Table Of Contents - Honda SXS700M4 Service Manual

Table of Contents

A Few Words About Safety2
How To Use This Manual3
Symbols4
Table Of Contents5
General Information7
Service Rules8
Abbreviation8
Model Identification8
Type Code9
Serial Numbers/Labels9
Specifications10
Pgm-Fi System Specifications11
Ignition System Specifications11
Electric Starter Specifications11
Fuel System Specifications11
Lubrication System Specifications12
Cooling System Specifications12
Cylinder Head/Valve/Camshaft Specifications12
Cylinder/Piston Specifications13
Alternator/Starter Clutch Specifications13
Drivetrain System Specifications13
Steering System Specifications13
Drive Shaft/Final Gear Specifications14
Wheel/Suspension Specifications14
Brake System Specifications14
Battery/Charging System Specifications14
Lights/Meters/Switches Specifications15
Standard Torque Values15
Engine & Frame Torque Values15
Lubrication & Seal Points20
Engine20
Frame21
Cable & Harness Routing23
Source Of Emissions38
Exhaust Emission Control System38
Crankcase Emission Control System38
Servicing The Honda38
Noise Emission Control System39
Fuel Permeation Emission Control System39
Rebuilt Engine39
Lift And Support Points39
Technical Features40
Bolted Frame Connections40
Drive Shaft Boots With Low-Profile Boot Bands40
Bed Tilt Prevention System (4 Person Type)40
2. Frame/Body Panels/Exhaust System41
Service Information42
Tool42
Troubleshooting42
Body Panel Locations43
Front Seat44
Seat Cushion Removal/Installation44
Backrest Removal/Installation44
Headrest Removal/Installation45
Seat Frame Removal/Installation45
Rear Seat (4 Person Type Only)46
Seat Removal/Installation46
Seat Damper Removal/Installation46
Seat Disassembly/Assembly47
Rear Center Cover (4 Person Type Only)47
Removal/Installation47
Right Middle Fender Removal/Installation48
Left Middle Fender Removal/Installation48
Right Seat Bottom Cover Removal/Installation48
Left Seat Bottom Cover Removal/Installation49
Rear Step (4 Person Type Only)49
Mud Protector (2 Person Type Only)49
Rear Foot Well (4 Person Type Only)50
Left Rear Foot Well Removal/Installation50
Right Rear Foot Well Removal/Installation50
Rear Side Cover50
Front Side Cover51
Floor Panel51
Front Hood52
Front Grille52
Front Heat Guard52
Front Fender53
Front Door Panel Removal/Installation53
Rear Door Panel Removal/Installation (4 Person Type Only)54
Door Hinge Removal/Installation54
Door Handle And Latch Removal/Installation54
Rear Seat Latch Cover Removal/Installation (4 Person Type Only)55
Rear Seat Latch Removal/Installation (4 Person Type Only)55
Instrument Panel56
Front Floor Cover57
Front Bumper57
Maintenance Lid58
Cargo Bed58
Bed Damper Removal/Installation58
Cargo Bed Removal/Installation58
Bed Side Cover Removal/Installation59
Rear Step Guard Removal/Installation (4 Person Type Only)59
Bed Center Cover Removal/Installation (4 Person Type Only)60
Bed Front Panel Removal/Installation60
Bed Top Cover Removal/Installation61
Bed Under Cover Removal/Installation62
Bed Release Lever Removal/Installation62
Tailgate Removal/Installation63
Front Side Net Removal/Installation64
Rear Side Net Removal/Installation (4 Person Type Only)64
Occupant Protective Structure (Ops)65
Front Ops Removal/Installation65
Upper Middle Ops Removal/Installation65
Rear Upper Ops Removal/Installation (4 Person Type Only)66
Rear Side Ops Removal/Installation (4 Person Type Only)66
Rear Lower Ops Removal/Installation (4 Person Type Only)66
Seat Belt Instructions67
Front Seat Belt/Retractor67
Rear Seat Belt/Retractor Person Type Only)68
Front Buckle68
Rear Buckle68
Front Under Guard Removal/Installation69
Middle Under Guard Removal/Installation69
Rear Under Guard Removal/Installation69
Exhaust System Removal/Installation70
Exhaust Pipe Disassembly/Assembly71
Muffler Disassembly/Assembly71
Maintenance73
Maintenance Minder Indicator74
Maintenance Schedule75
Fuel Line76
Throttle Operation76
Air Cleaner77
Air Cleaner Housing Drain Tube78
Spark Plug79
Battery79
Valve Clearance80
Engine Oil81
Level Check81
Oil Change82
Oil Filter Replacement83
Radiator Coolant83
Recommended Antifreeze83
Cooling System83
Inspection84
Drive Shaft Boots84
Final Drive Oil85
Front Final Gear Case85
Rear Final Gear Case85
Brake Fluid86
Brake Pads Wear87
Brake Light Switch87
Hydraulic Brake88
Brake Pedal Height88
Brake System88
Parking Brake89
Underbody89
Suspension90
Spark Arrester90
Exhaust System91
Wheels/Tires91
Tie-Rod And Joint Boot91
Gear Box Boot And Operation Check92
Rotational Play Check92
Steering System92
Turning Load Check93
Rack Guide Adjustment93
Wheel Alignment94
Front Toe Inspection94
Turning Radius Inspection95
Side Net95
Chassis Lubrication Points96
Pgm-Fi System97
Symptom Troubleshooting99
Component Location100
Pgm-Fi System Diagram101
Pgm-Fi Troubleshooting Information102
System Description102
Mcs Information103
Dtc Readout103
Erasing Dtc104
Circuit Inspection104
Inspection At Pcm Connector104
Pgm-Fi Dtc Index105
Dtc 1-1 (Map Sensor Low Voltage)106
Pgm -Fi Dtc Troubleshooting106
Dtc 1- (Map Sensor High Voltage)107
Otc 7-1 (Ect Sensor Low Voltage)108
Otc 7-2 (Ect Sensor High Voltage)109
Dtc 8-1 (Tp Sensor Low Voltage)110
Tp Sensor/Map Sensor (Sensor Unit)110
Dtc 8-2 (Tp Sensor High Voltage)112
Dtc 9-1 (Iat Sensor Low Voltage)113
Dtc 9-2 (Iat Sensor High Voltage)114
Dtc 11 -1 (Vs Sensor)115
Dtc 12-1 (Fuel Injector)116
Dtc 29-1 (Iacv)117
Dtc 33-2 (Eeprom)119
Dtc 64-1 (Drive Power Low Voltage)119
Dtc 64-2 (Drive Power High Voltage)120
Mil Circuit Inspection121
Tp Sensor Reset Procedure122
Ect Sensor123
Iat Sensor123
Vs Sensor123
Pcm124
Power/Ground Line Inspection124
Power Input Line124
Engine Idle Speed125
Idle Speed Inspection125
Ignition System127
System Diagram128
Ignition System Inspection131
Peak Voltage Adaptor Connection131
Ignition Coil Primary Peak Voltage131
Ckp Sensor Peak Voltage132
Ignition Coil133
Ignition Timing134
Electric Starter135
Starter Motor136
Disassembly138
Assembly140
Starter Relay Switch142
Operation Inspection142
Function Inspection143
Diode143
Ground Line143
Brake Inhibitor Relay144
Relay Inspection144
Fuel System147
System Components148
Fuel Line Inspection151
Fuel Pressure Relieving151
Quick Connect Fitting Removal151
Quick Connect Fitting Installation152
Fuel Pressure Increasing153
Fuel Pressure Test154
Fuel Flow Inspection154
Fuel Pump155
Disassembly/Assembly156
Installation158
Main Relay/Fuel Pump Relay159
Main Relay Circuit Inspection159
Fuel Pump Relay Circuit Inspection160
Fuel Tank161
Air Cleaner Housing162
Intake Air Duct163
Accelerator Pedal163
Throttle Body165
Iacv169
Fuel Injector170
Lubrication System173
Lubrication System Diagram174
Oil Pressure Check176
Oil Pump176
Oil Cooler182
System Flow Pattern186
System Testing188
Coolant (Hydrometer Test)188
Radiator Cap/System Pressure Inspection189
Coolant Replacement189
Preparation189
Replacement/Air Bleeding190
Thermostat191
Water Pump192
Mechanical Seal Inspection192
Cooling Fan/Shroud194
Radiator196
Radiator Reserve Tank197
Cylinder Head/Valve/Camshaft199
Cylinder Compression203
Cylinder Head Cover Removal/Disassembly203
Rocker Arm/Shaft205
Push Rod205
Cam Follower205
Cylinder Head Removal206
Cylinder Head Disassembly207
Cylinder Head Inspection207
Valve Spring208
Valve/Valve Guide208
Valve Guide Replacement209
Valve Seat Inspection/Refacing209
Valve Seat Refacing210
Camshaft211
Cylinder Head Assembly214
Cylinder Head Installation215
Cylinder Head Cover Assembly/Installation216
Shaft216
Cam Chain Tensioner Lifter219
Cylinder/Piston221
Cylinder/Piston Removal224
Piston Removal225
Cylinder/Piston Inspection225
Piston/Piston Ring226
Connecting Rod227
Cylinder Stud Bolt Replacement227
Cylinder/Piston Installation228
Piston Ring Installation228
Cylinder Installation229
Alternator/Starter Clutch231
Alternator Stator/Starter Reduction Gears235
Alternator Cover Removal235
Stator/Ckp Sensor Removal/Installation237
Bearing Replacement238
Alternator Cover Installation238
Flywheel/Starter Clutch240
Starter Clutch Disassembly/Inspection241
Starter Clutch Assembly242
13. Sub-Transmission/Gearshift Linkage245
Rear Crankcase Cover249
Output Shaft Bearing250
Countershaft Bearing251
Sub-Transmission253
Countershaft255
Output Shaft255
Reverse Idle Gear256
Shift Fork And Shaft256
Shift Drum256
Gearshift Spindle256
Gear Selector Lever Linkage260
Gear Selector Cable Adjustment261
Crankcase/Crankshaft/Balancer263
Crankcase Separation267
Crankshaft268
Crankshaft And Balancer Installation270
Crankcase Bearing Replacement271
Rear Crankcase271
Front Crankcase272
Crankcase Assembly273
Engine Removal/Installation277
Engine Removal280
Engine Installation284
16. Drivetrain System289
A/T Clutch Pc Solenoid Valve Operation Inspection293
Shift Solenoid Valve Operation Inspection294
Line Oil Pressure295
Shift Clutch Oil Pressure296
Hydraulic Circuit Troubleshooting Chart297
Drivetrain System Diagram299
Drivetrain Troubleshooting Information300
Self-Diagnosis System300
Fail-Safe Function300
Drivetrain Dtc Index301
Drivetrain Dtc Troubleshooting302
Dtc 4-1, Dtc 4-3302
Dtc 4-2 (A/T Clutch Pc Solenoid Valve High Input)303
Dtc 15·1 (Shift Solenoid Valve A-Short)304
Dtc 15-2 (Shift Solenoid Valve A-Open)305
Dtc 16-1 (Shift Solenoid Valve B-Short)306
Dtc 16-2 (Shift Solenoid Valve B-Open)307
Dtc 31-1 (System Voltage Low)308
Dtc 32-1 (Fail Safe Relay Circuit)309
Dtc 41 -1 (Gear Position Switch Circuit)309
Dtc 44-1 (Eot Sensor Low Voltage)311
Dtc 44-2 (Eot Sensor High Voltage)312
Shift Valve Body313
Emergency Valve Function313
Disassembly/Inspection314
Solenoid And Emergency Valves314
Orifice Control And Shift Valves316
Shift And Orifice Control Valves318
Front Crankcase Cover322
Torque Converter328
Torque Converter Installation330
Shift Clutch/Mainshaft/Countershaft332
1St Shift Clutch Removal332
Mainshaft Disassembly332
Countershaft Disassembly333
Shift Clutch Disassembly333
Mainshaft/Countershaft334
Clutch Drum And Piston335
Clutch Disc And Plate335
Clutch Return Spring335
Shift Clutch Assembly336
Clutch Initial Clearance Check338
Countershaft Assembly339
Mains Haft Assembly341
1 St Shift Clutch Installation341
Gear Position Switch342
Eot Sensor343
Steering Wheel348
Steering Column And Shaft348
Tie-Rod Ball Joint351
Steering Gear Box353
Drive Shaft/Final Gear363
Front System Components364
Rear System Components365
Front Drive Shaft Removal370
Rear Drive Shaft Removal370
Front Drive Shaft Installation375
Rear Drive Shaft Installation375
Front Final Drive Removal376
Operation Check378
Front Propeller Shaft379
Front Final Clutch381
Pinion Joint Ball Bearing Replacement382
Differential Lock Clutch387
Half Shaft Bearing Replacement389
Front Final Gear Disassembly/Inspection392
Backlash Inspection392
Differential Removal393
Gear Tooth Contact Pattern Check394
Differential Inspection396
Ring Gear Removal396
Pinion Gear Removal396
Pinion Joint Needle Bearing Replacement398
Front Final Gear Case Bearing Replacement398
Differential Bearing398
Pinion Needle Bearing399
Front Final Gear Assembly401
Pinion Gear Installation401
Ring Gear Installation402
Final Gear Case Assembly403
Front Final Drive Installation404
Rear Final Drive Removal407
Propeller Shaft409
Universal Joint409
Universal Joint Disassembly/Assembly410
Rear Final Drive Disassembly/Inspection411
Final Gear Case Disassembly412
Pinion Gear Bearing/Shim Replacement416
Rear Final Drive Gear Case Bearing Replacement417
Ring Gear Bearing417
Rear Final Drive Assembly419
Ring Gear Clearance Inspection421
Rear Final Drive Installation423
Drive Mode Selector Lever Linkage425
Drive Mode Selector Cable Adjustment427
Wheel/Suspension431
Wheels436
Tires436
Tire Repair438
Recommended Tire Pressure Front439
Front Wheel Hub/Knuckle440
Brake Disc Replacement442
Front Suspension Arm445
Ball Joint Replacement447
Upper Arm447
Lower Arm448
Front Shock Absorber450
Rear Wheel Hub/Knuckle451
Rear Suspension Arm453
Stabilizer Arm And Link453
Suspension Arm Fastener Tightening456
Rear Shock Absorber457
20. Brake System459
Brake Fluid Replacement/Air Bleeding464
Brake Fluid Draining464
Brake Fluid Filling/Bleeding465
Brake Pad/Disc466
Front Brake Pad Replacement466
Rear Brake Pad Replacement467
Brake Disc Inspection468
Master Cylinder470
Front Brake Caliper474
Rear Brake Caliper478
Brake Pedal484
Parking Brake Lever485
Battery/Charging System487
Battery Charging489
Battery Testing489
Voltage Inspection490
Charging System Inspection491
Current Leakage Inspection491
Charging Voltage Inspection491
Alternator Charging Coil492
Regulator/Rectifier492
Wire Harness Inspection492
Lights/Meters/Switches493
Headlight495
Bulb Removal/Installation495
Brake/Taillight496
Combination Meter496
Digital Clock Adjustment497
Serial Communication Line498
Speedometer499
Accessory Socket500
Ignition Switch501
Headlight Switch502
Headlight Relay502
Headlight Relay Circuit Inspection503
Cooling Fan Motor504
Fuel Meter Inspection506
Fuel Level Sensor Inspection506
Fuel Level Sensor Removal/Installation507
Parking Brake Switch508
L=~~~~~~~============================= Wiring Diagram509
Index512