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Table of Contents

   Summary of Contents for Honda NSA700A DN-1 2009

  • Page 1 2 0 0 9...
  • Page 2 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.
  • Page 3: How To Use This Manual

    THIS PUBLICATION ARE BASED ON THE LAT­ EST PRODUCT INFORMATION AVAILABLE AT WIRING DIAGRAMS THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT TROUBLESHOOTING NOTICE AND WITHOUT INCURRING ANY OBLI­...
  • Page 4 Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 5: Table Of Contents

    1. GENERAL INFORMATION SERVICE R ULES..........1-2 FINAL DRIVE SPECIFICATIO NS....1-10 FRONT W H EEL/SU SPEN SIO N / MODEL IDENTIFICATION......1-3 STEERING SPEC IFICA TIO N S....1-10 GENERAL SPECIFICATIONS......1-6 REAR W HEEL/SUSPENSION SPEC IFICA TIO N S.........1-10 LUBRICATION SYSTEM SPECIFICATIONS..........
  • Page 6: Service Rules

    GENERAL INFORMATION SERVICE RULES 1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.
  • Page 7: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION SERIAL NUMBERS The Vehicle Identification Number (V.I.N) is stamoed on the right side of the steering head. VEHICLE IDENTIFICATION NUMBER The engine serial number is stamped on the left side of the crankcase. ENGINE SERIAL NUMBER...
  • Page 8 GENERAL INFORMATION The throttle body identification num ber is stamped on the throttle drum side of the throttle body. THROTTLE BODY IDENTIFICATION NUMBER LABELS The Safety Certification Label is located on left side of the frame. The Emission Control Information Label (U.S.A.) is located on left side of the frame.
  • Page 9 GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL...
  • Page 10: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS SPECIFICATIONS ITEM 2,343 mm (92.2 in) DIMENSION Overall length 837 mm (33.0 in) Overall width 1,120 mm (44.1 in) Overall height 1,609 mm (63.3 in) Wheelbase 713 mm (28.1 in) Seat height 308 mm (12.1 in) Footpeg height 137 mm (5.4 in) Ground clearance...
  • Page 11: Lubrication System Specifications

    95 °C (203 °F) Fully open 8 mm (0.3 in) m inim um at 95 °C (203 °F) Valve lift Pro Honda HP coolant or equivalent high quality ethylene Recommended antifreeze glycol antifreeze containing corrosion protection inhibitors (1:1 mixture with distilled water)
  • Page 12: Cylinder Head/valve Specifications

    GENERAL INFORMATION CYLINDER HEAD/VALVE SPECIFICATIONS Unit: mm (in) STANDARD SERVICE LIMIT ITEM 1,569 ±9 8 kPa Cylinder compression at 400 min 1 (rpm) (16.0 ± 1.0 kgf/cm2 , 227.6 ± 14 psi) 0.15 ±0.02 (0.006 ±0.001) Valve clearance 0.20 ±0.02 (0.008 ±0.001) 40.52 (1.595) 40.541 -40.701 (1.5961 -1.6024) Camshaft...
  • Page 13: Hft Specifications

    GENERAL INFORMATION HFT SPECIFICATIONS Unit: mm (in STANDARD SERVICE LIMIT ITEM HFT oil pressure (at idle) More than 127 kPa (1.3 kgf/cm2, 18 psi) (at 80°C/176°F) Return spring free length 33.8(1.33) 31.8(1.25) N/D (Neutral/ drive) clutch 0.7 - 0.9 (0.03 - 0.04) Initial clearance Oil temperature sensor resistance 20 °C (68 °F)
  • Page 14: Final Drive Specifications

    Fork Spring free length 444.5(17.50) 435.6(17.15) Tube runout 0.20 (0.008) Pro Honda Suspension Fluid SS-8 Recommended fork fluid (10W) or equivalent Fluid level 105 (4.1) Fluid capacity 475 ± 2.5 cm3 (16.1 ± 0.08 US oz, 16.7 ± 0.09 Imp oz) Steering head bearing preload 1 1 .9 - 15.6 N (1 .2- 1.6 kgf)
  • Page 15: Hydraulic Brake Specifications

    GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS ___________________________ Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 Brake disc thickness t 3 .9 -4 .1 (0 .1 5 -0 .1 6 ) | 3.5(0.14) Brake disc warpage 0.30(0.012) Master cylinder I.D.
  • Page 16: Lights/meters/switches Specifications

    GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight (High) 12 V - 5 5 W Headlight (Low) 12 V - 5 5 W Brake/taillight License light 12 V - 5 W Front turn signal light 12 V - 21/5 W x 2 Rear turn signal light 12 V - 2 1 W x 2 Instrument light...
  • Page 17: Torque Values

    GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES FASTENER TYPE N m (kgf-m, Ibf ft) FASTENER TYPE N m (kgf-m, Ibf-ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt and nut 10(1.0, 7) 6 mm screw 9.0 (0.9, 6.6) (Include SH flange bolt)
  • Page 18 GENERAL INFORMATION FUEL SYSTEM (PGM-FI) THREAD TORQUE REMARKS Q'TY ITEM N m (kgf-m, Ibf-ft) DIA. (mm) 5.2 (0.53, 3.8) PAIR check valve cover bolt 12(1.2, 9) Fuel pump mounting nut 0.5 (0.1, 0.4) Bank angle sensor mounting bolt 5.4 (0.55, 4.0) Fuel injector m ounting bolt 3.4 (0.35, 2.5) IACV cover bolt...
  • Page 19 GENERAL INFORMATION TORQUE THREAD REMARKS ITEM Q'TY DIA. (mm) N-m (kgf-m, Ibf-ft) Cam damper/primary drive gear bolt 138(14.1, 102) Apply engine oil to the threads and seating sur­ face. Primary driven gear bolt 17(1.7,13) Apply engine oil to the threads and seating sur­ face.
  • Page 20 GENERAL INFORMATION FINAL DRIVE THREAD TORQUE Q'TY REMARKS ITEM DIA. (mm) N-m (kgf-m, Ibf-ft) Pinion retainer 147(15,108) Pinion retainer lock washer bolt 10(1.0, 7) Pinion joint nut 108(11,80) Apply locking agent. Final gear case cover bolt 47 (4.8, 35) Apply locking agent. Final gear case cover bolt 25 (2.5, 18) Apply locking agent.
  • Page 21 GENERAL INFORMATION HYDRAULIC BRAKE TORQUE THREAD REMARKS ITEM Q'TY DIA. (mm) N-m (kgf-m, Ibf-ft) 5.4 (0.6, 4.0) Brake caliper bleed valve Front master cylinder reservoir cap screw 1.5(0.15, 1.1) Front brake pad pin 17.2(1.8, 13) 17.2(1.8, 13) Rear brake pad pin 2.5 (0.26, 1.8) Brake pad pin plug 35 (3.6, 26)
  • Page 22: Lubrication & Seal Points

    GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION REMARKS MATERIAL Molybdenum Rocker arm slipper surface disulfide oil (a Rocker arm shaft outer surface mixture of 1/2 Connecting rod small end inner surface engine oil and 1/2 Crankpin/journal molybdenum Camshaft lobes/journals disulfide grease) Valve stem (valve guide sliding surlace) Engine oil...
  • Page 23 Output shaft splines (universal jo in t side) Final drive pinion jo in t splines Cable lubricant Throttle cable outer inside Handlebar grip rubber inside Honda bond A or equiva­ lent Apply 0.1 g Brake lever-to-master piston contacting area Silicone grease...
  • Page 24: Cable & Harness Routing

    GENERAL INFORMATION CABLE & HARNESS ROUTING LEFT HANDLEBAR SWITCH WIRE BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLES BRAKE ■ FRON" HOSE ▼ SIDE RIGHT FRONT TURN COMBINATION 20P LEFT FRONT TURN SIGNAL 3P CONNECTOR CONNECTOR SIGNAL 3P CONNECTOR HEADLIGHT Lo HEADLIGHT Hi...
  • Page 25 GENERAL INFORMATION 1-21...
  • Page 26 GENERAL INFORMATION UPPER SIDE 85° - 95 RIGHT HANDLEBAR SWITCH RIGHT SIDE 8P (GRAY) CONNECTOR LEFT HANDLEBAR SWITCH 12P (GRAY) CONNECTOR TURN SIGNAL RELAY 1-22...
  • Page 27 GENERAL INFORMATION FRONT SIJR HARNESS FRONT WHEEL SPEED SENSOR 2P (BLUE) CONNECTOR 10P (BLUE) CONNECTOR FRONT SUB HARNESS 14P (GRAY) CONNECTOR RIGHT HANDLEBAR SWITCH 6P (GRAY) CONNECTOR LEFT HANDLEBAR SWITCH 3P (GRAY) CONNECTOR JUNCTION 24P CONNECTOR 1 JUNCTION 24P CONNECTOR 2 UPPER FUEL TANK HAZARD SWITCH 3P LEVEL SENSOR WIRE...
  • Page 28 GENERAL INFORMATION EXCEPT CALIFORNIA TYPE: AIR SUCTION HOSE AIR SUPPLY HOSE FUEL HOSES PARKING BRAKE CABLE REAR BRAKE CRANKCASE VACUUM PIPE BREATHER HOSE HOSE UPPER UPPER SIDE SIDE PARKING REAR BRAKE BRAKE PIPE CABLE LEFT LEFT PARKING SIDE SIDE BRAKE CABLE REAR BRAKE PIPE...
  • Page 29 GENERAL INFORMATION CALIFORNIA TYPE: EVAP VACUUM AIR SUCTION HOSE HOSE AIR SUPPLY HOSE PARKING BRAKE CABLE REAR BRAKE CRANKCASE VACUUM PIPE BREATHER HOSE HOSE UPPER UPPER SIDE SIDE PARKING REAR BRAKE BRAKE PIPE CABLE LEFT LEFT PARKING SIDE SIDE BRAKE CABLE REAR BRAKE PIPE...
  • Page 30 GENERAL INFORMATION FUEL TANK FUEL TANK DRAIN HOSE BREATHER HOSE UPPER FUEL SIDE HOSk...
  • Page 31 GENERAL INFORMATION FUEL HOSE FUEL TANK FUEL TANK DRAIN HOSE UPPER BREATHER HOSE FUEL SIDE...
  • Page 32 GENERAL INFORMATION EXCEPT CALIFORNIA TYPE: CALIFORNIA TYPE: FUEL TANK 1-28...
  • Page 33 GENERAL INFORMATION CAUFORNIA TYPE: EVAP PURGE CONTROL SOLENOID VALVE-TO- THROTTLE BODY HOSE FUEL TANK BREATHER HOSE-TO-EVAP CANISTER EVAPPURGE CONTROL SOLENOID VALVE EVAP CANISTER-TO- EVAP PURGE CONTROL EVAP CANISTER SOLENOID VALVE HOSE...
  • Page 34 GENERAL INFORMATION TURN SIGNAL RELAY REAR BRAKE RESERVOIR REAR BRAKE LIGHT SWTCH WIRE REAR BRAKE PIPE SIDESTAND SWITCH WIRE STARTER MOTOR CABLE VS SENSOR SIDE STAND SWITCH VS SENSOR WIRE WIRE FRONT SIDE STARTER WATER RADIATOR MOTOR CABLE HOSES HOSfc UPPER U P P E R S SIDE...
  • Page 35 GENERAL INFORMATION UPPER UPPER SIDE FRAME SIDE MAIN WIRE SWASH PLATE STARTER MOTOR HARNESS CONTROLMOTOR CABLE CABLE REAR WHEEL SPEED SENSOR SIDE STAND RIGHT WIRE SWITCH WIRE SIDE BATTERY GROUND CABLE FUEL HOSES FUEL PUMP/FUEL LEVEL SENSOR WIRE REAR WHEEL SPEED SENSOR WIRE PARKING...
  • Page 36 GENERAL INFORMATION 1-32...
  • Page 37 GENERAL INFORMATION ENGINE SUB HARNESS 14P (GRAY) CONNECTOR A UPPER SIDE CKP SENSOR WIRE SENS0R W |RE ♦ cy/1 left SIDE ENGINE SUB ALTERNATOR ENGINE SUB HARNESS (14P WIRE HARNESS CONNECTOR) 1-33...
  • Page 38 GENERAL INFORMATION NEUTRAL SWITCH RELAY TCM 33P (BLACK) CONNECTOR OIL LEVEL SWITCH TCM 5P (BLACK) RELAY CONNECTOR REGULATOR/ RECTIFIER NEGATIVE POSITIVE BANK ANGLE MAIN FUSE (40 A) SENSOR HFT FUSE (10 A) SIDE STAND SWITCH 2P(GREEN) CONNECTOR STARTER RELAY POSITIVE (+) CABLE 2P (BLACK) POSITIVE (+) MAIN RELAY...
  • Page 39 GENERAL INFORMATION TAILLIGHT WIRE RIGHT REAR TURN SIGNAL WIRE LEFT REAR TURN SIGNAL WIRE SEAT LOCK CABLE 1-35...
  • Page 40 GENERAL INFORMATION r e m o v e t h e \ ENGINE GROUND LEFT SHROUD TERMINAL FRAME GROUND TERMINAL 1-36...
  • Page 41: Emission Control Systems

    6,C O O km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. WARRANTY COMPLIANCE Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system v/arranty in effect. SOURCE OF EMISSIONS The combustior process and fuel evaporation produces carbon monoxide, oxides of nitrogen and hydrocarbons.
  • Page 42 GENERAL INFORMATION and PGM-FI system. No adjustment should be made about the exhaust emission control systems. The exhaust emission control system is separate from the crank case emission control system. SECONDARY AIR SUPPLY SYSTEM The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR (Pulse Secondary A ir Injection) control valve.
  • Page 43: Noise Emission Control System

    GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE) This model complies with California A ir Resources Board (CARB) evaporative emission requirement. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the engine is "...
  • Page 44 2. TECHNICAL FEATURE , H FT..............2-2...
  • Page 45: System Overview

    TECHNICAL FEATURE SYSTEM OVERVIEW This motorcycle uses the HFT in a powertrain. The HFT is an infinitely variable automatic transmission device that shifts the transm ssion and transmits power by converting the engine power into hydraulic pressure. In addition to the automatic transmission function, the HFT also includes following components: •...
  • Page 46 TECHNICAL FEATURE TORQUE TRANSMISSION COMPONENTS Engine torque is transm itted through the cam damper/primary drive gear to the HFT. When the starting clutch is operated, engine torque is transm itted to the HFT. This input torque is converted to hydraulic pressure within the HFT according to engine speed.
  • Page 47 TECHNICAL FEATURE OIL CIRCUITS The oil circuit of this motorcycle is separated into two different circuits. One is for engine lubrication, the other is for oper­ ating/lubricating the HFT. This motorcycle features a separate a il pump rotor, oil pressure relief valve and oil filter for operating/lubricating the HFT, which is independent from engine lubrication.
  • Page 48 TECHNICAL FEATURE N/D SOLENOID VALVE HFT OIL PRESSURE SENSOR SPOOL VALVE OIL FILTER (FOR ENGINE LUBRICATION) NEUTRALOIL PRESSURE SWITCH N/D CLUTCH OIL PRESSURE RELIEF VALVE (FOR ENGINE LUBRICATION) OIL LEVEL SWITCH OIL PUMP OIL PUMP ROTOR ROTOR (FOR ENGINE (FOR HFT) LUBRICATION)
  • Page 49 TECHNICAL FEATURE CAM DAMPER/PRIMARY DRIVE GEAR The cam damper/primary drive gear installed on the crankshaft consists of the collar, lifter, spring (two pieces), holder, pri­ mary drive gear and associated fasteners. LIFTER CAM DAMPER/ PRIMARY DRIVE GEAR The lifter has three bosses that engage three grooves on the prim ary drive gear. The lifter and prim ary drive gear are forced together by the pressure of springs located between the holder and lifter.
  • Page 50 TECHNICAL FEATURE HFT POWER TRANSMISSION Engine power is transm itted to the oil pump side of the HFT. The hydraulic pressure delivered from the oil pump is trans­ mitted to the oil m otor side of the HFT and output shaft. Power transmission is controlled by the starting clutch.
  • Page 51 TECHNICAL FEATURE • When the clutch is disengaged: HIGH PRESSURE CAVITY When the engine speed is low (1,200 rpm), weight ro ll­ WEIGHT ROLLER (LOW PRESSURE) ers are positioned at the center of the starting clutch outer. Engine power is not transmitted as the oil pres­ sure in the high and low pressure cavities is equal (high pressure is not generated).
  • Page 52 TECHNICAL FEATURE AUTOMATIC TRANSMISSION SYSTEM The automatic transmission system of the HFT is divided into two sections, oil pump side (input) and oil m otor side (out­ put). Each section is equipped w ith a swash plate, pistons and distributor valves. The HFT controls the output torque by adjusting the angle of the oil m otor side swash plate.
  • Page 53 TECHNICAL FEATURE CIRCULATION OF OIL FOR POWER TRANSMISSION Torque transmission of the HFT utilizes the circulation of the high-pressure oil (supplied from the oil pump to the oil motor and low-pressure oil (returned from the oil motor to the oil pump). HIGH-PRESSURE OIL: FROM THE PUMP TO MOTOR LOW-PRESSURE OIL: FROM THE MOTOR TO PUMP \ ________ / \ ________ /...
  • Page 54 TECHNICAL FEATURE OIL FLOW VOLUME CONTROL In the event that the clutch valve returns toward the starting clutch side, such as rapid acceleration on low speed riding, the oil in the damper cavity positioned in the left side of the clutch valve flow s into the orifice at the clutch valve end. The rapid change of the clutch valve position is restricted by the oil flo w into the damper cavity.
  • Page 55 TECHNICAL FEATURE OIL MOTOR SIDE SWASH PLATE AND TRANSMISSION RATIO One of the functions of the oil m otor is to change the transmission ratio by controlling the tilt angle of the motor side swash plate, which changes the amount o f the oil supplied to the oil motor. The amount of the oil supplied to the motor side swash plate determines the difference of the revolution speed between the pump side swash plate and cylinder.
  • Page 56 TECHNICAL FEATURE LOCKUP MECHANISM In the top ratio, there is no torque m ultiplication a3 the m otor side swash plate is not tilted. However, there is friction loss and compression loss caused by oil circulation. The lockup mechanism improves the efficiency of the engine torque trans­ mission.
  • Page 57 TECHNICAL FEATURE N/D (NEUTRAL/DRIVE) CLUTCH The N/D clutch is a hydraulically operated multi-plate type. Hydraulic pressure is applied to the pressure plate and is regi lated electronically. When the rider selects "N' on the drive mode select switch, it is equivalent to the neutral position of a conventional geai driven transmission.
  • Page 58 TECHNICAL FEATURE The neutral oil pressure sensor is located in the N/D clutch oil circuit and detects neutral position. The oil pressure o f the N/D clutch is co n tro lle d by the N/D solenoid valve. In neutral position, oil pressure is not applied to the clutch as the N/D solenoid valve is closed. In drive position, the spool valve is pressurized as the N/D solenoid valve is opened.
  • Page 59 TECHNICAL FEATURE ELECTRONIC CONTROL OF N/D CLUTCH The N/D clutch can be shifted into neutral or drive mode at the rider's w ill, w ith the N/D select switch. This system is equipped with an electronic fail-safe function to prevent shifting the N/D clutch w ithout the rider's input, in the event of accidental switch operation or low oil level.
  • Page 60 TECHNICAL FEATURE N/D SHIFTING MECHANISM Shifting between neutral and drive modes is accomplished by the rider operating the N/D select switch. The neutral oil pressure switch detects the mode by the change in oil pressure. The engine w ill stop if the throttle is opened during shift­ ing to prevent movement of the vehicle.
  • Page 61: Riding Mode

    TECHNICAL FEATURE RIDING MODE T h e H FT has tw o a u to m a tic m o d e s (D , S) and a 6-sp eed m an u al m o d e. T h e E C M m o n ito rs th e sensors in th e m o to rcy c le and th e ric er o p e rated sw itch position . T h e a n g le o f th e oil m o to r side sw ash p late, w h ich d e te rm in e s th e tra n s m iss io n ratio , is reg u lated b y th e sw ash p late co ntro l m otor.
  • Page 62 TECHNICAL FEATURE OVERVIEW OF THE HFT SENSORS OIL LEVEL SW ITCH The oil level switch is in stalled in the lo w e r rig h t side o f th e crankcase an d d etects th e oil level. Afloat is incorporated in th e switch.
  • Page 63 TECHNICAL FEATURE TRANSMISSION OIL PRESSURE SENSOR The oil pressure sensor is installed in the rig h t crankcase cover and detects the oil pressure in the HFT o il circuit. T h e re is a p iezo electric e le m e n t in th e sw itch . T h e s en so r o u tp u ts th e signal a m p lifie d by th e e le m e n t. T h e o u tp u t sign ch ang es lin e a rly according to oil p ressu re ch an g e.
  • Page 64 3. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATION......3-2 INNER LOWER C O W L........3-9 BODY PANEL REMOVAL C H A R T....3-2 MUFFLER PROTECTO R......3-10 SERVICE INFORMATION......3-3 EXHAUST PIPE PROTECTOR....3-10 TROUBLESHOOTING........3-3 UNDER C O W L ........
  • Page 65: Body Panel Location

    FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATION (1) Pillion seat (page 3-4) (10) R ig ht side co ver (p a g e 3-14) (19) L in d er co w l co v er (p a g e 3-9) (20) M u ffle r p ro te cto r (p ag e 3-10) (2) M a in seat (p ag e 3 -4 ) (11) Front fe n d e r (p a g e 3-12)
  • Page 66: Service Information

    FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers rem o v a l and in s ta lla tio n o f th e b o d y p anels and e x h a u s t system . •...
  • Page 67: Main Seat/pillion Seat

    FRAME/BODY PANELS/EXHAUST SYSTEM MAIN SEAT/PILLION SEAT REMOVAL/INSTALLATION U n h o o k th e p illion seat lock u sin g th e ig n itio n key. R e m o v e th e p illion seat b a c k w a rd by releasin g the PILLIO N SEAT fo u r hooks.
  • Page 68: Front Side Cowl

    FRAME/BODY PANELS/EXHAUST SYSTEM FRONT SIDE COWL REMOVAL/INSTALLATION R e m o v e th e re a rv ie w m irro r (p a g e 3-4). R e m o v e th e m ain s e a t(p a g e 3-4). Be careful not to Re m o v e a socket b o lt, th re e trim clips and fro n t side damage the side...
  • Page 69: Center Cowl

    FRAME/BODY PANELS/EXHAUST SYSTEM CENTER COWL REMOVAL/INSTALLATION R e m o v e th e right and left fro n t side co w l (p ag e 3-5). R e m o v e th e tw o bolts, tw o screw s an d d isco n nect th e hazard sw itch 4P (G ray) connector.
  • Page 70: Upper Cowl

    FRAME/BODY PANELS/EXHAUST SYSTEM UPPER COWL REMOVAL/INSTALLATION R e m o v e th e c e n te r c o w l (p a g e 3-5). R e m o v e th e fo u r screw s a n d fo u r trim clips. R e m o v e th e u p p e r co w l fo rw a rd by rele asin g th e tw o hoo ks a n d tw o bosses.
  • Page 71: Inner Cowl

    FRAME/BODY PANELS/EXHAUST SYSTEM INNER COWL REMOVAL/INSTALLATION R em o ve th e righ t and left fro n t side co w l (p ag e 3-5). W A SH ER LEFT IN N E R C O W L R e m o v e a screw , w a s h e r, tw o trim clips an d left in n er cow l.
  • Page 72: Under Cowl Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM UNDER COWL COVER REMOVAL/INSTALLATION R e m o ve a screw an d rig h t u n d er co w l cover. In th e s a m e m a n n e r, re m o v e th e left u n d e r cow l cover.
  • Page 73: Muffler Protector

    FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER PROTECTOR REMOVAL/INSTALLATION R em o ve a socket bolt, ru b b e r w a s h e r and m u ffle r protector. In stallatio n is in th e re verse o rd e r o f rem oval. RUBBER WASHER M U FFLE R...
  • Page 74: Under Cowl

    FRAME/BODY PANELS/EXHAUST SYSTEM UNDER COWL RIGHT UNDER COWL REMOVAL/ INSTALLATION R e m o v e th e right m a in step (p a g e 3-9). R e m o v e th e m u ffle r p ro te c to r (p a g e 3 -1 0 ). R e m o v e th e tw o socket b olts a n d rig h t u n d e r cow l by releasin g th e tw o hooks.
  • Page 75: Front Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION R e m o v e th e fo u r so cket bolts, co llar and side reflec­ COLLAR SO C KET tors, th e n re m o v e th e fro n t fe n d e r d o w n w a rd . FR O N T FEDER In s ta lla tio n is in th e reverse o rd e r o f re m o va l.
  • Page 76: Grab Rail Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM GRAB RAIL COVER REMOVAL/INSTALLATION R e m o v e th e seat c o w l (p a g e 3 -12). G R A B RAIL COVER R elease th e seven ta b s an d re m o v e th e g rab rail cover.
  • Page 77: Left Side Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM LEFT SIDE COVER REMOVAL/INSTALLATION 3-11). R e m o v e th e left u n d e r c o w l (p a g e R e m o v e th e th re e socket b olts, th re e co llars a n d left side cover.
  • Page 78: Rear Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REMOVAL/INSTALLATION R e m o v e th e tail lig h t a s s e m b ly (p a g e 22-9). 2P CONNECTOR SC R E W S D isconnect th e license lig h t 2P connector. R em o ve th e six screw s an d re ar fe n d e r.
  • Page 79: Muffler

    FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER REMOVAL R e m o ve th e m u ffle r p ro te cto r (p a g e 3-10) BOLTS S O C K E T B O L T/N U T Loosen th e m u ffle r b an d bolts. R em o ve th e socket b o lt, n u t and m u ffler.
  • Page 80 FRAME/BODY PANELS/EXHAUST SYSTEM Loosen th e e x h a u s t p ip e b a n d b olts and re m o v e the BOLTS e x h a u s t pipe. R e m o v e th e gasket. G A S K E T R e m o v e th e e x h a u s t p ip e jo in t nuts.
  • Page 81 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION G A S K E T S 21 N-m (2.1 kgf-m , 15 Ibf-ft) 17 N m (1.7 kgf-m , 13 Ibf-ft) G A S K E T E X H A U S T PIPE G A S K E T MUFFLER 17 N -m (1.7 kgf-m , 13 Ibf-ft)
  • Page 82 FRAME/BODY PANELS/EXHAUST SYSTEM Install the rear e x h a u s t pipe. Install th e e x h a u s t p ip e jo in t nuts, but n ot tig h te n yet. J O IN T N U T S Install a n e w e x h a u s t p ip e gasket to th e rea r exh au s t G A S K E T pipe.
  • Page 83 FRAME/BODY PANELS/EXHAUST SYSTEM________ Install th e w a s h e r, b o lt a n d m o u n tin g n u t, b u t not B O L T /M O U N T IN G N U T /W A S H E R tig h te n yet.
  • Page 84 4. MAINTENANCE SECONDARY AIR SUPPLY SYSTEM •••• •4-1 6 SERVICE IN FO R M A TIO N ......4-2 MAINTENANCE SCHEDULE....... 4-4 EVAPORATIVE EM ISSIO N CONTROL SYSTEM (CALIFORNIA TY P E )....•4-17 FUEL LINE............4-5 FINAL DRIVE O IL ........
  • Page 85: Service Information

    MAINTENANCE SERVICE INFORMATION GENERAL • Place th e m o to rc y c le on level g ro u n d b e fo re startin g a n y w o rk. • G aso lin e is e x tre m e ly fla m m a b le and is e x p lo s iv e u n d e r certain conditions. •...
  • Page 86 MAINTENANCE TORQUE VALUES Spark plug 16 N -m (1.6 kg f-m , 12 Ibf-ft) A p p ly e n g in e oil to the th re a d s and Engine oil filte r cartrid g e 2 6 N -m (2.7 k g f-m , 20 Ibf-ft) sea tin g surface Engine oil drain bolt 2 5 N -m (2.5 kg f-m , 18 Ibf-ft)
  • Page 87: Maintenance Schedule

    T h e fo llo w in g item s req u ire s o m e m e c h an ica l k n o w le d g e . C ertain ite m s (p a rtic u la rly th o s e m arked * and * * ) m a y requir m o re tech n ical in fo rm a tio n a n d to o ls. C on su lt an au th o rized Honda d e ale r.
  • Page 88: Fuel Line

    MAINTENANCE FUEL LINE R e m o v e th e cen ter co w l (p a g e 3-6). C heck th e fu el lin e fo r d e te rio ra tio n , d a m a g e or leakage.
  • Page 89: Air Cleaner

    MAINTENANCE M a jo r a d ju s tm e n t is m a d e w ith th e lo w er ad ju ster. A D JU S T E R R e m o v e th e a ir c le a n e r h ousing (p ag e 6-50). Loosen th e lock nut, tu rn th e a d ju s te r as re q u ired .
  • Page 90: Spark Plug

    MAINTENANCE R e m o v e th e air c le a n e r h o u sin g (p a g e 6 -50). C heck th e crankcase b re a th e r hose fo r d e te rio ra tio n , d a m a g e o r leakage.
  • Page 91: Valve Clearance

    MAINTENANCE Replace th e plug if th e cen ter electro d e is rounded A lw ays use as show n in th e illustration. s p e c ifie d sp a rk plugs on this SPECIFIED SPARK PLUG: motorcycle.
  • Page 92 MAINTENANCE R e m o v e th e c y lin d e r h ead co ver (p a g e 9-6). T IM IN G HOLE CAP R e m o v e th e tim in g a n d cran ksh aft h ole caps. >...
  • Page 93 MAINTENANCE REAR: R otate th e cran ksh aft clockw ise and alig n th e "RT" IN D E X N O TC H m ark on th e fly w h e e l w ith th e in d ex notch on the a lte rn a to r cover.
  • Page 94: Engine Oil

    RECOMMENDED ENGINE OIL: O ther viscosities shown Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or in the char, may be used when an equivalent motor oil average...
  • Page 95: Engine Oil Filter (cartridge)

    MAINTENANCE OIL CHANGE NOTE: C h a n g e th e oil w ith e n g ne w a rm and th e m o to rc y ­ cle on its s id estan d to assure c o m p le te and rapid d ra in in g .
  • Page 96: Hft Oil Filter (element)

    MAINTENANCE C oat a n e w O -rin g w ith oil an d install it to th e oil fil­ te r cartrid g e . A p p ly oil to th e th re a d s o f a n e w oil filte r c a rtrid g e . Install th e oil filte r c a rtrid g e and tig h te n it to th e sp ecified to rq u e .
  • Page 97: Engine Idle Speed

    MAINTENANCE C o at a n e w O -rin g w ith o il and install it to th e oil fil­ te r cover. Install th e sp rin g o n to the oil filte r cover. S P R IN G Install th e oil filte r cover an d tig h te n th e bolts.
  • Page 98: Radiator Coolant

    (c o o la n t p re p a ­ ration: p age 7-6). RECOMMENDED ANTIFREEZE: Pro Honda HP coolant or equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors (1:1 mixture w ith distilled...
  • Page 99: Secondary Air Supply System

    MAINTENANCE SECONDARY AIR SUPPLY SYSTEM • This m o d e l is e q u ip p e d w ith a built-in seco nd ary a ir s u p p ly system . T h e pulse secondary a ir su p ­ PAIR CHECK VALVE p ly system is located on th e cy lin d e r head cover.
  • Page 100: Evaporative Emission Control

    MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE) C heck th e hoses b e tw e e n th e fu e l tank, E VA P canis­ te r, EVA P purge co ntro l so le n o id v a lv e fo r d e te rio ra ­ tio n , d a m a g e or loose co nn ectio n.
  • Page 101: Brake Fluid

    MAINTENANCE OIL CHANGE S u p p o rt the m o to rc y c le secu rely an d raise th e rear w h e e l o ff th e g ro u n d . R e m o v e th e oil fille r cap and d ra in bolt/sealing w a s h e r fro m th e final g e a r case, s lo w ly turn th e rear w h e e l and d ra in th e oil.
  • Page 102 ■ MAINTENANCE If th e flu id level is n ear th e "LOW ER" level rrark, re m o v e th e screw s, re s e rv o ir cap, set p late an d d ia ­ SCREWS R ESERVO IR CAP p h rag m .
  • Page 103: Brake Pads Wear

    MAINTENANCE BRAKE PADS WEAR FRONT BRAKE PADS C heck the b rake pad fo r w e a r. R eplace th e brake pads if e ith e r pad is w o rn to th e w e a r lim it g ro o v e . For brake pad re p la c e m e n t (p a g e 17-14).
  • Page 104: Brake Lever Adjustment

    MAINTENANCE M a k e sure th e fro n t w h e e l d oes n ot tu rn w h ile the re ar b rake pedal is a p p lie d . firm ly apply the brake lever or pedal, and check that no air has entered the system.
  • Page 105: Brake Light Switch

    MAINTENANCE BRAKE LIGHT SWITCH NOTE: • T h e b rake lig h t switch on th e fro n t brake m a ster c y lin d e r c a n n o t be a d ju sted . If th e fro n t brake lig h t sw itch actuation and b rake e n g a g e m e n t are not syn ch ro n ized , e ith e r rep lace th e sw itch or th e m a lfu n c tio n in g parts o f th e system .
  • Page 106: Headlight Aim

    MAINTENANCE Loosen th e lock nut. Turn th e rear w h e e l s lo w ly by h a n d an d tu rn th e adjust bolt u ntil th e re is a slight drag. Unlock th e parking b rake le v e r ay p ullin g it.
  • Page 107: Suspension

    MAINTENANCE Check th e sidestand ig n itio n c u t-o ff system : astride th e m o to rcy c le raise th e sidestand. S ta rt the e n g in e w ith th e tra n s m is s io n in neutral, th en shift th e tra n sm is s io n into...
  • Page 108: Nuts, Bolts, Fasteners

    MAINTENANCE NUTS, BOLTS, FASTENERS C heck th a t all chassis nuts an d bolts a re tig h te n e d to th e ir c o rre c t to rq u e va lu e s (p ag e 1-13). C heck th a t all c o tte r pins, safety clips, hose clam p s an d c ab le stays a re in place and p ro p e rly secured.
  • Page 109: Steering Head Bearings

    MAINTENANCE Check th e tires fo r cuts, e m b e d d e d nails, o r o th e r d a m a g e . Check th e fro n t and re a r w h e e ls fo r trueness. M e a s u re th e tre a d d epth at th e c e n te r o f th e tires.
  • Page 110 5. LUBRICATION SYSTEM LUBRICATION SYSTEM D IA G R A M ..5-2 OIL PUM P DRIVEN G E A R ......5-5 OIL P U M P ............5-6 SERVICE IN F O R M A T IO N ......5-3 OIL C O O LER ........
  • Page 111 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM C A M S H A F T < ----- 1 P IS TO N C R A N K S H A FT PRESSU R E RELIEF VALVE OIL SIKAINbH H FT U N IT O IL PRESSURE S W ITCH N /D CLU TCH...
  • Page 112 LUBRICATION SYSTEM SERVICE INFORMATION GENERAL ACAUTIO N Used engine oil m a y cause skin ca n c e r if re p e a te d ly left in contact w ith th e skin fo r p ro lo n g e d periods. A lth o u g h th is is unlikely unless you handle used oil on a d a ily basis, it is still ad visab le to th o ro u g h ly w ash y o u r hands w ith so ap and water as soon as possible after h a n d lin g used oil.
  • Page 113 LUBRICATION SYSTEM TOOLS TROUBLE SHOOTING O il level to o lo w • Oil c o n s u m p tio n • External oil leak • W o rn piston rings • Im p ro p e rly in stalled piston rings •...
  • Page 114 LUBRICATION SYSTEM OIL PRESSURE INSPECTION Rem ove the EOP sw itch (p a g e 5-15). Install th e oil p ressu re g a u g e a tta c h m e n t to the switch base Connect the oil p ressu re g a u g e to th e oil pressure gauge atta c h m e n t.
  • Page 115: Oil Pump

    LUBRICATION SYSTEM R e m o v e th e oil p u m p d riv e chain an d oil p u m p DRIVE driven year. C H A IN In stallatio n is in th e reverse o rd e r o f re m o v a l. DR IVE N GEAR OIL PUMP REMOVAL...
  • Page 116 LUBRICATION SYSTEM R em o ve th e bolts. O IL P U M P A S S E M B L Y Place the oil p um p a s s e m b ly u p s id e d o w n . O IL P U M P B O D Y D O W E L P IN S R em ove th e oil p u m p b o d y fro m th e oil p um p...
  • Page 117 LUBRICATION SYSTEM R e m o v e th e w a s h e r, drive sh aft, d riv e pin, in n e r D R |VE p|N DRIVF S H A F T W A S H F R ro to r and o u te r ro to r.
  • Page 118 LUBRICATION SYSTEM B O D Y C LE A R A N C E T e m p o ra rily a s s e m b le th e in n er ro to r, o u te r ro to r, R n n Y d riv e pin and p u m p sh a ft in to the p u m p b o d y.
  • Page 119 LUBRICATION SYSTEM OIL PUMP ASSEMBLY Install a n e w O -rin g to the pressure re lie f va lv e B. PRESSURE RELIEF V A LV E B Install th e p ressu re relief v a lv e B to th e oil p u m p body.
  • Page 120 LUBRICATION SYSTEM Install th e oil p um p base to th e oil p u m p body. BASE P U M P B O D Y Install a n ew O -ring to th e pressu re re lie f va lv e A. PRESSU R E RELIEF V A LV E A Install the pressure re lie f v a lv e A to th e oil pum p cover.
  • Page 121 LUBRICATION SYSTEM__________________________ Place the oil pum p assem bly upside down. OIL PUMP ASSEMBLY Install and tighten the bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft) A p p ly engine oil to a new seal ring and install it OIL STRAINER onto the oil strainer.
  • Page 122: Oil Cooler

    LUBRICATION SYSTEM OIL COOLER REMOVAL Remove the left side cover (page 3-15). WATER HOSES Drain the engine oil (page 4-12). Drain the coolant fro m the system (page 7-6). Remove the oil filte r (page 4-12). Loosen the band screws, then disconnect the water hoses from the w ater pump.
  • Page 123: Eop Switch

    LUBRICATION SYSTEM Install the washer and oil cooler bolt. Hold the oil cooler by yo u r hand and tighten the bolt to the specified torque. TORQUE: 64 N-m (6.5 kgf-m, 47 Ibf-ft) Connect the w ater hoses and tighten the hose band screws securely (page 7-10).
  • Page 124 LUBRICATION SYSTEM REMOVAL/INSTALLATION Install a new O-ring in to the oil cooler groove. | BOLT/WASHER/ Remove the dust cover. 1 SWITCH WIRE Remove the bolt, w asher and disconnect the EOP sw itch w ire. DUST COVER Remove the EOP switch. EOP SWITCH A p p ly sealant to the EOP sw itch threads.
  • Page 125 LUBRICATION SYSTEM Connect the EOP sw itch wire term inal and tighten BOLT/WASHER/ the b o lt w ith w asher to the specified torque. SWITCH WIRE TORQUE: 1.9 N m (0.19 kgf-m, 1.4 Ibf-ft) Install the dust cover. S tart the engine and check that there are no oil leaks.
  • Page 126 6. FUEL SYSTEM (PGM-FI) AIR CLEANER H O U S IN G ......6-50 COMPONENT LOCATION......6-2 SERVICE INFORMATION......6-3 IN S U LA TO R ........... 6-53 THROTTLE B O D Y ......... 6-54 SYMPTOM TROUBLESHOOTING....6-5 IN JEC TO R ............6-58 PGM-FI SYSTEM LOCATION.......6-6 IA C V ..............
  • Page 127: Component Location

    FUEL SYSTEM (PGM-FI)_________ COMPONENT LOCATION...
  • Page 128: Service Information

    FUEL SYSTEM (PGM-FI) SERVICE INFORMATION GENERAL • Before disconnecting fuel feed hose, relieve pressure fro m the system by disconnecting the quick connect fittin g ir the fuel pump (page 6-37). • Bending or tw istin g the control cable w ill im pair sm ooth operation and could cause the cable to stick o r bend, resulting in loss of vehicle control.
  • Page 129 FUEL SYSTEM (PGM-FI) TOOLS Fuel pressure gauge Im rie diagnostic tester (m odel 625) ECM test harness 33P 07406-0040004 o r Peak voltage adaptor 070MZ-MCA0100 07HGJ-0020100 w ith com m ercially available digital m u ltim e te r (impedance 10 MQ/DCV m in im u m ) SCS connector Inspection adaptor...
  • Page 130: Symptom Troubleshooting

    FUEL SYSTEM (PGM-FI) SYMPTOM TROUBLESHOOTING When the m otorcycle has one o f these sym ptom s, check the DTC or MIL blinking, refer to the DTC index (page 6-14) and begin the appropriate tro u b le sh o o tin g procedure. If there are no DTC/MIL blinking stored in the ECM m em ory, do the diag­ nostic procedure fo r the sym pto m , in sequence listed below , u ntil you fin d the cause.
  • Page 131: Pgm-fi System Location

    FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM LOCATION MAP SENSOR ECTSENSOR IAT SENSOR PAIR CONTROL REAR SOLENOID VALVE INJECTOR CMP SENSOR BANK ANGLE SENSOR FRONT INJECTOR IACV VS SENSOR CKP SENSOR SENSOR FUSE/RELAY BOX...
  • Page 132: Pgm-fi System Diagram

    FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM DIAGRAM FI IGN PUMP RELAY SUB FUSE ENGINE STOP IGNITION MAIN FUSE SUB FUSE SWITCH SWITCH R — cr^ty- R/BI R/BI W/BI — W/BI RIG ^ W/BI BATTERY MAIN RELAY Bl/W SUB FUSE BANKANGLE SENSOR CONTROL RELAY FUEL CUT...
  • Page 133: Connector Locations

    FUEL SYSTEM (PGM-FI) CONNECTOR LOCATIONS FRONT SIDE LOCATION Note 1: Remove the center cow l (page 3-6). ---- ,---------------------- > A l l ----- 1 -------- m . ✓ 1 -------- □ _____ 1 ______ £ -A12 > B33* BJ3 A33 ' A23 ECM 33P (GRAY) ECM 33P (BLACK)
  • Page 134 FUEL SYSTEM (PGM-FI) Note 3: Remove the center cowl (page ECTSENSOR 3P (GRAY) CONNFCTOR (Note 3) Note 4: Remove the left under cowl (page 3-11). VS SENSOR 3P (BLACK) CONNECTOR (Note 4) IACV 4P (BLACK) FRONT INJECTOR 2P (GRAY) CONNECTOR TP SENSOR 3P (BLACK) CMP SENSOR 2P (BLACK) CONNECTOR...
  • Page 135 FUEL SYSTEM (PGM-FI) Note 5: Remove the seat (page 3-4). Note 6: Remove the rig h t seat cow l (page 3-12). CKP SENSOR 2P (RED) CONNECTOR (Note 6)
  • Page 136: Pgm-fi Troubleshooting Information

    FUEL SYSTEM (PGM-FI) PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "interm ittent fa ilu re " means a system m ay have had a failure, but it checks OK now. If the IVIL does not com e on, check for poor contact or loose pins at all connectors related to the circu it th a t o f the troublesho otin g.
  • Page 137 FUEL SYSTEM (PGM-FI) MIL Blink Pattern • If the HDS pocket tester is not available, DTC can be read fro m the ECM m em ory by the M IL blink pattern. • The num ber o f MIL blinks is the equivalent the main code o f the DTC (the sub code cannot be displayed by the MIL).
  • Page 138 FUEL SYSTEM (PGM-FI) Reading DTC with the MIL Turn the ig n ition sw itch to OFF. SCS CONNECTOR Remove the main seat (page 3-4). Remove th e d u m m y connector and short DLC te rm i­ nals using the special to o l.
  • Page 139: Dtc Index

    FU EL S Y S T E M (P G M -F I) DTC INDEX Function Failure Refer to Symptom/Fail-safe function (MILblinks) MAP sensor circuit lo w voltage (less than 0.2 V) • Engine operates norm a lly 6-15 1-1 (D •...
  • Page 140: Dtc Troubleshooting

    FUEL SYSTEM (PGM-FI) DTC TROUBLESHOOTING DTC 1-1 (M A P S E N S O R L O W V O L T A G E ) 1. MAP Sensor System Inspection Turn the ignition sw itch ON and engine stop sw itch "...
  • Page 141 FUEL SYSTEM (PGM-FI) 5. MAP Sensor Inspection Replace the MAP sensor w ith a know n good one (page 6-64). Clear the DTC (page 6-12). Turn the ig n itio n sw itch ON and engine stop s w itc h " Q Check the MAP sensor w ith the HDS.
  • Page 142 FUEL SYSTEM (PGM-FI) 4. MAP Sensor Output Line Open Circuit Inspec­ tion Disconnect the ECM 33P connectors. ECM 33P (LIGHT GRAY) CONNECTOR Check fo r c o n tin u ity at the Light green/yellow (Wire side o f fem ale term inal) w ire between the MAP sensor 3P (Black) connec­...
  • Page 143 FUEL SYSTEM (PGM-FI) D TC 7-1 (EC T S E N S O R L O W V O L T A G E ) 1. ECT Sensor System Inspection Turn the ig n itio n switch ON and engine stop sw itch "O".
  • Page 144 FUEL SYSTEM (PGM-FI) D TC 7 -2 (ECT S E N S O R H IG H V O L T A G E ) • Before starting the inspection, check fo r loose or poo r contact on the ECT sensor 3P (Gray) con­ nector and recheck the DTC.
  • Page 145 FUEL SYSTEM (PGM-FI) D TC 8-1 (TP S E N S O R L O W V O L T A G E ) • Before starting the inspection, check fo r loose or poor contact on the TP sensor 3P (Black) connec­ to r and recheck the DTC.
  • Page 146 ______________________________________________________ FU EL S Y S T E M (P G M -F I) 5. TP Sensor Output Line Short Circuit Inspection Disconnect the TP sensor 3P (Black) connector. TP SENSOR 3P (BLACK) CONNECTOR Check fo r continuity between the TP sensor 3P (W ire side o f fem ale term inal) connector term inal o f the w ire harness side and ground.
  • Page 147 FUEL SYSTEM (PGM-FI) 3. TP Sensor Input Voltage Inspection Turn the ig nitio n switch ON and engine stop TP SENSOR 3P (BLACK) CONNECTOR sw itch " Q (W ire side o f fem ale term inal) M easure the voltage at the w ire harness side. Connection: Yellow/red (+) - Green/orange (-) Is the voltage w ith in 4.75 5.25 V?
  • Page 148 FUEL SYSTEM (PGM-FI) DTC 9-2 (IAT SENSOR HIGH VOLTAGE) • Before starting the inspection, check fo r loose or poor contact on the IAT sensor connector and recheck the DTC. 1. IAT Sensor System Inspection Turn the ignition sw itch ON and engine stop sw itch "...
  • Page 149 FUEL SYSTEM (PGM-FI) DTC 11-1 (VS SENSOR) • Before starting the inspection, check fo r loose or p oor contact on the VS sensor 3P connector and recheck the DTC. 1. VS Sensor System Inspection S upport the m otorcycle securely and raise the rear wheel o ff the ground.
  • Page 150 FUEL SYSTEM (PGM-FI) VS Sensor Pulse Line Open C ircu it Inspection Turn the ignition sw itch OFF. Disconnect the ECM 33P connectors (page 6-8). Check fo r co n tin uity between the ECM 33P (Light gray) connector and VS sensor 3P connector o f the w ire harness side.
  • Page 151 FUEL SYSTEM (PGM-FI) D TC 12-1 (N o.1 REAR IN JE C TO R ) • Before starting the inspection, check fo r loose or poor contact on the injector 2P (Gray) connector and recheck the DTC. INJEC­ POWER SIGNAL SIGNAL INPUT LINE LINE...
  • Page 152 FUEL SYSTEM (PGM-FI) 4. Injector Signal Line Open Circuit Inspection Turn the ignition sw itch OFF. FRONT INJECTOR 2P (GRAY) CONNECTOR Disconnect the ECM 33P (Black) connector (page (Wire side o f fem ale term inal) Check fo r c o n tin u ity between the ECM 33P (Black) c o rn e c to r and in jector 2P (Gray) connec­...
  • Page 153 FUEL SYSTEM (PGM-FI) D TC 18-1 (C M P S E N S O R ) • Before starting the inspection, check for loose or poo r contact on the CMP sensor 2P (Black) con­ nector and recheck the DTC. 1.
  • Page 154 FUEL SYSTEM (PGM-FI) D TC 19-1 (CKP S E N S O R ) • Before starting the inspection, check fo r loose or poo r contact on the CKP sensor connector and recheck the DTC. 1. CKP Sensor Peak Voltage Inspection Turn the ig n itio n sw itch OFF.
  • Page 155 FUEL SYSTEM (PGM-FI)__________________________ D TC 21-1 (O S E N S O R ) • Before starting the inspection, check fo r loose or poor contact on the O sensor 4P (W hite) connec­ to r and recheck the DTC. 1.
  • Page 156 FUEL SYSTEM (PGM-FI) 4. O Sensor Inspection Heplace th e O sensor w ith a new one. Clear the DTC. Start the engine and w arm up the engine until the coolant tem perature is 80 °C (176 °F). Test-ride the m otorcycle. Check the O sensor w ith the HDS pocket tester.
  • Page 157 FUEL SYSTEM (PGM-FI) 4. O Sensor Heater Open c irc u it Inspection Turn the ig n itio n sw itch OFF. ECM 33P (LIGHT GRAY) CONNECTOR Disconnect the ECM 33P (Gray) connector. (W ire side o f fem ale term inal) Check fo r c o n tin u ity between the ECM 33P (Gray) connector and O sensor 4P (W hite) con­...
  • Page 158 FUEL SYSTEM (PGM-FI) 3. IACV Circuit Continuity Inspection Disconnect the ECM 33P (Black) connector. Check fo r continuities between the ECM 33P (Black) co rn e cto r te rm inals and the IACV 4P (Black) connector term inals. CONNECTION: A19 - Yellow/blue A27 - G reen/w hite A16 - Green A29 - Green/yellow...
  • Page 159 FUEL SYSTEM (PGM-FI) D TC 53-1 (T C M S IG N A L ) • Before starting the inspection, check fo r loose or poo r contact on the TCM 33P (Black) connector and recheck the DTC. 1. TCM Signal Line Open C ircuit Inspection Turn the ig n itio n switch OFF.
  • Page 160 FUEL SYSTEM (PGM-FI) DTC 68-1 (E N G IN E IN H IB IT O R S IG N A L ) • Before starting the inspection, check fo r loose or poor contact on the TCM 33P (Black) connector and recheck the DTC.
  • Page 161: Mil Circuit Inspection

    FUEL SYSTEM (PGM-FI) MIL CIRCUIT INSPECTION If the engine can be started but the MIL does not com e on w hen the ig n itio n sw itch ON and engine stop switch "O", check the follow s: Check for operation o f the com bination m eter fu n c­ tio n properly.
  • Page 162: Fuel Line Inspection

    ■ __________________________________________________________ FUEL SYSTEM (PGM-FI) FUEL LINE INSPECTION FUEL PRESSURE RELIEVING/QUICK CONNECT FITTING REMOVAL • Before disconnecting fuel feed hose, relieve pres­ sure from the system as fo llo w in g procedures. 1. Turn the ignition switch OFF. Remove the seat (page 3-4). 2.
  • Page 163 FUEL SYSTEM (PGM-FI) 8. To prevent dam age a rd keep foreign m atter out, cover tho disconnected connoctor and pipo ond w ith plastic bags. Q U IC K C O N N E C T F IT T IN G IN S T A L L A T IO N •...
  • Page 164 FUEL SYSTEM (PGM-FI) 3. Make sure the connection is secure and th a t the pawls are firm ly locked into place; check visu a lly and by pulling the connector. 4. Make sure the ru bb er cap is in place (between the retainer tab and stopper on pipe).
  • Page 165 FUEL SYSTEM (PGM-FI)__________________________ FUEL FLOW INSPECTION Remove the seat (page 3-4). Turn the ig n itio n sw itch OFF. Open the fuse/relay box and rem ove the fuel cut relay. J u m p the te rm inals o f the w ire harness side using a RELAY CONNECTOR ju m p e r w ire as show n.
  • Page 166: Fuel Pump

    FUEL SYSTEM (PGM-FI) FUEL PUMP INSPECTION Turn th e ig n itio n switch ON, engine stop sw itch "O" and co n firm th a t the fuel pum p operates fo r a few seconds. If the fu e l pum p does not operate, inspect as fo l­ lows: Turn th e ig n itio n sw itch OFF.
  • Page 167 FUEL SYSTEM (PGM-FI) Remove the nuts. Loosen the nuts in a crisscross pattern in several steps. Rem ove the fuel pum p assem bly w ith the packing. Be careful n o t to PACKING dam age the fuel level sensor. IN S P E C T IO N Check the fuel pum p assem bly fo r damage.
  • Page 168: Fuel Cut Relay

    FUEL SYSTEM (PGM-FI) Install and tighten the fuel pum p m ounting nuts to NUTS the specified torque in the specified sequence as shown. TORQUE: 12 N-m (1.2 kgf-m , 9 Ibf-ft) Connect the fuel pum p 3P (Black) connector. 3P (BLACK) CONNECTOR Connect the quick connect fittin g (page 6-38).
  • Page 169: Upper Fuel Tank

    FUEL SYSTEM (PGM-FI) UPPER FUEL TANK R E M O V A L Remove the center cow l (page 3-6). 2P (BLUE) CONNECTOR Drain the fuel fro m the upper fuel tank. Disconnect the upper fuel level sensor 2P (Blue) connector.
  • Page 170 FUEL SYSTEM (PGM-FI) Remove the bolts, washers, collars and upper fuel I BOLTS/WASHERS/COLLARS tank. UPPER FUEL TANK BOLTS/COLLARS INSTALLATION WASHER BREATHER HOSE UPPER FUEL TANK COLLAR FUEL HOSE CLIP FUEL HOSE Install the upper fuel tank, washers, collars and bolts. Tighten the bolts securely.
  • Page 171 FUEL SYSTEM (PGM-FI) Always replace the Install a new fuel hose and fuel hose clip. FUEL HOSE FUEL HOSE fuel hose and hose CLIP clip with a n e w one. C onnect the upper and low er fuel lank brealher UPPER hose to the upper fuel tank.
  • Page 172: Breather Separator

    FUEL SYSTEM (PGM-FI) BREATHER SEPARATOR REMOVAL Disconnect the upper breather hose. SCREWS t O-RING UPPER Remove the three screws, breather separator, BREATHER retainer and O-ring. HOSE BREATHER SEPARATOR RETAINER INSTALLATION Install a new O-ring onto the breather separator RETAINER O-RING Install the breather separator and retainer by align­...
  • Page 173: Lower Fuel Tank

    FUEL SYSTEM (PGM-FI) LOWER FUEL TANK R E M O V A L Remove the upper fuel tank (page 6-44). Relieve the fuel pressure and disconnect the quick connect fittin g (page 6-37). Remove the m u ffle r (page 3-16). Disconnect the fuel level sensor 3P (Black) connec- tor.
  • Page 174 FUEL SYSTEM (PGM-FI) Lower th e sub fram e and tighten the p ivo t nut SUB FRAME NUT/WASHER securely. PIVOT NUT Install and tig h te n the lo w e r fuel tank p ivo t bolt/nut, m ounting b o lt securely w ith washers. BOLTS/WASHERS PIVOT BOLT Install and tig h te n the sub fram e m o u n tin g bolt...
  • Page 175: Air Cleaner Housing

    FUEL SYSTEM (PGM-FI) Connect the fo llo w in g : CKP sensor 2P (Red) connector sensor 4P (Black) connector PGM-FI sub harness 4P connector PGM-FI sub harness 14P (Gray) connector Connect the fuel level sensor 3P (Black) connector. 3P (BLACK) CONNECTOR Install the m u ffle r (page 3-16).
  • Page 176 FUEL SYSTEM (PGM-FI) Remove the a ir cleaner housing m ou ntin g bolts. BOLTS Loosen the air cleaner housing connecting tube band screws. Lift up the a ir cleaner housing and disconnect the PAIR AIR SUPPLY HOSE crankcase breather hose and PAIR a ir supply hose. Remove the air cleaner housing.
  • Page 177 FUEL SYSTEM (PGM-FI) INSTALLATION AIR CLEANER ELEMENT MIDDLE CASE AIR CLEANER CASE COVER LOWERCASE Connect the crankcase breather hose and PAIR air PAIR AIR SUPPLY HOSE su pp ly hose to the a ir cleaner housing. BREATHER HOSE Connect the air cleaner housing connecting tube to the th ro ttle body, then tighten the band screws securely.
  • Page 178: Insulator

    ■ FUEL SYSTEM (PGM-FI) m o u n tin g In s ta ll a n d t i g h t e n th e a i r c le a n e r h o u s i n g bolts securely.
  • Page 179: Throttle Body

    FUEL SYSTEM (PGM-FI) THROTTLE BODY R E M O V A L NOTE: • Bending o r tw istin g the control cables w ill im p a ir sm ooth operation and could cause the cables to stick or bind, resulting in loss o f vehicle control. •...
  • Page 180 FUEL SYSTEM (PGM-FI) Loosen the lock nuts and rem ove the th ro ttle cables. Loosen the insulator band screws. SCREWS Lift up the th ro ttle body and release the in je cto r CLAMP w ire fro m the clam p. Remove the th ro ttle body.
  • Page 181 FUEL SYSTEM (PGM-FI) NOTE: • The th ro ttle body is factory pre-set. Do not disas­ sem ble in a w ay other than show n in this m an­ ual. • Do not snap th e th ro ttle valve fro m fu lly open to fu lly closed after the th ro ttle cable has been rem oved.
  • Page 182 FUEL SYSTEM (PGM-FI) INSTALLATION Install the injector w ire to the c amp. CLAMP Install the th ro ttle body and tighten the insulator band screws. C onnect the th ro ttle cable ends to the th ro ttle drum . THROTTLE CABLES THROTTLE DRUM 6-57...
  • Page 183: Injector

    FUEL SYSTEM (PGM-FI) Connect the rear in jector 2P (Gray) connector. 2P (GRAY) CONNECTOR Connect the fo llo w in g : 4P (BLACK) CONNECTOR IACV 4P (Black) connector 2P (GRAY) CONNECTOR TP sensor 3P (Black) connector Front injector 2P (Gray) connector Connect the quick connect fittin g at the th ro ttle b ody (page 6-38).
  • Page 184 FUEL SYSTEM (PGM-FI) REMOVAL Remove the upper fuel tank (page 6-44). Front injector side; FRONT: FRONT INJECTOR 2P (GRAY) CONNECTOR Remove the center cow l (page 3-6). Rear injector side: Relieve the fuel pressure and disconnect the quick connect fittin g (page 6-37). Clean around the in jector base and fuel hose quick connector w ith com pressed air before rem oving the injector, and De sure th a t no debris is allowed to...
  • Page 185 FUEL SYSTEM (PGM-FI) Remove the seal ring and O-ring. SEAL RING O-RINGS INSTALLATION Coat a new O -ring and new ring w ith engine oil. — m SEAL RING INJECTOR seal Install a new O -ring and new seal ring, being careful Replace the seal not to damage.
  • Page 186 FUEL SYSTEM (PGM-FI) Install the injector in to the th ro ttle body. Be careful not to FRONT: BOLTS INJECTOR HOLDER damage the seal Install and tighten the bolts to the specified torque. ring. TORQUE: 5.4 N m (0.55 kgf-m, 4.1 Ibf-ft) THROTTLE BODY ■...
  • Page 187: Iacv

    FUEL SYSTEM (PGM-FI) IACV INSPECTION The IACV is installed on the th ro ttle body and is 4P CONNECTOR operated by the step m otor. W hen the ignition sw itch is turned ON, the IACV operates fo r a few seconds.
  • Page 188 FUEL SYSTEM (PGM-FI) Remove the fo llo w in g from the IACV body: T orx screws Setting plate TORX SCREWS IACV SETTING PLATE IACV INSTALLATION Turn the slide valve clockwise until lig h tly seated on IACV. Install the IACV, aligning slide valve groove w ith the pin.
  • Page 189: Map Sensor

    FUEL SYSTEM (PGM-FI) Install and tigh ten the to rx screw to the specified torque. TORQUE: 2.1 N m (0.21 kgf-m, 1.5 Ibf-ft) TORX SCREWS Install new O-rings to the IACV body. Install the IACV body to the throttle body. IACV COVER Install and tig hte n the screw to the specified torque.
  • Page 190: Iat Sensor

    FUEL SYSTEM (PGM-FI) IAT SENSOR REMOVAL/INSTALLATION Remove the air cleaner housing (page 6-50). IAT SENSOR Remove the screw and IAT sensor fro m the air cleaner housing. Installation is in the reverse order o f rem oval. ECT SENSOR REMOVAL/INSTALLATION Drain th e coolant (page 7-6).
  • Page 191 FUEL SYSTEM (PGM-FI) Remove the bolt, CMP sensor and O-ring fro m the CMP SENSOR O-RING rear cylinder head. BOLT INSTALLATION A pply oil to a new O -ring and install it onto the CMP sensor. Install the CMP sensor into the cylinder head. Install and tig h te n the bolt securely.
  • Page 192: Bank Angle Sensor

    FUEL SYSTEM (PGM-FI) BANK ANGLE SENSOR INSPECTION Remove the left seat cow l (page 3-12). Connect the special to o l between the bank angle sensor and w ire harness. TOOL: Inspection adaptor 07GMJ-ML80100 Turn the ignition sw itch ON and engine stop switch "O".
  • Page 193: Fi/ign/pump Relay

    FUEL SYSTEM (PGM-FI) Installation is in the reverse order o f rem oval. Install tne bank angle sensor with " " TORQUE: 0.5 N-m (0.05 kgf-m, 0.4 Ibf-ft) mark facing up. FI/IGN/PUMP RELAY INSPECTION Remove the seat (page 3-4). Open the fuse/relay box and rem ove the FI/IGN/ PUMP relay.
  • Page 194 FUEL SYSTEM (PGM-FI) ECM POWER/GROUND LINE INSPECTION ENGINE DOES NOT START (MIL NO BLINKS) 1. ECM Power Input Voltage Inspection Disconnect the ECM 33P connectors (page 6-68). Turn the ig n itio n sw itch ON and engine stop sw itch "O". M easure the voltage at the ECM 33P (Black) con­...
  • Page 195 FUEL SYSTEM (PGM-FI) 4. FI/IG N /PUM P Relay Inspection 1 Turn the ig n itio n sw itch OFF. Open the fuse/relay box and rem ove the FI/IGN/ PUMP relay (page 6-68). Turn the ig n itio n switch ON and engine stop sw itch "O".
  • Page 196: Secondary Air Supply System

    FUEL SYSTEM (PGM-FI) SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION S tart the engine and w arm it up u ntil the coolant tem perature is 80 °C (176 °F). Stop the engine. Remove the a ir cleaner elem ent (page 4-6). Check th a t th e secondary a ir intake p o rt is clean and free o f carbon deposits.
  • Page 197: Pair Control Solenoid Valve

    FUEL SYSTEM (PGM-FI) PAIR CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Remove the air cleaner housing (page 6-50) Remove the PAIR solenoid valve fro m the stay. Disconnect the PAIR solenoid valve 2P (Black) con­ nector. Disconnect the air suction and air supply hoses fro m the PAIR solenoid valve.
  • Page 198: 0 2 Sensor

    FUEL SYSTEM (PGM-FI) PAIR CHECK VALVE REMOVAL/INSTALLATION Remove the upper fuel tank (page 6-44). PAIR CHECK VALVE COVER Remove the bolts and PAIR check valve cover. Remove the PAIR check valve fro m the cylinder head cover. Check the reed fo r dam age or fatigue. Replace if necessary.
  • Page 199 FUEL SYSTEM (PGM-FI) Remove the O sensor unit using the special tool. TOOL: sensor wrench 07LAA-PT50101 NOTE: • Do not use an im pact w rench w h ile rem oving or installing the O sensor. • Be careful not to damage the sensor w ire. INSTALLATION Install the O sensor and tighten it securely.
  • Page 200: Evap Purge Control Solenoid Valve/canister (california Type)

    FUEL SYSTEM (PGM-FI) EVAP PURGE CONTROL SOLENOID VALVE/CANISTER (CALIFORNIA TYPE) REMOVAL/INSTALLATION Rem ove the inner low er cow l (page 3-12). Disconnect the fo llo w in g : EVAP purge control solenoid valve 2P connector. Fuel tank breather hose (to fuel tank) Canister-to-purge control solenoid valve hose EVAP canister hose EVAP canister drain hose...
  • Page 201 FUEL SYSTEM (PGM-FI) INSPECTION Remove the EVAP purge control solenoid valve (page 6-75). Check th a t air should not *'low (A) to (B), o n ly when a 12V battery is connected to the EVAP purge con­ tro l solenoid valve term inals. Check the resistance betv/een the te rm ina ls o f the EVAP purge control solenoid valve.
  • Page 202 7. COOLING SYSTEM SYSTEM FLOW PATTERN......7-2 THERMOSTAT HOUSING......7-9 SERVICE INFORMATION......7-3 RADIATOR/COOLING FAN...... 7-10 TROUBLESHOOTING......... 7-4 WATER PUM P........... 7-15 SYSTEM TESTING........7-5 RADIATOR RESERVE TAN K....7-17 FAN MOTOR RELAY.........7-18 COOLANT REPLACEMENT......7-6 THERMOSTAT..........7-8...
  • Page 203: System Flow Pattern

    COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR CAP RESERVE TANK RADIATOR WATER PUMP...
  • Page 204: Service Information

    8 m m (0.3 in) m in im u m at 95 (203 °F) °C Pro Honda HP coolant or equivalent high q u a lity ethylene Recommended antifreeze glycol antifreeze containin g corrosion protection in h ib ito rs...
  • Page 205: Troubleshooting

    COOLING SYSTEM TROUBLESHOOTING Engine temperature too high • Faulty tem perature indicator • Therm ostat stuck closed • Faulty radiator cap • Insufficient coolant • Passages blocked in radiator, hoses or w ater jacket • A ir in system • Faulty cooling fan m o tor •...
  • Page 206: System Testing

    COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the rig h t fro n t side cowl (page 3-5). Remove the radiator cap. Test the coolant specific gravity using a hydrom e- HYDRQMETER ter. STANDARD COOLANT CONCENTRATION: 1:1 (d istilled w a te r and th e recom m ended antifreeze) Look fo r contam ination and replace the coolant if necessary.
  • Page 207: Coolant Replacement

    M ix only distilled, lo w m ineral w ater w ith the rec­ om m ended antifreeze. ANTIFREEZE RECOMMENDED ANTIFREEZE: SOLUTION Pro Honda HP coolant or equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors (ETHYLENE GLYCOL BASE...
  • Page 208 _______________________ COOLING SYSTEM Remove the fo llo w in g . RADIATOR CAP Right fro n t side cow l (page 3-5) Left under cow l (page 3-11) Remove the radiator cap. Drain the coolant from the system by rem oving the drain bolt and sealing washer.
  • Page 209: Thermostat

    COOLING SYSTEM __________________ Remove the reserve tank cap. RESERVE TANK CAP Fill the reserve tank to the upper level line w ith the recom m ended coolant. Install the follow ing :. Left under cow l (page 3-11) UPPER LINE Right fro n t side cowl (page 3-5) LOWER LINE THERMOSTAT...
  • Page 210: Thermostat Housing

    COOLING SYSTEM INSPECTION V isually inspect the th erm o stat fo r damage. Do not let the THERMOMETER thermostat cr Heat the w ater w ith an electric heating elem ent to thermometer toucn operating tem perature fo r 5 minutes. Suspend the th e rm o sta t in heated w ater to check its the pan, or you wHI THERMOSTAT...
  • Page 211: Radiator/cooling Fan

    COOLING SYSTEM Loosen the band screw and disconnect the w ater hoses. Install the therm ostat housing assembly in the Tighten the water reverse order o f removal. hose band screw to the specified range. WATER HOSE 0 - 1 . 0 mm (0 -0 .0 4 in) RADIATOR/COOLING FAN NOTE:...
  • Page 212 COOLING SYSTEM Loosen the band screw and disconnect the lower radiator w ater hose. Remove the radiator upper bolt and collar. BOLT/COLLAR u u r " — ' Remove the radiator low er b olt and collar. Release the radiator g rom m et fro m the fram e boss and rem ove the radiator.
  • Page 213 COOLING SYSTEM Remove the nut and cooling fan. COOLING FAN Release the fan m o to r w ire from the clamp. SHROUD NUTS Remove the nuts and fan m o to r fro m the shroud. CLAMP FAN MOTOR ASSEMBLY COOLING FAN RADIATOR...
  • Page 214 COOLING SYSTEM Install the fan m o to r o n to th e shroud and tighten NUTS SHROUD the nuts. Install the fan m o to r w ire to the clamp. CLAMP FAN MOTOR Install the cooling fan unto the m otor shaft, aligning the fla t surfaces.
  • Page 215 COOLING SYSTEM INSTALLATION Install the radiator assembly, aligning its grom m et GROMMET/BOSS w ith the fram e boss. Install the radiator low er bolt and collar. BOLT/COLLAR RADIATOR Install the radiator upper bolt and collar. BOLT/COLLAR Connect the upper radiator hose and tig h te n the hose band screw securely.
  • Page 216: Water Pump

    COOLING SYSTEM Connect the low e r radiator w ater hose and tighten the hose band screw securely. 0 - 1 . 0 mm ( 0 - 0 .0 4 in) Connect the fan m o to r 2P (Black) connector. Route the hoses pm ancl bleed the cooling system (page 7-6).
  • Page 217 COOLING SYSTEM WATER PUMP COVER REMOVAL Drain the coolant fro m the system (page 7-6). Loosen the band screw and disconnect the w ater hoses. W A T E R H O SE Remove the bolts, sealing w asher and w ater pum p cover.
  • Page 218: Radiator Reserve Tank

    COOLING SYSTEM Install the w ater pum p cover, e new sealing w asher and bolts. Tighten the bolts in a crisscross pattern in several steps. BOLT/SEALING WASHER C unnecl the w atei hoses and tighten the hose band screw securely. Fill and bleed the cooling system (page 7-6).
  • Page 219: Fan Motor Relay

    COOLING SYSTEM FAN MOTOR RELAY INSPECTION Remove the seat (page 3-4) Open the fuse/relay box and rem ove the fan m o tor relay. Connect an ohm m eter to the fan m oto r relay con- MOTOR RELAY nector term inals. Connect a 12 V battery to the fan m o to r relay con­...
  • Page 220 8. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION......8-2 ENGINE REMOVAL........8-4 SERVICE INFORMATION......8-3 ENGINE INSTALLATION......8-9...
  • Page 221 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION...
  • Page 222 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • A hoist or equivalent is required to supp ort the m otorcycle when rem oving and installing the engine. • A floor jack or oth er adjustable su p p o rt is required to su p p o rt and m aneuver the engine. •...
  • Page 223: Engine Removal

    ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 4-12). Drain the coolant from the system (page 7-6). Disconnect the CMP sensor 2P (Black) connector (page 6-65). Remove the fo llo w in g : Throttle body (page 6-54) Rear insulator (page 9-13) Spark plug caps (page 4-7) Exhaust system (page 3-16) Radiator (page 7-10)
  • Page 224 ENGINE REMOVAL/INSTALLATION Disconnect the PAIR air supply hose fro m the rear PAIR AIR SUPPLY HOSE PAIR check valve cover. REAR PAIR CHECK VALVE COVER Remove the bolts, fro n t PAIR check valve cover and BOLTS PAIR check valve. FRONT PAIR CHECK VALVE COVFR/PAIR CHECK VALVE Disconnect the control m o to r 2P (Black) connector...
  • Page 225 ENGINE REMOVAL/INSTALLATION____________ Disconnect the CKP sensor 2P (Red) connector. 2P (RED) CONNECTOR Disconnect the fo llo w ing : 2P (BLACK) BOLT/NEUTRAL Neutral/drive solenoid 2P (Black) connector CONNECTOR SWITCH WIRES Lock up solenoid 2P (Gray) connector Oil pressure sensor 3P (Black) connector Remove the bolt and disconnect the neutral sw itch wires.
  • Page 226 ENGINE REMOVAL/INSTALLATION Loosen the band screw and disconnect the w ater WATER HOSE hose. Remove th e bolt and disconnect the ground cablc. BOLT GROUND CABLE Remove the rear engine m ou n ting n u t and bolt. HANGER PLA’ ES Remove the engine hanger plate bolts and rear engine hanger olates.
  • Page 227 ENGINE REMOVAL/INSTALLATION Remove the low er engine m ounting nut and bolt. MOUNTING BOLT/NUT Release the jo in t boot from the side gear case. M ove the engine forw ard and release the output During dngine shaft fro m the universal jo in t in the sw ingarm . removal, hold the Turn the engine counterclockw ise 90 degrees in the engine securely and...
  • Page 228: Engine Installation

    ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION NOTE: • Route the w ires, hoses and cables properly (page Place the engine into the fram e fro m rig h t side at During e n g in s the engine tu rn in g counterclockw ise 90 degrees. installation, h o ld the engine secu rely and Turn the engine clockwise 90 degrees in the fram e.
  • Page 229 ENGINE REMOVAL/INSTALLATION Install the rear engine hanger plates and bolts. HANGER PLATES Tighten the bolts to the specified torque. TORQUE: 26 N-m (2.7 kgf-m, 19 Ibf-ft) Install and tighten the rear engine m ounting bolt and nut to the specified torque. TORQUE: 39 N-m (4.0 kgf-m, 29 Ibf-ft) BOLTS MOUNTING BOLT...
  • Page 230 ___________________________________ ENGINE REMOVAL/INSTALLATION Connect the oil pressure sw itch w ire and tighten the BOLT/OIL PRESSURE bolt to the specified torque. SWITCH WIRE TORQUE: 1.9 N m (0.19 kgf m, 1.4 Ibf ft) Connect the EOT sw itch 2P (Black) connector and 3P (BROWN) CONNECTOR swash plate angle sensor 3P (Brown) connector.
  • Page 231 ENGINE REMOVAL/INSTALLATION Connect the oil reserve sensor connectors (Pink/ OIL RESERVE SENSOR blue anc Yellow/red wires). CONNECTOR Install the w ire clamp. (Pink/blue w ire) CLAMP OIL RESERVE SENSOR CONNECTOR (Yellow/red w ire) Connect the control m o to r 2P (Black) connector and CONTROL MOTOR 2P (BLACK) CONNECTOR VS senscr 2P (Black) connector.
  • Page 232 ENGINE REMOVAL/INSTALLATION Connect the w ater hoses and tig h te n the hose band screws securely. 0 - 1 . 0 m m (0 - 0 .0 4 in) Install the left step bracket and bolts. Tighten the bolts securely. Install the fo llow ing: T hrottle body (page 6-57) Rear insulator (page 9-25)
  • Page 233 9. CYLINDER HEAD/VALVE COMPONENT LOCATION....... - 9-2 CYLINDER HEAD DISASSEMBLY..9-15 SERVICE INFORMATION......-9-3 VALVE GUIDE REPLACEMENT -.....9-18 TROUBLESHOOTING........9-5 VALVE SEAT INSPECTION/REFACING • 9-20 CYLINDER COMPRESSION......9-6 CYLINDER HEAD ASSEMBLY....9-23 CYLINDER HEAD COVER REMOVAL..9-6 CYLINDER HEAD INSTALLATION..9-25 CAMSHAFT REMOVAL......9-7 CAMSHAFT INSTALLATION....
  • Page 234: Component Location

    CYLINDER HEAD/VALVE________ COMPONENT LOCATION 23 N m (2.3 kgf-m, 17 Ibf-ft)
  • Page 235: Service Information

    __________________________________________________________ CYLINDER HEAD/VALVE SERVICE INFORMATION GENERAL • This section covers service o f the rocker arm , cam shaft, cylinde r head and valve. • The cylinder head services can be done w ith the engine installed in the fram e. •...
  • Page 236 CYLINDER HEAD/VALVE TOOLS Valve guide reamer, 5.510 m m Valve guide driver, 5.5 m m Valve spring com pressor 07984-2000001 07742-0010100 07757-0010000 07984-200000D U.S.A. only Valve guide d river Cutter holder, 5.5 mm Valve seat cutter, 27.5 mm (45° EX) 07743-0020000 07781-0010101 07780-0010200...
  • Page 237: Troubleshooting

    CYLINDER HEAD/VALVE TROUBLESHOOTING • Engine top-end problem s usually affect engine perform ance. These can be diagnosed by a com pression test, o r by trac­ ing top-end noise w ith a sounding rod o r stethoscope. • If the performance is poor at low speeds, check fo r w h ite smoke in the crankcase breather hose. If the hose is smoky, check for a seized piston ring (page 10-4).
  • Page 238: Cylinder Compression

    CYLINDER HEAD/VALVE CYLINDER COMPRESSION W arm up the engine to norm al operating tem pera­ To measure the ture. cylinder Stop the engine, disconnect the spark plug caps and compression o f rem ove one spark plug at a time. each cylinder, Install a com pression gauge into the spark plug remove only one...
  • Page 239: Camshaft Removal

    CYLINDER HEAD/VALVE REAR Remove th e upper fuel tank (page 6-44). BOLTSA/VASHERS/RUBBER SEALS Disconnect the a ir supply hose from the PAIR check valve cover. Remove the cylind er head cover bolts, w ashers and rubber seals. AIR SUPPLY HOSE Remove the c ylin d e r head cover and gasket.
  • Page 240 CYLINDER HEAD/VALVE Turn the crankshaft clockwise and align the "RT" m ark (front cylinder: "FT" mark) w ith the index notch on the alternator cover. Make sure the piston is at TDC (Top Dead Center) on the exhaust stroke so the piston is at TDC on the com pression stroke when rem oving the cam shaft holder.
  • Page 241 CYLINDER HEAD/VALVE R em ove th e C M P sen so r rotor. Rear cylinder heao FRONT: R E A R :, only: C M P S E N S O R R OTOR Attach a piece of R em ove th e c a m sprocket fro m th e c a m s h a ft flang e. wire to the cam cham to prevent it front falling into the...
  • Page 242 CYLINDER HEAD/VALVE CAM LOBE HEIGHT C heck the cam lo b e surfaces to r scoring or evidence o f insufficient lu b ricatio n . M e a s u re each cam lobe heig h t. SERVICE LIMITS: IN: 40.52 mm (1.595 in) EX: 40.53 mm (1.596 in) NOTE: C heck th e rocker a rm if th e cam lo b e is w o rn or...
  • Page 243 CYLINDER HEAD/VALVE CAMSHAFT OIL CLEARANCE C lean o ff a n y oil fro m th e jo u rn a ls o f th e cam shaft h olders, cylin d e r head an d ca m s h a ft. Put th e c a m s h a ft o n to th e c y lin d e r head and lay a strip o f p la s tig a u g e le n g th w is e on each cam shaft jo u rn a l.
  • Page 244 CYLINDER HEAD/VALVE R e m o v e th e lock nuts and v a lv e ad ju stin g screw s. ROCKER ARM/ROCKER ARM SHAFT INSPECTION Check th e s lid in g surface o f th e rocker arm s fo r w e a r or d a m a g e w h e re th ey co ntact th e cam sh aft, o r fo r clo g g ed oil holes.
  • Page 245: Cylinder Head Removal

    CYLINDER HEAD/VALVE CYLINDER HEAD REMOVAL NOTE: • T h e fro n t c y lin d e r h ead uses th e s am e service p ro c ed u re as th e re a r cylin der head. R e m o v e th e fo llo w in g : IN S U L A T O R /O -R IN G C y lin d e r h ead co v e r (p a g e 9-6)
  • Page 246 CYLINDER HEAD/VALVE R em o v e the cam chain te n sio n er. C AM C H A IN TE N S IO N E R Remove the fo llo w in y cylinder head bolts and nuts: Loosen llitt bulla 10 m m N U T S /W A S H E R S and nuts in a...
  • Page 247: Cylinder Stud Bolt Replacement

    CYLINDER HEAD/VALVE CYLINDER STUD BOLT REPLACEMENT Th re ad tw o nuts o n to th e stud and tig h te n them 12 m m S T U D BOLT to g e th e r, an d use a w re n c h on th e m to tu rn th e stud bolt out.
  • Page 248 CYLINDER HEAD/VALVE R e m o v e th e v a lv e sp rin g co m p resso r, th en re m o v e Do n o t reuse the S P R IN G SEAT the retainer, spring and valve.
  • Page 249 CYLINDER HEAD/VALVE VALVE STEM, VALVE GUIDE Check each valve fo r bending, burning, scratches or ab n o rm a l w e a r. Insert th e v a lv e s in th e ir o rig in a l p o sitio n s in th e cyl­ in d e r h ead .
  • Page 250: Valve Guide Replacement

    CYLINDER HEAD/VALVE_____________________ CAM CHAIN GUIDE C heck th e cam chain g u id e fo r w e a r o r d am ag e. C A M C H A IN G U ID E R eplace th e cam chain g u id e if necessary. CAM CHAIN TENSIONER Check th e cam chain te n s io n e r fo r w e a r o r d am ag e.
  • Page 251 CYLINDER HEAD/VALVE E xcept U .S .A . procedure: V A LV E G U ID E DRIVER A d ju s t th e v a lv e g u id e d riv e r to th e v a lv e g u id e h eig h t.
  • Page 252: Valve Seat Inspection/refacing

    CYLINDER HEAD/VALVE VALVE SEAT INSPECTION/REFACING INSPECTION Clean all intake and e x h a u s t v a lv e s th o ro u g h ly to H A N D -L A P P IN G TOO L re m o v e carbon deposits.
  • Page 253 CYLINDER HEAD/VALVE VALVE SEAT REFACING NOTE. • F o llo w th e refacer m a n u fa c tu re r's operatin g instructions. • Reface th e valve seat w h e n e v e r th e v a lv e guide has been replaced.
  • Page 254 CYLINDER HEAD/VALVE U sin g a 60° cu tter, rem o ve th e b o tto m 1/4 o f th e old seat. TOOLS: Interior cutter, 30 mm (IN) 07780-0014000 Interior cutter, 26 mm (EX) 07780-0014500 Cutter holder, 5.5 mm 07781-0010101 or equivalent com­...
  • Page 255: Cylinder Head Assembly

    CYLINDER HEAD/VALVE CYLINDER HEAD ASSEMBLY C O TTE R S S P R IN G RETAINER VA LV E S P R IN G S P R IN G S E A T S T E M S EA L G U ID E IN TA K E V A LV E...
  • Page 256 CYLINDER HEAD/VALVE Install th e cotters using a special tool. Grease the cotters S PR IN G C O M PR ESSO R to ease installation. TOOL: Valve spring compressor 07757-0010000 NOTE: C om pressing th e v a lv e springs m o re than n eces­ sary w ill cause loss o f v a lv e sp rin g ten sio n .
  • Page 257: Cylinder Head Installation

    CYLINDER HEAD/VALVE CYLINDER HEAD INSTALLATION NOTE: • T h e c y lin d e r rear h ead uses th e s a m e service p ro c ed u re as th e fro n t cylin der head. •...
  • Page 258 CYLINDER HEAD/VALVE Install the cylin d e r head to th e cylinder. 10 m m N U T S /W A S H E R S A p p ly engine oil to th e each bolts and nuts th read s an d seating surfaces.
  • Page 259: Camshaft Installation

    CYLINDER HEAD/VALVE Install a n e w O -rings to th e w a te r hose jo ints. O -R IN G Install the water hose joints and tighten the bolts securely. B OLTS W A T E R H O S E J O IN T Install a n e w G -ring to th e in s u lato r g ro o ve .
  • Page 260 CYLINDER HEAD/VALVE A p p ly e n g in e oil to th e v alve ad ju stin g s crew lock nut threads and seating surface. Install th e v a lv e ad ju stin g screw and lock nut. NOTE: •...
  • Page 261 CYLINDER HEAD/VALVE FRONT CYLINDER TDC SETTING R e m o v e th e re a r c y lin d e r h ead uuver (p a g e 9-G) and If the rear cylinder IN D E X N O TCH check th e re a r c y lin d e r c a m s h a ft p osition as fo llo w s : has not beer, serviced, begir...
  • Page 262 CYLINDER HEAD/VALVE T h e n check th e id en tificatio n m ark "F" on th e fro n t "F" M ARK cam sh aft. If th e "F" m ark faces up, tu rn th e cran ksh aft clock­ w is e 2 9 /4 5 (2 3 2 °) tu rn (align th e "RT"...
  • Page 263 CYLINDER HEAD/VALVE Install th e c a m sp ro cket to th e ca m chain w ith the C A M C H A IN "UP" m ark facing inside. UP" M A R K Install th e cam sprocket on th e c a m s h a ft fla n g e and FRONT: R E A R :, check th a t th e tim in g m arks a lig n w ith th e upper...
  • Page 264: Cylinder Head Cover Installation

    CYLINDER HEAD/VALVE____________________ A d ju s t th e v a lv e c learan ce (p a g e 4-8). Fill th e oil pockets in th e h ead w ith en g in e oil. CYLINDER HEAD COVER INSTALLATION C lean th e gasket g ro o v e and c y lin d e r head m atin g surface o*' th e c y lin d e r head cover.
  • Page 265 CYLINDER HEAD/VALVE Install th e ru b b e r seals as show n. Install th e w a s h e rs and tig h te n th e c y lin d e r head c o ve r bolts to th e specified torque. TO R Q U E : 10 N m (1.0 k g f-m , 7 Ib f-ft) Install th e PAIR system (p a g e 6-72).
  • Page 266 10. CYLINDER/PISTON 10-4 COMPONENT LOCATION......10-2 CYUNDER/PISTON REMOVAL SERVICE INFORMATION ......10-3 CYUNDER/PISTON INSTALLATION..10-9 TROUBLESHOOTING....... 10-3 10-1...
  • Page 267 CYLINDER/PISTON_____________ COMPONENT LOCATION...
  • Page 268 CYLINDER/PISTON SERVICE INFORMATION GENERAL • This section covers service o f the p iston and c y lin d er. T o service th ese parts, th e e n g in e m u s t be re m o v e d fro m th e frame.
  • Page 269: Cylinder Removal

    CYLINDER/PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL NOTE: T h e re a r c y lin d e r uses th e s a m e service p rocedure as th e fro n t cylinder. R e m o v e the c y lin d e r head (p a g e 9-13). BOLTS R e m o v e the bolts and w a te r hose jo in t.
  • Page 270: Piston Removal

    CYLINDER/PISTON R e m o ve th e gasket and d o w e l pins. G A S K E T C lean o ff an y g asket m a te ria l fro m th e cylin der Be careful not to damage the gasket u p p er surface.
  • Page 271 CYLINDER/PISTON_____________________________ N ever use a w ire C lean carbon deposits fro m th e ring g ro o ve s w ith a used piston ring th a t w ill be discarded. brush; it w ill scratch the groove. INSPECTION PISTON/PISTON RING Inspect th e piston rings for s m o o th m o v e m e n t by...
  • Page 272 CYLINDER/PISTON M e a s u re th e p iston pin O .D . at th re e points. SERVICE LIMIT: 17.98 mm (0.708 in) M e a s u re th e piston pin b ure I.D. SERVICE LIMIT: 18.05 mm (0.711 in) C alcu late th e p isto n -to -p is to n p ir clearance.
  • Page 273 CYLINDER/PISTON C heck th e c y lin d e r w a ll fo r scratches o r w e a r. M e a s u re th e c y lin d e r I.D. at th re e levels on th e X an d Y axes.
  • Page 274: Piston Ring Installation

    CYLINDER/PISTON CYLINDER/PISTON INSTALLATION PISTON RING INSTALLATION A p p ly oil to th e piston an d piston ring o u te r surface. Be careful not to C a re fu lly install th e piston rings in to th e p iston ring g ro o ve s w ith th e m a rk in g s facing up.
  • Page 275: Cylinder Installation

    CYLINDER/PISTON A p p ly e n g in e oil to th e piston pin o u te r surface. Place a clean shop "IN" M A RK PISTON to w e l over the Install the piston with the "in" mark facing intake crankcase to side.
  • Page 276 CYLINDER/PISTON A p p ly en g in e oil to th e c y lin d e r w a ll, piston cu ter Be careful n o t to C Y IIN D F R surface and piston rings. damage tne p is to n rings and cylinder R oute th e cam chain th ro u g h th e c y lin d e r an d install...
  • Page 277 11. HFT COMPONENT LOCATION....... 11-2 N/D (Neutral/Drive) CLUTCH....11-77 SERVICE INFORMATION......11-4 HFT............11-89 HFT INITIALIZATION (TCM RESET)..11-93 SYMPTOM TROUBLESHOOTING...11-7 SWASH PLATE CONTROL MOTOR..11-97 HFT ELECTRICAL SYSTEM LOCATION..........11-15 SWASH PLATE ANGLE SENSOR..11-99 HFT SYSTEM DIAGRAM......11-16 EOT SENSOR.........11-102 CONNECTOR LOCATIONS....11-17 EOP SENSOR.........11-103 HFT TROUBLESHOOTING...
  • Page 278: Component Location

    COMPONENT LOCATION 11-2...
  • Page 280: Service Information

    SERVICE INFORMATION GENERAL • Engine oil viscosity, oil level and th e use o f oil ad d itives have an effect on H FT system d is e n g a g e m e n t. Check the e n g in e oil first if th e re is transm issio n a n c /o r N /D (n eu tra l/d riv e) clutch p ro b lem (p a g e 4-11).
  • Page 281 TOOLS Remover w e ig h t SC S co n n ecto r Test p ro be 07741-0010201 0 7 0 P Z -Z Y 3 0 1 00 07ZA J-R D JA 110 or 07936-37102 0 A (U .S .A . only) Oil pressure g aug e G e a r h o ld e r, M 2.5 Oil pressure hose...
  • Page 282 D river Clutch spring co m p resso r Bolt set 0 7 7 4 9 -0 0 1 0 0 0 0 attachm ent 0 7G A E -P G 4 020 0 07H A E -P L 50100 o r 0 7 G A E -P G A A 200 (U .S .A .
  • Page 283: Symptom Troubleshooting

    SYMPTOM TROUBLESHOOTING When th e m o to rc y c le has o n e o f th e s e s y m p to m s , c h e c k th e s h ift in d ic a to r b lin k in g o f th e c o m b in a tio n m e te r (page 11-21).
  • Page 284 HARD TO START ENGINE CRANKS BUT W ON'T START 1. Engine Oil Level and Condition Inspection C heck th e en g in e o il level and co n d itio n (p a g e 4-11). A re the engine o il level a n d c o n d itio n n o rm a l? - G O T O STEP 2.
  • Page 285 ■ ________________________________________________________________ HFT MOTORCYCLE CREEPS WITH DRIVE POSITION AT THE IDLE 1. Engine O il Level and C o n d itio n In sp ection Check th e e n g in e oil level end co n d itio n (p ag e 4-11). A re the engine o il level and c o n d itio n norm al? - G O T O S TE P 2.
  • Page 286 5. Spool Valve and HFT Oil Passage Inspection Inspect th e fo llo w in g : S po o l v a lv e (p a g e 11-71) H FT oil passage (page 11-72) A re the spool valve and HFT o il passage n o rm a l? - R eplace th e e n g in e o il, th en p e rfo rm th e H FT in itializatio n p ro ced u re (p a g e 11-93) and recheck.
  • Page 287 EXCESSIVE NOISE/VIBRATION DETECT THE EXCESSIVE NOISE AND/OR VIBRATION Engine Oil Level and Condition Inspection Check th e en gin e oil level and c o n d itio n (p a g e 4-11). Are the engine o il level a n d c o n d itio n n o rm a l? - G O TO S TE P 2.
  • Page 288 HFT OIL PRESSURE INSPECTION C heck the e n g in e oil level and c o n d itio n (page 4-11). R e m o v e the EOP sen sor (p a g e 11-103). C on n ect the special tools. TOOLS: Oil pressure gauge 07YAJ-0010200 or...
  • Page 289 HFT INSPECTION WITH THE ENGINE INSTALLED IN THE FRAME SWASH PLATE MOVABLE INSPECTION AT HFT OIL MOTOR SIDE R e m o v e th e fo llo w in g : S w ash plate co ntro l m o to r (p a g e 11-97) S w a s h plate a n g le s en so r (p a g e 11-100) T u rn th e reduction g e a r w ith a s c rew d riv e r and check th e sw ash p late and ball nut m o v e m e n t.
  • Page 290 TURNING INSPECTION AT HFT OIL PUMP SIDE Remove the fo llo w in g : P rim ary d riv e n g e a r (p a g e 11-67) N /D clutch (p a g e 11-77) H old th e HFT sh aft and tu rn th e H FT at th e oil p u m p side.
  • Page 291: Hft Electrical System Location

    _________________________________________________________________________ HFT ELECTRICAL SYSTEM LOCATION M O D E SELECT S W IT C H N /D SELECT S W IT C H SHIFT SWITCH COMBINATION M ETER O IL LEVEL S W IT C H RELAY S W A S H PLATE N E U TR A L C O N T R O L M O T O R S W IT C H RELAY...
  • Page 292: Hft System Diagram

    HFT SYSTEM DIAGRAM DOWN SIDESTAND SWITCH B l : Blade B r: Brown A1 w ) : N unber of MIL blinks Y :Yellow 0 : Orange :Theengine does not start if there is malfunction B u : Blue Lb: Light blue G : Green Lg: Light green R : Red...
  • Page 293: Connector Locations

    CONNECTOR LOCATIONS Note: Remove th e pillion seat (page 3-4). Note: Remove the left side cover (p ag e 3 -15). (BLACK) CONNECTOR 11-17...
  • Page 294 N ote: R e m o v e th e rig h t fro n t side co w l (p a g e 3-5). R IG H T H A N D LE B A R S W IT C H 6P (G R A Y ) C O N N E C T O R LEFT H A N D LE B A R S W IT C H 3P (G R A Y ) C O N N E C TO R...
  • Page 295 Note: R em o ve the rig h t side c o v e r (p ag e 3-14). Note: R em ove the ra d ia to r reserve ta n k (p a g e 7-17). 11-19...
  • Page 296 N ote: R e m o ve th e cen ter cowl (p a g e 3-6). ECM 33P (BLACK) ECM 33P (G RA Y) C O N N E C T O R C O N N E C TO R Note: R e m o ve th e u p p er cowl (p ag e 3-7).
  • Page 297: Hft Troubleshooting Information

    HFT TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Interm ittent Failure The term "in te rm itten t failu re" m e a n s a system m ay have had a fa ilu re , b u t it checks OK n o w . If th e s h ift i n d i c a t o r d o e s not come on, check fo r p o o r c o n tact o r loose pins at all co nn ecto rs related to th e circuit th a t yo u a re tro u b le s h o o tin g .
  • Page 298 Shift indicator Blink Pattern • If th e H DS pocket te s te r is n o t a v a ila b le , DTC can be read fro m th e T C M m e m o ry by th e s h ift i n d i c a t o r b l i n k pattern •...
  • Page 299 HDS POCKET TESTER INFORMATION • T h e H D S can re a d o u t th e DTC, fre e ze d ata, c u rre n t d a ta and o th er T C M co nd itio n . H o w to co n n e c t th e H D S P o cket T e s te r Turn th e ig n itio n sw itch to OFF.
  • Page 300 CLEARING DTC C on n ect the H D S Pocket T e s ter to th e DLC (page 11-23). C lear th e DTC w ith th e H D S w h ile th e e n g ire is sto p ped . T o c lear th e D TC w ith o u t H D S , re fe r to th e fo llo w in g p ro cedu re.
  • Page 301 7. Turn the ignition switch to OFF. . Read the DTC with the shift i n d i c a t o r ( p a g e 11-23). The self-diagnostic memory is erased if the shift indicator goes o ff and starts blinking as follows. 2 sec.
  • Page 302: Dtc Index

    DTC INDEX Refer to Function Failure Symptom/Fail-safe function ("-" blinks) • Poor engine acceleration 11-28 TP sensor circuit low voltage (less than 0.273 V) 8 -1 • Fail-safe value: 0° • Loose or ooor contact of the TP sensor connec­ •...
  • Page 303 Refer to Function Failure Symptom/Fail-safe function blinks) • W on’t switch neutral/drive 11-50 41-1 (41) N/D select switch circuit malfunction • Loose or poor contact of the N/D select switch connector • N/D select switch or its circuit malfunction • Shift change does not operate (Man­ 11-51 42-2 (42) Shift switch circuit malfunction...
  • Page 304: Dtc Troubleshooting

    DTC TROUBLESHOOTING DTC 8-1 (TP SENSOR LOW VOLTAGE) 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch " O " . Check the TP sensor w ith the HDS with the throt­ tle fully closed. Is about 0.5 V indicated? - •...
  • Page 305 5. TP Sensor Input Voltage Inspection Check fo r continuity between the engine sub ENGINE SUB HARNESS 20P (Black) harness 20P (Black) connector and TCM 33P CONNECTOR (Main wire harness (Black) connector of the main wire harness side. side of female terminal) Connection: A31 (Yellow/red) - Yellow/red TOOL: Test probe...
  • Page 306 DTC 9-1 (EOP SENSOR LOW VOLTAGE) • This problem code will be indicated when EOP sensor, its circuit and HFT oil pressure low. 1. HFT Oil Pressure Inspection Inspect the HFT oil pressure (page 11-12). Is the o il pressure norm al? - GO TO STEP 2.
  • Page 307 5. EOP Sensor Input Voltage Line Open Circuit Inspection Turn the ignition switch OFF. EOP SENSOR 3P CONNECTOR Disconnect the TCM 33P (Black) connector. (Wire side of female terminal) Check for continuity between the EOP sensor 3P connector and TCM 33P (Black) connector of the wire harness side.
  • Page 308 3. EOP Sensor O utput/Ground Line Open Circuit Inspection Turn the ignition switch OFF. TCM 33P (Black) CONNECTOR Disconnect the TCM 33P (Black) connector. (Wire side of female terminal) Check for continuity between the wire harness side EOP sensor connector terminals and ECM connector terminals.
  • Page 309 DTC 11-1 (VS SENSOR) • Before starting inspection, Check for loose or poor connectors on the VS sensor 3P (Black) con­ nector and TCM 33P (Black) connector, then check the DTC. 1. Speedometer Inspection Test-ride the motorcycle and check the speed meter (page Does the speedom eter operate n o rm a lly ? - GO TO STEP 2.
  • Page 310 5. VS Sensor Ground Line Open Circuit Inspection Check fo r continuity between the wire harness VS SENSOR 3P (Black) CONNECTOR side VS sensor 3P (Black) connector terminal and (Wire side of female terminal) TCM connector terminal. Connection: Green - Ground TOOL: Test probe 07ZAJ-RDJA110...
  • Page 311 2. N/D Solenoid Valve Inspection Remove the N/D solenoid valve (page 11 -107). Measure the resistance at the N/D solenoid valve 2P connector terminals. Is th e resistance w ith in 1 4 - 1 7 Q (20°C /68F)7 - GO TO STEP 3. - Faulty N/D solenoid valve.
  • Page 312 . Neutral Oil Pressure Switch Inspection Replace the neutral oil pressure switch (page 11- 106). Reset the self diagnosis memory data from the TCM (page 11-24). Test-ride the motorcycle, then check the HDS. Is DTC 14-1 in d ic a te d ? - Replace the TCM w ith a new one, and recheck (HFT initialization procedure: page 11-93).
  • Page 313 4. N/D Solenoid Valve Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the TCM 33P (Black) connector. TCM 33P (Black) CONNECTOR (Wire side of female terminal) Check for continuity between the wire harness side N/D solenoid valve 2P (Black) connector ter­ minals and TCM connector terminals.
  • Page 314 2. Lock Up Solenoid Valve Operate Inspection Connect a 12 V battery to the lock up solenoid valve 2P connector terminals. Check that air does not flo w (A) to (C). A ir should flo w (A) to (B). Does th e lock up s olenoid valve operate? - GO TO STEP 3.
  • Page 315 DTC 19-1 (ENGINE SPEED SIGNAL) • Before starting inspection. Check for loose or poor connectors on the TCM 33P (Black) connec­ to r and ECM (Gray) connector, then check the DTC. 1. Engine Speed Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: TCM 33P (Black) connector ECM 33P (Gray) connector...
  • Page 316 DTC 25-1 (SW ASH PLATE ANGLE SENSOR LOW VOLTAGE) • Before starting inspection, Check for loose or poor connectors on the swash plate angle sensor 3P connector and TCM 33P (Black) connector, then check the DTC. • When removing the swash plate angle sensor, Perform the HFT initialization procedure (page 11- 93).
  • Page 317 4. Swash Plate Angle Sensor O utput Inspection Turn the ignition switch "OFF". SWASH PLATE ANGLE Disconnect the TCM 33P (Black) connector. SENSOR 3P CONNECTOR Check for continuity between the TCM 33P con­ (Wire side of female terminal) nector and the movable drive face position sen­ sor 3P connector of the w ire harness side.
  • Page 318 2. Swash Plate Angie Sensor Resistance Inspection Inspect the resistance of the swash plate angle sensor shaft groove turning. CONNECTION: A - B Is there resistance w ith in 0 to 1 .6 - 2.4 k£2 (20°C/ 68 °FJ? - GO TO STEP 3. - Faulty swash plate angle sensor.
  • Page 319 2. Swash Plate Angle Sensor Resistance Inspection Measure the resistance at the swash plate angle 3PCONNECTOR sensor A and C terminals of the sensor side. {Sensor side of CONNECTION: A - C male terminal) Is there resistance w ith in 1.6 - 2.4 k£2 (20 C / 6 8 F)7 - GO TO STEP 3.
  • Page 320 . Swash Plate Control M otor Line Open Circuit Inspection Disconnect the swash plate control m otor 2P MOTOR 2P (Black) CONNECTOR (Black) connector. (Wire side of female terminal) Check for continuity between the TCM 5P con­ nector terminals and the swash plate control Red/black m otor 2P (Black) connector terminals of the wire harness side.
  • Page 321 __________________________________ 9. Swash Plate Control M otor Operate Inspection (Clockwise) A pply battery voltage to the control m otor 2P MOTOR 2P (Black) CONNECTOR connector terminals and check that the control (M otor side of male terminal) m otor operation. Does the c o n tro l m o to r turn (C lockw ise)? - G O TO STEP 10.
  • Page 322 2. Swash Plate Control M otor Input Voltage Inspection Install the HFT m otor fuse 30 A. Disconnect the TCM 5P (Black) connector. Measure the voltage at the TCM connector ter­ minal of the wire harness side. Connection: Red/yellow (+) - Green/White (-) Does the b a tte ry voltage e x is t? - GO TO STEP 3.
  • Page 323 5. Swash Plate Control M otor Continuity Inspection Remove th“ swash plate control motor (page 11- MOTOR 2P (Black) CONNECTOR 97). (M otor side of male terminal) Check fo r continuity at the swash plate control m otor connector terminals of the m otor side. Is the re c o n tin u ity ? - GO TO STEP - Faulty swash plate control motor.
  • Page 324 DTC 31-1 (TCM INPUT VOLTAGE CIRCUIT HIGH VOLTAGE) 1. Charging System Inspection Inspect the charging system (page 19-8). Is the charging system n o rm a lly ? - GO TO STEP 2. - Faulty regulator/rectifier. 2. Failure Reproduction Reset t ie self diagnosis memory data from the TCM (page 11-24).
  • Page 325 DTC 34-1 (BOOSTER CIRCUIT) 1. Failure Reproduction Reset the self diagnosis memory data fro rr the TCM (page 11-24). Perform the HFT initialization procedure (page 11- 93). Test-ride the motorcycle, then check the HDS. Is DTC 34-1 in d ica te d ? - Replace the TCM with a new one, and recheck (HFT initialization procedure: page 11-93).
  • Page 326 DTC 41-1 (N /D SELECT SWITCH) • Before starting inspection, Check fo r loose or poor connectors on the right handlebar switch (Gray) connector and TCM 33P (Black) connector, then check the DTC. 1. N/D Select Switch Inspection Turn the ignition switch OFF. Disconnect the right handlebar switch P (Gray) connector.
  • Page 327 4. N/D Select Switch Line Short Circuit Inspection Check for continuity between the right handlebar W hite/yellow switch P (Gray) connector terminal of the main wire harness side and ground. Connection: W hite/yellow - Ground W hite/blue - Ground Is there co n tin u ity? - •...
  • Page 328 3. Shift Switch Line Open Circuit Inspection Disconnect the TCM 33P (Black) connector. LEFT HANDLEBAR SWITCH 3P (Gray) Check fo r continuity between the left handlebar CONNECTOR (Main wire harness switch 3P (Gray) connector and TCM 33P con­ side of female terminal) nector of the wire harness side.
  • Page 329 3. EOT Sensor O utput Line Short Circuit Inspection Turn the ignition switch OFF. EOT SENSOR 2P CONNECTOR Disconnect the TCM 33P (Black) connector. (Wire side of female terminal) Check for continuity between the wire harness side EOT sensor 2P connector terminal and ground.
  • Page 330 3. EOT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. TCM 33P (Black) CONMECTOR Disconnect the jum per wire and TCM 33P (Black) (Wire side of female terminal) connector. Check for continuity between the EOT sensor 2P connector terminals and TCM 33P connector ter­ minals.
  • Page 331 2. Neutral Oil Pressure Sw itch Inspection Replace the neutral oil pressure switch (page 11-106). Reset the self diagnosis memory data from the TCM (page 11-24). Test-ride the motorcycle, then check the HDS. Is DTC 45-1 in d ic a te d ? - Replace the TCM w ith a new one, and recheck (HFT initialization procedure: page 11-93).
  • Page 332 Is there c o n tin u ity ? - G O TO STEP 7. - Faulty oil level switch relay. 11-56 Revised December 2010. 2009 NSA700A ©2010 Am erican Honda Motor Co.. Inc. - All Rights Reserved - MSV 13476 (1011)
  • Page 333 Does the b a tte ry voltage e x is t? - Replace the ECM with a new one, and recheck. - Open circuit in the yellow/blue wire. 11-57 Revised December 2010. 2009 NSA700A ©2010 American Honda Motor Co.. Ir»c - All Rights Reserved - MSV 13476 (1011)
  • Page 334: Indicator Circuit Troubleshooting

    INDICATOR CIRCUIT TROUBLESHOOTING MODE/SHIFT INDICATOR If the riding and gear shift condition are normal but the mode/shift indicator does not come on when the ignition switch is ON and engine stop switch "O", check as follows: NOTE: • Check the combination meter power ground line before troubleshooting(page 22-9).
  • Page 335 ___________________________________________________________________ HFT NEUTRAL INDICATOR If the HFT is neutral position but the neutral indica­ tor does not come on when the ignition switch is ON and engine stop switch "O", check as follows: NOTE: • Check the combination meter power ground line before troubleshooting(page 22-9).
  • Page 336: Mode Select Switch Circuit Troubleshooting

    MODE SELECT SWITCH CIRCUIT TROUBLESHOOTING If the HST does not shift mode while running or stopping (D mode), when the mode select switch is operated, check as follows: 1. Mode Select Switch O utput Voltage Inspection Turn the ignition switch OFF. Disconnect the TCM 33P (Black) connector (page 11-17).
  • Page 337 3. Mode Select Switch O utput Voltage Inspection Turn the ignition switch OFF. RIGHT HANDLEBAR SWITCH P (Gray) Connect the right handlebar switch P (Withe) CONNECTOR (Main wire harness side connector at the main wire harness side of of female terminal) White/black and Blue/black terminals with a jum per wire.
  • Page 338: Left Crankcase Cover

    LEFT CRANKCASE COVER REMOVAL Remove the left side cover (page 3-15). Drain the engine oil (page 4-12). Drain the coolant (page 7-6). Loosen the hose clamp screws and disconnect the water hoses from the water pump cover. WATER HOSES Loosen the hose clamp screws and disconnect the LEFT CRANKCASE COVER lower radiator hose from the left crankcase.
  • Page 339 INSPECTION Turn the inner race of HFT bearing with your finger. HFT BEARING The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the left crankcase. Remove and discard the bearing if the race does not turn smoothly and quietly, or if it fits loosely in the left crankcase.
  • Page 340 Apply a locking agent to the bearing set plate bolt BOLTS/SET threads (page 1-18). Install the bearing set plates and tighten the bolts securely. Apply a locking agent to the oil separator bolt threads (page 1-18). Install the oil separator and tighten the bolts securely.
  • Page 341 Install the clamp and bolts then tighten the bolts in a BOLT/ crisscross pattern in several steps CLAMP BOLTS LEFT CRANKCASE COVER Connect the lower radiator hose to the left crank­ LEFT CRANKCASE COVER case. Tighten the band screw to the specified range as shown.
  • Page 342: Cam Damper/primary Drive Gear

    CAM DAMPER/PRIMARY DRIVE GEAR REMOVAL Drain the engine oil (page 4-12). CAM DAMPER/ BOLT/WASHER Drain the coolant (page 7-6). PRIMARY DRIVE GEAR Remove the left crankcase cover (page 11-62). Hold the cam damper/primary drive gear using the special tool and remove the center bolt and washer. TOOL: Universal holder 07725-0030000...
  • Page 343: Primary Driven Gear

    Apply engine oil to the center bolt threads and BOLTA/VASHER install the center bolt and washer. NOTE: • Install the washer with its rolled edge facing the engine side. Hold the cam damper/primary drive gear using the special tool. TOOL: Universal holder 07725-0030000 Tighten the center bolt and washer to the specified...
  • Page 344 INSPECTION Check the primary driven gear teeth fo r wear or damage. PRIMARY DRIVEN GEAR INSTALLATION Install the dowel pin. DOWEL PIN Install the prim ary driven gear to the HFT, aligning its hole with the dowel pin. Align the orimary drive gear teeth using a fa t blade screwdriver with primary driven gear teeth.
  • Page 345: Right Crankcase Cover

    Apply engine oil to the bolts threads and install the bolts. Hold the cam damper/primary drive gear using the special tool. TOOL: Gear holder, 2.5 07724-0010100 or 07724-001A100 (U.S.A. only) Tighten the bolts to the specified torque. TORQUE: 17 N m (1.7 kgf-m, 13 Ibf ft) Install the left crankcase cover (page 11-64).
  • Page 346 Remove the dowel pin and dowel pins/O-rings. B e care fu l n o to DOWEL PIN d a m a g e th e m e tin g Clean off the sealant from the mating surface. surface. NOTE: • The dowel pins w ith O-rings have two purposes; to fix the position of the right crankcase cover and to act as oil passages.
  • Page 347 Remove the hydraulic pipe and O-ring from the guide. O-RING GUIDE HFT HYDRAULIC PIPE Remove the feed pipe set bolt and O-ring from the right crankcase cover. Remove the hydraulic pipe and O-ring. SPOOL VALVE Remove the bolts and spool valve body from the right crankcase cover.
  • Page 348 Remove the plate from the spool valve body. The plate is under s p rin g p re s s u re . SPOOL VALVE BODY Hemove the spring and spool valve. Clean all parts and blow dry them. Check the spool valve fo r wear or damage. Check the valve spring for wear or fatigue.
  • Page 349 ___________ Install the plate. Be careful n o t to lose th e spring. Install the spool valve budy to the right crankcase RIGHT CRANKCASE COVER and tighten the bolts securely. SPOOL VALVE BODY BOLTS HFT HYDRAULIC PIPE Coat a new O-ring w ith engine oil and install it to the hydraulic pipe.
  • Page 350 Install and tighten the feed pipe set bolt to the spec- ified torque. TORQUE: 18 N m (1.8 kgf-m, 13 Ibf ft) FEED PIPE SET BOLT N/D CLUTCH HYDRAULIC PIPE Coat a new O-ring with engine oil and install it into inside of the guide.
  • Page 351 BEARING REPLACEMENT N/D CLUTCH BEARING Remove the N/D clutch hydraulic pipe (page 11-70). BEARING REMOVER Remove the N/D clutch bearing using the special tools. TOOLS: 07936-3710100 Remover handle Bearing remover, 20 mm 07936-3710600 Remover weight 07741-0010201 or HANDLE 07936-371020A (U.S.A. only) N/D CLUTCH BEARING l WEIGHT...
  • Page 352 HFT___________________________________________ IN STALLATIO N Clean the mating surfaces of the right crankcase and DOWEL PIN cover. Coat new O-rings with engine oil. Install the dowel pins and O-rings. NOTE: • The dowel pins with O-rings have tw o purposes; to fix the position of the right crankcase cover and to act as oil passages.
  • Page 353: N/d (neutral/drive) Clutch

    Connect the fo lowing: BOLT/ EOP sensor 3P (Gray) connector WASHER/ N/D solenoid valve 2P (Black) connector DUST COVER WIRE Lock up solenoid valve 2P (Gray) connector CLAMP Oil level sv/itch connectors (Pink/blue and Yel­ low/red wires) Connect the neutral oil pressure switch wire tighten the terminal bolt/washer to the specified torque.
  • Page 354 BEARING INSPECTION Turn the inner race of the bearing with your finger. N/D CLUTCH The bearing should turn sm oothly and quietly. < BEARING Also check that the bearing outer race fit lightly in the right crankcase. Remove and discard the bearing if the races do not turn smoothly and quietly, or if it fit loosely in the right crankcase.
  • Page 355 DISASSEM BLY Remove the snap ring, washer and secondary gear N/D CLUTCH from the N/D clutch assembly. ASSEMBLY WASHER SFCONDARY GFAR SNAP RING Remove the needle bearing and washer. NEEDLE BEARING WASHER Remove the N/D clutch shaft and O-rings. N/D CLUTCH SHAFT O-RINGS Remove the stopper ring and end plate.
  • Page 356 Remove the three clutch discs and three clutch DISCS plates. CLUTCH CLUTCH PLATES Remove the wave spring from the clutch drum. WAVE SPRING CLUTCH DRUM clutch drum. Install the special tools to the CLUTCH SPRING COMPRESSOR ATTACHMENT B TOOLS: (Use ATTACHMENT A in U.S.A.) Clutch spring compressor attachment A 07LAE-PX40100...
  • Page 357 Compress the return spring using special tools. Compressing the return spring more Remove the snap ring. than necessary w ill cause loss o f tension. SNAP RING Remove the special tools. SPRING RETAINER SNAP RING Remove the snap ring, spring retainer and return spring.
  • Page 358 INSPECTION PRIMARY GEAR Check the prim ary gear teeth for wear or damage. PRIMARY GEAR SECONDARY GEAR Check the secondary gear oil holes for clogs. HOLES Check the secondary gear teeth fo r wear or damage. SECONDARY GEAR NEEDLE BEARING Check the needle bearing turns sm oothly and q ui­...
  • Page 359 RETURN SPRING Check the return spring free length. RETURN SPRING SERVICE LIMIT: 31.8 mm (1.25 in) Replace the spring if it is shorter than the service limit. CLUTCH DISC/PLATE Check the clutch disc for wear. CLUTCH PLATE Replace the clutch discs if they are worn to the Replace the clutch clutch disc grooves.
  • Page 360 ASSEM BLY END PLATE CLUTCH DISCS STOPPER RING CLUTCH PLATES WAVE SPRING WASHER NEEDLE BEARING SECONDARY GEAR N/D CLUTCH SHAFT WASHER SNAP RING O-RINGS CLUTCH DRUM O-RINGS CLUTCH PISTON — SNAP RING RETURN SPRING SPRING RETAINER Clean the clutch drum inner surface. CHECK VALVE OIL HOLES Blow open the clutch drum oil holes and clutch pis­...
  • Page 361 Install the clutch piston into the clutch drum with Be careful n o t to rotating it until s fu lly seated. CLUTCH PISTON deform th e O -ring. CLUTCH DRUM Install the return spring, spring retainer and snap Install the snap ring SPRING RETAINER ring.
  • Page 362 HFT_______________________________________ Compress the return spring using special tools. C om pressing the re tu rn s p rin g m o re . ,, ... Install the snap ring. than necessary w ill cause loss o f tension. SNAP RING Remove the special tools.
  • Page 363 Coat new O-rings w ith engine oil and install them to the neutral/clutch shaft. N/D CLUTCH SHAFT Install the N/D clutch shaft and O-rings. O-RINGS Apply engine oil to a new needle bearing. NEEDLE BEARING Install the washer and needle bearing. WASHER Install the secondary gear, washer and snap ring to N/D CLUTCH...
  • Page 364 Remove the stopper ring and end plate. Measure the end plate tabs thickness and record it. Calculate the new end plate thickness using the equation below. A = (B - 0.8) + C A: New end plate thickness B: Recorded clearance C: Old end plate thickness Select a new end plate with a correct one and install 3LATE NUMBER...
  • Page 365: Hft

    REMOVAL NOTICE The HFT is factory pre-set. Do not disassemble the HFT. Remove the following: HFT SHAFT GEAR Engine (page 8-4) Right crankcase cover (page 11-69) N/D clutch assembly (page 11-77) Remove the snap ring and HFT shaft gear from the HFT shaft.
  • Page 366 Remove the bolts and HFT. Remove the dowel pins and O-ring. NOTE: • The dowel pins with O-rings have two purposes; to fix the position of the HFT and to act as oil pas­ sages. INSPECTION REDUCTION GEAR/SHAFT Check the reduction gear and reduction gear shaft for wear or damage.
  • Page 367 SWASH PLATE MOVABLE INSPECTION AT HFT OIL MOTOR SIDE Turn the gear and check the swash plate and ball nut movement. GEAR The reduction gear should t u n smoothly. SWASH PLATE TURNING INSPECTION AT HFT OIL PUMP SIDE Hold the HFT shaft and turn the HFT at the oil pump Hold side.
  • Page 368 Install the HFT and tighten the bolts to the specified torque. HFT UNIT TORQUE: 12 N m (1.2 kgf-m, 9 Ibf ft) BOLTS Apply engine oil to the reduction gear and shaft and install them into the HFT. SHAFT REDUCTION GEAR Assemble the crankcase (page 13-16).
  • Page 369: Hft Initialization (tcm Reset)

    HFT INITIALIZATION (TCM RESET) • Always initialize the HFT after any of the follow ­ ing services, which alter the phase of swash plate and swash plate angle sensor, have been performed: - HFT removal/installation - TCM replacement - Swash plate angle sensor removal/installation •...
  • Page 370 5. Turn the ignition switch ON while pushing the shift switch (-). IGNITION SWITCH 6. Check the shift indicator blinks to "1" > SHIFT INDICATOR 7. Release the shift switch (-). Start the engine. Check the shift indicator blinks to "2". <...
  • Page 371 th e s w a s h p a te to p p o s itio n ). 10-Check that the shift indicator blinks to "5" (The TCM writes the measurement memory). 11.Turn the ignition switch OFF. The shift indicator goes off. 11-95...
  • Page 372 12.Remove the SCS connector from the DLC. DUMMY CONNECTOR Install the dum m y connector. SCS CONNECTOR 13.lnstall the pillion seat (page 3-4). HFT INITIALIZATION FAILURE SYMPTOM • If the HFT initialization fails, check the following table to find the cause of the problem. SHIFT INDICATOR PROBLEM PROCEDURE...
  • Page 373: Swash Plate Control Motor

    SWASH PLATE CONTROL MOTOR REMOVAL Remove the left side cover (page 3-15). SWASH PLATE Disconnect the swash plate control m otor 2P (Black) 2P (BLACK) CONNECTOR CONTRO- MOTOR connector. Remove the bolts and swash plate control motor. BOLTS Remove the O-ring. O-RING 11-97...
  • Page 374 INSPECTION Connect a 12 V battery to the swash plate control m otor terminal. SWASH PLATE Check the swash plate control m otor is turning CONTROL MOTOR when 12 V battery is connected. If the swash plate control m otor is not turning, replace the swash plate control motor.
  • Page 375: Swash Plate Angle Sensor

    Install the swash plate control m otor and tighten the BOLTS holts securely. Connect the swash plate control m otor 2P (Black) SWASH PLATE connector. 2P (BLACK) CONNECTOR CONTROL MOTOR Install the left side cover (page 3-15). SWASH PLATE ANGLE SENSOR INSPECTION •...
  • Page 376 Connect an ohmmeter to the swash plate angle sen­ 3PCONNECTOR sor A and B terminals. (Sensor side of Inspect the resistance of the swash plate angle sen­ male terminal) sor shaft groove turning. Connection: A - B Standard: 0 to 1.6 - 2.4 (20 C/68 F) f t ] If the resistance is out of the standard value, replace...
  • Page 377 Turn the swash plate angle sensor and align the bolt SWASH PI ATF holes. ANGLE SENSOR Apply locking agent to the bolt threads. Install and tighten the bolts to the specified torque. TORQUE: 6 N m (0.61 kgf-m, 4.4 Ibf ft) BOLTS Connect the swash plate angle sensor 3P connector.
  • Page 378: Eot Sensor

    Apply grease to the oil seal lip and install it to the right crankcase. Coat the swash plate angle sensor shaft with engine oil and install it by aligning its projection w ith the swash plate groove. OIL SEAL SWASH PLATE ANGLE SENSOR SHAFT Coat a new O-ring w ith engine oil and install it to the shaft holder.
  • Page 379: Eop Sensor

    INSPECTION Suspend the EOT sensor in a pan of engine oil on an electric heating element and measure the resistance through the sensor as the water heats up. • Soak the EOT sensor in engine oil up to its threads with at least 40 mm (1.6 in) from the bot­ tom of the pan to the bottom of the sensor.
  • Page 380: Oil Level Switch

    Remove the O-ring. NOTE: • Keep the foreign matters and sealant out from the HFT oil passages, as they could cause HFT malfunction. Coat a new O-ring with engine oil and install it. Install the EOP sensor and tighten it to the specified torque.
  • Page 381 INSPECTION Connect an ohmmeter to the o I level switch term i­ CLOSE CONTACT POINT: nals. Measure the resistance through the sensor as fo l­ low. Close contact point: Set the oil level switch w ith same direction of the oil level switch installed.
  • Page 382: Neutral Oil Pressure Switch

    NEUTRAL OIL PRESSURE SWITCH INSPECTION Remove the right side cover (page 3-14). Turn the gnition switch OFF. Remove the dust cover. Remove the bolt/washer and disconnect the neutral oil pressure switch wire. Check for continuity between the neutral oil pres­ sure switch terminal and ground.
  • Page 383: N/d (neutral/drive) Solenoid Valve

    N/D (Neutral/Drive) SOLENOID VALVE REM O VAL Remove the right side cover (page 3-14). P 2P (BLACK) N/D SOLENOID Disconnect the N/D solenoid valve 2P (Black) con­ CONNECTOR VALVE nector. Remove the bolts and N/D solenoid valve. BOLT Remove the O-rings. O-RINGS INSPECTION Measure the resistance between the N/D solenoid...
  • Page 384 Connect a 12 V battery to the N/D solenoid valve 2P c o n n e c to r te r m in a ls . Check that air does not flo w (A) to (C). Air should flow (A) to (B). ,! n i ©...
  • Page 385: Lock Up Solenoid Valve

    LOCK UP SOLENOID VALVE REMOVAL Remove the right side cover (page 3-14). LOCK UP Disconnect the lock up solenoid valve 2P (Gray) con­ SOLENOID VALVE nector. 2P (GRAY) CONNECTOR Remove the bolts and lock up solenoid valve. BOLT Remove the O-rings. O-RINGS INSPECTION Measure the resistance between the lock up sole­...
  • Page 386 Connect a 12 V battery to the lock up solenoid valve 2P connector terminals. Check that air does not flo w (A) to (C). Air should flo w (A) tc (B). INSTALLATIO N Coat new O-rings w ith engine oil and install them to LOCK UP the lock up solenoid valve.
  • Page 387: Oil Level Switch Relay

    There should be continuity only when the 12 V bat­ tery is connected. 11-111 Revised: December 2010. 2009 NSA700A ©2010 American Honda Motor Co.. Inc. - A ll Rights Reserved • MSV 13476 (1011)
  • Page 388: Mode Select Switch

    MODE SELECT SWITCH Remove the right cowl (page 3-5). f r o n t s id e Disconnect the right handlebar switch 6P (Gray) connector. Check for continuity between the wire terminals of the right handlebar switch 6P (Gray) connector. MODE SELECT SWITCH Continuity should exist between the color coded wire terminals as follows:...
  • Page 389: Shift Switch

    _____________________________________________ SHIFT SWITCH Remove the right front side cowl (page 3-5). 3P (GRAY) CONNECTOR Disconnect the left handlebar switch 3P (Gray) con­ nector. Check for cont nuity between the wire terminals of the left handlebar switch 3P (Gray) connector. Continuity should exist between the color coded wire terminals as follows: SHIFT SWITCH 11-113...
  • Page 390: N/d (neutral/drive) Select Switch

    HFT__________________________________________ N /D (Neutral/Drive) SELECT SWITCH Remove the right front side cowl (page 3-5). Disconnect the right handlebar switch 6P (Gray) connector. Check for continuity between the wire terminals of the right handlebar switch 6P (Gray) connector. Continuity should exist between the color coded wire terminals as follows: 11-114...
  • Page 391: Tcm

    REMOVAL/INSTALLATION • When the TCM replaced, perform the HFT initial­ ization procedure (page 11-93). Remove the right seat cowl (page 3-12). BAND 33P (BLACK) CONNECTOR Disconnect the TCM 33P (Black) and 5P (Black) con­ nectors. Remove the band and TCM. Installation is in the reverse order of removal.
  • Page 392 3. FI/IGN/PUMP Relay inspection 1 Turn the ignition switch OFF. FI/IGN PUMP RELAYJL Remove the main seat (page 3-4). Open the fuse/relay box and remove the FI/IGN/ PUMP relay. Turn the ignition switch ON and engine stop switch "O". Measure the voltage at the FI/IGN/PUMP relay terminals.
  • Page 393 5. FI/IGN/PUMP Relay inspection 2 Turn the ignition switch OFF. Jump the FI/IGN/PUMP relay connector term i­ nals. FI/IGN PUMP RELAY TERMINAL Turn the ignition switch ON and engine stop switch "O". Measure the voltage between the TCM 33P (Black) connector and ground. Red/yellow Connection: A3 (+) - Ground (-) Is there b a tte ry voltage?
  • Page 394 12. ALTERNATOR/STARTER CLUTCH 12-2 CKP SENSOR/STATOR REMOVAL..12-4 COMPONENT LOCATION SERVICE INFORMATION • 12-3 FLYWHEEL/STARTER CLUTCH....12-5 12-3 CKP SENSOR/STATOR TROUBLESHOOTING..INSTALLATION........12-11 12-1...
  • Page 395 ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION...
  • Page 396 ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL • This section covers service of the alternator stator and flywheel. All service can be done w ith the engine installed in the frame. • For alternator stator inspection, refer to page 19-8. • For starter motor service, refer to page 21-6. SPECIFICATIONS Unit: m m (in) STANDARD...
  • Page 397 ALTERNATOR/STARTER CLUTCH CKP SENSOR/STATOR REMOVAL Remove the right seat cowl (page 3-12). Disconnect the regulator/rectifier 3P (Black) connec­ tor. Disconnect the CKP senso' 2P (Red) connector. Release the wires from the clamps. Remove the bolts, harness clamp and alternator TCDM AxrtD rr»\,cD Loosen the bolts in \ ' f cover.
  • Page 398: Flywheel Removal

    ALTERNATOR/STARTER CLUTCH Remove the bolts, CKP sensor and stator wire GROMMET holder. Remove the wire grommets. HOLDER R em ove th e socket b o lts and stator. STATOR BOLTS FLYWHEEL/STARTER CLUTCH FLYWHEEL REMOVAL Remove the alternator cover (page 12-4). BOLT/WAHSER Remove the flywheel bolt and washer while holding the flywheel using a special tool.
  • Page 399 ALTERNATOR/STARTER CLUTCH Remove the washer, needle bearing and w oodruff WOODRUFF KEY WASHER key from the crankshaft. NOTE: • When removing the w oodruff key, be careful not to damage the key groove and crankshaft. • Do not lose the w oodruff key. I NEEDLE BEARING Remove the starter reduction gear and shaft.
  • Page 400: Starter Clutch Inspection

    ALTERNATOR/STARTER CLUTCH Remove the starter clutch bolts while holding the FLYWHEEL HOLDER flywheel using a special tool. TOOL: Flywheel holder 07725-0040001 or equivalent com­ mercially available BOLTS Remove the starter clutch from the flywheel. FLYWHEEL STARTER CLUTCH STARTER CLUTCH INSPECTION NEEDLE BEARING Check the needle bearing fo r abnormal wear or Mppni _...
  • Page 401 ALTERNATOR/STARTER CLUTCH S T A R T E R D R IV E N G E A R Check the one-way clutch sprag contact surface for wear or damage. Measure the driven gear O.D. S E R V IC E LIMIT: 57.73 mm (2.273 in) Measure the driven gear I.D.
  • Page 402: Flywheel Installation

    ALTERNATOR/STARTER CLUTCH Install the starter clutch to the flywheel. FLYWHEEL STARTER CLUTCH Hold the flywheel using a special tool. TOOL: Flywheel holder 07725-0040001 or equivalent com­ mercially available Clean and apply a locking agent to the starter clutch bolt threads. Install and tighten the bolts to the specified torque.
  • Page 403 ALTERNATOR/STARTER CLUTCH Install the w oodruff key to the key groove of the During w o o d ru ff NEEDLE BEARING WOODRUFF KEY crankshaft. key installation, be carefui n o t to Apply engine oil to the needle bearing and install it dam age the key to the crankshaft.
  • Page 404 ALTERNATOR/STARTER CLUTCH CKP SENSOR/STATOR INSTALLATION CKP SENSOR WIRE STATOR ALTERNATOR SOCKET BOLTS COVER 12 N m (1.2 kgf-m, 9 Ibf fti Install the stator to the alternator cover. STATOR Clean and apply a locking agent to the bolt threads (page 1-18). Install and tighten the stator socket bolts to the specified torque.
  • Page 405 ALTERIMATOR/STARTER CLUTCH Clean o ff the sealant from the alternator cover m at­ ing surface. Apply liquid sealant (Three Bond 1207B or equiva­ Do n o t w ip e o ff the lent) to the alternator cover mating surface. excessive sealant by using the organic solvent.
  • Page 406 ALTERNATOR/STARTER CLUTCH Connect the CKP sensor 2P (Red) connector. Route the wires 2P (RED) CONNECTOR properly Install the wires to the clamps. (page 1-20). CLAMPS Connect the regulator/rectifier 3P (Dlack) connector. 3P (BLACK) CONNECTOR Install the right seat cowl. Check the engine oil level (page 4-11). 12-13...
  • Page 407 13. CRANKCASE/CRANKSHAFT CRANKSHAFT/CONNECTING ROD •..13-6 COMPONENT LOCATION......13-2 SERVICE INFORMATION......13-3 CRANKPIN BEARING......13-9 TROUBLESHOOTING....... 13-4 MAIN JOURNAL BEARING....- 13-11 CRANKCASE SEPARATION ....13-5 CRANKCASE ASSEMBLY....- 13-16 13-1...
  • Page 408: Component Location

    CRANKCASE/CRANKSHAFT COMPONENT LOCATION Q > .. 42 N-m (4.3 kgf-m, 31 Ibf-ft) 12 N-m (1.2 kgf-m, 9 Ibf-ft) 13-2...
  • Page 409 CRANKCASE/CRANKSHAFT SERVICE INFORMATION GENERAL • The crankcase must be separated to service the following: - Oil pump (page 5-6) - Crankshaft/connecting rod (page 13-6) ! - HFT (page 11-89) • The following parts must be removed before separating the crankcase: - Oil filter (page 4-12) - Water pump (page 7-15) - Cylinder head (page 9-13)
  • Page 410 CRANKCASE/CRANKSHAFT SPECIFICATIONS Unit: mm (ini STANDARD SERVICE LIMIT ITEM 0.30 (0.012) Connecting rod big end side 0 .1 5 -0 .30 (0.006-0.012) Crankshaft cleararce 0.07 (0.003) 0.028 - 0.052 (0.0011 - 0.0020) Crankpin bearing oil clearance 0.07 (0.003) Main journal oil clearance 0.020 - 0.038 (0.0008 - 0.0015) 0.03(0.001) Crankshaft runout...
  • Page 411: Crankcase Separation

    CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Remove the engine from the frame (page 8-4). Refer to Service Information (page 13-3) for removal of necessary parts before separating the crankcase. Remove the bolt and cam chain tensioner setting plate. Remove the front side cam chain from the crank­ shaft.
  • Page 412: Crankshaft/connecting Rod

    CRANKCASE/CRANKSHAFT Remove the oil pipe and O-rings. Remove the oil pipe and O-rings from the left crank­ OIL PIPE /O-RINGS case. CRANKSHAFT/CONNECTING ROD NOTE: • During crankshaft and connecting rod service, be careful not to damage the main journal or crank pin bearing inserts.
  • Page 413: Connecting Rod Removal

    CRANKCASE/CRANKSHAFT SIDE CLEARANCE INSPECTION Before removing the connecting rods, check the big FEELER GAUGE end side clearance. Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big end. SERVICE LIMIT: 0.30 mm (0.012 in) CONNECTING ROD REMOVAL Remove the crankpin bearing cap nuts and the bear- Tap the side o f the...
  • Page 414: Crankshaft Inspection

    CRANKCASE/CRANKSHAFT CRANKSHAFT INSPECTION Check the camshaft journal surfaces fo r damage, discoloration or scratch. CRANKSHAFT RUNOUT Place the crankshaft on a stand or V-blocks. 10 mm (0.4 in) 10 mm 0.4 in) Set a dial indicator on the main journals. Rotate the crankshaft two revolutions and read the 40 mm runout.
  • Page 415: Crankpin Bearing

    CRANKCASE/CRANKSHAFT CRANKSHAFT INSTALLATION Apply molybdenum disulfide oil to the main journal CRANKSHAFT bearing inserts and install the crankshaft into the right crankcase Assemble the crankcase (page 13-16). CRANKPIN BEARING NOTICE Do n o t interchange the bearing inserts. They m ust be in sta lle d in th e ir o rig in a l locations o r the correct bearing o il clearance m a y n o t be obtained, resulting in engine damage.
  • Page 416 CRANKCASE/CRANKSHAFT A pply engine oil to the threads and seating surfaces Do n o t rotate the of the bearing cap nuts. crankshaft during inspection. Carefully install the connecting rods and bearing caps on the correct crankpins. Install the bering cap nuts and tighten them in sev­ eral steps alternately.
  • Page 417: Main Journal Bearing

    CRANKCASE/CRANKSHAFT CRANKPIN BEARING SELECTION TABLE: CONNECTING ROD I.D CODE NUMBER 46.008 - 46.016 mm 46.000-46.008 mm (1.8110-1.8113 in) (1.8113-1.8116 in) CRANKPIN O.D. 42.985-42.993 mm CODE LETTER (Black) (Blue) (1.6923- 1.6926 in) 42.977-42.985 mm (Purple) (1.6920-1.6923 in) (Blue) BEARING THICKNESS: IDENTIFICATION COLOR A (Purple): Thick B (Blue):...
  • Page 418 CRANKCASE/CRANKSHAFT Clean o ff any oil from the crankshaft journals. Measure and record the crankshaft main journal O.D. SERVICE LIMIT: 52.976 mm (2.0857 in) Calculate the main journal oil clearance. SERVICE LIMIT: 0.07 mm (0.003 in) If the clearance exceeds the service lim it, select the bearing (page 13-10).
  • Page 419 CRANKCASE/CRANKSHAFT Depending upon the results of the above measure­ BEARING SUPPORT I.D. CODE LETTER ments there are four possible scenarios fo r main bearing selection: • Crankshaft and crankcase are replaced • Crankcase only is replaced • Crankshaft only is replaced •...
  • Page 420: Bearing Installation

    CRANKCASE/CRANKSHAFT In case of main bearing replacement only: MAIN JOURNAL O.U. 52 988 - 52.994 nm 52.982 - 52 988 mm 52.976 - 52.982 mm 52.970 - 52.976 mm (2.0861-2.0864 n| (2.0857 - 20859 in) (2.0654 - 2.0857 in) (2.0859 - 2 0861 in) BEARING 58.058-58.070 mm O.S.
  • Page 421 CRANKCASE/CRANKSHAFT Set the hydraulic press. TOOL: Metal installer set 070MF-MEG0200 Press the new bearings until the metal installer INSTALLER SET flange fully seats. BEARING Make sure the bearing mating line aligns with the f index mark on the crankcase. Check the oil clearance (page 13-11). •...
  • Page 422: Crankcase Assembly

    CRANKCASE/CRANKSHAFT CRANKCASE ASSEMBLY NOTE: Be careful not to damage the crankcase mating sur­ faces. Clean the left and right crankcase mating surfaces thoroughly. Make sure the all parts are installed in the right crankcase. Apply liquid sealant (Three Bond 1207B or equiva­ lent) to the crankcase mating surfaces.
  • Page 423 CRANKCASE/CRANKSHAFT Coat new O -rirgs w ith engine oil and install th e n to DOWEL PINS/O-R NGS the dowel pins. Install the dowel pins into the right crankcase. DOWEL PINS Install the left crankcase over the right crankcase. RIGHT CRANKCASE Install the left crankcase bolts.
  • Page 424 14. FINAL DRIVE COMPONENT LOCATION......14-2 FINAL DRIVE DISASSEMBLY/ INSPECTION..........14-9 SERVICE INFORMATION......14-4 FINAL DRIVE ASSEMBLY..... 14-17 TROUBLESHOOTING.......14-7 FINAL DRIVE INSTALLATION..... 14-21 FINAL DRIVE REMOVAL......14-8 SIDE GEAR CASE........14-22...
  • Page 425: Component Location

    FINAL DRIVE__________________ COMPONENT LOCATION 14-2...
  • Page 426 FINAL DRIVE...
  • Page 427: Service Information

    FINAL DRIVE SERVICE INFORMATION GENERAL • The final drive gear assembly and final drive shaft must be removed together. • Replace the ring and pinion gears as a set. • Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case, the extension lines from the gear engagement surfaces should intersect at one point.
  • Page 428 FINAL DRIVE TOOLS Driver Attachment, 32 x 35 mm Attachment, 52 x 55 mm 07749-0010000 07746-0010100 07746-0010400 Driver, 40 mm I.D. Oil seal driver, 55.7 x 60.3 mm Pilot, 19 mm 07746-0030100 07965-KE80200 07746-0041400 Pinion holder Pinion holder attachment Attachment, 25 mm I.D. 07746-0030200 070MB-0010110 070MB-0010120...
  • Page 429 FINAL DRIVE Remover handle Puller shaft/nut Bearing remover, 30 mm 07936-3710100 07936-8890300 07931-ME40000 07931-MEA010B and 07931-HB3020A U.S.A. only Remover weight Bearing remover, 20 mm Holder handle 07936-3710600 07PAB-0010400 07741-0010201 07936-371020A U.S.A. only Not available in U.S.A. Attachment, 42 x 47 mm Attachment, 62 x 68 mm Pilot, 17 mm 07746-0040400...
  • Page 430: Troubleshooting

    FINAL DRIVE TROUBLESHOOTING Excessive noise • Worn or scored ring gear shaft and driven flange • Scored driven flange and wheel hub • Worn or scored drive pinion and splines • Worn pinion and ring gears • Excessive backlash between pinion and ring gears •...
  • Page 431: Final Drive Removal

    FINAL DRIVE FINAL DRIVE REMOVAL Drain the final drive oil (page 4-18). Remove the following: Rear wheel (page 16-6). Rear brake caliper (page 17-33) Rear brake disc (page 17-19) Rear parking brake (page 17-36) Remove the four mounting nuts and final drive gear case assembly from the swingarm.
  • Page 432: Final Drive Disassembly/ Inspection

    FINAL DRIVE Turn the pinion joint and check that the pinion and RING GEAR SHAFT PINION JOINT ring gears turn smoothly and quietly w ithout bind­ ing. If the gears do not turn smoothly or quietly, the gears and/or bearing may be damaged or faulty. They must be checked after disassembly;...
  • Page 433 Set a horizontal type dial indicator on the ring gear, th ro u g h th e o il fille r hole. Turn the ring gear back and forth to read the back­ lash. STANDARD: 0.05 - 0.15 mm (0.002 - 0.006 in) SERVICE LIMIT: 0.30 mm 10.012 in) Remove the dial indicator.
  • Page 434 FINAL DRIVE GEAR TOOTH CONTACT PATTERN CHECK Description of the tooth: COAST SIDE TOE (inside of gear) (contacts when engine brak'ng is applied) DRIVE SIDE HEEL (out sice of gear) (contacts when engine power is applied) Clean the sealing material off the mating surfaces of Keep d u s t a n d d irt Apply Prussian Blue the gear case and cover, being careful not to dam­...
  • Page 435 FINAL DRIVE Replace the pinion gear shim w ith a thicker one if Too High the contact pattern i3 too high, toward the focc. FACE FACE DRIVE COAST SIDE SIDE Replace the pinion gear shim w ith a thinner one if Too Low: the contact pattern is too ow, toward the flank.
  • Page 436 FINAL DRIVE Heat the gear case cover to 80°C (176°F) evenly Be sure to wear using a heat gun. heavy g lo v e s w h e n handling the heated NOTE: gear case. Do not use a torch to heat the gear case cover; it may cause warping.
  • Page 437 FINAL DRIVE Remove *.he bolt and retainer lock plate. LOCK PLATE Remove the pinion retainer using the special tool. RETAINER WRENCH TOOL: Retainer wrench 07910-MA10100 Remove the O-ring and oil seal from the pinion OIL SEAL retainer. O-RING Install the special tools onto the pinion gear shaft PULLER SHAFT and gear case.
  • Page 438 FINAL DRIVE PINION GEAR BEARING/SHIM REPLACEMENT Pull the pinion gear bearing from the shaft w ith a commercially available bearing puller. Remove the pinion gear shim. BEARING/SHIM Select the replacement shim (page 14-10) SHIM Install the shim and a new bearing onto the pinion gear.
  • Page 439 FINAL DRIVE Drive two new ring gear bearings into the gear case DRIVER until limy are fully seated using the special tools. TOOLS: Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 ATTACHMENT PINION NEEDLE BEARING Rotate the stopper ring until the end of the stopper ring appears in the access hole.
  • Page 440: Final Drive Assembly

    FINAL DRIVE Make sure the stopper ring is securely set in the groove ot the gear case. STOPPER RING FINAL DRIVE ASSEMBLY PINION GEAR INSTALLATION PINION GEAR SHIM INNER RACES O-RING RETAINER PINION JOINT JOINT NUT PINION BEARING OIL SEAL LOCK PLATE A or B Drive the pinion gear assembly into the gear case DRIVER...
  • Page 441 FINAL DRIVE Drive a new oil seal into the pinion retainer w ith the marked side facing up until it is fully seated. TOOLS: DRIVER Driver 07749-0010000 Attachment, 44 x 49.5 mm 07945-3330300 Pack grease into the seal lip cavity. OIL SEAL ' ' ATTACHMENT Coat a new O-ring w ith grease and install it into the...
  • Page 442 FINAL DRIVE Clean the threads of the pinion gear shaft and pin­ ion jo in t nut thoroughly. JUINI NU! Apply locking agent to the joint nut threads and install the pinion jo in t and jo in t nut onto the pinion gear shaft.
  • Page 443 FINAL DRIVE Heat the gear case cover to 80°C (176°F) evenly Be sure to wear using a heat gun. heavy gloves when handling the heated NOTE: gear case. Do not use a torch to heat the gear case cover; it may cause warping.
  • Page 444: Final Drive Installation

    FINAL DRIVE Apply locking agent to the threads of the case cover 8 mm BOLTS -OlTOI 10 mm bolts. Install the bolts, and tighten them in a crisscross 10 mm BOLTS pattern in several steps until the cover evenly touches the gear case. Tighten the two 10 mm bolts to the specified torque in several steps alternately.
  • Page 445: Side Gear Case

    FINAL DRIVE Apply 2 g (0.07 oz) or more of molybdenum PINION JOINT disulfide grease to the pinion jo in t splines. Install the drive shaft into the pinion joint until the Make sure the stopper ring seats in the pinion jo in t spline groove. stopper ring is seated properly by pulling on the drive...
  • Page 446 FINAL DRIVE REMOVAL Remove the following: SNAP RING Right crankcase cover (page 11-69) Neutral/drive clutch assembly (page 11-77) Remove the snap ring and final driven gear. H N A L U K IV tN CibAK Remove the following: VS SENSOR3P Left side cover (page 3-15) ' (BLACK) CONNECTOR Final gear case (page 14-8)
  • Page 447 FINAL DRIVE Remove the oil orifice f'o m the side gear case OIL ORIFICE assembly. Remove the O-rings from the oil orifice. B E A R IN G IN S P E C T IO N Remove the side gear case assembly (page 14-22). Turn the inner race of final driven gear bearing with your finger.
  • Page 448 FINAL DRIVE DISASSEMBLY Remove the bolts. 60 mm NOTE: When removing the side gear case bolts (60 mm), note the location of the bolts. BOLTS Remove the following: O-RING Final shaft/bearing holder assembly DOWEL PIN Shim Dowel pin O-ring FINAL SHAFT/BEARING HOLDER ASSEMBLY Set the special tools to the final shaft assembly.
  • Page 449 FINAL DRIVE Remove the following: Damper collar Damper cam Damper spring DAMPER CAM DAMPER SPRING INSPECTION DAMPER CAM Check the damper cam dogs for damage or exces­ DOGS sive wear. DAMPER COLLAR Check the damper collar slot for damage or exces­ sive wear.
  • Page 450 FINAL DRIVE DAMPER SPRING Measure the free length of the damper spring. SERVICE LIMIT: 108 mm (4.3 in) OPERATION Temporarily install the following: Dowel pin DOWEL PIN Shim Final shaft/bearing holder assembly FINAL SHAFT/BEARING SHIM HOLDER ASSEMBLY Install the bolts. 60 mm NOTE.
  • Page 451 FINAL DRIVE BACKLASH INSPECTION/GEAR TOOTH CONTACT PATTERN CHECK NOTE: Perform the backlash inspection and contact pattern POINT OF check wnenever you replace the final shaft, output INTERSECTION shaft, bearings, bearing holder and gear case. The extension lines from the gear engagement surfaces should intersect at one point.
  • Page 452 FINAL DRIVE SHIM REPLACEMENT Remove the bolts and final shaft/bearing holder FINAL SHAFT/BEARING assembly from the side gear case. HOLDER ASSEMBLY NOTE: 60 mm When removing the side gear case bolts (60 mm), note the location of the bolts. BOLTS Remove the shim and O-ring from the gearing holder.
  • Page 453 FINAL DRIVE Remove the final shaft/bearing holder assembly OUTPUT SHAFT GEAR from the gear ease (page 14 25). Apply thin coat of Prussian Blue to the output shaft gear teeth. Reinstall the final shaft/bearing holder assembly w ith the shim. Rotate the final shaft counterclockwise several times.
  • Page 454 FINAL DRIVE OUTPUT SHAFT SHIM REPLACEMENT Remove the bolts and output shaft/bearing holder BOLTS assembly. OUTPUTSHAFT/BEARING HOLDER ASSEMBLY Remove the shim and O-ring from the bearing SHIM holder. Select the replacement shim (page 14-30). Coat a new O-ring with engine oil and install it into the bearing holder groove.
  • Page 455 FINAL DRIVE Remove the outer lock nut using a special tool. LOCK NUT WRENCH TOOL: Lock nut wrench, 36 x 47.8 mm 07916-MB00002 OUTER LOCK NUT Remove the bolts and final shaft/bearing holder 60 mm assembly from the side gear case. NOTE: When removing the side gear case bolts (60 mm), note the location of the bolts.
  • Page 456 FINAL DRIVE Press the bearing out of the bearing holder using the special tools and a hydraulic press. DRIVER TOOLS: Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 ATTACHMENT/ Pilot, 30 mm 07746-0040700 PILOT OUTPUT SHAFT DISASSEMBLY Hold the side gear case in a vise with soft jaws. OIL SEAL Remove the stopper ring and oil seal.
  • Page 457 FINAL DRIVE Remove the outer lock nut using a special tool. TOOL: Lock nut wrench, 36 x 47.8 mm 07916-MB00002 Remove the bolts and output shaft/bearing holder BOLTS assembly from the side gear case. Remove the shim and O-ring. O-RING SHIM Press the output shaft out of the bearing holder using a hydraulic press.
  • Page 458 FINAL DRIVE Press the bearing out of the bearing holder using DRIVER the special tools and a hydraulic press. TOOLS: 07749-0010000 Driver 07746-0010500 Attachment, 62 x 68 mm 07746-0040700 Pilot, 30 mm ATTACHMENT/PILOT Remove the side gear case bearing using the special BEARING REMOVER tools.
  • Page 459 FINAL DRIVE OUTPUT SHAFT ASSEMBLY Drive a new bearing into the gear case with marked side facing up. TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746 0010300 Pilot, 17 mm 07746-0040400 Press a new bearing into the bearing holder w ith the marked side facing up.
  • Page 460 FINAL DRIVE Support the bearing inner race and press the output If the fina l s h a ft OUTPUT SHAFT shaft into the hearing holder re q u ire s replacement, the final a n d o u tp u t shafts m u s t be replaced as a set.
  • Page 461 FINAL DRIVE A pply engine oil to the threads and seating surface ATTACHMENT new inner lock nut. Hold the output shaft and tighten a new inner lock SHAFT HOLDER nut to the specified torque using the special tools. TOOLS: Shaft holder 07PAB-0010100 (Not available in U.S.A.)
  • Page 462 FINAL DRIVE FINAL SHAFT ASSEM BLY FINAL SHAFT SHIM O-RING BEARING HOLDER O-RING BEARING (5206) OUTER LOCK NUT INNER LOCK NUT DAMPER SPRING DAMPER CAM DAMPER COLLAR Press a new bearing into the bearing holder with the DR'VER marked side facing up. TOOLS: Driver 07749-0010000...
  • Page 463 FINAL DRIVE Coat a new O-ring w ith engine oil and install it into DOWEL PIN O-RING the bearing holder groove. Install the dowel pin and shim. NOTE: When the bearing, shaft, holder and/or case have been replaced, use the 0.50 mm (0.020 in) shim fo r initial reference.
  • Page 464 FINAL DRIVE Stake the inner lock nut to the final shaft groove. OUTER LOCK NUT Stake the outer lock nut to the bearing holder groove. Stake INNER LOCK NUT ASSEM BLY Remove the bolts. 60 mm NOTE: When removing the side gear case bolts (60 mm), note the location of the bolts.
  • Page 465 FINAL DRIVE Set the special tools to the final shaft assembly. BEARING SEPARATOR SET TOOLS: Bearing separator set 07931-4630000 Recoil pulley holder 07SMB-HM70100 RECOIL PULLEY HOLDER Compress the damper spring until the cotter groove is visible. WASHER Install the washer and cotters securely. COTTER Remove the special tools.
  • Page 466 FINAL DRIVE IN STALLATIO N Coat new O-rings w ith engine oil and install them OIL ORIFICE into the oil orifice grooves. Install the oil orifice into the side gear case assem­ bly. Coat a new O-ring with engine oil and install it into SIDE GEAR CASE ASSEMBLY the side gear case assembly groove.
  • Page 467 FINAL DRIVE Install the final driven gear and new snap ring. NOTE: Install the snap ring w ith its rolled edge facing the engine side. Install the follow ing: N/D clutch assembly (page 11 -88) Right crankcase cover (page 11-76)
  • Page 468 15. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION......15-2 FRONT WHEEL.........15-10 SERVICE INFORMATION......15-3 FORK............15-16 TROUBLESHOOTING....... 15-5 STEERING STEM........15-25 HANDLEBAR..........15-6 15-1...
  • Page 469: Component Location

    FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION 15-2...
  • Page 470: Front Wheel

    435.6(17.15) Fork Spring free length 444.5(17.50) 0.20 (0.008) Tube runout Pro Honda Suspension Fluid SS-8 Recommended fork fluid (10W) or equivalent Fluid level 105 (4.1) Fluid capacity 475 ± 2.5 cm3 (16.1 ± 0.08 US oz, 16.7 ± 0.09 Imp oz) Steering head bearing preload 11.9-15.6 N (1.2-1.6 kgf)
  • Page 471 FRONT WHEEL/SUSPENSION/STEERING TOOLS Driver Ball race remover Attachment, 42 x 47 mm 07749-0010000 C7953-MJ10000 07746-0010300 Not available in U.S.A. Attachment, 52 x 55 mm Pilot, 20 mm Bearing remover shaft 07GGD-0010100 07746-0310400 G7746-0040500 Driver shaft Slider weight Bearing remover head, 20 mm 07947-KA50100 07746-0050600 07949-3710001...
  • Page 472: Fork

    FRONT WHEEL/SUSPENSION/STEERING Race remover attachment Ball race remover 07946-3710500 07953-MJ1000B U.S.A. only Use with a long drift TROUBLESHOOTING Hard steering • Steering top thread too tig ht • Worn or damaged steering head bearings • Bent steering stem • Insufficient tire pressure •...
  • Page 473: Handlebar

    FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the right and left front side cowls (page 3- SCREWS Remove the upper and lower handlebar covers (page 3-5). Remove the screws and handlebar weights. Remove the screws and left handlebar switch hous­ ing. SCREWS GRIP Disconnect the front brake light switch wire connec­...
  • Page 474 Apply Honda bond A or equivalent to the inside sur­ face of the handlebar grip and to the outside surace of the throttle pipe. Wait 3 - 5 minutes and install the grip.
  • Page 475 FRONT WHEEL/SUSPENSION/STEERING_________ Install the switch/throttle housing to the handlebar. SWITCH/THROTTLE HOUSING Install the handlebar and nuts. HANDLEBAR Tighten the nuts to the specified torque. TORQUE: 55 N m (5.6 kgf-m, 41 lbf-ft) NUTS Install tha clamps and bolts. CLAMPS Tighten the bolts securely. BOLTS Install the switch/throttle housing, aligning Align...
  • Page 476 Clean the inside surface of the right handlebar grip and the outside surface of the throttle pipe. Apply Honda bond A or equivalent to the inside sur­ face of the handlebar grip and to the outside surface of the throttle pipe. W ait 3 - 5 minutes and install the grip.
  • Page 477 FRONT WHEEL/SUSPENSION/STEERING Install the screws to the left switch housing. SCREW (UPPER SIDE) Tighten the upper screw first, then tighten the lower screw. TORQUE: 2.5 N m (0.26 kgf-m, 1.8 lbf-ft) SCREW (LOWER SIDE) Install the handlebar weights Install and tighten the screws. TORQUE: 10 N-m (1.0 kgf m, 7 lbf-ft) Install the right and left front side cowls (page 3-5).
  • Page 478 FRONT WHEEL/SUSPENSION/STEERING Loosen the left axle pinch bolts. Remove the axle shaft and front wheel Remove Ihe right and left side collars. | RIGHT SIDE COLLAR LEFT SIDE COLLAR | INSPECTION AXLE Set the front axle in V-blocks. Turn the axle and measure the runout using a dial indicator.
  • Page 479 FRONT WHEEL/SUSPENSION/STEERING WHEEL RIM Check the rim runuul by placing the wheel in a true- ing stand. Spin the wheel slow ly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)
  • Page 480 FRONT WHEEL/SUSPENSION/STEERING D ISASSEM BLY Remove the bolts and front pulser ring. FRONT PULSER RING BOLTS Remove the bolts and brake discs. Do not reuse the BRAKE DISC BOLTS Remove the dust seals. bolts' DUST SEAL Install the remover head into the bearing. Replace the wheel REMOVER HEAD From the opposite side of the wheel, install the...
  • Page 481 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY LEFT DUST SEAL RIGHT DUST SEAL FRONT PULSER RING LEFT BRAKE DISC LEFT WHEEL BEARING (6204UU) RIGHT WHEEL 20 N m (2.0 kgf-m, RIGHT BRAKE BEARING (6204UU) 15 lbf-ft) DISC Drive in a new right bearing squarely with the Never install the old DRIVER marked side facing up until it is fu lly seated.

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