2000–2006 Honda RVT1000R / RC51 Service & Repair Manual (P/N 61GN402)

This two-PDF repair set covers the 2000-2002 Honda RVT1000R / RC51, with a separate 2000-only parts and exploded-view reference. The service manual was issued in March 2002 and carries the model-year split through its specifications and procedures, using “’00-’01” and “After ’01” designations where the 2002 machine differs. It is written for readers who have already acquired basic knowledge of Honda motorcycle, motor-scooter, or ATV maintenance, so it assumes workshop familiarity rather than teaching first-time mechanical fundamentals.

• 585-page PDF set: a 467-page Honda service manual for the 2000-2002 RVT1000R / RC51 and a 118-page Parts Info & Drawings file limited to the 2000 RVT1000R. Coverage stops at 2002.
• Fuel-system coverage follows PGM-FI self-diagnosis from system layout and MIL failure codes through service-check-connector testing, sensor and injector checks, fuel-pump and cut-off-relay diagnosis, ECM testing, throttle-body service, starter-valve synchronization, and California-only evaporative-emissions equipment.
• Engine chapters document engine removal and installation, cylinder-compression testing, camshaft and gear-driven cam-train service, cylinder-head disassembly, valve-guide replacement, valve-seat refacing, head assembly, cam timing, and final valve-clearance adjustment.
• Driveline repair includes hydraulic-clutch fluid replacement and bleeding, master- and slave-cylinder service, clutch-pack inspection, primary-drive work, alternator and flywheel removal, starter-clutch and torque-limiter checks, crankcase separation, six-speed transmission repair, and shift-fork/shift-drum inspection.
• For chassis and brake repair, the manual details front-wheel and fork disassembly, fork inspection and reassembly, steering-bearing replacement and preload checks, rear-wheel service, shock removal, suspension-linkage and swingarm-bearing work, brake-fluid bleeding, and front and rear master-cylinder and caliper rebuilding.
• Electrical diagnosis spans battery condition and current-leakage testing, alternator output, regulator/rectifier checks, ignition peak-voltage testing, starter-motor and relay fault tracing, combination-meter circuits, speed and temperature sensing, switches, lighting, and fan controls.
• The 58 exploded component views use numbered callouts with matching parts-description tables. Factory reference data covers torque tables, fluid capacities, pressure tests, wear limits, clearances, electrical test values, and named special tools such as the valve-spring compressor 07757-0010000, flywheel holder 07725-0040000, rotor puller 07733-0020001, and clutch-center holder 07724-0050002.

Year-Specific Service Coverage

The ’00-’01/After ’01 break is carried through the repair information instead of being reduced to a blanket year claim. Relevant changes include throttle-body identification and bore, cooling-system capacity and fan control, fork spring and fluid data, steering-stem hardware, front-brake components, lighting and fuse arrangements, and engine/swingarm mounting procedures. California models receive dedicated evaporative-emissions maintenance and fuel-system coverage.

Diagnostic material is equally specific. Useful examples include the Cable & Harness Routing views, PGM-FI System Diagram and sensor-location pages, MIL malfunction-code charts, the electric-starter troubleshooting flowchart, the radiator-fan circuit schematic, and the full-page Wiring Diagram. Section-level troubleshooting also isolates hard starting, power loss, poor low- or high-speed performance, charging faults, ignition faults, brake drag, and handling complaints.

Parts Identification and Repair Limits

The 2000 parts reference adds exploded plates for the camshaft and valves, crankcase, transmission, clutch, throttle body, brakes, front fork, steering stem, swingarm, radiators, starter system, and front and rear wire harnesses. Its pages are marked PartsFish and pair drawing callouts with parts descriptions; it should be used as a 2000 component-identification aid, not as a 2001-2002 factory parts catalog.

Two manual-specific cautions matter during deeper work. The throttle-body section warns that disturbing the white-painted factory-set screws can upset throttle and idle-valve synchronization. The crankshaft section uses select-fit, color-coded crankpin and main-journal bearing inserts; incorrect selection or oil clearance can cause major engine damage. Rear-suspension coverage includes shock removal, bushing inspection, disposal preparation, and linkage/swingarm bearing repair, but the nitrogen-charged damper unit is not to be disassembled.

Workshop Safety

Support the motorcycle with a hoist or equivalent before engine, wheel, fork, steering, or suspension work. Switch the ignition off before starter or electrical service, and allow the engine and radiator to cool before removing the radiator cap.