Honda SXS700M2 Manuals

Manuals and User Guides for Honda SXS700M2. We have 1 Honda SXS700M2 manual available for free PDF download: Service Manual

Honda SXS700M2 Service Manual

Honda SXS700M2 Service Manual (514 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 61.15 MB

Table of Contents

A few Words about Safety
2
How to Use this Manual
3
Symbols
4
Table of Contents
5
General Information
7
Abbreviation
8
Model Identification
8
Service Rules
8
General Information
17
- Engine
  20
- Lubrication & Seal Points
  20
- Frame
  21
- Cable & Harness Routing
  23
- Lift and Support Points
  39
  - Noise Emission Control System
    39
  - Rebuilt Engine
    39
- Technical Features
  40
- Bed Tilt Prevention System (4 Person Type)
  40
- Bolted Frame Connections
  40
- Drive Shaft Boots with Low-Profile Boot Bands
  40
2. Frame/Body Panels/Exhaust System
41
Maintenance
73
- Maintenance Minder Indicator
  74
- Service Information
  74
- Maintenance Schedule
  75
- Fuel Line
  76
- Throttle Operation
  76
- Air Cleaner
  77
- Air Cleaner Housing Drain Tube
  78
- Battery
  79
- Spark Plug
  79
- Valve Clearance
  80
- Engine Oil
  81
  - Level Check
    81
  - Oil Change
    82
- COOLING System
  83
  - Oil Filter Replacement
    83
  - Radiator Coolant
    83
  - Recommended Antifreeze
    83
- Drive Shaft Boots
  84
- Inspection
  84
- Final Drive Oil
  85
  - Front Final Gear Case
    85
  - Rear Final Gear Case
    85
- Brake Fluid
  86
- Brake Light Switch
  87
- Brake Pads Wear
  87
- Brake Pedal Height
  88
- Brake System
  88
  - Hydraulic Brake
    88
  - Parking Brake
    89
- Underbody
  89
- Spark Arrester
  90
- Suspension
  90
- Exhaust System
  91
- Tie-Rod and Joint Boot
  91
  - Wheels/Tires
    91
  - Gear Box Boot and Operation Check
    92
  - Rotational Play Check
    92
- STEERING System
  92
  - Rack Guide Adjustment
    93
  - Turning Load Check
    93
  - Front Toe Inspection
    94
  - Wheel Alignment
    94
- Side Net
  95
- Turning Radius Inspection
  95
- Chassis Lubrication Points
  96
PGM-FI System
97
- Service Information
  98
- Symptom Troubleshooting
  99
- Component Location
  100
- PGM-FI System Diagram
  101
- PGM-FI Troubleshooting Information
  102
  - System Description
    102
  - DTC Readout
    103
  - MCS Information
    103
  - Circuit Inspection
    104
  - Erasing DTC
    104
  - Inspection at PCM Connector
    104
- PGM-FI DTC Index
  105
- DTC 1-1 (Map Sensor Low Voltage)
  106
- Pgm -Fi Dtc Troubleshooting
  106
- 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 Inspection
    121
  - TP Sensor/Map Sensor (Sensor Unit)
    121
  - TP Sensor Reset Procedure
    122
- ECT Sensor
  123
- IAT Sensor
  123
- VS Sensor
  123
- Pcm
  124
- Power Input Line
  124
- Engine Idle Speed
  125
- Power/Ground Line Inspection
  124
- Idle Speed Inspection
  125
Ignition System
127
- Component Location
  128
- System Diagram
  128
  - Ignition Coil Primary Peak Voltage
    131
  - Ignition System Inspection
    131
  - Peak Voltage Adaptor Connection
    131
  - CKP Sensor Peak Voltage
    132
- Ignition Coil
  133
- Ignition Timing
  134
- Electric Starter
  135
- Component Location
  136
- Starter Motor
  136
- System Diagram
  136
  - Disassembly
    138
  - Starter Motor
    138
  - Assembly
    140
  - Operation Inspection
    142
- Starter Relay Switch
  142
  - Function Inspection
    143
  - Ground Line
    143
- Brake Inhibitor Relay
  144
Diode
143
- Relay Inspection
  144
- Fuel System
  147
- System Components
  148
- Service Information
  150
- Fuel Line Inspection
  151
  - Fuel Pressure Relieving
    151
  - Quick Connect Fitting Removal
    151
  - Quick Connect Fitting Installation
    152
  - Fuel Pressure Increasing
    153
  - Fuel Flow Inspection
    154
  - Fuel Pressure Test
    154
- Fuel Pump
  155
  - Disassembly/Assembly
    156
  - Installation
    158
  - Main Relay Circuit Inspection
    159
  - Main Relay/Fuel Pump Relay
    159
  - Fuel Pump Relay Circuit Inspection
    160
  - Fuel Tank
    161
- Air Cleaner Housing
  162
- Accelerator Pedal
  163
- Intake Air Duct
  163
- Throttle Body
  165
- Iacv
  169
- Fuel Injector
  170
Lubrication System
173
- Lubrication System Diagram
  174
- Oil Pressure Check
  176
- Oil Pump
  176
- Oil Cooler
  182
- Cooling System
  185
- System Flow Pattern
  186
- Service Information
  187
- Troubleshooting
  187
  - Coolant (Hydrometer Test)
    188
  - System Testing
    188
  - Coolant Replacement
    189
  - Preparation
    189
  - Radiator Cap/System Pressure Inspection
    189
  - Replacement/Air Bleeding
    190
- Thermostat
  191
- Mechanical Seal Inspection
  192
- Water Pump
  192
- Cooling Fan/Shroud
  194
- Radiator
  196
- Radiator Reserve Tank
  197
- Cylinder Head/Valve/Camshaft
  199
- Cylinder Compression
  203
- Cylinder Head Cover Removal/Disassembly
  203
- Cam Follower
  205
- Push Rod
  205
- Rocker Arm/Shaft
  205
- Cylinder Head Removal
  206
- Cylinder Head Disassembly
  207
- Cylinder Head Inspection
  207
- Valve Spring
  208
- Valve/Valve Guide
  208
- Valve Guide Replacement
  209
- Valve Seat Inspection/Refacing
  209
- Valve Seat Refacing
  210
- Camshaft
  211
- Cylinder Head Assembly
  214
- Cylinder Head Installation
  215
- Cylinder Head Cover Assembly/Installation
  216
Shaft
216
- Cam Chain Tensioner Lifter
  219
- Cylinder/Piston
  221
- System Components
  222
- Cylinder/Piston Removal
  224
- Cylinder/Piston Inspection
  225
  - Piston Removal
    225
  - Piston/Piston Ring
    226
  - Connecting Rod
    227
  - Cylinder Stud Bolt Replacement
    227
- Cylinder/Piston Installation
  228
- Piston Ring Installation
  228
- Cylinder Installation
  229
- Alternator/Starter Clutch
  231
Alternator/Starter Clutch
233
- Alternator Cover Removal
  235
- Alternator Stator/Starter Reduction Gears
  235
- Stator/Ckp Sensor Removal/Installation
  237
- Alternator Cover Installation
  238
- Bearing Replacement
  238
- Flywheel/Starter Clutch
  240
- Starter Clutch Disassembly/Inspection
  241
- Starter Clutch Assembly
  242
13. Sub-Transmission/Gearshift Linkage
245
- System Components
  246
- Service Information
  247
- Troubleshooting
  248
- Rear Crankcase Cover
  249
  - Output Shaft Bearing
    250
  - Countershaft Bearing
    251
- Sub-Transmission
  253
  - Countershaft
    255
  - Output Shaft
    255
  - Gearshift Spindle
    256
- Gear Selector Lever Linkage
  260
- Reverse Idle Gear
  256
- Shift Drum
  256
- Shift Fork and Shaft
  256
- Gear Selector Cable Adjustment
  261
- Crankcase/Crankshaft/Balancer
  263
- Crankcase Separation
  267
- Crankshaft
  268
- Crankshaft and Balancer Installation
  270
- Crankcase Bearing Replacement
  271
- Rear Crankcase
  271
- Front Crankcase
  272
- Crankcase Assembly
  273
- Engine Removal/Installation
  277
- Engine Removal
  280
Engine Removal/Installation
282
Engine Installation
284
16. Drivetrain System
289
- System Components
  290
- Service Information
  291
- A/T Clutch PC Solenoid Valve Operation Inspection
  293
- Symptom Troubleshooting
  293
  - Shift Solenoid Valve Operation Inspection
    294
  - Line Oil Pressure
    295
  - Shift Clutch Oil Pressure
    296
  - Hydraulic Circuit Troubleshooting Chart
    297
  - Drivetrain System Diagram
    299
- Drivetrain Troubleshooting Information
  300
  - Fail-Safe Function
    300
  - Self-Diagnosis System
    300
- Drivetrain DTC Index
  301
- Shift Valve Body
  313
  - Disassembly/Inspection
    314
  - Solenoid and Emergency Valves
    314
  - Orifice Control and Shift Valves
    316
  - Shift and Orifice Control Valves
    318
  - Front Crankcase Cover
    322
- Torque Converter
  328
  - Torque Converter Installation
    330
  - 1St Shift Clutch Removal
    332
  - Mainshaft Disassembly
    332
  - Shift Clutch/Mainshaft/Countershaft
    332
  - Countershaft Disassembly
    333
  - Shift Clutch Disassembly
    333
  - Mainshaft/Countershaft
    334
  - Clutch Disc and Plate
    335
  - Clutch Drum and Piston
    335
  - Clutch Return Spring
    335
  - Shift Clutch Assembly
    336
  - Clutch Initial Clearance Check
    338
  - Countershaft Assembly
    339
  - 1 St Shift Clutch Installation
    341
- Gear Position Switch
  342
- EOT Sensor
  343
- Mains Haft Assembly
  341
- Steering System
  345
- Steering Column and Shaft
  348
- Steering Wheel
  348
- Tie-Rod Ball Joint
  351
- Steering Gear Box
  353
- Drive Shaft/Final Gear
  363
- Front System Components
  364
- Rear System Components
  365
- Front Drive Shaft Removal
  370
- Rear Drive Shaft Removal
  370
- Front Drive Shaft Installation
  375
- Rear Drive Shaft Installation
  375
- Front Final Drive Removal
  376
- Operation Check
  378
- Front Propeller Shaft
  379
- Front Final Clutch
  381
- Pinion Joint Ball Bearing Replacement
  382
- Differential Lock Clutch
  387
- Half Shaft Bearing Replacement
  389
- Backlash Inspection
  392
- Front Final Gear Disassembly/Inspection
  392
- Differential Removal
  393
- Gear Tooth Contact Pattern Check
  394
- Differential Inspection
  396
- Pinion Gear Removal
  396
- Ring Gear Removal
  396
- Differential Bearing
  398
- Front Final Gear Case Bearing Replacement
  398
- Pinion Joint Needle Bearing Replacement
  398
- Pinion Needle Bearing
  399
- Front Final Gear Assembly
  401
- Pinion Gear Installation
  401
- Ring Gear Installation
  402
- Final Gear Case Assembly
  403
- Front Final Drive Installation
  404
- Rear Final Drive Removal
  407
- Propeller Shaft
  409
- Universal Joint
  409
- Universal Joint Disassembly/Assembly
  410
- Rear Final Drive Disassembly/Inspection
  411
- Final Gear Case Disassembly
  412
- Pinion Gear Bearing/Shim Replacement
  416
- Rear Final Drive Gear Case Bearing Replacement
  417
- Ring Gear Bearing
  417
- Rear Final Drive Assembly
  419
- Ring Gear Clearance Inspection
  421
Drive Shaft/Final Gear
423
- Rear Final Drive Installation
  423
- Drive Mode Selector Lever Linkage
  425
- Drive Mode Selector Cable Adjustment
  427
- Wheel/Suspension
  431
Wheel/Suspension
432
- System Components
  432
- Service Information
  434
- Troubleshooting
  435
- Tires
  436
- Wheels
  436
  - Tire Repair
    438
  - Recommended Tire Pressure Front
    439
- Front Wheel Hub/Knuckle
  440
- Brake Disc Replacement
  442
- Front Suspension Arm
  445
  - Ball Joint Replacement
    447
  - Upper Arm
    447
  - Lower Arm
    448
- Front Shock Absorber
  450
- Rear Wheel Hub/Knuckle
  451
- Rear Suspension Arm
  453
  - Stabilizer Arm and Link
    453
  - Suspension Arm Fastener Tightening
    456
- Rear Shock Absorber
  457
20. Brake System
459
- System Components
  460
- Service Information
  462
- Troubleshooting
  463
- Brake Fluid Draining
  464
- Brake Fluid Replacement/Air Bleeding
  464
- Brake Fluid Filling/Bleeding
  465
- Brake Pad/Disc
  466
  - Front Brake Pad Replacement
    466
  - Rear Brake Pad Replacement
    467
  - Brake Disc Inspection
    468
- Master Cylinder
  470
- Front Brake Caliper
  474
- Rear Brake Caliper
  478
- Brake Pedal
  484
- Parking Brake Lever
  485
  - Battery/Charging System
    487
  - Battery Charging
    489
  - Battery Testing
    489
  - Voltage Inspection
    490
  - Charging System Inspection
    491
  - Charging Voltage Inspection
    491
  - Current Leakage Inspection
    491
  - Alternator Charging Coil
    492
  - Regulator/Rectifier
    492
  - Wire Harness Inspection
    492
  - Lights/Meters/Switches
    493
- Component Location
  494
- Service Information
  494
  - Bulb Removal/Installation
    495
  - Headlight
    495
  - Brake/Taillight
    496
- Combination Meter
  496
  - Digital Clock Adjustment
    497
  - Serial Communication Line
    498
  - Speedometer
    499
- Accessory Socket
  500
- Ignition Switch
  501
- Headlight Relay
  502
- Headlight Switch
  502
- Headlight Relay Circuit Inspection
  503
- Cooling Fan Motor
  504
  - Fuel Level Sensor Inspection
    506
  - Fuel Meter Inspection
    506
- Brake Light Switch
  507
- Fuel Level Sensor Removal/Installation
  507
- Parking Brake Switch
  508
L=~~~~~~~============================= WIRING DIAGRAM
509
Index
512

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