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Honda Manuals
Motorcycle
2003 ST1300
Service manual
Table Of Contents - Honda 2003 ST1300 Service Manual
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Also See for 2003 ST1300
:
Setup instructions
(23 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
A Few Words About Safety
2
Service Information
2
Important Safety Precautions
2
Contents
3
Symbols
4
General Information
5
Service Rules
6
Model Identification
6
General Specifications
8
Lubrication System Specifications
10
Fuel System (Programmed Fuel Injection) Specifications
10
Cooling System Specifications
10
Cylinder Head/Valves Specifications
11
Clutch/Primary Shaft Specifications
11
Transmission/Final Output Shaft Specifications
12
Alternator/Starter Clutch Specifications
12
Crankshaft/Piston/Cylinder Specifications
12
Final Drive
13
Front Wheel/Suspension/Steering Specifications
13
Rear Wheel/Suspension Specifications
13
Hydraulic Brake Specifications
14
Battery/Charging System Specifications
14
Ignition System Specifications
14
Electric Starter Specifications
15
Lights/Meters/Switches Specifications
15
Standard Torque Values
16
Engine & Frame Torque Values
16
Tools
23
Lubrication & Seal Points Engine
25
Cable & Harness Routing
31
Brake Pipe Routing
52
Source Of Emissions
53
Crankcase Emission Control System
53
Exhaust Emission Control System (Secondary Air Supply System)
54
Evaporative Emission Control System
55
Noise Emission Control System
55
Emission Control Information Labels
56
Vacuum Hose Routing Diagram Label
56
Frame/Body Panels/Exhaust System
57
Body Panel Locations
58
Body Panel Removal Chart
59
Frame/Body Panels/Exhaust System Service Information
60
Frame/Body Panels/Exhaust System Troubleshooting
60
Frame/Body Panels/Exhaust System Torque Values
60
Seat
61
Trim Clips Removal
61
Trim Clips Installation
61
Saddlebag
62
Side Cover
62
Rear Cowl Grab Rail Center Cover
63
Rear Cowl Rear Grab Rail
63
Rear Fender A
64
Rear Fender B
65
Inner Lower Cowl
65
Lower Cowl Removal/Installation
66
Lower Cowl Disassembly/Assembly
66
Mirror Cover
67
Rearview Mirror
67
Middle Cowl
68
Engine Guard Cover
68
Inner Cowl
68
Middle Cowl Removal/Installation
69
Left Middle Cowl Disassembly/Assembly
69
Right Middle Cowl Disassembly/Assembly
70
Windscreen Removal
70
Windscreen Installation
71
Upper Cowl
72
Inner Screen Cowl
72
Meter Panel
73
Muffler
74
Exhaust Pipe
74
Seat Rail
75
Left Step Holder
75
Maintenance
77
Maintenance Service Information
78
Maintenance Specifications
78
Maintenance Torque Values
78
Maintenance Schedule
79
Fuel Line
80
Throttle Operation
81
Air Cleaner
82
Spark Plug Removal
82
Spark Plug Inspection
83
Reusing A Spark Plug
83
Replacing A Spark Plug
84
Valve Clearance Inspection
84
Valve Clearance Adjustment
86
Engine Oil Level Inspection
87
Engine Oil & Filter Change
88
Engine Idle Speed
90
Radiator Coolant
90
Cooling System
91
Secondary Air Supply System
92
Final Drive Oil Level Check
93
Final Drive Oil Change
93
Brake Fluid
94
Front Brake
94
Rear Brake
94
Front Brake Pads Wear
95
Rear Brake Pads Wear
95
Brake System Inspection
96
Brake Light Switch
97
Brake Lever Adjustment
97
Brake Pedal Height Adjustment
97
Headlight Aim
98
Clutch System/Clutch Fluid
98
Side Stand
99
Front Suspension Inspection
99
Rear Suspension Inspection
100
Rear Suspension Adjustment
100
Nuts, Bolts, Fasteners
101
Wheels/Tires
101
Rebound Damping Adjuster
101
Recommended Tire Pressure And Tire Size
101
Steering Head Bearings
102
Lubrication System
103
Lubrication System Diagram
104
Lubrication System Service Information
105
Lubrication System Torque Values
105
Lubrication System Troubleshooting
106
Oil Pressure Inspection
107
Oil Strainer/Pressure Relief Valve Removal
108
Oil Strainer/Pressure Relief Valve Inspection
109
Oil Strainer/Pressure Relief Valve Installation
109
Oil Pump Removal
111
Oil Pump Disassembly
111
Oil Pump Inspection
112
Oil Pump Assembly
113
Oil Pump Installation
114
Oil Cooler Removal
115
Oil Cooler Installation
115
Fuel System (Programmed Fuel Injection)
117
Component Location
118
Fuel System Service Information
119
Fuel System Specifications
119
Fuel System Troubleshooting
120
Fuel System Torque Values
120
System Location
121
Fuel System Diagram
122
Pgm-Fi (Programmed Fuel Injection) System
123
Self-Diagnostic Procedure
123
Self-Diagnosis Reset Procedure
124
Peak Voltage Inspection Procedure
125
Test Harness Connection
125
Test Harness Terminal Layout
126
Pgm-Fi Self-Diagnosis Malfunction Indicator Lamp (Mil) Failure Codes
127
Pgm-Fi Troubleshooting
130
Fuel Tank Drain
166
Fuel Line Inspection
167
Fuel Pressure Inspection
167
Fuel Flow Inspection
169
Fuel Pump Inspection
170
Fuel Pump Removal
170
Fuel Filter Replacement
171
Fuel Filter Installation
171
Fuel Cut-Off Relay Inspection
172
Upper Fuel Tank Removal
172
Lower Fuel Tank Removal
173
Lower Fuel Tank Installation
174
Upper Fuel Tank Installation
175
Air Cleaner Housing Removal
176
Air Cleaner Housing Installation
178
Throttle Body Removal
180
Throttle Body Vacuum Hose Routing
184
Injector Inspection
187
Injector Removal
187
Injector Installation
188
Pressure Regulator Removal/Installation
189
Se Thermal Valve Removal
190
Se Thermal Valve Installation
190
Starter Valve Disassembly
191
Starter Valve Assembly
192
Starter Valve Synchronization
194
Map Sensor Output Voltage Inspection
196
Map Sensor Removal/Installation
196
Iat Sensor Removal/Installation
197
Ect Sensor Removal/Installation
197
Cam Pulse Generator Removal/Installation
198
Tp Sensor Inspection
198
Bank Angle Sensor Inspection
200
Bank Angle Sensor Removal/Installation
201
Engine Stop Relay Inspection
201
Knock Sensor Removal/Installation
202
Ecm (Engine Control Module) Removal/Installation
202
Ecm (Engine Control Module) Power/Ground Line Inspection
203
Pair Solenoid Valve Removal/Installation
203
Pair Solenoid Valve Inspection
204
Evap Purge Control Solenoid Valve Removal
204
Evap Canister
205
Evap Purge Control Solenoid Valve Inspection
205
O2 Sensor Removal
206
System Flow Pattern
209
Cooling System Service Information
210
Cooling System Torque Values
210
Cooling System Troubleshooting
211
System Testing Coolant (Hydrometer Test)
212
Coolant Gravity Chart
212
Radiator Cap/System Pressure Inspection
213
Coolant Replacement
213
Thermostat Removal
215
Thermostat Inspection
217
Thermostat Installation
217
Radiator Removal
220
Radiator Disassembly
221
Radiator Assembly
222
Radiator Reserve Tank Removal/Installation
224
Water Pump
225
Mechanical Seal Inspection
225
Mechanical Seal Replacement
225
Engine Removal/Installation
228
Engine Removal
231
Engine Installation
235
Cylinder Head/Valves
242
Cylinder Head/Valves Component Location
243
Cylinder Head/Valves Service Information
244
Cylinder Head/Valves Torque Values
245
Valve Timing/Cylinder Number
245
Cylinder Head/Valves Troubleshooting
246
Cylinder Compression Test
247
Cylinder Head Cover Removal
247
Cylinder Head Cover Disassembly
248
Left Cylinder Camshaft Removal
249
Camshaft Inspection
252
Right Cylinder Camshaft Removal
252
Camshaft Holder
252
Camshaft Runout
253
Cam Lobe Height
253
Camshaft Oil Clearance
253
Cylinder Head Removal
254
Cylinder Head Disassembly
256
Cylinder Head Inspection
257
Valve Spring
258
Valve Lifter
258
Valve Lifter Bore
258
Cam Chain Tensioner/Cam Chain Guide
258
Valve Guide Replacement
259
Valve/Valve Guide
259
Valve Seat Inspection/Refacing
260
Valve Seat Refacing
261
Cylinder Head Assembly
264
Cylinder Head Installation
266
Camshaft Installation
268
When Both The Left And Right Cylinder Camshafts Are Removed
268
If The Left Cylinder Camshaft Only Is Removed
270
If The Right Cylinder Camshaft Only Is Removed
271
Cylinder Head Cover Assembly
272
Cylinder Head Cover Installation
273
Cam Chain Tensioner Lifter Removal
275
Cam Chain Tensioner Lifter Installation
275
Clutch/Primary Shaft
277
Clutch/Primary Shaft Component Location
278
Clutch/Primary Shaft Service Information
280
Clutch/Primary Shaft Torque Values
280
Clutch/Primary Shaft Troubleshooting
281
Clutch Fluid Replacement/Air Bleeding
282
Clutch Fluid Draining
282
Clutch Fluid Filling/Bleeding
282
Clutch Master Cylinder Removal
283
Clutch Master Cylinder Disassembly
284
Clutch Master Cylinder Inspection
285
Clutch Master Cylinder Assembly
286
Clutch Master Cylinder Installation
287
Clutch Slave Cylinder Removal
288
Clutch Slave Cylinder Disassembly
289
Clutch Slave Cylinder Inspection
289
Clutch Slave Cylinder Assembly
289
Front Crankcase Cover Removal
290
Clutch Slave Cylinder Installation
290
Clutch Removal
291
Clutch Inspection
293
Clutch Installation
296
Primary Drive Gear Removal
299
Primary Drive Gear Disassembly/Assembly
300
Primary Drive Gear Installation
300
Primary Damper Shaft Removal
301
Primary Damper Shaft Disassembly
302
Primary Damper Shaft Inspection
302
Primary Damper Shaft Assembly
304
Front Crankcase Cover Installation
306
Primary Damper Shaft Installation
306
Transmission/Final Output Shaft
308
Transmission/Final Output Shaft Component Location
309
Transmission/Final Output Shaft Service Information
310
Transmission/Final Output Shaft Torque Values
310
Transmission/Final Output Shaft Troubleshooting
311
Gearshift Pedal Removal
312
Gearshift Pedal Installation
312
Final Output Shaft Removal
313
Final Output Shaft Inspection
314
Final Output Shaft Installation
315
Transmission Removal
317
Transmission Disassembly
318
Transmission Inspection
319
Transmission Assembly
322
Transmission Installation
325
Alternator/Starter Clutch
327
Alternator/Starter Clutch Component Location
328
Alternator/Starter Clutch Service Information
329
Alternator/Starter Clutch Troubleshooting
329
Alternator/Starter Clutch Torque Values
329
Alternator Removal
330
Alternator Disassembly
331
Alternator Inspection
332
Rotor Shaft Bearing/Oil Seal
333
Rear Rotor Shaft Bearing Replacement
333
Alternator Driven Gear Removal
337
Damper Shaft Bearing Replacement
339
Damper Shaft Bearing Installation
341
Alternator Drive Gear/Starter Clutch Removal
344
Alternator Drive Gear/Starter Clutch Inspection
345
Alternator Drive Gear/Starter Clutch Disassembly
346
Alternator Drive Gear Replacement
347
Alternator Drive Gear Assembly
348
Crankcase/Balancer
351
Crankcase/Balancer Component Location
352
Crankcase/Balancer Service Information
353
Crankcase/Balancer Troubleshooting
353
Crankcase/Balancer Torque Values
353
Crankcase Separation
354
Balancer Removal
355
Balancer Disassembly
356
Balancer Inspection
357
Balancer Bearing Selection
357
Balancer Assembly
359
Balancer Installation
360
Backlash Adjustment
362
Crankcase Assembly
363
Crankshaft/Piston/Cylinder
366
Crankshaft/Piston/Cylinder Component Location
367
Crankshaft/Piston/Cylinder Service Information
368
Crankshaft/Piston/Cylinder Troubleshooting
368
Side Clearance Inspection
369
Crankshaft Removal
369
Crankshaft Inspection
370
Crankshaft Installation
370
Main Journal Bearing Inspection
371
Main Journal Bearing Oil Clearance Inspection
371
Bearing Installation
373
Main Journal Bearing Selection Table
373
Bearing Thickness
373
Crankpin Bearing Inspection
374
Crankpin Bearing Oil Clearance Inspection
374
Crankpin Bearing Selection
375
Piston/Cylinder
376
Crankpin Bearing Installation
376
Piston/Connecting Rod Removal
376
Piston Removal
377
Piston Disassembly
377
Piston Inspection
378
Connecting Rod Inspection
379
Connecting Rod Selection
379
Cylinder Inspection
379
Piston Assembly
380
Piston Installation
381
Final Drive Component Location
384
Final Drive Service Information
385
Final Drive Specifications
385
Final Drive Torque Values
385
Final Drive Troubleshooting
386
Final Drive Removal
387
Drive Shaft Removal/Disassembly
387
Universal Joint Removal
387
Final Drive Inspection
388
Backlash Inspection
388
Final Drive Gear
389
Ring Gear Removal/Shim Replacement
389
Ring Gear Installation
391
Gear Tooth Contact Pattern Check
394
Pinion Gear Removal/Shim Replacement
395
Pinion Gear Installation
397
Case Bearing Replacement
400
Breather Hole Cleaning
401
Gear Case Assembly
401
Final Drive Installation
403
Drive Shaft Assembly/Installation
403
Front Wheel/Suspension/Steering
404
Front Wheel/Suspension/Steering Component Location
405
Front Wheel/Suspension/Steering Service Information
406
Front Wheel/Suspension/Steering Torque Values
406
Front Wheel/Suspension/Steering Troubleshooting
407
Handlebars Removal
408
Handlebars Installation
411
Handlebar Weight Replacement
412
Front Wheel Removal
416
Front Wheel Inspection
417
Front Wheel Disassembly
418
Front Wheel Assembly
419
Front Wheel Installation
421
Fork Removal
423
Fork Disassembly
424
Fork Inspection
426
Fork Pipe/Slider/Damper
427
Fork Pipe Bushing
427
Brake Caliper Pivot Bearing Replacement
428
Fork Assembly
429
Fork Installation
433
Steering Stem Removal
434
Steering Stem Bearing Replacement
436
Steering Stem Installation
441
Steering Head Bearing Pre-Load
444
Rear Wheel/Suspension
445
Rear Wheel/Suspension Component Location
446
Rear Wheel/Suspension Service Information
447
Rear Wheel/Suspension Torque Values
447
Rear Wheel/Suspension Troubleshooting
448
Rear Wheel Removal
449
Rear Wheel Inspection
450
Rear Wheel Bearing
450
Rear Wheel Rim Runout
450
Rear Wheel Disassembly
451
Final Driven Flange Disassembly/Assembly
452
Rear Wheel Assembly
453
Rear Wheel Installation
455
Shock Absorber Removal
456
Shock Absorber Inspection
457
Shock Absorber Disposal Procedure
457
Shock Absorber Installation
458
Swingarm Removal
458
Shock Absorber Disassembly/Inspection
460
Shock Absorber Assembly
462
Hydraulic Brake
465
Hydraulic Brake Component Location
466
Hydraulic Brake Service Information
468
Hydraulic Brake Torque Values
469
Hydraulic Brake Troubleshooting
470
Brake Fluid Replacement/Air Bleeding
471
Brake Fluid Draining
471
Brake Fluid Filling/Air Bleeding
473
Front Brake Pad Replacement
478
Rear Brake Pad Replacement
479
Brake Disc Inspection
480
Front Master Cylinder Removal
481
Front Master Cylinder Disassembly
481
Front Master Cylinder Inspection
483
Front Master Cylinder Assembly
483
Front Master Cylinder Installation
485
Secondary Master Cylinder Removal
486
Secondary Master Cylinder Inspection
487
Secondary Master Cylinder Assembly
487
Rear Master Cylinder Removal
489
Rear Master Cylinder Disassembly
490
Rear Master Cylinder Inspection
491
Rear Master Cylinder Assembly
492
Rear Master Cylinder Installation
494
Proportional Control Valve
495
Delay Valve
495
Front Brake Left Caliper Removal
496
Front Brake Right Caliper Removal
496
Front Brake Caliper Disassembly
497
Front Brake Caliper Inspection
498
Front Brake Caliper Assembly
499
Right Caliper Installation
500
Left Caliper Installation
501
Rear Brake Caliper Removal
501
Rear Brake Caliper Disassembly
502
Rear Brake Caliper Inspection
503
Rear Brake Caliper Assembly
504
Rear Brake Caliper Installation
505
Brake Pedal Removal/Installation
505
Anti-Lock Brake System (Abs)
507
Anti-Lock Brake System (Abs) System Diagram
508
Anti-Lock Brake System (Abs) Service Information
509
Anti-Lock Brake System (Abs) Torque Values
509
Before Starting Troubleshooting
510
Summary Of Abs Pre-Start Self-Diagnosis System
510
Retrieval/Erasure Of Problem Code
511
Problem Code Indication Pattern
512
Before Troubleshooting
513
Symptom-To-System Chart
513
Diagnostic Troubleshooting Flow Chart
514
Anti-Lock Brake System (Abs) Troubleshooting
515
Wheel Speed Sensor
537
Air Gap Inspection
537
Air Gap Replacement
537
Abs Front Modulator Removal
539
Abs Front Modulator Installation
540
Abs Rear Modulator Removal
541
Abs Rear Modulator Installation
542
Abs Control Unit Removal/Installation
543
Battery/Charging System
544
Battery/Charging System System Diagram
545
Battery/Charging System Service Information
546
Battery/Charging System Troubleshooting
547
Battery Removal/Installation
548
Battery Voltage Inspection
548
Battery Testing
549
Battery Charging
550
Charging System Inspection
551
Current Leakage Inspection
551
Charging Voltage Inspection
551
Wire Harness Inspection
551
Rotor Coil
552
Battery Charging Line
552
Battery Voltage Line
552
Stator Coil
553
Ignition System
554
Ignition System Diagram
555
Ignition System Service Information
556
Ignition System Torque Values
556
Ignition System Troubleshooting
557
No Spark At All Plugs
557
Ignition System Inspection
558
Ignition Coil Primary Peak Voltage
558
Ignition Pulse Generator Peak Voltage
559
Ignition Coil
560
Ignition Pulse Generator Removal/Installation
560
Ignition Timing
561
Electric Starter
563
Electric Starter System Diagram
564
Electric Starter Service Information
565
Electric Starter Troubleshooting
566
Starter Motor Removal
568
Starter Motor Disassembly
568
Starter Motor Inspection
569
Starter Motor Assembly
571
Starter Motor Installation
573
Starter Relay Switch Operation Inspection
573
Ground Line Inspection
574
Starter Relay Voltage Inspection
574
Continuity Inspection
574
Diode Removal
575
Diode Inspection
575
Diode Installation
575
Lights/Meters/Switches
576
Lights/Meters/Switches System Location
577
Lights/Meters/Switches Service Information
578
Lights/Meters/Switches Torque Values
578
Lights/Meters/Switches Troubleshooting
579
Speed Sensor/Speedometer
579
Headlight Bulb Replacement
580
Headlight Removal/Installation
580
Headlight Aiming System Inspection
581
Aiming Motor Replacement
582
Headlight Aiming Knob
583
Position Light Bulb Replacement
584
Turn Signal Bulb Replacement
584
Tail/Brake Light Bulb Replacement
585
Combination Meter Removal/Installation
586
Combination Meter Disassembly/Assembly
586
Combination Meter Power/Ground Line Inspection
587
Speedometer/Vehicle Speed Sensor System Inspection
587
Vehicle Speed Sensor Inspection
588
Speedometer/Vehicle Speed Sensor Removal/Installation
588
Tachometer System Inspection
589
Coolant Temperature Gauge/Sensor System Inspection
590
Coolant Temperature Gauge/Sensor Removal
590
Coolant Temperature Gauge/Sensor Ect Sensor Unit Inspection
590
Coolant Temperature Gauge/Sensor Installation
591
Fuel Level System Malfunction Indicator
592
Fuel Level System Troubleshooting
593
Open Air Temperature Sensor Removal/Installation
595
Fan Motor Relay
596
Open Air Temperature Sensor Inspection
596
Oil Pressure Switch Inspection
596
Oil Pressure Switch Removal/Installation
597
Fuel Level Sensor Removal/Installation
598
Ignition Switch Inspection
598
Ignition Switch Removal/Installation
599
Handlebar Switches
600
Clutch Switch
601
Front Brake Light Switch
601
Rear Brake Light Switch
601
Neutral Switch Inspection
602
Neutral Switch Removal/Installation
602
Side Stand Switch Inspection
602
Side Stand Switch Removal
603
Side Stand Switch Installation
603
Horn
604
Headlight Relay
604
Main Stop Relay
605
Turn Signal/Hazard Relay Inspection
605
Windscreen Adjuster (Deluxe Type Only) System Inspection
606
Screen Adjusting Switch
608
Screen Main Relay
608
Screen Up/Down Relay
609
Wiring Diagrams
612
Standard
613
Deluxe
614
Technical Features
615
Engine Layout
616
Engine Illustration
616
Power Output
617
Alternator Drive Train
618
Dual Shaft Balancer
619
Dual Fuel Tank Layout
620
Travel Computer
620
Indication Of Possible Travel Distance And Fuel Remaining
621
Windscreen Height Adjuster Outline
622
Windscreen Height Adjuster Component Parts
622
Troubleshooting
624
Engine Does Not Start Or Is Hard To Start
625
Engine Lacks Power
625
Poor Performance At Low And Idle Speed
627
Poor Performance At High Speed
628
Poor Handling
629
Index
630
Previous
Page
1
...
632
633
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Table of Contents
Troubleshooting
Frame/Body Panels/Exhaust System Service Information
60
Lubrication System Troubleshooting
106
Fuel System Troubleshooting
120
PGM-FI Troubleshooting
130
Cooling System Troubleshooting
211
Cylinder Head/Valves Troubleshooting
246
Clutch/Primary Shaft Troubleshooting
281
Transmission/Final Output Shaft Troubleshooting
311
Alternator/Starter Clutch Service Information
329
Crankcase/Balancer Service Information
353
Crankshaft/Piston/Cylinder Service Information
368
Final Drive Troubleshooting
386
Front Wheel/Suspension/Steering Troubleshooting
407
Rear Wheel/Suspension Troubleshooting
448
Hydraulic Brake Troubleshooting
470
Before Starting Troubleshooting
510
Before Troubleshooting
513
Diagnostic Troubleshooting Flow Chart
514
Anti-Lock Brake System (ABS) Troubleshooting
515
Battery/Charging System Troubleshooting
547
Ignition System Troubleshooting
557
Electric Starter Troubleshooting
566
Lights/Meters/Switches Troubleshooting
579
Fuel Level System Troubleshooting
593
Troubleshooting
624
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2003 st1300a
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