Honda VT750DC Service Interval And Recommended Maintenance Manual

VT750C / CD / CD2

SHADOW/SHADOW DELUXE/ACE

1998 - 2003

Service Intervals

and

Recommended

Maintenance

HondaVT750DCACE

2ServiceIntervalandRecommendedMaintenanceManual

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Disclaimer:

Thearticlesinthe“ServiceIntervalandRecommendedMaintenanceManual”(this

document)andthosethatmaybepostedintheforumsofthe750ace.comwebsiteare

meantforinformationpurposesonly.Theseproceduresandmodificationsarenot

manufacturerapprovedinstructionsormodificationsandtheymaynotbelegalinsome

municipalities.750ace.comisfurnishingthisinformation“asis”.750ace.comdoesnot

provideanywarrantyofthesearticleswhatsoever,whetherexpressed,implied,or

statutory,including,butnotlimitedto,anywarrantyofperformanceorfitnessfora

particularpurposeoranywarrantythatthecontentsofthearticleswillbeerror‐free.

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HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual3

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HondaVT750ShadowA.C.E.

(AmericanClassicEdition)

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ServiceIntervalsandRecommendedMaintenance

TaskMaintenanceItemNotes:1000km

(600mi)

6400km

(4000mi)

12800km

(8000mi)

19200km

(1200mi)

25600km

(16000mi)

32000km

(20000mi)

38400km

(24000mi)

01DriveChain Inspect&LubeEvery800km(500mi)

02BrakeFluid(4) IIRIIR

03BrakeWear  IIIIII

04BrakeSystem I I I I

05BrakeLightSwitch   I I I

06HeadlightAim   I I I

07ClutchSystem IIIIIII

07SideStand   I I I

09Suspension   I I I

10Nuts,Bolts,Fasteners I I I I

11Wheels/Tires IIIIIII

12SteeringHeadBearings I I I I

13FuelLine   I I I

14ThrottleOperation   I I I

15CarburetorChoke   I I I

16AirCleaner(2)   R  R

17CrankcaseBreather(3) CCCCCC

18SparkPlugs  IRIRIR

19ValveClearances I I I I

20EngineOil R R R R

21EngineOilFilter R R R R

22Carb.Synchronization   I I I

23EngineIdleSpeed IIIIIII

24RadiatorCoolant(4)  I I R

25CoolingSystem   I I I

26‐31ReplacementInstructionsandAdjustments forBrakes,Coolant,andPilotScrew

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 I=Inspect

 C=Clean

 R=Replace

Note1:Athigherodometerreadings,repeatatthefrequencyintervalestablishedhere.

Note2:Servicemorefrequentlywhenridinginunusuallywetordustyareas.

Note3:Servicemorefrequentlywhenridinginrainoratfullthrottle.

Note4:Replaceevery2years,oratindicatedodometerinterval,whichevercomesfirst.

HondaVT750DCACE

4ServiceIntervalandRecommendedMaintenanceManual

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HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual5

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TableofContents

Task#01‐DriveChain..................................................................................................................................................7

Task#02‐BrakeFluid...................................................................................................................................................9

Task#03‐BrakeWear................................................................................................................................................10

Task#04‐BrakeSystem.............................................................................................................................................11

Task#05‐BrakeLightSwitch.....................................................................................................................................13

Task#06‐HeadlightAim............................................................................................................................................14

Task#07–Clutch........................................................................................................................................................15

Task#08‐SideStand..................................................................................................................................................16

Task#09‐Suspension.................................................................................................................................................17

Task#10‐Nuts,BoltsandFasteners..........................................................................................................................18

Task#11‐Wheels&Tires...........................................................................................................................................23

Task#12‐SteeringHeadBearings..............................................................................................................................24

Task#13‐FuelLine&Filter........................................................................................................................................24

Task#14‐ThrottleOperation.....................................................................................................................................25

Task#15‐CarburetorChoke......................................................................................................................................26

Task#16‐AirCleaner.................................................................................................................................................26

Task#17‐CrankcaseBreather...................................................................................................................................27

Task#18‐SparkPlugs.................................................................................................................................................28

Task#19‐ValveInspection/Adjustment..................................................................................................................32

Task#20‐EngineOil&Filter......................................................................................................................................41

Task#21‐Removal&InstallationoftheWheels.......................................................................................................43

Task#22‐CarburetorSynchronization......................................................................................................................47

Task#23‐EngineIdleSpeed......................................................................................................................................49

Task#24‐RadiatorCoolant........................................................................................................................................49

Task#25‐CoolingSystem..........................................................................................................................................50

Task#26‐RearBrakeShoeReplacement..................................................................................................................51

Task#27‐FrontBrakePadReplacement...................................................................................................................56

Task#28‐ReplacingtheCoolant................................................................................................................................58

Task#29‐FrontBrakeDiscInspection&Limits.........................................................................................................62

Task#30‐FrontBrakeBleeding.................................................................................................................................63

Task#31‐PilotScrewAdjustment.............................................................................................................................65

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HondaVT750DCACE

6ServiceIntervalandRecommendedMaintenanceManual

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HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual7

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Task #01 - Drive Chain

The service life of the drive chain is dependent upon

proper lubrication and adjustment. Poor maintenance can

cause premature wear or damage to the drive chain and

sprockets. The drive chain should be inspected prior to

every day's riding, adjusted for slack when required and

lubricated every 800km or following any riding done in

rain.

Inspection:

Check the slack in the lower drive chain run about

halfway between the sprockets. Ideally you want about

3/4" of play. When the play reaches 1" you need to

adjust the chain tension. Also check for Damaged Rollers,

Loose Pins or Missing O-rings. The chain requires

replacement for any of those. Dry or Rusted links require

immediate lubrication. Kinked or Binding Links require

lubrication and also need to be worked free. If they can't

be worked free then the chain needs to be replaced.

Lubrication:

The drive chain on this motorcycle is equipped with small

O-rings between the link plates. These O-rings retain

grease inside the chain to improve it's service life.

Therefore, it is not a good idea to use high pressure

water or steam cleaning to clean this chain. You should

use an SAE 80 or 90 gear oil or an O-ring safe chain

wax to lube this chain. Personally, I prefer the chain wax

as it does not spray the tire and chain guard and when

applied properly, it makes for less chain noise while

riding.

Before lubing, I ride my bike for 20 mins to warm the

chain up, then I clean my chain with a lightweight oil

such as LPS-1 or 2, using a dry cloth to wipe off the dirt

and excess oil. Then I spray a nice even coat of gear wax

and let it sit for 30 mins before riding.

HondaVT750DCACE

8ServiceIntervalandRecommendedMaintenanceManual

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Wear Inspection:

Check the chain wear label on the left-hand swing arm

when adjusting the chain. If the arrow mark(6) is in the

red zone(5) after adjusting the slack to the proper

amount, then the chain is worn and requires

replacement.

Replacement Chain (stock sprocket): DID525V8 or

RK525SMOZ5

Adjustment:

1. Place the motorcycle on it's side stand with the

transmission in neutral.

2. Loosen the axle nut(1).

3. Turn both adjusting bolts(2) an equal number of turns

until the correct drive chain slack is obtained.

(counterclockwise to tighten chain) Roll the motorcycle

forward and check tension again. Then check that the

axle is aligned by making sure the index marks(3) align

with the scales(4) on both sides of the swing arm.

4. Tighten axle nut to 69 ft-lbs (93 N-m) torque.

Sprockets:

Check the rear sprocket for excessively worn teeth or

broken and missing teeth. Use the diagram to the left as

a guide. Do this more often if your bike has an aluminum

rear sprocket instead of steel.

HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual9

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Task #02 - Brake Fluid

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The Brake fluid level should be checked before every

day's ride and during every maintenance cycle. The fluid

should be changed every 2 years or at 19,200 km

(12,000 miles), whichever comes first. The

recommended brake fluid is Honda DOT 4.

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Inspection:

With the motorcycle in an upright position, check the

fluid level using the sight glass on the reservoir. If the

level is at or below the LOWER level mark (1), check

your brake pads for wear. If your pads are not worn,

then check your brake system closely for leaks.

- Break Wear Inspection

HondaVT750DCACE

10ServiceIntervalandRecommendedMaintenanceManual

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Task #03 - Brake Wear

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The front brake wear is measured at the pads on the

brake unit itself, and they should be checked at each

regular maintenance interval.

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Inspection:

Looking up at the pads from under the caliper assy, you

will see cutouts (1) on each pad. If either pad is worn to

the base of the cutout, then you must replace both pads

as a set.

See Also...

- Rear Brake Shoe Replacement

HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual11

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Task #04 - Brake System

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The 750 ACE has excellent brakes for it's class. The

brakes are also one of the most important safety items

on your motorcycle and should be checked frequently

and maintained to the highest standards. Both the front

and rear brakes are completely independent of each

other and if one should fail, then the other brake will still

work.

The front brake on the ACE is a Disc-type brake and it

provides most of the stopping power during normal use.

Inspection of this brake includes checking the pads for

wear, checking the fluid level of the reservoir, checking

the disc for condition and wear and checking the whole

system for leaks. The front brake system is completely

hydraulic and self adjusting. No adjustment of the

calipers, brake lever or stoplight switch is possible or

needed for this brake.

- Brake Wear

- Brake Fluid Level

- Front Brake Pad Replacement

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The rear brake on the ACE is a more simple Drum-style

brake. In normal use, this brake only provides about

25% of the stopping power. Anymore and the rear wheel

would lock up. It is also the brake most often used when

the bike is standing still at a light, for example. It is

inspected for wear at the drum, pedal height and free

play and the stop light switch actuation point.

- Break Wear Inspection

- Break Light Switch Adjustment

- Brake Pedal Height Adjustment

- Brake Pedal Free Play Adjustment

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Pedal Height:

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Astopperboltisprovidedtoallowadjustmentofthe

pedalheight.Loosenthelocknut(1)andturnthestopper

bolt(2).Whentheheightiswereyouwantit,tightenthe

locknut(1).

HondaVT750DCACE

12ServiceIntervalandRecommendedMaintenanceManual

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Free Play:

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Wheneverpedalheightisadjustedorwhentherearbrake

isgettingworn,youshouldcheckandadjustthefreeplay

atthebrakepedal.Measuredatthetipofthebrakepedal

(3),freeplayshouldbekeptbetween20‐30mm(0.8‐

1.2in).

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Makefreeplayadjustmentsbyforcingthebrakearm

forward(5)andthenturningtheadjustingnut(4).Turning

itinthedirectionof(A)decreasesfreeplaywhileturning

itinthedirectionof(B)increasesfreeplay.Makesurethe

adjustingnutcut‐outisseatedonthebrakearm(5)when

finished.

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WARNING:Ithasbeenmyexperiencethatthisadjusting

nutcanbackoffonit'sown(perhapsduetotheincreased

vibrationofmyaftermarketpipes)andIhadanear

disasteronthe401HWYoncewhenitbackedoffsofar

thatIhadnorearbrakes.Iwouldrecommendinstallinga

second'jamnut'behindthisadjuster.Iinstalledafiber

locknutasajamnutandithasnotmovedatallsince

then.

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HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual13

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Task #05 - Brake Light Switch

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Check the brake light switch operation and adjustment

by applying the brakes with the ignition turned on.

Operation of either the front brake lever or the rear

brake pedal should illuminate the rear brake light.

Note: The front brake light switch is incorporated into

the handlebar lever assy and is not adjustable. If the

switch fails to operate, then you will have to find the

fault and/or replace the switch assembly.

The rear brake switch is adjustable. Proper adjustment of

the switch will have the light coming on just before the

brakes actually engage. Before adjusting this switch,

make sure you have your rear brake pedal height and

free play properly adjusted in accordance with the

instructions.

To adjust the rear brake switch, grasp the switch body

firmly and turn just the adjustment nut. Make sure you

do not allow the switch body itself to turn as the wires

inside can break off. After you have made the

adjustment, double check that it operates properly.

HondaVT750DCACE

14ServiceIntervalandRecommendedMaintenanceManual

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Task #06 - Headlight Aim

Headlight aim is very important and should be checked

regularly. A misadjusted headlight might not shine far

enough down the road for you to see properly or it might

be so high that it blinds oncoming traffic. Also, there are

usually regulations in the area you reside about exactly

how a headlight should be aimed and you should review

these before doing any adjustments yourself.

The procedure I have put below is a basic means of

adjusting your headlight and should satisfy most

regulations. If in doubt, get a certified shop to check it.

The first thing you need to do is find a nice level area to

park your bike that has a light colored flat surface about

25 feet in front of it. A driveway and a garage door might

work here, as long as it is level. You also have to be

mounted on your bike to simulate a proper riding

condition when you take your measurements. A buddy

helping you here might be handy.

First, with your weight on the bike and the bike held

upright, take a measurement from the center of your

headlight to the ground. Now go to the wall that is 25

feet in front of you and mark a spot at the same height.

Draw a line through this mark (use a level). Now draw

another line two inches lower. Go back to the bike and

turn on the low beam. You want to adjust the low beam

so that the upper area of the light just rests on the lower

line and is a little to the right of your bike's centerline. To

adjust the headlight beam vertically, you turn the

adjustment screw on the bottom of the headlight can. To

adjust the headlight beam horizontally, you turn the

screw on the side of the headlight can.

If your headlight has a combined low/high beam lamp in

the same reflector, then you only have to adjust for the

low beam. If you have a separate high beam lamp, then

you have to adjust for high beam separately. To adjust

the high beam, follow the same steps but aim the upper

area of the light to just touch the upper line instead of

the lower.

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HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual15

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Task #07 – Clutch

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Clutch Adjustment may be required if the motorcycle

stalls when shifting into gear or tends to creep; or if the

clutch slips, causing the engine to race ahead when

accelerating hard or climbing steep hills. Free play at the

lever (1) should be kept between 10-20mm (0.4-0.8in).

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For minor adjustments, adjust the free play at the lever

end as follows...

1. Loosen the locknut (2) and turn the adjuster (3).

Direction (A) increases free play while direction (B)

decreases free play.

2. Tighten the locknut (2) when done.

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If the adjustment can't be reached at the lever end, then

adjust it further from the clutch end as follows...

1. Loosen the locknut (4) and turn the adjusting nut (5)

as required. Direction (A) increases free play and

direction (B) decreases it. Tighten the locknut (4) when

done.

NOTE: If proper adjustment can't be made using both

methods above, then you may need to replace the

clutch.

Other Checks:

Check the clutch cable for kinks or signs if wear that could cause sticking or failure. Lubricate the clutch cable

with a good penetrating lubricant to prevent premature wear and failure. Apply the lubricant to both ends of the

cable and work it in by operating the clutch lever several times.

HondaVT750DCACE

16ServiceIntervalandRecommendedMaintenanceManual

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Task #08 - Side Stand

The ACE is equipped with a side stand only, on the left

side of the bike. It only needs to be checked for damage

or loss of return spring tension and for the safety cut-out

switch proper operation.

Sit on the bike and keep it vertical. Check the side stand

for proper movement and for return spring tension. A

broken or damaged spring (1) can allow the side stand to

drop while riding, causing it to scrape and causing the

engine to quit.

To check the safety cut-out feature, sit on the bike and

turn the ignition on. With the side stand down, the side

stand light (6) on the tank gauge cluster should be

illuminated. Move the side stand up and the light should

go out.

Next, start the engine and with the clutch in, put the bike

in gear. Now lower the side stand... the engine should

stop as soon as you lower it.

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HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual17

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Task #09 - Suspension

Warning: Loose, worn or damaged suspension parts impair motorcycle stability and control. Repair or replace

any damaged components before riding. Riding a motorcycle with faulty suspension increases your risk of an

accident and possible injury.

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FRONT

Check the action of the fork by operating the front brake

and compressing the front suspension several times.

Check the entire fork assembly for signs of leaks,

damage or loose fasteners. Replace damaged

components which cannot be repaired and tighten all

nuts and bolts.

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REAR

Support the motorcycle securely using a lift or hoist and

raise the rear wheel off the ground. Check for worn

swing arm bearings by grabbing the rear wheel and

attempting to move the wheel side to side. Replace the

bearings if any looseness is noted.

HondaVT750DCACE

18ServiceIntervalandRecommendedMaintenanceManual

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Check the action of the shock absorbers by compressing

them several times. Check the entire shock absorber

assembly for signs of leaks, damage or loose fasteners.

Replace damaged components which cannot be repaired

and tighten all nuts and bolts.

Refer to shock absorber service.

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Task #10 - Nuts, Bolts and Fasteners

Check that all chassis nuts, bolts and screws are tightened to their correct torque values as per the service

manual, pages 1-13 to 1-16 (see below) at the interval shown in the Maintenance Schedule. Also check that all

cotter pins, slip clips, hose clamps and cable stays are in place and properly secured.

All the above said, I doubt anyone is going to go around and re-torque every nut and bolt on the bike, but you

should at the very least, put a wrench on all the major attachments (like wheel nuts, triple-tree attachments,

etc) and check for tightness. Make it also a practice to be constantly touching things on your bike, whenever

you are working on it. Don't be shy and tug and pull on things to check if they are loose. Also, constantly keep

your eyes roaming over things, looking for something that has come loose or is missing. After a while, you'll

find that "out of place" things jump right out at you.

Here also are scans of all the torques, directly from the factory service manual. I figured this was the best way

to post the torque values as I did not want to rip off the work of other people who took the time to transcribe

the values into a web page (Like Blacktop did on his site). I also did not want to run the risk of introducing

errors using OCR software or by me typing them all out, so scans you get! Use them wisely... at the very least,

try and get a hold of an accurate torque wrench when doing critical work on areas where proper torque is

needed (like cylinder head bolts, as an example).

HondaVT750CDACE

ServiceIntervalandRecommendedMaintenanceManual19

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HondaVT750DCACE

20ServiceIntervalandRecommendedMaintenanceManual

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Honda VT750DC, 1998 VT750CD2 Shadow, 1999 VT750C Shadow, 2000 VT750C Shadow, 2000 VT750CD Shadow Deluxe, 2001 VT750C Shadow, 2001 VT750CD2 Shadow, 2002 VT750C Shadow, 2002 VT750CD Shadow Deluxe, 2003 VT750C Shadow Service Interval And Recommended Maintenance Manual

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