2003 honda shadow spirit 750 repair manuel

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2003 Honda Shadow Spirit 750 VT 750DC Custom speedometer dial installation

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Filed Under (Honda) by admin on 06-11-2011

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DO NOT REMOVE THE 3 PHILLIP SCREWS ON THE BACK OF THE SPEEDOMETER. This will unscrew the circuit board and the main components inside the speedometer, and possibly damage it. Just leave those 3 screws alone. They won’t make your customization any easier if they are removed. This is the hard part. Turn the speedometer face down on a soft towel on a sturdy table, bench, etc. I used a regular flat screwdriver to do this step. There is a chrome metal ring holding the glass on the speedometer. It is factory sealed. On the bottom side of this ring start prying with a flat screwdriver under the bottom lip of the metal ring. This will be a slow process (patience, patience, patience) so don’t get in a hurry and ruin the wife’s kitchen table like I did. Go around the metal ring with a flat screwdriver prying it up as straight as you can. It’s easier doing this every millimeter or two. I had to do this about 3 times all the way around the ring. After you pry the lip of the ring up all the way around enough to loosen it up considerably, gently pull the ring off of the speedometer. The glass should come off with it. Put the glass with the chrome ring aside for later. You might want to use a soft lint free towel to rest it on

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2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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2003-2004 HONDA GL 1800/A Frame Weld Safety Recall

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Filed Under (Honda) by admin on 15-12-2010

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there is no punch mark on the VIN plate as specified in this Service Bulletin, proceed to the REPAIR PROCEDURE section of this Service Bulletin. IMPORTANT: Due to the complexity of this campaign it is imperative that you check iN and your Dealer Responsibility Report before you begin repairs. If iN or your Dealer Responsibility Report indicate the Safety Recall has been performed, but you confirm the unit is not punched and the repair has actually been done (by inspecting the weld), please contact the Warranty HelpLine at (800) 421-1900, option 7. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510)  Frame Weld Inspection Chart (S0516) You MUST provide your TIG welder with the following items:  2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511)  2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) Welding Template Box (S0512) All of the above items were shipped to you with Service Bulletin GL1800 #14. If you need additional copies of these materials, you may order them from Resolve at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. DISASSEMBLY OVERVIEW You will be removing the following components from the vehicle as instructed in the Dealer Booklet : Handlebar weights Rear view mirrors Swingarm pivot covers Rider foot pegs Seat Side covers/Engine side covers Fairing pockets Fairing molding Meter panel Top shelter Battery Fuel tank Main wiring harness ground Front lower fairing Front exhaust pipe protector Muffler/exhaust pipe Antenna Whip(s) Coolant reserve tank Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: Before you send the motorcycle to the welder, you MUST check for lower crossmember frame weld cracks.  If your inspection reveals no cracks in or on either the Left or Right lower cross- member frame welds, proceed to the REPAIR PROCEDURE OVERVIEW section of this Service Bulletin.  If your inspection identifies a crack or cracks in or on either the Left or Right lower crossmember frame welds, perform the following procedure: Place the grinding template (S0512) on the crossmember. Using a suitable felt marker, draw a line on the weld with the crack, drawing the line along the entire edge of the the template (this line will be 89 mm long). If the crack falls within the length of this line (89 mm) , prepare the motorcycle for welding per the Dealer Procedures and advise the welder to use the Cracked Weld Repair Manual (S0515). After the bike has returned from the welder, prepare the frame and re-assemble the motorcycle per the Dealer Procedures . Then, proceed

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The Honda Ace/ Spirit 750 Lowering Kit from INSTATALLATION

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Filed Under (Honda) by admin on 16-11-2011

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The installation of the Scootworks Ace/Spirit Lowering Kit follows the same procedure as replacing the rear shocks. However, Scootworks wanted to assist you as much as possible with the installation process, and developed this instruction package. If there are any steps you feel need improvement in instructions, please email support@scootworks.com and specify the area you are having trouble with. Unpacking! The shipping container and contents must be inspected by the purchaser for damage to goods immediately upon receipt of goods, and a claim must be filed with the carrier if damage is discovered. The purchaser must contact Scootworks within 24 hours from receipt of damaged goods to file a claim, and for further instructions. Your Scootworks Ace/Spirit Lowering Kit will come packed with a left and right side lowering assembly, two large flat washers, two M8 x 1.25 hex head bolts, and these printed instructions

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2003 Honda ST1300/A Wire Harness Inspection and Repair Manual

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Filed Under (Honda) by admin on 21-04-2011

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REPAIR PROCEDURE Note: While completing this procedure DO NOT disconnect the 2-pin connector unless repair of the wire harness is required. 1. If not previously done, complete the ST1300/A #1 Service Bulletin before starting this procedure. 2. Remove the seats, left saddlebag, and left side panel by following the instructions in section 2 of the Service /l/Ianua/on pages 2-5 and 2-6. 3. Secure the centerstand assist handle out of the way. 4. Remove the rear shock adjuster support bar top bolt and move the bar out of the way. 5. Locate the ignition cord leading to the 2P connector and check the two black and white wires for chafing. |GNlTl6N con BLACK AND WHITE WIRES Chafing V I may OOCUF _ in this area 2-PIN CONNECTOR 2of6 – If the insulation is still intact and copper wire is not showing, proceed to the Preventative Measure section of this bulletin. – lf copper wire is showig, wrap the exposed area of the wire with a good quality electrical tape and proceed to the Preventative Mea- sure section of this bulletin. Preventative Measure: 1. Place the length of PVC split tubing around the ignition cord, butting up against the con- nector. Rotate the split toward the inside of the motorcycle. 2. Use good quality electrical tape to cinch the end of the PVC split tubing together (at the end that is touching the 2-pin connector), together. Secure the PVC split tubing to the ignition cord at the other end with electrical tape. 3. Secure the ignition cord and wire harness cord to the rear sub-frame with a commer- cially available wire band. The 2-pin connector should be routed behind and to the rear of where the rear shock adjuster support bar is located. ~! IR ARNESS C R COR W EH O D

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2002-2003 HONDA GL1800 BANK ANGLE SENSOR MOUNTING SCREWS REPAIR MANUAL

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Filed Under (Honda) by admin on 22-04-2011

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REPAIR PROCEDURE 1. Insert the ignition key into the lock cylinder and open the fairing pocket lid by turning the key clockwise. Remove the two trim clips by pushing the cen- ter pins in. Remove the two screws. Disconnect the opener  cable and remove the right fairing pocket. 2. To access the bank angle sensor, remove the two mounting screws  securing the connector holder. Place the holder to the side. 3. To check for the proper screw size, slightly tighten both bank angle sensor screws. If the screws are tight, reassemble the unit and apply the identification mark. If the screws spin in the holes, proceed to Step 4. 4. Using a magnetic screwdriver, remove and discard one of the two 4 mm screws securing the bank angle sensor assembly. Replace with a 5 x 12 mm self-tapping screw (see the PARTS INFORMATION section on page 3 for the proper screw for this repair). Repeat for the other screw. 5. Reinstall the removed parts in the reverse order of removal. IDENTIFICATION Apply a white paint dot in the center of the under- side of the right fairing pocket lid as shown. This will indicate that the Safety Recall has been per- formed on this unit

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MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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Honda Shadow Aero 750 Turn Signal Cancellation Unit Installation Procedures

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Filed Under (Honda) by admin on 29-11-2010

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Left TurnSignal Right TurnSignal Turn Signal Switch (for ref. Only) CIRCUIT CONNECTIONS AFTER INSTALLATION of Cancellation Unit Original+12 volts motorcycle supply power for flasher Ground (thiswiredoesnot exist on all models) Output to switch Power Power Red Yellow Gray Green Ground Green/Red Blue/Red Turn Signal Cancellation Unit Identify the positive power wire to the turn signal flasher. A test light with the probe touched to this wire will stay on steady and flash with the turn signals. Cut the wire and install the connectors observing the polarity as shown. Connect the Red and Yellow wires as shown. not Identify the flasher output wire to the signal switch and attach the gray wire by soldering or use the supplied red tap connector. Place the unit in a suitable area on your particular motorcycle. It is suggested under the seat providing access to the turn signal flasher. Connect the units ground (green) wire to frame (neg) ground Assure it’sareliable connection. IF THE GROUND WIRE BECOMES DISCONNECTED THE UNIT WILL BURN UP. using the supplied ring terminal. Identify the brake light circuit per the motorcycle wiring diagram. Using a test light verify the correct circuit using the following procedure. Connect the test light alligator clip (negative side) to frame ground. Using the positive tip probe the circuit. The proper circuit will illuminate the the brake is applied. Attach the Green/Red wire to this circuit. test light when The factory cancellation time is set at approximately 23 flashes. The length of time for cancellation can be decreased to approximately 15 counts by setting the program listed in the programming box

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HONDA SHADOW AERO 750 STRAIGHTSHOT HS EXHAUST SYSTEM

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Filed Under (Honda) by admin on 03-11-2011

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Install mounting bracket (stamped 359-P) in the original bracket mounting position, using two 10mm bolts and
one 10mm nut (supplied)(Figure 2). 2. Remove head pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark the outside edge of each heat shield to show location of hose clamp mounting clips (Figure 3). 3. Slide flanges onto head pipes and lay head pipes into
heat shields. Loosely install hose clamps by feeding tail end of clamp into heat shield clips (Figure 3). Take note of screw head direction (Figure 4). Screw head should be accessible when system is installed on motorcycle for adjustment purposes. Use #20 hose clamps for head pipe areas and #28 hose clamps for muffler areas.
4. Using stock nuts, carefully install head pipes into exhaust ports (Assistance may be required). NOTE: Do not tighten at this time.

Honda Shadow Aero 750 Kuryakyn Grips Installation Manual

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Filed Under (Honda) by admin on 26-10-2010

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Pull grip and chrome grommet off of throttle sleeve. (Here is the pic of doing the same thing on the clutch side.) Here is what you will be left with (I temporarily glued the threaded nipple back on the throttle sleeve for illustration…again, it will NOT be needed.)
Step 4: Clean off old glue with denatured alcohol. Note that an old pair of under shorts serves as an EGGSELENT rag for this use! Step 5: Remove grip from clutch side. End cap simply pulls straight off, split rubber OEM grip and pull it off, taking the chrome grommet on the end with it. With enough brute force, you can simply pull the end cap off and FORCE the grip off, but it is MUCH easier if you split it.

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