Table Of Contents - Honda MUV700 big red Service Manual

Table of Contents

A Few Words About Safety2
Safety Information2
Important Safety Precautions2
Contents3
Symbols4
General Information5
Table Of Contents5
Service Rules6
Abbreviation6
Model Identification7
Serial Numbers7
Labels8
General Specifications9
Lubrication System9
Specifications11
Fuel System Specifications11
Cooling System Specifications11
Cylinder Headivalve/Camshaft Specifications12
Alternator/Starter Clutch Specifications12
Sub-Transmission/Gearshift Linkage Specifications13
Crankcase/Crankshaft/Balancer Specifications13
Drivetrain System Specifications13
Front Wheel/Suspension Specifications13
Steering System Specifications13
Rear Wheel/Suspension20
Brake System Specifications20
Front Driving Mechanism21
Lubrication & Seal Points22
Cable & Harness Routing25
Emission Control Systems50
Source Of Emissions50
Exhaust Emission Control System50
Crankcase Emission Control System50
Noise Emission Control System51
Fuel Permeation Emission Control System51
Rebuilt Engine51
Lift And Support Points52
Technical Features53
Muv Overview54
Outline54
Occupant Protecteve Structure (Ops), Door And Cargo Bed54
Muv Steering System55
Elr (Emergency Locking Retractor) Seat Belt55
Pgm-Fi System56
Integrated Sensor Throttle Body56
Iacv (Idle Air Control Valve)57
Automatic Transmission System59
Torque Converter60
Hydraulic Valve Function61
Shift Clutch Hydraulic Circuit And Operation62
Selectable 4Wd And Differential Lock System66
2Wd/4Wd Final Clutch Operation66
2Wd To 4Wd67
4Wd To 2Wd67
Differential Lock Clutch Operation68
Normal Operation To Differential Lock69
Differential Lock To Normal Operation69
Frame/Body Panels/Exhaust System71
Frame/Body Panels/Exhaust System Service Information72
Frame/Body Panels/Exhaust System Torque Values72
Frame/Body Panels/Exhaust System Tools72
Frame/Body Panels/Exhaust System Troubleshooting72
Body Panel Locations73
Seat Cushion74
Seat Frame74
Seat Center Cover75
Headrest75
Backrest75
Seat Under Cover76
Engine Front Cover76
Parking Brake Lever Bracket77
Center Frame Cover77
Crossbar78
Door Panel79
Door Hinge79
Door Handle And Latch79
Side Panel81
Mudguard82
Floor Panel82
Floor Cross Plate83
Instrument Panel83
Footrest Panel84
Front Hood Removal/Installation84
Front Grille85
Front Hood Disassembly/Assembly85
Front Bumper86
Maintenance Lid86
Cargo Bed Damper86
Cargo Bed Damper Removal/Installation87
Cargo Bed Damper Disassembly/Assembly87
Bed Side Panel87
Bed Base Panel88
Bed Front Panel88
Tailgate89
Release Lever90
Side Net91
Occupant Protective Structure (Ops)91
Top Ops91
Front Ops92
Rear Ops92
Seat Belt Instructions92
Belt/Retractor93
Retractor Function Check93
Fuel Tank Plate/Cover94
Buckle94
Exhaust System Removal95
Exhaust System Installation96
Exhaust Pipe Disassembly/Assembly97
Maintenance99
Maintenance Service Information100
Maintenance Torque Values101
Maintenance Tool101
Maintenance Schedule102
Fuel Line103
Throttle Operation103
Air Cleaner104
Air Cleaner Housing Drain Tube106
Spark Plug106
Battery107
Valve Clearance108
Clearance109
Engine Oil Level Check110
Engine Oil Change111
Engine Oil Filter Replacement112
Cooling System113
Radiator Coolant113
Cooling System Inspection113
Recommended Antifreeze113
Drive Shaft Boots114
Differential Oil114
Front Final Gear Case114
Rear Final Gear Case115
Brake Fluid116
Brake Pads Wear117
Foot Brake Switch117
Brake System118
Hydraulic Brake118
Brake Pedal Height119
Parking Brake119
Underbody120
Suspension121
Spark Arrester121
Exhaust System122
Wheels/Tires122
Tire Rotation122
Wheels/Tires Inspection122
Tie- Rod And Joint Boot123
Steering System123
Gear Box Boot And Operation Check123
Rotational Play Check124
Turning Load Check124
Rack Guide Adjustment124
Wheel Alignment125
Front Toe Inspection125
Turning Radius Inspection126
Chassis Lubrication Points127
Lubrication System Diagram130
Lubrication System Service Information131
Lubrication System Specifications131
Lubrication System Torque Values131
Lubrication System Tools131
Lubrication System Troubleshooting132
Oil Pressure Check133
Oil Pump Removal134
Oil Pump Disassembly134
Oil Pump Inspection136
Oil Pump Assembly137
Oil Pump Installation139
Oil Cooler Removal141
Oil Cooler Disassembly141
Oil Cooler Assembly142
Oil Cooler Installation143
Fuel System (Pgm-Fi)145
Fuel System (Pgm-Fi) Components146
Fuel System (Pgm-Fi) Service Information148
Fuel System (Pgm-Fi) Specifications148
Fuel System (Pgm-Fi) Torque Values148
Fuel System (Pgm-Fi) Tools149
Fuel System (Pgm-Fi) Symptom Troubleshooting150
Fuel System (Pgm-Fi) Component Location151
Fuel System (Pgm-Fi) Diagram152
Pgm-Fi Connector Location153
Pgm-Fi Troubleshooting Information155
Pgm-Fi System Description155
Hds Pocket Tester Information156
Dtc Readout156
Mil Blink Pattern156
Mil Check156
Erasing Dtc157
Circuit Inspection157
Inspection At Pcm Connector157
Pgm-Fi Dtc Index158
Dtc Troubleshooting159
Dtc 1-1 (Map Sensor Low Voltage)159
Dtc 1-2 (Map Sensor High Voltage)160
Dtc 7-1 (Ect Sensor Low Voltage)161
Dtc 7-2 (Ect Sensor High Voltage)162
Dtc 8-1 (Tp Sensor Low Voltage)163
Dtc 8-2 (Tp Sensor High Voltage)165
Dtc 9-1 (Iat Sensor Low Voltage)166
Dtc 9-2 (Iat Sensor High Voltage)167
Dtc 11-1 (Vs Sensor)168
Dtc 12-1 (Fuel Injector)169
Dtc 29-1 (Iacv)170
Dtc 33-2 (Eeprom)172
Dtc 64-1 (Drive Power Low Voltage)172
Dtc 64-2 (Drive Power High Voltage)173
Mil Circuit Inspection174
Fuel Line Inspection175
Fuel Pressure Relieving175
Quick Connect Fitting Removal175
Quick Connect Fitting Installation177
Fuel Pressure Test179
Fuel Flow Inspection180
Fuel Pump Inspection180
Fuel Pump Removal181
Fuel Pump Installation181
Main Relay/Fuel Pump Relay Removal/Installation182
Relay Inspection182
Main Relay Circuit Inspection183
Fuel Pump Relay Circuit Inspection183
Power Input Line Inspection183
Relay Coil Ground Line Inspection183
Fuel Tank Removal/Installation184
Air Cleaner Housing Removal/Installation185
Intake Air Duct Removal/Installation186
Accelerator Pedal Removal/Installation186
Throttle Body Removal189
Throttle Body Installation190
Iacv Inspection192
Iacv Removal192
Iacv Installation193
Fuel Injector Replacement193
Tp Sensor/Map Sensor (Sensor Unit) Replacement195
Tp Sensor Reset Procedure196
Ect Sensor Replacement197
Vs Sensor Removal/Installation197
Pcm198
Power/Ground Line Inspection198
Power Ground Line198
Engine Idle Speed199
Idle Speed Inspection199
Cooling System Flow Pattern202
Cooling System Service Information203
Cooling System Troubleshooting203
Cooling System Torque Value203
Cooling System Testing204
Coolant (Hydrometer Test)204
Standard Coolant Concentration204
Radiator Cap/System Pressure Inspection205
Coolant Replacement Preparation205
Cooling System Replacement/Air Bleeding206
Thermostat Removal207
Thermostat Inspection207
Thermostat Installation208
Water Pump209
Mechanical Seal Inspection209
Water Pump Removal209
Water Pump Installation210
Cooling Fan Removal/Installation211
Cooling Fan Disassembly/Assembly212
Radiator Removal/Installation213
Radiator Reserve Tank Removal/Installation214
Engine Removal/Installation215
Engine Removal/Installation System Components216
Engine Removal/Installation Service Information217
Engine Removal218
Oil Cooler218
Engine Installation223
Cylinder Head/Valve/Camshaft231
Cylinder Head/Valve/Camshaft System Components232
Cylinder Head/Valve/Camshaft Service Information233
Cylinder Head/Valve/Camshaft Tools234
Cylinder Head/Valve/Camshaft Troubleshooting235
Cylinder Compression236
Cylinder Head Cover Removal/Disassembly236
Rocker Arm/Shaft238
Push Rod238
Cam Follower238
Cylinder Head Removal239
Cylinder Head Disassembly240
Cylinder Head Inspection240
Valve Spring241
Valve/Valve Guide241
Valve Guide Replacement242
Valve Seat Inspection/Refacing243
Camshaft Removal246
Camshaft Inspection247
Camshaft Installation247
Cylinder Head Assembly249
Cylinder Head Installation250
Cylinder Head Cover Assembly/Installation251
Cylinder/Piston255
Cylinder/Piston System Components256
Cylinder/Piston Service Information257
Cylinder/Piston Troubleshooting257
Cylinder/Piston Torque Values257
Cylinder/Piston Specifications257
Cylinder/Piston Removal258
Cylinder/Piston Inspection259
Piston/Piston Ring260
Connecting Rod261
Cam Chain Tensioner Lifter261
Cylinder Stud Bolt Replacement261
Cylinder/Piston Installation262
Piston Ring Installation262
Alternator/Starter Clutch265
Alternator/Starter Clutch System Components266
Alternator/Starter Clutch Service Information267
Alternator/Starter Clutch Specification267
Alternator/Starter Clutch Torque Values267
Alternator/Starter Clutch Tools267
Alternator/Starter Clutch Troubleshooting268
Alternator Stator/Starter Reduction Gears269
Alternator Cover Removal269
Alternator Cover Inspection270
Stator/Ckp Sensor Removal/Installation271
Bearing Replacement272
Alternator Cover Installation272
Flywheel/Starter Clutch Removal274
Starter Clutch Disassembly/Inspection275
Starter Clutch Assembly276
Sub-Transmission/Gearshift Linkage279
Sub-Transmission/Gearshift Linkage System Components280
Sub-Transmission/Gearshift Linkage Service Information281
Sub-Transmission/Gearshift Linkage Torque Values281
Sub-Transmission/Gearshift Linkage Tools281
Sub-Transmission/Gearshift Linkage Troubleshooting282
Rear Crankcase Cover Removal283
Rear Crankcase Cover Bearing Replacement284
Rear Crankcase Cover Installation285
Sub-Transmission Disassembly287
Sub-Transmission Inspection289
Reverse Idle Gear290
Shift Fork And Shaft290
Shift Drum290
Gearshift Spindle290
Gear Selector Lever Linkage Disassembly293
Gear Selector Lever Linkage Assembly294
Gear Selector Cable Adjustment294
Crankcase/Crankshaft/Balancer297
Crankcase/Crankshaft/Balancer System Components298
Crankcase/Crankshaft/Balancer Service Information299
Crankcase/Crankshaft/Balancer Tools299
Crankcase/Crankshaft/Balancer Troubleshooting301
Crankcase Separation302
Crankshaft Removal303
Crankshaft Inspection304
Crankshaft And Balancer Installation305
Crankcase Bearing Replacement306
Rear Crankcase306
Front Crankcase307
Crankcase Assembly308
Drivetrain System311
Drivetrain System Components312
Drivetrain System Service Information313
Drivetrain System Tools314
Drivetrain System Symptom Troubleshooting316
A/T Clutch Pc Solenoid Valve Operation Inspection316
Shift Solenoid Valve Operation Inspection317
Line Oil Pressure319
Shift Clutch Oil Pressure319
Hydraulic Circuit Troubleshooting Chart320
Drivetrain Component Location321
Drivetrain System Diagram322
Drivetrain Connector Location323
Drivetrain Troubleshooting Information325
Self-Diagnosis System325
Fail-Safe Function325
Drivetrain Dtc Index326
Troubleshooting326
Drivetrain Dtc Troubleshooting327
Dtc 4-1327
Dtc 4-3327
Dtc 4-2 (A/T Clutch Pc Solenoid Valve High Input)328
Dtc 15-1 (Shift Solenoid Valve)329
Dtc 15-2 (Shift Solenoid Valve)330
Dtc 16-1 (Shift Solenoid Valve B-Short)331
Dtc 16-2 (Shift Solenoid Valve B-Open)332
Dtc 31-1 (System Voltage Low)333
Dtc 32-1334
Dtc 41-1 (Gear Position Switch Circuit)334
Dtc 44-1 (Eot Sensor Low Voltage)336
Dtc 44-2 (Eot Sensor High Voltage)337
Shift Valve Body338
Emergency Valve Function338
Shift Valve Body Removal338
Shift Valve Body Disassembly/Inspection339
Shift And Orifice Control Valves343
Solenoid And Emergency Valves345
Front Crankcase Cover Removal347
Front Crankcase Cover Inspection348
Front Crankcase Cover Bearing Replacement349
Front Crankcase Cover Installation349
Torque Converter Removal352
Torque Converter Inspection353
Torque Converter Installation354
1St Shift Clutch Removal357
Mainshaft Disassembly357
Shift Clutch/Mainshaft Icountershaft357
Countershaft Disassembly358
Shift Clutch Disassembly358
Clutch Drum And Piston360
Clutch Disc And Plate360
Clutch Return Spring360
Shift Clutch Assembly361
Clutch Initial Clearance Check363
Countershaft Assembly364
Mainshaft Assembly365
1St Shift Clutch Installation366
Gear Position Switch Replacement367
Eot Sensor Replacement368
Front Wheel/Suspension369
Front Wheel/Suspension System Components370
Front Wheel/Suspension Service Information371
Front Wheel/Suspension Torque Values371
Front Wheel/Suspension Tools372
Front Wheel/Suspension Troubleshooting373
Front Wheel Removal374
Front Wheel Installation374
Tires Removal374
Tire Repair376
Tire Assembly377
Front Wheel Hub And Knuckle Removal378
Front Wheel Hub And Knuckle Inspection380
Brake Disc Replacement380
Ball Joint Replacement381
Front Wheel Hub And Knuckle Installation382
Front Suspension Arm Removal385
Front Suspension Arm Inspection386
Front Suspension Arm Ball Joint Replacement386
Front Suspension Arm Installation387
Front Shock Absorber Removal389
Front Shock Absorber Inspection389
Front Shock Absorber Installation389
Steering System Components392
Steering System Service Information393
Steering System Torque Values393
Steering System Tools393
Steering System Troubleshooting394
Steering Wheel Removal/Installation395
Steering Column And Shaft Removal395
Steering Column And Shaft Inspection396
Steering Column And Shaft Installation396
Tie-Rod Ball Joint Removal397
Tie-Rod Ball Joint Inspection398
Tie-Rod Ball Joint Installation399
Steering Gear Box Removal399
Steering Gear Box Disassembly403
Steering Gear Box Inspetion404
Steering Gear Box Assembly405
Steering Gear Box Installation409
Rear Wheel/Suspension System Components414
Rear Wheel/Suspension Service Information415
Rear Wheel/Suspension Specifications415
Rear Wheel/Suspension Torque Values415
Rear Wheel/Suspension Tools415
Rear Wheel/Suspension Troubleshooting416
Rear Wheel Removal417
Rear Wheel Installation417
Rear Wheel Hub/Knuckle Removal417
Rear Wheel Hub/Knuckle Inspection418
Rear Wheel Hub/Knuckle Brake Disc Replacement419
Rear Wheel Hub/Knuckle Bearing Replacement419
Rear Wheel Hub/Knuckle Installation420
Rear Suspension Arm Removal423
Upper Arm424
Stabilizer Arm And Link424
Rear Suspension Arm Inspection425
Rear Suspension Arm Installation425
Suspension Arm Fastener Tightening427
Rear Shock Absorber Removal428
Rear Shock Absorber Inspection428
Rear Shock Absorber Installation428
Brake System Components430
Brake System Service Information432
Brake System Torque Values432
Brake System Troubleshooting433
Brake System Tools433
Brake Fluid Replacement/Air Bleeding434
Brake Fluid Draining434
Brake Fluid Filling/Bleeding435
Brake Pad/Disc436
Front Brake Pad Replacement436
Rear Brake Pad Replacement437
Brake Disc Inspection438
Master Cylinder Disassembly439
Master Cylinder Inspection440
Master Cylinder Assembly440
Front Brake Caliper Disassembly443
Rear Brake Caliper Disassembly447
Rear Brake Caliper Assembly451
Brake Pedal Removal455
Brake Pedal Installation455
Brake Pedal Disassembly455
Brake Pedal Assembly456
Parking Brake Lever Removal/Installation457
Front Driving Mechanism System Components460
Front Driving Mechanism Service Information461
Front Driving Mechanism Specifications461
Front Driving Mechanism Tools462
Front Driving Mechanism Troubleshooting464
Front Drive Shaft Removal465
Front Drive Shaft Disassembly/Inspection465
Front Drive Shaft Assembly467
Front Drive Shaft Installation469
Front Final Drive Removal470
Front Final Drive Operation Check472
Front Propeller Shaft Disassembly/Inspection473
Front Propeller Shaft Assembly474
Front Final Clutch Disassembly/Inspection475
Pinion Joint Ball Bearing Replacement476
Clutch476
Pinion Joint Ball Assembly478
Front Differential Lock Clutch Disassembly/Inspection481
Half Shaft Bearing Replacement483
Front Final Gear Disassembly/Inspection486
Backlash Inspection486
Differential Removal487
Bearing Inspection488
Gear Tooth Contact Pattern Check488
Differential Inspection490
Ring Gear Removal490
Pinion Gear Removal490
Pinion Ball Bearing And Shim Replacement491
Pinion Joint Needle Bearing Replacement492
Case Bearing Replacement492
Pinion Needle Bearing493
Front Final Gear Assembly494
Pinion Gear Installation495
Ring Gear Installation495
Final Gear Case Assembly496
Front Final Drive Installation497
Drive Mode Selector Lever Linkage Removal500
Drive Mode Selector Lever Linkage Installation501
Drive Mode Selector Cable Adjustment502
Rear Driving Mechanism505
Rear Driving Mechanism System Components506
Rear Driving Mechanism Service Information507
Rear Driving Mechanism Specifications507
Rear Driving Mechanism Torque Values507
Rear Driving Mechanism Tools508
Rear Driving Mechanism Troubleshooting510
Rear Drive Shaft Removal511
Rear Drive Shaft Disassembly/Inspection511
Rear Drive Shaft Assembly513
Rear Final Drive Removal516
Rear Final Drive Inspection517
Propeller Shaft517
Universal Joint Disassembly/Assembly518
Operation Check518
Rear Differential Lock Clutch519
Rear Final Gear Disassembly/Inspection525
Pinion Gear Bearing And Shim Replacement530
Differential Bearing530
Rear Final Gear Assembly533
Rear Final Drive Installation536
Battery/Charging System539
Battery/Charging System Component Location540
Battery/Charging System Diagram540
Battery/Charging System Service Information541
Battery/Charging System Specifications Battery/Charging System Tools542
Battery/Charging System Troubleshooting543
Battery Removal/Installation544
Voltage Inspection544
Battery Testing544
Battery Charging544
Charging System Inspection545
Current Leakage Inspection545
Charging Voltage Inspection545
Alternator Charging Coil Inspection546
Regulator/Rectifier546
Wire Harness Inspection546
Ignition System547
Ignition System Component Location548
Ignition System Diagram548
Ignition System Service Information549
Ignition System Specifications549
Ignition System Torque Values549
Ignition System Tools549
Ignition System Troubleshooting550
Ignition System Inspection551
Peak Voltage Adaptor Connection551
Ignition Coil Primary Peak Voltage551
Ckp Sensor Peak Voltage552
Ignition Coil Removal/Installation553
Ignition Timing554
Electric Starter555
Electric Starter Component Location556
Electric Starter System Diagram556
Electric Starter Service Information557
Electric Starter Specification557
Electric Starter Troubleshooting558
Starter Motor Removal560
Starter Motor Disassembly/Inspection560
Starter Motor Assembly563
Starter Motor Installation565
Starter Relay Switch Operation Inspection566
Starter Relay Switch Circuit Inspection566
Ground Line566
Power Input Line566
Starter Relay Switch Function Inspection567
Diode Inspection567
Brake Inhibitor Relay Removal/Installation568
Brake Inhibitor Relay Inspection568
Brake Inhibitor Relay Circuit Inspection569
Lights/Meters/Switches571
Lights/Meters/Switches Component Location572
Indicators572
Ignition Switch572
Lights/Meters/Switches Service Information573
Lights/Meters/Switches Specifications573
Lights/Meters/Switches Torque Values573
Lights/Meters/Switches Tools573
Headlight Bulb Replacement574
Headlight Removal/Installation574
Brake/Taillight Replacement575
Indicators Bulb Replacement575
Accessory Socket Inspection576
Accessory Socket Replacement576
Ignition Switch Inspection577
Ignition Switch Replacement577
Lighting/Dimmer Switch Inspection578
Lighting/Dimmer Switch Replacement578
Engine Temperature Indicator System Inspection579
Cooling Fan Motor System Inspection581
Low Fuel Indicator System Inspection583
Foot Brake Switch Inspection586
Foot Brake Switch Replacement586
Parking Brake Switch Inspection587
Parking Brake Switch Replacement587
Wiring Diagram589
Engine Does Not Start Or Is Hard To Start592
Engine Lacks Power593
Poor Performance At Low And Idle Speed595
Poor Performance At High Speed596
Index597