2009 Honda Vtx 1300 Manual

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2009 Honda Vtx 1300 Owners Manual

• 2

  Contents
• 3

  Symbols
• 4

  General Information
• 4

  Service Rules
• 5

  Model Identification
• 6

  General Specifications
• 8

  Lubrication System Specifications
• 8

  Fuel System Specifications
• 8

  Cooling System Specifications
• 9

  Cylinder Head/Valve Specifications
• 9

  Cylinder/Piston Specifications
• 10

  Clutch/Gearshift Linkage Specifications
• 10

  Crankshaft/Transmission Specifications
• 10

  Final Drive Specifications
• 11

  Front Wheel/Suspension/Steering Specifications
• 11

  Rear Wheel/Suspension Specifications
• 11

  Hydraulic Disc Brake Specifications
• 12

  Battery/Charging System Specifications
• 12

  Ignition System Specifications
• 12

  Electric Starter/Starter Clutch Specifications
• 12

  Lights/Meters/Switches Specifications
• 13

  Standard Torque Values
• 13

  Engine Torque Values
• 15

  Frame Torque Values
• 17

  Tools
• 19

  Lubrication & Seal Points
• 22

  Cable & Harness Routing
• 34

  Evaporative Emission (Evap) Control System
• 35

  Source of Emissions
• 35

  Crankcase Emission Control System
• 36

  Exhaust Emission Control System (Pulse Secondary Air Injection System)
• 37

  Noise Emission Control System
• 38

  Vehicle Emission Control Information Update Label
• 38

  Vacuum Hose Routing Diagram Label
• 39

  Frame/Body Panels/Exhaust System Service Information
• 39

  Frame/Body Panels/Exhaust System Troubleshooting
• 40

  Cylinder Head Shroud
• 40

  Rear/Front Seat
• 40

  Side Cover Removal
• 40

  Side Cover Installation
• 41

  Fuel Tank
• 41

  Steering Side Cover
• 41

  Left Crankcase Rear Cover
• 42

  Footrest Assembly Removal/Installation
• 43

  Rear Fender
• 44

  Exhaust System Removal
• 44

  Exhaust System Installation
• 46

  Exhaust System Disassembly/Assembly
• 47

  Maintenance Service Information
• 47

  Maintenance Specifications
• 49

  Maintenance Schedule
• 50

  Fuel Line
• 50

  Throttle Operation
• 51

  Carburetor Choke
• 51

  Air Cleaner
• 52

  Crankcase Breather
• 52

  Spark Plug
• 53

  Valve Clearance Inspection
• 56

  Engine Oil Level Check
• 56

  Engine Oil Filter
• 57

  Engine Idle Speed
• 58

  Radiator Coolant
• 59

  Cooling System
• 59

  Secondary Air Supply System
• 60

  Evaporative Emission Control System
• 60

  Final Drive Oil Level Check
• 61

  Final Drive Oil Change
• 61

  Front Brake Fluid
• 62

  Brake Pad Wear
• 62

  Rear Brake Fluid
• 63

  Brake System
• 63

  Brake Light Switch
• 63

  Headlight Aim
• 63

  Clutch System
• 64

  Side Stand
• 65

  Nuts, Bolts, Fasteners
• 65

  Front Suspension Inspection
• 65

  Rear Suspension Inspection
• 66

  Wheels/Tires
• 66

  Steering Head Bearings
• 68

  Lubrication System Service Information
• 69

  Lubrication System Troubleshooting
• 70

  Oil Pressure Check
• 71

  Oil Pump/Pressure Relief Valve Removal
• 72

  Oil Pump Disassembly
• 73

  Oil Pump Inspection
• 73

  Pressure Relief Valve
• 74

  Oil Pump Assembly
• 75

  Oil Pump Installation
• 78

  Fuel System Service Information
• 79

  Fuel System Troubleshooting
• 80

  Air Cleaner Housing Removal
• 80

  Air Cleaner Housing Installation
• 81

  Carburetor Removal
• 82

  Carburetor Disassembly/Inspection
• 82

  Throttle Position Sensor/Carburetor Heater
• 83

  Vacuum Chamber
• 84

  Air Cut-Off Valve
• 84

  Accelerator Pump
• 85

  Float Chamber
• 86

  Carburetor Cleaning
• 87

  Carburetor Assembly
• 88

  Float and Jets
• 88

  Float Level Inspection
• 92

  Carburetor Installation
• 93

  Intake Manifold Removal
• 94

  Intake Manifold Installation
• 95

  Pilot Screw Adjustment
• 95

  Idle Drop Procedure
• 96

  High Altitude Adjustment
• 97

  Secondary Air Supply System Inspection
• 98

  Pair Check Valve Inspection
• 99

  Evap Canister Removal/Installation
• 99

  Evap Purge Control Valve Inspection
• 100

  Evap Carburetor Air Vent (Cav) Control Valve Inspection
• 103

  Cooling System Service Information
• 104

  Cooling System Troubleshooting
• 105

  System Testing Coolant (Hydrometer Test)
• 105

  Standard Coolant Concentration
• 106

  Radiator Cap/System Pressure Inspection
• 106

  Coolant Replacement Preparation
• 107

  Replacement/Air Bleeding
• 108

  Thermostat Removal
• 109

  Thermostat Inspection
• 109

  Thermostat Installation
• 110

  Radiator/Cooling Fan Removal/Installation
• 110

  Radiator/Cooling Fan Disassembly
• 111

  Radiator/Cooling Fan Assembly
• 112

  Water Pump Mechanical Seal Inspection
• 112

  Water Pump Removal
• 113

  Water Pump Installation
• 115

  Radiator Reserve Tank Removal/Installation
• 117

  Engine Removal/Installation Service Information
• 118

  Engine Removal
• 122

  Engine Installation
• 126

  Cylinder Head/Valve Service Information
• 127

  Cylinder Head/Valve Troubleshooting
• 128

  Cylinder Compression
• 128

  Cylinder Head Cover Removal
• 129

  Rocker Arm Removal
• 130

  Camshaft Removal
• 130

  Rocker Arm Inspection
• 131

  Camshaft Inspection
• 132

  Camshaft Journal
• 132

  Camshaft Oil Clearance
• 133

  Cylinder Head Removal
• 134

  Cylinder Head Disassembly
• 134

  Cylinder Head Inspection
• 135

  Valve Spring
• 135

  Valve/Valve Guide
• 136

  Valve Guide Replacement
• 136

  Cam Chain Tensioner/Guide
• 137

  Valve Seat Inspection/Refacing
• 138

  Refacing
• 140

  Cylinder Head Assembly
• 141

  Cylinder Head Installation
• 142

  Camshaft Installation
• 142

  Front Camshaft
• 144

  Rear Camshaft
• 145

  Rocker Arm Installation
• 146

  Cylinder Head Cover Installation
• 149

  Cylinder/Piston Service Information
• 150

  Cylinder/Piston Troubleshooting
• 151

  Cylinder Removal
• 152

  Piston Removal
• 153

  Piston/Piston Ring Inspection
• 154

  Connecting Rod Inspection
• 154

  Cylinder Inspection
• 155

  Cylinder Stud Bolt Replacement
• 155

  Oil Jet Inspection
• 155

  Reed Valve
• 156

  Piston Ring Installation
• 156

  Piston Installation
• 157

  Cylinder Installation
• 160

  Clutch/Gearshift Linkage
• 161

  Clutch/Gearshift Linkage Service Information
• 162

  Clutch/Gearshift Linkage Troubleshooting
• 163

  Right Crankcase Cover Removal
• 163

  Clutch Disassembly
• 166

  Lifter Bearing Inspection
• 166

  Clutch Spring Inspection
• 167

  Clutch Center Inspection
• 167

  Rubber Damper Inspection
• 167

  Clutch Lifter Rod Inspection
• 167

  Clutch Disc Inspection
• 168

  Clutch Plate Inspection
• 168

  Clutch Outer Guide Inspection
• 168

  Mainshaft Inspection
• 168

  Clutch Outer
• 169

  Clutch Assembly
• 171

  Gearshift Linkage Removal
• 172

  Gearshift Linkage Inspection
• 172

  Gearshift Linkage Installation
• 174

  Primary Drive Gear Removal
• 174

  Primary Drive Gear Installation
• 175

  Primary Driven Gear Removal
• 176

  Primary Driven Gear Installation
• 177

  Right Crankcase Cover Installation
• 178

  Clutch Lifter Arm Removal
• 180

  Clutch Lifter Arm Installation
• 183

  Crankshaft/Transmission Service Information
• 184

  Crankshaft/Transmission Troubleshooting
• 185

  Crankcase Separation
• 185

  Crankshaft Removal
• 186

  Side Clearance Inspection
• 186

  Connecting Rod Removal
• 186

  Crankshaft Inspection
• 186

  Crankpin Bearing Inspection
• 187

  Crankpin Bearing Selection
• 187

  Oil Clearance
• 188

  Main Bearing Inspection
• 189

  Connecting Rod Selection
• 190

  Connecting Rod Installation
• 190

  Crankshaft Installation
• 191

  Balancer Shaft Removal
• 192

  Balancer Shaft Installation
• 192

  Transmission/Output Gear Case Disassembly
• 194

  Shift Fork/Shaft Inspection
• 195

  Gear/Bushing/Shaft
• 196

  Output Gear Oil Seal
• 197

  Countershaft
• 200

  Right Crankcase Bearing Replacement
• 201

  Left Crankcase Bearing Replacement
• 202

  Crankcase Assembly
• 205

  Final Drive Service Information
• 206

  Final Drive Troubleshooting
• 207

  Final Drive Removal
• 207

  Final Drive Inspection
• 208

  Final Drive Disassembly/Inspection
• 208

  Backlash Inspection
• 209

  Final Gear Case Separation
• 209

  Gear Tooth Contact Pattern Check
• 211

  Ring Gear Removal/Shim Replacement
• 212

  Pinion Gear Removal
• 213

  Case Bearing Replacement
• 213

  Pinion Bearing/Shim Replacement
• 213

  Ring Gear Bearing
• 214

  Pinion Needle Bearing
• 216

  Final Drive Assembly
• 216

  Pinion Gear
• 218

  Ring Gear Installation
• 220

  Final Gear Case Assembly
• 222

  Final Drive Installation
• 225

  Front Wheel/Suspension/Steering Service Information
• 227

  Front Wheel/Suspension/Steering Troubleshooting
• 228

  Handlebar Removal
• 229

  Handlebar Installation
• 231

  Front Wheel Removal
• 232

  Front Wheel Inspection
• 232

  Front Wheel Disassembly
• 232

  Axle
• 232

  Wheel Rim
• 233

  Front Wheel Assembly
• 234

  Wheel Center Adjustment
• 234

  Wheel Balance
• 235

  Front Wheel Installation
• 236

  Fork Removal
• 236

  Fork Disassembly
• 238

  Fork Inspection
• 238

  Fork Spring
• 238

  Fork Tube/Slider/Piston
• 239

  Fork Assembly
• 242

  Fork Installation
• 242

  Steering Stem Removal
• 245

  Steering Stem Installation
• 248

  Steering Bearing Pre-Load
• 250

  Rear Wheel/Suspension Service Information
• 251

  Rear Wheel/Suspension Troubleshooting
• 252

  Rear Wheel Removal
• 252

  Rear Wheel Inspection
• 253

  Rear Wheel Disassembly
• 253

  Final Driven Flange
• 255

  Rear Wheel Assembly
• 257

  Rear Wheel Installation
• 258

  Shock Absorber
• 259

  Swingarm Removal
• 260

  Swingarm Inspection
• 260

  Pivot Bearing Outer Race Replacement
• 261

  Swingarm Installation
• 265

  Hydraulic Disc Brake Service Information
• 266

  Hydraulic Disc Brake Troubleshooting
• 267

  Brake Fluid Replacement/Air Bleeding
• 267

  Brake Fluid Draining
• 268

  Brake Fluid Filling/Bleeding
• 269

  Front Brake Pad Replacement
• 270

  Rear Brake Pad Replacement
• 270

  Brake Disc Inspection
• 271

  Front Master Cylinder Disassembly
• 272

  Front Master Cylinder Inspection
• 272

  Front Master Cylinder Assembly
• 274

  Front Brake Caliper Disassembly
• 275

  Front Brake Caliper Inspection
• 275

  Front Brake Caliper Assembly
• 277

  Rear Master Cylinder/Brake Pedal Removal
• 278

  Master Cylinder Disassembly
• 278

  Master Cylinder Inspection
• 278

  Master Cylinder Assembly
• 279

  Master Cylinder Installation
• 280

  Brake Pedal
• 281

  Rear Brake Caliper Disassembly