Table Of Contents - Honda NSA700A DN-1 2009 Service Manual

Table of Contents

Symbols2
Contents3
How To Use This Manual3
A Few Words About Safety4
Service Information4
Important Safety Precautions4
General Information5
Table Of Contents5
Service Rules6
Abbreviation6
Model Identification7
Serial Numbers7
Labels8
Throttle Body Identification Number8
Emission Control Information Label9
General Specifications10
Lubrication System Specifications11
Fuel System (Pgm-Fi) Specifications11
Cooling System Specifications11
Cylinder Head/Valve Specifications12
Cylinder/Piston Specifications12
Hft Specifications13
Alternator/Starter Clutch Specifications13
Crankcase/Crankshaft Specifications13
Final Drive Specifications14
Front Wheel/Suspension/Steering Specifications14
Hydraulic Brake Specifications15
Battery/Charging System Specifications15
Ignition System Specifications15
Electric Starter Specification15
Lights/Meters/Switches Specifications16
Standard Torque Values17
Engine & Frame Torque Values17
Lubrication & Seal Points22
Cable & Harnes Routing24
Except California Type28
Emission Control Systems41
Exhaust Emission Requirement41
Noise Emission Requirement41
Source Of Emissions41
Crankcase Emission Control System41
Exhaust Emission Control System42
Secondary Air Supply System42
Three-Way Catalytic Converter42
Evaporative Emission Control System (California Type)43
Noise Emission Control System43
Fuel Permeation Emission Control System43
Technical Feature44
Hft System Overview45
Torque Transmission Components46
Oil Circuits47
Cam Damper/Primary Drive Gear49
Hft Power Transmission50
Starting Clutch50
Automatic Transmission System52
Hydraulic Pressure Flow52
Oil Circuit In The Hft52
Circulation Of Oil For Power Transmission53
Distributor Valve53
Oil Flow Volume Control54
Oil Motor Side Swash Plate And Transmission Ratio55
Lockup Mechanism56
N/D (Neutral/Drive) Clutch57
Electronic Control Of N/D Clutch59
Detecting Condition Of The Oil Level59
Fail-Safe For A N/D Shift Problem59
Fail-Safe Function When Oil Level Is Low59
N/D Shifting Mechanism60
Riding Mode61
Overview Of The Hft Sensors62
Oil Level Switch62
Neutral Oil Pressure Switch62
Transmission Oil Pressure Sensor63
Swash Plate Angle Sensor63
Frame/Body Panels/Exhaust System64
Body Panel Location65
Body Panel Removal Chart65
Torque Values66
Troubleshooting66
Excessive Exhaust Noise66
Poor Performance66
Main Seat/Pillion Seat67
Rearview Mirror67
Front Side Cowl68
Center Cowl69
Handlebar Cover69
Upper Cowl70
Inner Cowl71
Shroud71
Under Cowl Cover72
Main Step72
Inner Lower Cowl72
Muffler Protector73
Exhaust Pipe Protector73
Under Cowl74
Right Under Cowl Removal/Installation74
Left Under Cowl Removal/Installation74
Front Fender75
Seat Cowl75
Grab Rail Cover76
Left Side Cover77
Rear Fender78
Final Drive Cover78
Right Side Cover78
Muffler79
Exhaust Pipe79
Maintenance84
Maintenance Tool86
Maintenance Schedule87
Fuel Line88
Throttle Operation88
Air Cleaner89
Crankcase Breather89
Spark Plug Removal90
Spark Plug Inspection90
Valve Clearance Inspection91
Spark Plug Installation91
Engine Oil Level Check94
Recommended Engine Oil94
Engine Oil Filter (Cartridge)95
Oil Change95
Oil Capacity95
Hft Oil Filter (Element)96
Engine Idle Speed97
Idle Speed Inspection97
Radiator Coolant98
Cooling System98
Final Drive Oil100
Oil Level Check100
Evaporative Emission Control100
System (California Ty P100
Brake Fluid101
Brake Pads Wear103
Front Brake Pads103
Rear Brake Pads103
Brake System Inspection103
Brake Lever Adjustment104
Brake Pedal Height Adjustment104
Brake Light Switch105
Brake Lock Operation105
Headlight Aim106
Sidestand106
Front Suspension Inspection107
Rear Suspension Inspection107
Nuts, Bolts, Fasteners108
Wheels/Tires108
Recommended Tire Pressure108
Steering Head Bearings109
Lubrication System110
Lubrication System Diagram111
Lubrication System Service Information112
Lubrication System Torque Values112
Lubrication System Tools113
Lubrication System Troubleshooting113
Oil Level Too Low113
Low Oil Pressure113
Oil Pressure Inspection114
Oil Pump Driven Gear114
Oil Pump115
Pressure Relief Valve117
Body Clearance118
Tip Clearance118
Side Clearance118
Oil Pump Assembly119
Oil Cooler Removal122
Oil Cooler Installation122
Eop Switch Inspection123
Eop Switch Removal/Installation124
Fuel System (Pgm-Fi)126
Fuel System Component Location127
Fuel System Service Information128
Fuel System Torque Values128
Fuel System Tools129
Fuel System Symptom Troubleshooting130
Pgm-Fi System Location131
Pgm-Fi System Diagram132
Connector Locations133
Front Side Location133
Pgm-Fi Troubleshooting Information136
Intermittent Failure136
Fail-Safe Function136
Dtc (Diagnostic Trouble Code)136
Hds Pocket Tester Information137
Mil Blink Pattern137
Mil Check137
Current Dtc/Freeze Dtc137
Clearing Dtc138
Circuit Inspection138
Inspection At Ecm Connector138
Dtc Index139
Dtc Troubleshooting140
Dtc 1.1 (Map Sensor Low Voltage)140
Dtc 1.2 (Map Sensor High Voltage)141
Dtc 2-1 (Map Sensor)142
Dtc 7-1 (Ect Sensor Low Voltage)143
Dtc 7-2 (Ect Sensor High Voltage)144
Dtc 8-1 (Tp Sensor Low Voltage)145
Dtc 9-1 (Iat Sensor Low Voltage)147
Dtc 9-2 (Iat Sensor High Voltage)148
Dtc 11-1 (Vs Sensor)149
Dtc 12-1 (No.1 Rear Injector)151
Dtc 18-1 (Cmp Sensor)153
Dtc 19-1 (Ckp Sensor)154
Dtc 21-1 (O2 Sensor)155
Dtc 23-1 (O2 Sensor Heater)156
Dtc 29-1 (Iacv)157
Dtc 33-2 (Eeprom)158
Dtc 53-1 (Tcm Signal)159
Dtc 68-1 (Engine Inhibitor Signal)160
Mil Circuit Inspection161
Fuel Line Inspection162
Fuel Pressure Relieving/Quick Connect Fitting Removal162
Quick Connect Fitting Installation163
Fuel Pressure Test164
Fuel Flow Inspection165
Fuel Pump Inspection166
Fuel Pump Removal166
Fuel Cut Relay Inspection168
Upper Fuel Tank Removal169
Upper Fuel Tank Installation170
Breather Separator Removal172
Breather Separator Installation172
Lower Fuel Tank Removal173
Lower Fuel Tank Installation174
Air Cleaner Housing Removal175
Air Cleaner Housing Installation177
Insulator Removal/Installation178
Throttle Body Removal179
Throttle Body Installation182
Injector Inspection183
Injector Removal184
Injector Installation185
Iacv Inspection187
Iacv Removal187
Iacv Installation188
Map Sensor Removal/Installation189
Iat Sensor190
Ect Sensor190
Cmp Sensor190
Bank Angle Sensor192
Fi/Ign/Pump Relay193
Ecm193
Ecm Power/Ground Line Inspection194
Secondary Air Supply System Inspection196
Pair Control Solenoid Valve197
Pair Check Valve198
0 2 Sensor198
Evap Purge Control Solenoid Valve/Canister (California Type)200
Cooling System Flow Pattern203
Cooling System Service Information204
Cooling System Troubleshooting205
Engine Temperature Too High205
Engine Temperature Too Low205
Coolant Leaks205
Cooling System Testing206
Coolant (Hydrometer Test)206
Standard Coolant Concentration206
Radiator Cap/System Pressure Inspection207
Coolant Replacement207
Coolant Replacement/Air Bleeding207
Thermostat Removal209
Thermostat Inspection210
Thermostat Installation210
Thermostat Housing Removal/Installation210
Radiator/Cooling Fan Removal211
Thermostat Disassembly212
Thermostat Assembly213
Water Pump Mechanical Seal Inspection216
Water Pump Cover Removal217
Water Pump Cover Installation217
Radiator Reserve Tank Removal/Installation218
Fan Motor Relay Inspection219
Engine Removal/Installation220
Engine Removal223
Engine Installation228
Cylinder Head/Valve233
Cylinder Head/Valve Component Location234
Cylinder Head/Valve Service Information235
Cylinder Head/Valve Torque Values235
Cylinder Head/Valve Tools236
Cylinder Head/Valve Troubleshooting237
Cylinder Compression238
Cylinder Head Cover Removal238
Camshaft Removal239
Camshaft Runout241
Cam Lobe Height242
Camshaft Journal242
Cam Sprocket242
Cylinder Head242
Camshaft Holder Disassembly243
Camshaft Oil Clearance243
Rocker Arm/Rocker Arm Shaft Inspection244
Camshaft Holder Inspection244
Cylinder Head Removal245
Cylinder Stud Bolt Replacement247
Cylinder Head Disassembly247
Valve Spring248
Valve Stem, Valve Guide249
Valve Guide Replacement250
Cam Chain Guide250
Cam Chain Tensioner250
Valve Guide Projection Above Cylinder Head251
Valve Seat Inspection/Refacing252
Valve Seat Refacing253
Cylinder Head Assembly255
Cylinder Head Installation257
Camshaft Installation259
Camshaft Holder Assembly259
Front Cylinder Tdc Setting261
Both Cylinder Tdc Setting261
Rear Cylinder Tdc Setting261
Cylinder Head Cover Installation264
Cylinder/Piston266
Cylinder/Piston Component Location267
Cylinder/Piston Service Information268
Cylinder/Piston Troubleshooting268
Cylinder/Piston Removal269
Cylinder Removal269
Piston Removal270
Piston/Piston Ring271
Connecting Rod272
Cylinder272
Oil Jet273
Piston Ring Installation274
Cylinder Installation275
Hft277
Hft Component Location278
Hft Service Information280
Hft Torque Values280
Hft Tools281
Symptom Troubleshooting283
Hard To Start284
Engine Cranks But Won't Start284
Motorcycle Creeps With Drive Position At The Idle285
Start The Motorcycle With Neutral Position285
Lack Power/Defective Gear Shift286
Excessive Noise/Vibration287
Detect The Excessive Noise And/Or Vibration287
Hft Oil Pressure Inspection288
Hft Inspection With The Engine Installed In The Frame289
Turning Inspection At Hft Oil Pump Side290
Turning Inspection At Hft Oil Motor Side290
Hft Electrical System Location291
Hft System Diagram292
Hft Troubleshooting Information297
General Troubleshooting297
Dtc 41-1 (N/D Select Switch)326
Dtc 42-1 (Shift Switch)327
Dtc 44-1 (Eot Sensor Low Voltage)328
Dtc 44-2 (Eot Sensor High Voltage)329
Dtc 45-1 (Neutral Oil Pressure Switch)330
Dtc 46-1 (Oil Level Switch)331
Indicator Circuit Troubleshooting334
Mode/Shift Indicator334
Neutral Indicator335
Mode Select Switch Circuit Troubleshooting336
Left Crankcase Cover338
Primary Driven Gear343
Right Crankcase Cover345
Bearing Inspection346
N/D Clutch Hydraulic Pipe346
Spool Valve347
Hft Oil Passage Inspection348
Hft Hydraulic Pipe349
Swash Plate Movable Inspection At Hft Oil Motor Side367
Hft Initialization (Tcm Reset)369
Swash Plate Control Motor373
Eot Sensor378
Eop Sensor379
N/D (Neutral/Drive) Solenoid Valve383
Lock Up Solenoid Valve385
Oil Level Switch Relay387
Mode Select Switch388
Shift Switch389
N/D (Neutral/Drive) Select Switch390
Tcm391
Alternator/Starter Clutch394
Ckp Sensor/Stator Removal397
Flywheel/Starter Clutch398
Flywheel Removal398
Starter Driven Gear/Starter Clutch Removal399
Starter Clutch Inspection400
Needle Bearing400
One-Way Clutch/Clutch Outer400
Starter Driven Gear/Starter Clutch Installation401
Flywheel Installation402
Ckp Sensor/Stator Installation404
Crankcase/Crankshaft407
Crankcase/Crankshaft Component Location408
Crankcase/Crankshaft Service Information409
Crankcase/Crankshaft Torque Values410
Crankcase/Crankshaft Tools410
Crankcase/Crankshaft Troubleshooting410
Crankcase Separation411
Crankshaft/Connecting Rod412
Crankshaft Removal412
Side Clearance Inspection413
Connecting Rod Removal413
Crankshaft Inspection414
Connecting Rod Installation414
Crankshaft Runout414
Crankshaft Installation415
Crankpin Bearing415
Oil Clearance Inspection415
Main Journal Bearing417
Connecting Rod Selection417
Bearing Installation420
Crankcase Assembly422
Final Drive424
Final Drive Component Location425
Final Drive Service Information427
Final Drive Torque Values427
Final Drive Tools428
Final Drive Troubleshooting430
Excessive Noise430
Oil Leak430
Excessive Rear Wheel Backlash430
Final Drive Removal431
Backlash Inspection432
Final Drive Disassembly/ Inspection432
Final Gear Case Separation433
Gear Tooth Contact Pattern Check434
Ring Gear Removal/Shim Replacement435
Pinion Gear Removal436
Pinion Gear Bearing/Shim Replacement438
Case Bearing Replacement438
Ring Gear Bearing438
Pinion Needle Bearing439
Final Drive Assembly440
Pinion Gear Installation440
Ring Gear Installation442
Final Gear Case Assembly443
Final Drive Installation444
Side Gear Case445
Backlash Inspection/Gear Tooth Contact Pattern Check451
Shim Replacement452
Final Shaft Disassembly454
Output Shaft Shim Replacement454
Output Shaft Assembly459
Front Wheel/Suspension/Steering468
Component Location469
Front Wheel/Suspension/Steering Service Information470
Front Wheel/Suspension/Steering Torque Values470
Front Wheel/Suspension/Steering Tools471
Front Wheel/Suspension/Steering Troubleshooting472
Hard Steering472
Steers To One Side Or Does Not Track Straight472
Front Wheel Wobbles472
Fork472
Steering Stem472
Handlebar Removal473
Handlebar Installation474
Front Wheel Removal477
Front Wheel Inspection478
Axle478
Wheel Bearing478
Wheel Rim479
Wheel Balance479
Wheel Disassembly480
Wheel Assembly481