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Honda VT750CD ACE Service Interval Manual

1. 1998 2003 HONDA e 3 a K _ T 3 3 e 7 s t Mme Serviced Intervals VT750C CD CD2 me SHADOW SHADOW DELUXE ACE Honda VT750DC ACE 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 2 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Honda VT750 Shadow A C E American Classic Edition Service Intervals and Recommended Maintenance 1000 km 6400 km 12800 km 19200 km 25600 km 32000 km 38400 km 600 mi 4000 mi 8000 mi 1200 mi 16000 mi 20000 mi 24000 mi er E amp Lube Every 800 km 500 mi Geen S ae ea ed 07 Sidestand 9 R y 10 Nuts Bolts Fasteners a kat Baza 12 Steering Head Bearings S a SS 13 Fuel Line O Eed S EIA WW TI 26 31 Replacement Instructions and Adjustments for Brakes Cool
2. The reason why these screws need to be adjusted right is to prevent a condition known as lean misfire If the screws are set too lean as is often the case for new bikes the mixture at idle may become too lean and sometimes it won t completely ignite in the engine This unburned fuel them collects in the exhaust and ignites there causing a backfire The rider would notice this as rapid pops or bangs on deceleration sometimes called the Rice Crispy Snap Crackle and Pop This condition is NOT normal and NOT healthy for the engine It creates serious back pressure in the exhaust and can cause damage not only to the exhaust but also the engine and valves Now the service manual has a detailed procedure for setting the Pilot screws that involves making changes to obtain a specific RPM drop at idle but this requires you to have a shop with an accurate tach and also you can t properly adjust the forward cylinder with the air filter housing installed and running the bike without the air filter is not recommended So I ve created this simplified procedure that is more then adequate to meet the needs of the average ACE owner Step 1 The first step is to remove the air filter housing We are taking the whole housing off which is easier then removing just the filter Remove the two allen key bolts that secure the back of the housing and then loosen the screw on the clamp that secures the housing to the air box Then just pull the housing of
3. A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean contaminated disc with a high quality brake degreasing agent See Also Front Brake Bleeding Push the caliper pistons all the way in by pushing the caliper body inward to allow for installation of new brake pads NOTE Watch the brake fluid level in the reservoir as this operation will raise it Remove the pad pin plug and loosen the pad pin under the plug P 4 PAD PIN 56 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Remove the pad pin and the brake pads Install the new pads so that their ends rest on the pad retainer on the bracket properly Install the pad pin by pushing the pads against the pad Springs to align the pad pin holes and the pin holes in the pads and the caliper Tighten the pad pin to 13 Ib ft torque 1 8 kgf m Install and tighten the pad pin plug and torque to 2 2 lb ft 0 3 kgf m After replacement operate the brake lever to seat ro the caliper pistons against the pads PAD PIN Service Interval and Recommended Maintenance Manual 57 Honda VT750DC ACE Task 28 Replacing the Coolant Required Tools Step 1 Prepare the bike Wrenches 8mm 10mm 12mm Sockets 8mm 10mm 12mm Funnel Catch tray Large Small Snub nosed or Needle nosed Pliers Philips Screwdriver Bike Lift optional Park your bike in an area where spilled coo
4. ENGINE MOUNTING Front engine mounting bolt 2 10 M6540 Rear engine mounting bolt 1 10 54 6 5 40 Front angine bracket bolt H 26 2 7 20 Hoar angine bracket bolt E B 26 2 7 20 Gearshift arm pinch bolt 1 b 12 1 2 a CLUTCH GEARSHIFT LINKAGE Footpeg sat arm bolt 4 B 26 2 7 20 Gearshift pedal pivot bolt 1 10 34 3 5 25 FRONT WHEEL SUSPENSION STEERING Steering stem mut 1 24 103 10 5 761 1 See page 13 40 Top thread A 1 Zb i Top thread B L 26 E ai Top bridge pinch bolt 2 g 26 2 7 20 Bottom bridge pinch bolt H 10 49 5 0 36 Handlebar upper holder bolt a 23 2 3 17 Handlebar lower holder nut 2 B 26 2 7 20 Handlebar switch screw 4 5 3 0 3 2 2 Chuten lever holder bol E 5 12 1 2 9 Front aoe 1 14 69 6 0 43 Front axle pinch bolt 2 H 22 12 2 16 Froni brake disc bolt 6 a 42 4 3 31 NOTE amp Fork cap E a8 22 2 2 16 Fork socket bolt 2 8 3 0 22 NOTE 21 Honda VT750DC ACE 22 GENERAL INFORMATION FRAME Cont d REAR WHEEL SUSPENSION Rear axle mut Driven sprocket nut Agar shock absorber mounting bolt Swingarm pivot nut Swingarm pivot adjusting boli Swingarm pivot lock nut Drive chain slider screw Brake podal pivot bolt Rear brake stopper arm bolt Rear brake arm bolt Rear brake middle rod joint bolt HYDRAULIC BRAKE Brake caliper mounting bolt Caliper pin olt Bracket pin bolt Pad pin Pad pin plug Brake caliper bipoder Brake leve
5. 16 B mm flange bolt 8 mm head 9 0 9 6 5 10 mm hex belt and nut 34 3 5 25 6mm flange bolt 10 mm head and nut 12 1 2 3 12 mm hex bolt and nut 54 5 5 40 B mm flange bolt and nut 26 2 7 20 10 mm flange belt and nut 33 4 0 25 Torque specificatons listed below are for important festeners Others should be tightened to standard torque values listed above NOTES 1 Apply sealant to the threads Z Apply a locking agent to the threads 3 Apply grease to the threads 4 Stake B Apply oll to the threads and flange surface 6 Apply ail to the threads and O ring 7 U nmat 8 ALOC bolt replace with a new ona 9 Loft hand threads 16 CT boin 11 CT Bolt one side only ENGINE gem TORQUE Nem Ikgiem ibit DLA imm MAINTENANCE Spark plug 12 14 1 4 10 Crankshaft hole cap 22 1511 5 11 NOTE 3 Timing hole cap 20 15 15 11 NOTE 3 Valve adjusting screw lock nut 23 2 3 17 NOTER Oil drain bot 14 30 3 1 22 ON filter cartridge 290 10 1 0 7 MOTE 6 Vacuum plug 5 300 3 A3 Oil pressure switch PTS 12 1 2 5 MOTE 1 Oil pressure switch cord terminal screw 4 2 0 2 1 4 Oil pump cover bolt 13 1 3 5 NOTE 10 COOLING SYSTEM Be ZE Water pump cover bolt 6 13 11 3 9 NOTE 10 CLUTCH GEARSHIFT LINKAGE Clutch lifter plate bolt B 12 1 2 a Clutch center lock nut 18 128 13 0 94 NOTE 4 5 Primary drive g
6. 29 Front Brake DISC Inspection Se IMIS ee 62 Task 30 Front Brake BICC FE 63 FaSK 4S Les e SCPE s TH nn EE 65 Service Interval and Recommended Maintenance Manual 5 Honda VT750DC ACE 6 Service Interval and Recommended Maintenance Manual Task 01 Drive Chain Honda VT750CD ACE 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
7. 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 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 Service Interval and Recommended Maintenance Manual 15 Honda VT750DC ACE Task 08 Side Stand 16 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 Service I
8. ACE 54 on r Kap CES be peace ter U Py aa KK wt Indicator Pla T ci Remove the Felt Seal CLEANING Thoroughly clean out the inside of the brake drum and the brake panel before installing the new shoes Assembly Reference the exploded diagram above and the photos on the left for the following assembly instructions Grease the shaft of the brake cam and install it into the brake panel Apply oil to the felt seal and install it onto the front of the brake panel fitting it over the cam shaft Install the Indicator Plate on the brake cam making sure to align the wide tooth on the plate with the wide groove on the cam Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Install the brake arm on the brake cam aligning the punch marks on the arm with those on the cam Install and tighten the pinch bolt to 22 ft Ib 3 0 kgf m Apply grease to the brake shoe to cam contact surfaces Apply grease to the anchor pins Attach the springs to the new shoes and install them onto the brake panel Set Plate K EF a 5 Install the Set Plate and NEW Cotter Pins Install the brake panel back onto the wheel and re install the rear wheel onto the motorcycle ref Task 21 Removal amp Installation of the Wheels Cotter Pins Service Interval and Recommended Maintenance Manual 55 Honda VT750DC ACE Task 27 Front Brake Pad Replacement Warning
9. synchronization is stable by snapping the throttle several times and re checking idle speed and vacuum difference You might have to re adjust idle and synch several times to find the proper balance When everything seems stable and adjusted stop engine and disconnect the vacuum gauge and adapters Install the vacuum plugs and washers and tighten to 3 N m 2 2 Ibf ft of torque Install the rear cylinder head left side fin the air cleaner housing and the gas tank Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 23 Engine Idle Speed NOTE Perform this task with the engine at normal operating temperatures and the transmission in neutral Place the motorcycle on a level surface Engine MUST be warm for proper adjustment Hook a tachometer up to the ignition and adjust the idle speed using the throttle stop control knob Idle speed Should be 1000 100 rpm ae w ad EI mp g i 7 9 D THROTTLE STOP CONTROL KNOB Task 24 Radiator Coolant The ACE has a liquid cooled engine and therefore you must maintain a proper level of radiator coolant just like in a car Honda recommends that you use only Honda HP coolant or an equivalent high quality ethylene gylcol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines NOTICE Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages Us
10. you have a normal Stage I or III and you can t seem to get rid of them then look for another cause Exhaust leaks are a common one Also over time the jets in a bike s carbs can get clogged up When last did my Stage III jetting found my pilot jets almost half the diameter they were Supposed to be so I cleaned them with some fine wire and the bike idles much better afterwards Once you have the screws set to where you want them would suggest sealing the screw holes with a dab of silicone rubber This will keep them weatherproof and act as a thread locker If you need to get back to them for another adjustment just pry the silicone off with a small screwdriver 66 Service Interval and Recommended Maintenance Manual
11. 1 HWY once when it backed off so far that had no rear brakes would recommend installing a second jam nut behind this adjuster installed a fiber lock nut as a jam nut and it has not moved at all since then Service Interval and Recommended Maintenance Manual Task 05 Brake Light Switch SOMES P R 58 LRAT SPT CR Rae es ee darren 0 d GUANT Fi EA TAA Soran TRT COOLANT Cove Loree 918 Honda VT750CD ACE 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 Service Interval and Recommended Maintenance Manua
12. 2 3 17 Connecting rod bearing cap nu i g B 33 2 4 25 NOTES Neutral switch 1 10 12 1 2 5 ELECTRIC STARTER Startar motor cable nut 1 6 10 41 0 D 20 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Service Interval and Recommended Maintenance Manual GENERAL INFORMATION FRAME a THREAD TORQUE Gem or DIA Imm Mn ikgtm t REMARKS FRAME BODY PANELS EXHAUST SYSTEM Exhaust pipe joint mut 4 U 25 2 5 18 Muffler bracket nut 2 B 26 2 7 20 Mutter mounting bolt 7 D 26 2 7 20 Front seat bolt 1 26 2 7 20 Rear seat bolt 9109 65 Rear fonder 9 mm bolt B E 26 2 7 20 Grab rail 10 mm bolt 2 10 64 6 5 47 24mm nut 1 14 BB 9 0 65 14 mm bolt 1 14 108 11 0 BO Fuel tank bolt 1 B 1901 9 14 Fuel valve 1 Fe 34 3 5 25 Battery box b ll 1 6 10 1 0 7 Tool box cover Groe A 4 2 0 2 1 4 MAINTENANCE Air cleaner housing cover bolt 6 6 2 0 2 1 4 Side sand assembly 2 10 H 3 5 25 Side stand pivot bolt 1 l 10 1041 0 7 lock mut 1 10 79 3 0 22 Brake pedal stopper lock nut 1 6 10410 7 Spoke nipple 104 4 4 0 4 29 COOLING SYSTEM Radiator mounting balt 1 6 2 0 2 1 4 Radiator coolant drain boli 2 6 13 1 3 9 Fan motor bolt 3 5 A D A 2 2 Cooling fan nut 1 5 4 0 3 2 2 Radiator fillar bolt l E 5 9 00 9 6 5 Thermostat housing cover bolt 2 6 9 0 9 6 5 Fan motor switch 1 PT 1 8 g 0 8 5 8 MOTE 1 Water pump cover bolt i GC 13 1 3 81
13. 69 ft Ibs 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 Service Interval and Recommended Maintenance Manual Task 02 Brake Fluid Front brake fluid reservoir Rearview mirror Honda VT750CD ACE 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 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 Service Interval and Recommended Maintenance Manual 9 Honda VT750DC ACE Task 03 Brake Wear 10 Hrs ve The front brake wear is measured at the pads on the brake unit itself and they should be checked at each regular maintenance interval 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 Front Brake Pad Replacement Front Br
14. Loosen the axle pinch bolts 4 Pinch Bolts ie C i 4 Loosen then remove the axle bolt from the axle and then remove the axle and front wheel NOTE Do not operate the front brake level while the front wheel is removed This will make it difficult to fit the brake disc between the pads when reinstalling the wheel Gear box Installation 1 Install the front wheel between the fork legs so that the brake disc is positioned between the pads being careful not to damage the pads 2 Apply a thin coat of grease to the front axle and install it through the fork legs and wheel hub 3 Position the lug on the speedometer gear box against the back of the stopper on the fork leg 4 Install and tighten the front axle bolt to 42 Ib ft 5 Lower the bike so that the front wheel is touching the ground Then while holding the front brake on pump the front suspension up and down several times to seat the axle and check front brake operation 6 Tighten the axle pinch bolts to 16 Ib ft Service Interval and Recommended Maintenance Manual 45 Honda VT750DC ACE SPEED SENSOR 46 SPEE DOMETER CABLE 7 Install the soeedometer cable and tighten the screw securely Note VT750C and VT750CD CD2 1998 2000 8 Install the speed sensor and tighten the screw securely Note VT750C3 VT750CD3 VT750CD CDA after 2000 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 22 Carburetor Syn
15. SS Wa W LL BLEED VALVE Connect a tube to the Bleed Valve and put the other end in a clean container Loosen the Bleed Valve and pump the brake lever until no more fluid flows out of the Bleed Valve Service Interval and Recommended Maintenance Manual 63 Honda VT750DC ACE BRAKE BLEEDER Brake Fluid Filling Bleeding There are two different basic methods of filling and bleeding the front brakes You can do it either top down or bottom up The tool pictured to the left is a special Honda brake bleeding tool that sucks the fluid from the reservoir down Some other special brake bleeders Push the fluid up from a reservoir in the tool itself L BLEED VALVE Most of you will not have access to these specialized tools so the simplest way is to do a manual fill amp bleed First close the bleed valve and put a CLEAN tube on the bleed valve and then set the open end of the tube into a CLEAN container and fill that container up with enough new brake fluid to cover the end of the tube Always keep the end of the tube in the clean brake fluid so that you do not inadvertently suck air while bleeding Next fill the reservoir up with new clean brake fluid Pump the brake lever until pressure is felt Then squeeze the brake lever with steady pressure and WHILE DOING this crack open the bleed valve 1 2 turn DO NOT release the brake lever while the fluid is flowing Let the fluid flow for a short time and then close the blee
16. ake Disc Inspection amp Limits The rear brake is equipped with a brake wear indicator on the drum itself Inspection Have someone apply the rear brake An arrow 1 attached to the brake arm 2 moves toward a reference mark 3 on the drum 4 If when the rear brake is applied the arrows align then the rear brake is worn to limits and the shoes must be replaced See Also Rear Brake Shoe Replacement Service Interval and Recommended Maintenance Manual Task 04 Brake System Honda VT750CD ACE 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 The rear brake on the ACE is a more simple Drum style brake In nor
17. ant and Pilot Screw Task Maintenance Item Notes Ti 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 Service Interval and Recommended Maintenance Manual 3 Honda VT750DC ACE 4 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Table of Contents TASK ON DINGO E 7 Task H02 Brake DI EE 9 TaS K HOS Bake EE 10 TASK HOA BIKE SYS BEEN 11 Task HOS Brake ight SWIC oionn A Eed 13 Task HOG Headent AI os R 14 TOKIO C EE 15 T KROS E e aN TTT 16 RE EE TEE ele EE 17 Ta Kk lO SINUS BOIES ANG FASLOI EE 18 EK SN DE L L HE 23 Task H12 Steering Head Beal ING EE 24 Task FS Sue GING Sg FRE E 24 TISK LATNOM eT e e DEE 25 EE Koes Caro ele CHOKE asr a E 26 R ALG SAIC e E EE 26 EE e SC ran CaSe Breathe EE 27 Task HIS Spark At 28 Tasic 19 Valve Ns pect on AdjUstmMEN T 32 Task 20 E neme Ol Ge Fte eoa EE eg 41 Task 21 Removal amp Installation Of the Wheels sees 43 Task H22 EE EE EE EE EE eet 47 Task H23 Eneimne e SO CCG EE 49 TASK 24 Radiator COO ANG TTT 49 RT 25 COOMNME SVS BE 50 TasSk 26 Rear Brake e nn E EE 51 Task 827 Fro t Brake Pad RED ACO MIS EE 56 TASK4 28 Eelef LMC COO ANE EE 58 Task
18. chronization PVACUUM PLUG VACUUM PLU BE si hep e R VACUUM PLUG E 8 San KA Foz a j A Wad E p A P ST ch A H e 9 A SE L d Be iy ORT a al ed ATTACHMENT SCH A PEN E C LA ries be SS ee ee s E NOTE Perform this task with the engine at normal operating temperature and transmission in neutral Place the motorcycle on a level surface Remove the fuel tank mounting bolt and carefully raise the tank and support it above the frame and near enough to attach a tube from the tank to the fuel inlet tube Remove the air cleaner housing See valve task Remove the rear cylinder head left side fin Remove the vacuum plugs and washers from the cylinder head intake ports Connect the vacuum gauge and adapters TOOL Vacuum Gauge Attachment 07510 3000200 or 07LMJ 001000A USA only Service Interval and Recommended Maintenance Manual 47 Honda VT750DC ACE e N THROTTLE STOP CONTROL KNOB 48 ADJUSTING SCREW Connect a suitable tube between the tank and the fuel inlet line Turn fuel valve on and start engine Adjust the idle soeed to 1 000 100 rpm Check the difference in vacuum between each carburetor Note The base carburetor is the REAR carb No 1 Carburetor Vacuum Difference 27 kpa 20 mm Hg 0 7 in Hg Synch the carbs by turn the adjusting screw located between the two carbs and accessible through the hole provided in the frame Be sure that
19. d valve quickly WHILE STILL PUTTING PRESSURE ON THE BRAKE LEVER Once the valve is closed slowly ease up on the brake lever and let everything rest for a little while Make sure you do not drain the reservoir while doing the bleeding so top it up between each cycle Repeat this procedure until you no longer see any air bubbles coming out of the tube then test the feel of the brakes If the lever feels spongy keep bleeding a couple of more tries Once you are Satisfied with the feel of the brakes top up the reservoir to the full mark and then close it up making sure that the set plate is between the diaphragm and the cover 64 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 31 Pilot Screw Adjustment The carburetors on the ACE have what is called Pilot Screws that set the air fuel mixture for when the engine is at idle These screws are set at the factory and then covered with brass plugs and normally no adjustment is necessary on them However experience has taught us that a very large number of ACE s were delivered to customers with these screws incorrectly set and it is highly recommended that every ACE owner does this procedure to make sure these screws are set correctly Also any changes to the exhaust system may require you to re adjust the Pilot Screws such as the Stage 1 mod where the stock baffles are punched or Stage Ill where an aftermarket exhaust is used in conjunction with larger main jetting
20. e This is often caused by over advanced ignition timing poor engine cooling system efficiency scale stoppages low coolant level a very lean air fuel mixture or a leaking intake manifold When these conditions prevail even a plug of the correct heat range will overheat Service Interval and Recommended Maintenance Manual 29 Honda VT750DC ACE 30 Oil Fouled Oily coating caused by poor oil control Oil is leaking past worn valve guides or piston rings into the combustion chamber Causes hard starting misfiring and hesitation Pre I gnition Melted electrodes Insulators are white but may be dirty due to misfiring or flying debris in the combustion chamber Can lead to engine damage Check for the correct plug heat range over advanced ignition timing lean fuel mixture insufficient engine cooling and lack of lubrication Detonation Insulators may be cracked or chipped Can lead to piston damage The explosion that occurs in this situation apples extreme pressures on internal engine components Prime causes include ignition time advanced too far lean air fuel mixtures and insufficient octane rating of the gasoline Mechanical Damage May be caused by a foreign object in the combustion chamber or the piston striking an incorrect reach too long plug Causes a dead cylinder and could result in piston damage Find out what caused the damage and repair it When this condition is discovered check the other c
21. e the plugs or the boot 2 Clean any dirt from around the spark plug bases BEFORE removing the plug to prevent it from falling into a cylinder Then remove the spark plug using the plug wrench supplied in your tool kit 3 Inspect the plug using the guide above 4 Check the spark plug gap using a feeler gauge and the values listed above Adjust as necessary 5 Reinsert the new plug with washer attached and thread it in by hand to prevent cross threading Hand tighten the plug then make an additional 1 2 turn to compress the washer If reinstalling a used plug you Should only turn the plug an additional 1 8 to 1 4 turn instead The spark plug needs to be secure but DO NOT over tighten as the heads are made of aluminum and it is very easy to strip the threads Reinstall the spark plug boots 28 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Reading your Spark Plugs Normal Brown to grayish tan color and slight electrode wear Correct heat range for engine and operating conditions Worn Rounded electrodes with a small amount of deposits on the firing end Normal color Causes hard starting in damp or cold weather and poor fuel economy The voltage required to fire the plug has approximately doubled and will continue to increase with additional miles of travel Replace with new plugs Overheating Blistered white insulator eroded electrode and absence of deposits Results in shortened plug lif
22. e 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 figured this was the best way to post the torque values as 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 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 18 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE Mem kts Ittt aaa Nem k n btt 5 mm hex bolt and nut 610 5 36 Bom sere 7 4 0 4 29 6 mm hex bolt and nut 10 11 0 7 B mm screw 9 0 9 6 5 E mm hex bolt and nut 22 2 2
23. ear bolt 17 BB 19 0 65 NOTE 5 Gearshift return spring pin H 23 2 3 17 ka Oil pump driven sprocket bolt 6 15 1 5 11 MOTE 2 ENGINE MOUNTING Laft rear cover bolt 6 12 1 2 9 Drive sprocket bolt 6 1011 0 7h Drive chain guide plate bolt 6 12 1 2 3 Service Interval and Recommended Maintenance Manual 19 Honda VT750DC ACE GENERAL INFORMATION ENGINE Cont d 7 E Kee THREAD TORQUE ga ld DIA mm Nem jeten pg REMARKS ALTERNATOR STARTER CLUTCH Flywheel Balt 1 12 127 113 0 94 NOTE 5 9 Stator mounting socket bolt 4 G 12 1 2 9 NOTE 2 Starter one way clutch hosing bolt 6 3 29 3 0 22 NOTE 2 Stator wire holder socket balt 1 6 12 1 2 3 NOTE 2 ignition pulse generator bolt F 6 12 1 2 9 NOTE 2 CYLINDER HEADS VALVES Air Cleaner housing say mounting bolt 1 6 13 1 3 9 NOTE 10 EVAP air injection reed valve cover boli H 6 B 0 5 3 6 MOTE 10 Cylinder head cover bolt 4 d 1000 7 l Cam sprocket bolt 4 H 2 2 3 17 MOTE 2 Camshaft end holder bolt 4 B 1044 0 7 Camahat holder B mm bolt 6 B 23 2 3 17 B mnm nut 4 H 23 2 3 17 Cam chain tensioner mounting bolt 4 6 10 7 0 7 Cylinder head 6 mm bolt Z D 12 1 2 9 NOTER amp mm bait 4 a 23 12 3 17 NOTE 5 mm nut 2 a 23 2 3 17 NOTE 5 10 mm nut H 10 47 4 6 35 NOTE 6 Cylinder head fin socket bolt 15 6 10 1 0 7 Crankcase breather case cover bolt 3 6 12 1 2 9 CRANKCASE CRANKSHAFT TRANSMISSION l Crankcase mm bolt 13 B 23
24. ey should be torqued to 17 foot pounds so don t go Arnold on them and try to torque them to 100 ft pounds Service Interval and Recommended Maintenance Manual 39 Honda VT750DC ACE Step 11 Put it all back together Now that the valve clearances have been checked and adjusted you can start putting everything back together Just go in reverse of the instructions above and take note of the following 40 Clean the gasket surfaces on the cylinder heads before re installing the covers Put a little grease on the threads of the crankcase hole and timing hole caps Make sure you route the choke cables properly as you insert the carbs Make sure you tighten the carb drain screws before opening the fuel valve You lose a little oil from the heads check the level after you run it If you had to disconnect the coolant lines to get the head covers off make sure you check the coolant level after running the bike Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 20 Engine Oil amp Filter Recommended Oil Viscosity SAE 10W 40 Other viscosities shown in the chart below may be used when the average temperature in your riding area is within the indicated range Engine oil is the most important factor in the performance and life of your engine and as such it should be changed at the recommended intervals GAE 20W b Kafe Wee ae SAE 20W 40 a EE EE SAE 10W 40 SAE 10W 30 Honda recommends y
25. f Caution After each adjustment reinstall the air filter before running the bike to test it The bike will not run properly under power without the air filter attached SCREW seg S a e E Zh N A Een a A k k N N d Mi wh Ka RK N w W d tig ha P Za d hy Ve V K C e NW he NT J A WON af Wen Vd e SW S a N k wil Zem NJ gh X d x a e A Ki Y 5 ah N N Se SECH U d Se e S 1 SS ke Service Interval and Recommended Maintenance Manual 65 Honda VT750DC ACE Final Step Step 2 Remove the plug covering the pilot screw on the left carb rear cylinder see Pic A good way to do this is to drill a small hole in the plug be careful that you only drill just enough to get through the plug and not into the screw behind it Then take a PK screw or any sheet metal screw the kind with a point that is self tapping and screw it into the small hole you drilled until it grabs Then just pull the plug out using a pair of pliers on the PK screw head NOTE If you bought the bike used it s possible that the plugs have already been removed You will now see the small pilot screw under where the plug was Take a small flat screwdriver and gently turn the pilot screw IN clockwise until it seats counting the number of turns it takes Use gentle force as this screw is very thin and has O ring seals on it Now turn the screw OUT counter clockwise the number of turns in the table below e Stock exhaus
26. fuel tube from the v bottom of the fuel filter pump to filter Remove the fuel filter and rubber cushion from the filter bracket and then remove the other fuel tube Remove the rubber cushion from the filter and inspect the filter for damage and contamination Replace the filter if necessary taking note that the arrow on the filter body must be pointing towards the fuel pump down FUEL TUBES 24 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 14 Throttle Operation L C E Check for any deterioration or damage to the throttle cables 1 4 in 6 mm 1 12 ak Check the throttle grip for smooth operation Check that the throttle returns to full closed from full open smoothly and automatically in all handlebar positions If the throttle does not operate smoothly then dissemble the switch housing and disconnect the throttle cables at the right grip Then lubricate the cables thoroughly by Spraying a cable lubricant or light weight oil down the cable ends and operating the cable back and forth repeatedly Reassemble the throttle cables and switch housing and then readjust the free play as per the LOCK NUT ADJUSTER instructions below With the engine idling turn the handlebar all the way from stop to stop and ensure that the idle speed does not change If the idle soeed changes then check the freeplay below and also check the cables for proper routing interference and security Thr
27. g out the lower hose nipple Now you can reconnect the hose Here is the coolant you should be using It comes in 1 gallon 3 85 liter jugs which is more then enough to do the ACE Service Interval and Recommended Maintenance Manual Honda VT750CD ACE use one of these type of funnels that can attach directly to a jug and has a nice flexible hose on the end and a Shut off built in FILLING amp BLEEDING To fill the coolant first fill the reservoir up to the upper level line Then fill the radiator right up to the neck Let it sit for a few minutes and you ll hear the fluid gurgling as it settles into the passages in the engine Top up the rad again and wait a few more minutes Now cap the radiator and start the engine and run it for 1 or 2 mins ONLY Snapping the throttle a couple of times This will bleed the coolant and remove the air from inside the lines and passages Shut the bike off and remove the radiator cap and top up the fluid again and recap Also check the reservoir one more time and adjust the level if it s down a bit then cap it Step 7 Close up Re secure the neck cover and put the gas tank back in position and bolt on Install the seats Finally give the bike and work area a good hose down to remove any spilled coolant Ride the bike and recheck the level after a day or two Remember always check the level and top up the fluid using the reservoir ONLY The radiator should only be opened when doing the com
28. heel forward and remove the chain from the rear sprocket 9 Remove the rear wheel a a DS sis EE el E fa a Drive Train Installation 1 Position the wheel between the swing arms and loosely install the chain over the rear sprocket then slide the axle from the left side through the swing arm side collar wheel hub other side collar and opposite swing arm NOTE You might find it easier to have help Also always preferred holding the wheel against the left side collar and left swing arm until the axle was into the wheel hub then position the right side collar before Sliding the axle the rest of the way 2 Install the axle nut but don t tighten it yet 3 Connect the brake stopper arm to the brake panel with bolt seat washer washer and nut Tighten the nut to 14 Ib ft 4 Install the NEW cotter pin Connect the brake rod to the brake arm 5 Adjust the drive chain Ref Task 01 Drive Chain 6 Adjust the rear brake free play Ref Task 04 Brake System 7 Tighten the axle nut to 69 Ib ft Front Wheel Removal 1 Raise and support the motorcycle using a lift or jack 2 Remove the screw and speedometer cable from the Speedometer gear Note VT750C and VT750CD CD2 1998 2000 44 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE 2 Remove the screw and speed sensor from the Speedometer gear Note VT750C3 VT750CD3 VT750CD CD2 after 2000 dg aed 3
29. ing tap water may cause engine damage Use only low mineral drinking water or distilled water as part of the anti freeze solution Your ACE comes with a 50 50 solution of antifreeze and distilled water A higher concentration of antifreeze decreases the performance of the cooling system and is only recommended when additional protection from freezing is needed A concentration of less then 40 antifreeze will not provide proper corrosion protection for your aluminum engine So basically you should just keep it a 50 50 mixture or buy a pre mixed product that is equivalent to 50 50 Service Interval and Recommended Maintenance Manual 49 Honda VT750DC ACE 3 SC we The reserve tank is located behind the radiator 4 Check a P the coolant level in the reserve tank while the engine is ee at normal operating temperature It should be between c at eN a i if the UPPER 1 and the LOWER 2 level marks When the l f coolant level is at the LOWER mark then add new SCH Kaes coolant up to the UPPER mark Always add coolant to La ae the reserve tank only Do not attempt to open the radiator cap while the engine is hot Task 25 Cooling System Wash the motorcycle paying particular attention to the radiator grill Take the motorcycle for a run to bring it up to operating temperature and then let it sit and idle until the fan comes on If the fan fails to come on shut the motorcycle off before it gets too hot and fix the fan motor bef
30. l 13 Honda VT750DC ACE Task 06 Headlight Aim 14 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 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 cente
31. l you see the FT Mark line up with the line on the edge of the timing hole That means the front cylinder is now at TDC and all the valves are closed compression stroke Now measure the clearances with the feeler gauge There are two intake valves side by side and one exhaust valve per cylinder Start with the largest gap you can allow For example on the exhaust valve try to insert an 0 009 gauge between the rocker and the tappet If you can insert this gauge easily then the gap is excessive Once you have determined that there is adjustments to be made adjust each valve to it s minimum limit To adjust the valve loosen the lock nut using a 10mm box end wrench then turn the tappet adjusting screw using a 4mm box end wrench until the gauge just fits but still has some drag Now tighten the lock nut back up Recheck the gap after you tighten the lock nut because when you do the tightening it tends to pull everything together and loosen the gap up a bit It might take a little trial and error to hit the gap you are shooting for after everything is tight Once you are happy about the gaps recheck that ALL the lock nuts are tight Rear Cylinder Repeat this process with the rear cylinder now but this time you are rotating the crank until the rear cylinder rockers are all up and the mark you are lining up in the timing hole says RT Again once you are happy with the clearances double check that the lock nuts are tight By tight mean th
32. lant won t be a big issue It s impossible to change the coolant on this bike without getting some of it on the ground was able to catch the largest amount from the pump but all the other areas basically just let drain on the ground and then hosed up after Therefore make sure you do this in an area you can clean easily and that no children or pets are around If you have a bike lift it makes the job much easier Step 2 Move the gastank X W d V K AN While the service manual asks you to remove the gas tank you really only need to pull it aft a few inches so you can access the radiator cap Remove the seats and the tank mounting bolt and pull the tank back a few inches Just be careful with the fuel line on the left hand side With the tank back a few inches you can easily remove the one clip on the neck cover and access the radiator cap see arrow Remove the radiator cap now 58 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Step 3 Drain the front cyclinder and water pump Put your container under the water pump and remove the drain plug which is located on the bottom of the engine left side below the kick stand see arrow You are draining not only the front cylinder but also the radiator and the big hoses so there s almost 2 liters that comes out here Leave the plug out for now Remove the drain plug on the rear cylinder see arrow There s really no way to catch this fluid and i
33. mal 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 Pedal Height 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 Service Interval and Recommended Maintenance Manual 11 Honda VT750DC ACE 12 Free Play 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 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 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 had a near disaster on the 40
34. nge or any time it looks worn Fill the crankcase with the new oil until it reads on the dipstick 5 and then secure the cap Apx 2 4 litres capacity Start the engine and let it idle for 2 3 minutes While it is idling check that there are no leaks from the plug or the filter Stop the engine and let it sit for several minutes then check the level again and make sure the oil is at the upper 6 on the dipstick Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 21 Removal amp Installation of the Wheels IS Side Collar A erate gt mm eme pm Te TT T Drive Chain Adj Bolt Nut Washer Service Interval and Recommended Maintenance Manual uster ee Rear Wheel Removal To easily remove the rear wheel from the motorcycle you will need to be able to jack the bike up a fair distance apx 1 foot or more A motorcycle lift is ideal for this WARNING Do not jack the bike using the oil filter 1 Break the torque on the axle nut before jacking the bike 2 Jack the bike and secure it 3 Loosen the axle nut 4 Loosen the drive chain adjusters on both sides of the swing arm 5 Disconnect the brake rod from the brake arm 6 Remove the cotter pin nut washers and bolt from the stopper arm on the brake panel 43 Honda VT750DC ACE 7 Remove the axle nut right side collar and rear axle note the positions of the two side collars for reassembly 8 Slide the rear w
35. nterval and Recommended Maintenance Manual Honda VT750CD ACE Task 09 Suspension 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 Swing Arm Bearing Wear Check 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 Service Interval and Recommended Maintenance Manual 17 Honda VT750DC ACE Rear Shock Inspection 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 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 doubt anyone is going to go around and r
36. nual 35 Honda VT750DC ACE F d SE VALVE K m cz i TR NOB in SPARK PLUG CAP i ral Fi Sa Te at Y a z wi Bes w W d e CM P H a e ink Li s if s d Gei il un LAN Wi MN SH d S d W v j a a o Intake Insulator Screw BOLTS WA A 7 Remove all the spark plug caps Remove the bolts and then remove the rear cylinder left side fins and choke SE Valve knob and bracket also removed the forward cylinder ignition coil from the frame and moved it and the two plug wires back and out of the way to give a bit more access room above the cylinders Disconnect the sub air cleaner tube from the front side carburetor Loosen the intake insulator band clamp screw on the forward cylinder and remove the carburetors together through the LEFT HAND side of the bike Note the Honda service manual incorrectly says to remove through the right hand side They will only fit through the left hand side 36 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Step 6 Remove the sub air cleaner housings SUB AIR CLEANER HOUSING a Rear Cylinder Front Cylinder Remove the sub air cleaner housings from both cylinders The rear cylinder is only held on with one bolt and the front cylinder s is held on with 3 bolts Also remove the remaining fin covers from both sides of the front cylinder Step 7 Remove the Thermostat Housing Mounting Bolt Remove the m
37. ore proceeding with this task Check the radiator grill for clogging or damage Straighten bent fins with a small flat bladed screwdriver and remove insects mud or other obstructions with compressed air or low pressure water Replace the radiator if it is obstructed over more than 20 of its surface area Also check closely for leaks in the cooling hoses the water pump and the thermostat 50 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 26 Rear Brake Shoe Replacement BOLT 29 Nem 3 0 kgfm 22 Ibfeft INDICATOR PLATE FELT SEAL SPRINGS BRAKE SHOES BRAKE CAM BRAKE ARM H ei COTTER PINS E E BRAKE PANEL SET PLATE Remove the rear wheel ref Task 21 Removal amp Installation of the Wheels Pull the Brake Panel from the rear wheel Measure the brake drum inside diameter see photo Service Limit 181mm 7 13in Service Interval and Recommended Maintenance Manual 51 Honda VT750DC ACE 52 Cotter Pins Measure the brake lining thickness Service Limit 2mm 0 1in Disassembly Remove the Cotter Pins and Set Plate Remove the Brake Shoes and Springs Service Interval and Recommended Maintenance Manual Honda VT750CD ACE KE Remove the Pinch Bolt and Brake Arm HERG e ae Pinch Bolt he mn Remove the Indicator Plate Remove the Brake Cam Service Interval and Recommended Maintenance Manual 53 Honda VT750DC
38. ottle Free Play Measure the Free Play at the throttle grip flange Free play should be 2 6 mm 1 12 1 4 in For minor adjustments use the adjusters at the upper ends of the cables on the grip Loosen the lock nut and turn the adjust to obtain the free play After the adjustment tighten the lock nut securely and reposition the boot properly If you can not get the proper free play with the upper adjusters then adjust using the lower fittings on the carb end Same thing loosen the lock nuts turn the adjusters until you have the proper free play and then re secure the lock nuts After you have made ANY adjustments recheck the throttle operation and free play as outlined above Ke 4 Q C d g T ADJUSTER in OW LOCK NUT Service Interval and Recommended Maintenance Manual 25 Honda VT750DC ACE Task 15 Carburetor Choke RUBBER COVER ADJUSTER Task 16 Air Cleaner Mear aen Frai wai Haner Air caer aa 4 lock k K 1 26 The choke system uses a fuel enriching circuit controlled by an SE valve Starting Enrichment The choke knob on the left side of the motorcycle operates a split cable that operates the enriching circuit of each carburetor Check for smooth operation of the SE valve knob Check for any deterioration or damage to the valve cable If the operation is not smooth then pull the rubber cover away and lubricate the cable with a cable lubricant or a light weight oil To adjus
39. ou use an SAE 10W 40 4 Stroke Oil You can also use other viscosities as per this chart if the average temperatures in your riding area are within the limits L go 3a wpe E E EE 20 10 O 10 20 A0 40 C ZO edO DC wO Dm dF zs H First warm the oil up by taking your bike for a short ride To drain the oil remove the oil filler cap dipstick 5 on bottom picture the crankcase drain plug 1 and the gasket 2 Make sure to drain the oil in an approved container and dispose of it properly Service Interval and Recommended Maintenance Manual 41 Honda VT750DC ACE 42 Remove the oil filter 3 with a filter wrench or by hand and let the remaining oil drain out Discard the oil filter HINT If you don t have a proper oil filter wrench and the filter is on too tight to remove by hand you can use a long screwdriver and punch a hole through the filter in one side and out the other Then you can just turn the screw driver a bit to break the torque Pull the screwdriver out and remove it the rest of the way by hand Messy but a good trick to get the filter off ina pinch Apply a thin coat of oil to the new oil filter rubber seal 4 Install the new filter and snug it up BY HAND The torque Is only supposed to be 7 ft lbs and you can easily do this just with your hands Use a rag if your hands are too greasy for a good grip Check the condition of the oil plug gasket 2 and re use if it s ok Replace it every other oil cha
40. ounting bolt holding the thermostat housing and move the housing upward to give you room to remove the cylinder head covers Service Interval and Recommended Maintenance Manual 37 Honda VT750DC ACE Step 8 Remove the Cylinder Head Covers and Gaskets COVER COVER Sie AT GASKET pl N Ca k GASKET Front Cylinder Rear Cylinder Remove the cylinder head covers and gaskets Take care not to damage the gaskets or to scratch the clear coat finish on the covers You might also have to remove the coolant lines to get the covers out If you do watch that you don t spill coolant onto the heads and in the oil Take it slow and careful here Step 9 Remove the caps from the Crankcase and Timing Holes Crankshaft Hole Remove the caps from the crankcase hole and the sf ei timing hole on the left side crankcase cover Timing Hole 38 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Step 10 Inspect Adjust the Valve Clearances Front Cylinder You need to find Top Dead Centre TDC on the compression stroke of this cylinder The easiest way to do this is to use a socket on the crankshaft nut via the crankcase hole and rotate the crankshaft counterclockwise Make sure the bike is in neutral Now watch the rocker arms as you rotate the crankshaft slowly They will move up and down When you see all the rocker arms in the up position look in the timing hole and keep rotating the crank slowly unti
41. plete replacement as described above For day to day use just adding fluid to the reservoir is sufficient Service Interval and Recommended Maintenance Manual 61 Honda VT750DC ACE Task 29 Front Brake Disc Inspection amp Limits L rake Tag Tai KC R K DR H ee ke T 1tMagec R R lt 62 KR t awa 058 0 a wee eee ee e Visually inspect the disc for damage and cracks Measure the thickness of the disc at several points SERVICE LIMIT 5mm 0 2 in Replace the brake disc if the smallest measurement Is less then 5 mm Check the brake disc for warpage using a dial indicator while rotating the front wheel SERVICE LIMIT 0 30mm 0 012in If you get more the 0 30mm deflection then first check the front wheel bearings for excessive play If the bearings appear fine then replace the brake disc Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 30 Front Brake Bleeding Warning e Do not allow foreign material to enter the system when filling the reservoir e Avoid spilling fluid on painted plastic or rubber parts cover these areas with a rag whenever the system is serviced e Us only DOT 4 brake fluid from a sealed container e Do not mix different types of fluid as they are not compatible RESERVOIR Brake Fluid Draining Turn the handlebar to the left until the reservoir is level Remove the screws reservoir cover set plate and diaphragm be Er i rbai
42. r pivot bolt Brake lever pivot nut Master cylinder holder bolt Master cylinder cover screw Front brake light switch screw Brake hose oll bolt BATTERY CHARGING SYSTEM Battery box cover screw LIGH TS ME TERS SWITCHES Side stand switch mounting bolt Thenmosensor ch sch A s Be HN Ni wl hA ER a h lt zc sch d ch Ki pech eeh ef SO Cm mz 2am e oo E TORQUE N m kom Ibit 93 9 5 65 B8 9 0 65 26 2 7 20 33 9 0 65 25 2 5 18 64 6 5 47 03 2 2 d 13 5 25 20 2 0 14 29 3 0 22 24 13 5 25 30 13 1 22 26 2 7 20 13 1 3 91 18 41 8 13 3 0 3 2 2 6 0 6 4 3 140 1 0 7 0 6 6 3 12 12 5 2 0 2 1 4 1 0 1 0 7 24 3 5 25 10 1 0 7 10 1 0 7 12 1 2 9 NOTE 7 NOTE 7 NOTE Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Task 11 Wheels amp Tires While making sure the fork is not allowed to move raise the front wheel and check for play Turn the wheel and check that it rotates smoothly with no unusual noises If faults are suspect inspect the wheel bearings Take note that it is often found that the front wheel bearing on the right hand side will wear out faster than all the others This is because that wheel bearing is exposed to rain and moisture due to the left hand leaning stance of the bike on it s side stand and the natural way the tire sits turned to the left Inspect the spokes for loosen by
43. ring safe chain wax to lube this chain Personally 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 ride my bike for 20 mins to warm the chain up then 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 spray a nice even coat of gear wax and let it sit for 30 mins before riding Service Interval and Recommended Maintenance Manual 7 Honda VT750DC ACE Damaged Sprocket Wom Sprocked Teeth Teeth Replace E WW Keplace d 4 i a l i j P OTI Sprocket Teeth H r WK rf C00 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
44. rline 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 Service Interval and Recommended Maintenance Manual Task 07 Clutch 1 E a i 1 A k j l a wem pe D Ean gt pry E SE Y va Gem oa R aa IW Ki ke Other Checks Honda VT750CD ACE 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 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 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
45. rness is out of the clip holder on top Service Interval and Recommended Maintenance Manual 33 Honda VT750DC ACE Step 3 Remove the Steering Cover STEERING COVERS Remove the trim clips then remove the two halves as an assembly Remove the joint clip if you wish to separate the halves TRIM CLIPS Step 4 Remove the Air Cleaner amp Air Chamber Remove the two 2 air cleaner housing bolts not the 6 hex head bolts for the cover Then loosen the air cleaner housing to chamber band clamp with the screw Pull the air cleaner housing away For the air chamber you need to loosen the band clamps at the intakes for the carburetors Then pull the chamber a little ways from the frame and disconnect the crankcase breather tube from the chamber Remove the air chamber AIR CLEANER CHAMBER 34 Service Interval and Recommended Maintenance Manual Step 5 Remove the Carburetors FUEL TUBE Sub air Cleaner THROTTLE CABLES Tube i E S e e if E e d i SCREWS ES Oy e A H bi ha X K S d We SR Intake we Insulator Screw Honda VT750CD ACE Loosen the carburetor drain screws and drain the carbs Disconnect the fuel tube from the fuel joint Remove the screws and throttle cable holder Disconnect the sub air cleaner tube Loosen the intake insulator band clamp screw for the rear cylinder Remove the throttle cables from the throttle link Service Interval and Recommended Maintenance Ma
46. t no mods 2 and turns What was supposed to be the factory setting e Stage Punched exhaust baffles no new jets though 2 and 1 2 turns e Stage Punched exhaust or aftermarket pipes with baffles and Stage 1 Jets 3 Turns e Stage III Aftermarket exhaust and Stage III jets 3 and 1 4 turns Step 3 Repeat the above procedure with the right carb forward cylinder Use the same settings as above Some people choose to make the rear carb slightly more rich as it runs hotter so if you want make the back turn richer then the front the back is the left carb also Known as the BASE carb Now reinstall the air filter housing and take the bike for a test run Make sure to do lots of fast decelerations while downshifting to see if the exhaust pops on you An occasional pop is not uncommon especially when the bike is cold or the weather is cool and damp If however you are still getting lots of the misfires then go back and readjust each screw Lo further out Caution do not go more than 4 full turns out as the screw may come loose at about 4 and turns If you are unsure of where you left off then reseat the screws and count out again to get the right setting For bikes with extreme set ups such as open pipes and modified air intake systems you MAY have to go one size up in the pilot jets to get rid of the lean idle condition This is rare though and normally you can adjust the Pilot Screws to get rid of those pops If
47. t the friction turn the adjuster under the rubber cover If you find that there is an excessive Spring back on the cable then the cables may be routed wrong or binding in which case you may have to remove the carbs and re route the cables if you can t get the knob to stay open for Starting The air cleaner should be replaced approximately every 19 000 km 12 000 miles Change it sooner if you do a lot of riding in unusually wet or dusty areas Also if you are caught and have to do a long ride in heavy rain then afterward you should pull the air cleaning housing cover and wipe out the inside of the case 4 have found that water and mud can collect in here during a long ride in rain Replace Air Cleaner 1 Remove the six bolts 1 holding the cover 2 in place and remove the cover 2 Pull out the air cleaner 3 and discard 3 Clean out the inside of the case 4 4 Install a new air cleaner 5 Place the cover 2 back on and secure with the six bolts 1 Service Interval and Recommended Maintenance Manual Task 17 Crankcase Breather Hear sat Froni oral battery Sherif back i Honda VT750CD ACE The air cleaner case has a small tube in the bottom that allows the engine crankcase to vent Attached to this tube is a plastic sleeve that catches any oils and crud that is vented This tube should be cleaned out during every routine maintenance check Also as mentioned in the air cleaner section if yo
48. t will just drain over your engine so wash it up after Luckily there is very little fluid that comes from this drain Also when you open this drain port up this will release an air lock and let more fluid drain out the water pump Let things drain for a few minutes and then put both drain plugs back in and torque the bolts to 9 Ibf ft It is also advisable to use new Sealing washers Service Interval and Recommended Maintenance Manual 59 Honda VT750DC ACE Step 5 Drain and flush the reservoir Step 6 Filling and bleeding the new coolant ANTIFREEZE COOLANT ANTIGEL REFROIDISSANT re w et mani ant FER a ai PPa reg emt mme Ae neat emm TYPE 2 mr 60 Remove the cap from the coolant reservoir The service manual tells you to remove the reservoir and drain and flush it off the bike but that would mean removing the gas tank AND the radiator which is a pain so what did was just remove the lower hose from the reservoir see arrow and let it drain out Now there s a little bit that is left below the hose level so took my garden hose and put it in the filler hole and gently rinsed out the reservoir until all the old fluid had been washed out You can tell this when there is no more foaming and no green color anymore Let the water drain out and then take the new coolant and put a little into the filler at a time until the new coolant displaces the water left in there and green coolant is runnin
49. tapping them with a screwdriver They should sound clearly and all alike If one sounds different or makes a dull sound then tighten it with a spoke wrench or something similar The torque should be 2 9 foot pounds 4 N m Now raise the rear wheel and check for play and for spoke tightness as well With the rear tire you can have play in the wheel bearings and ALSO the swing arm pivot bearings so if you Suspect any faults make sure you isolate which area it comes from wheel bearings or pivot bearings Check the tire pressures according the values below Load under 90 kg 200 Ib Front 29 psi Rear 29 psi Load over 90 kg 200 Ib Front 29 psi Rear 36 psi Maximum Load 170 kg 375 Ib Stock Tire Sizes 120 90 17 64S front 170 80 15 M C 77S rear Stock Brands Dunlop D404F front D404 rear Bridgestone G701 front G702 rear Service Interval and Recommended Maintenance Manual 23 Honda VT750DC ACE Task 12 Steering Head Bearings Support the motorcycle securely and raise the front wheel off the ground Check that the handlebar moves freely from side to side If the handlebar moves unevenly binds or has vertical play then inspect the steering head bearings Task 13 Fuel Line amp Filter _ FUEL FILTER Dra n k Remove the left side cover Check the fuel lines for Z Ka deterioration damage or leakage Replace the fuel lines d Ze if necessary R Turn the fuel valve off Disconnect the
50. u drive through a lot of rain or dust then you should also clean out the inside of the case as well as the vent tube Clean Crankcase Breather 1 locate the tube at the bottom of the air cleaner housing on the back side 2 With a pair of narrow needle nose pliers squeeze the clip holding the drain trap in place 1 and pull it off 3 Clean the trap and the drain tube on the case and then reinstall the trap using the pliers to hold the clip open until the trap is seated on the drain Service Interval and Recommended Maintenance Manual 27 Honda VT750DC ACE Task 18 Spark Plugs The ACE has two spark plugs per cylinder so four plugs in total They should be inspected at every service and replaced every 12 800km or as conditions dictate Inspecting your spark plugs can tell you a great deal about the condition of your engine and how well in tune it is To help have constructed a simple guide for reading the conditions of your plugs The pictures and information were compiled from several other charts that various plug makers have published Recommended Plugs 1 Standard DPR8EA 9 NGK or X24EPR U9 DENSO 2 Cold Climate below 5 C 41 F DPR7EA 9 or X22EPR U9 3 Extended High Speed Riding DPR9EA 9 or X27EPR U9 Recommended spark plug Gap 0 80 0 90mm 0 031 0 035in To replace your plugs 1 Disconnect the spark plug boots from the spark plugs Avoid using pliers or any other tool to do this as you can damag
51. uple of special tools just for this job They are a feeler gauge and a 4mm open end wrench for the tappets or a special tool built for the job Required Tools Wrenches 4mm 8mm 10mm 12mm Sockets 8mm 10mm 12mm Allan Keys 22mm Hex 5 32 Hex 5mm Hex Feeler Gauge Set Needle Nose Pliers Philips Screwdriver Slotted Screwdriver Step 1 Prepare the bike Park your bike on a flat surface on it s side stand where you can work uninterrupted for 4 6 hours Also it would be good to lay out a piece of cardboard or a workbench so you can lay the various parts down and keep track of the hardware etc Start by removing the seat s and the side covers 32 Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Step 2 Remove the gas tank pour COLLAR Taa ze SPEEDOMETER COVER GROMMET P Remove the speedometer by removing the four hex head bolts Lift the assembly up and disconnect the 9 pin connector Now is a good time to clean under there FUEL TUBE Place a rag under the fuel valve to catch any fuel that comes out then remove the fuel tube from the valve by squeezing the clip ends and sliding the clip back down the tube Pull the tube from the valve On the other side of the tank there is a slim air vent tube that you can just pull off the tank easily Remove the fuel tank mounting bolt and then slide the tank back a bit and lift it clear of the bike Make sure the speedometer ha
52. ylinders to prevent a recurrence since it is possible for a small object to travel from one cylinder to another where a large degree of valve overlap exists Service Interval and Recommended Maintenance Manual Honda VT750CD ACE Gap Bridging Combustion deposits lodge between the electrodes Heavy deposits accumulate and bridge the electrode gap The plug ceases fire resulting in a dead cylinder Combustion deposits thrown loose may lodge between the electrodes causing a dead short and misfire Fluffy materials that accumulate on the side electrode may melt to bridge the gap when the engine is suddenly put under a heavy load Service Interval and Recommended Maintenance Manual 31 Honda VT750DC ACE Task 19 Valve Inspection Adjustment Inspecting and adjusting the valve clearances is probably the most difficult task that a regular ACE owner might attempt on their own Any owner that has a basic aptitude for maintenance and doesn t mind spending a day tearing their bike down can do this task and the biggest benefit is that it will save a hefty fee from the dealer Most bike shops if they do the job properly will charge at least 2 hours shop labor if not more If you are going to do this yourself then expect to take around 4 to 5 hours Also you will need a good work area with lots of room to lay out the parts you need to disassemble As for tools you will need the basic kit that is included with the bike as well as a co

Honda VT750CD ACE Service Interval Manual

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