removal and Installation192
Rear Grab Rails and Fender Stays-Removal and Installation192
Windshield (VT1100C2 Models)-Removal and Installation192
Electrical System193
Electrical Troubleshooting194
Battery-Removal, Inspection, Maintenance and Installation195
Battery-Charging195
Conventional Batteries195
Battery Charge-Time Table (Maintenance-Free Batteries)196
Fuses-Check and Replacement196
Lighting System-Check197
Turn Signal Lights/Brake Light/Taillight/License Plate Light197
Instrument and Indicator Lights197
Headlight Bulb-Replacement197
Headlight Aim-Check and Adjustment198
Headlight Assembly-Removal and Installation198
Turn Signal, Tail/Brake Light and License Plate Bulbs-Replacement198
Turn Signal Circuit and Relay-Check200
Brake Light Switches-Check and Replacement200
Turn Signal Assembly-Removal and Installation201
Taillight Assembly-Removal and Installation202
Instruments and Speedometer Cable-Removal and Installation203
Instrument and Indicator Lights-Replacement203
Ignition Main (Key) Switch-Check and Replacement204
Handlebar Switches-Check205
Left Handlebar Switches205
Right Handlebar Switches206
Handlebar Switches-Removal and Installation206
Neutral Switch-Check and Replacement206
Oil Pressure Switch-Check and Replacement207
Sidestand Switch-Check and Replacement208
Clutch Switch-Check and Replacement208
Horn-Check and Replacement208
Starter Relay Switch-Check and Replacement209
Clutch Diode-Check and Replacement209
Starter Motor, Drive Gear and Torque Limiter-Removal and Installation210
Charging System Testing-General Information and Precautions211
Charging System-Check211
Alternator-Check and Replacement211
Flywheel (Rotor)212
Voltage Regulator/Rectifier-Check and Replacement213
Starter Clutch Assembly-Removal, Inspection and Installation213
Wiring Diagrams215
Honda VT1100 Wiring Diagram-1985 and 1986 Models216
Honda VT1100 Wiring Diagram-1985 through 1986 Models217
Honda VT1100 Wiring Diagram-1987 through 1993 Models218
Honda VT1100 Wiring Diagram-1994 and 1995 Models220
Honda VT1100 Wiring Diagram-1996 and Later Models222
Conversion Factors224

Honda Shadow VT1100 - Owner's Manual

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