Advertisement

dummyhead
dummyhead
HOW TO USE THIS MANUAL
A Few Words About Safety
HOW TO USE THIS MANUAL
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. 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.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
0-1

Advertisement

Table of Contents
loading

Summary of Contents for Honda NC700 2012

  • Page 1 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 2 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 3 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 4: Table Of Contents

    dummyhead dummyhead CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE PGM-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM CYLINDER HEAD/VALVES CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) ALTERNATOR/STARTER CLUTCH CRANKCASE/TRANSMISSION/BALANCER CRANKSHAFT/PISTON/CYLINDER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ANTI-LOCK BRAKE SYSTEM (ABS) BATTERY/CHARGING SYSTEM...
  • Page 5 dummyhead dummyhead MEMO...
  • Page 6: General Information

    dummytext 1. GENERAL INFORMATION SERVICE RULES ··········································1-2 LUBRICATION & SEAL POINTS ··············· 1-23 MODEL IDENTIFICATION ····························1-3 CABLE & HARNESS ROUTING················· 1-25 SPECIFICATIONS ·········································1-6 EMISSION CONTROL SYSTEMS ·············· 1-86 TORQUE VALUES ······································1-15 TECHNICAL FEATURES···························· 1-87...
  • Page 7 SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda 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 8 dummyhead dummyhead GENERAL INFORMATION MODEL IDENTIFICATION NC700XA shown: NC700SA shown: This manual covers following types of NC700 models: NC700X NC700S TYPE NC700X NC700XA NC700XD NC700S NC700SA NC700SD Standard brake – – – – – – – – – – Be sure to refer to the procedure for the appropriate version of the NC700.
  • Page 9 dummyhead dummyhead GENERAL INFORMATION SERIAL NUMBERS The Vehicle Identification Number (V.I.N) [1] is stamped on the right side of the steering head. The registered number plate (E, F, ED, RU types) [1] and compliance plate (U type only) is attached on the left side of the steering head. The engine serial number [1] is stamped on the lower right side of the crankcase.
  • Page 10 dummyhead dummyhead GENERAL INFORMATION LABELS The color label [1] is attached on the right side of the rear frame. When ordering color-coded parts, always specify the designated color code. The Safety Certification Label (KO type) [1] is located on the left side of the rear frame.
  • Page 11 dummyhead dummyhead GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length NC700X/XA/XD 2,210 mm (87.0 in) NC700S/SA/SD 2,195 mm (86.4 in) Overall width E, ED, F, NC700X/XA/XD 830 mm (32.7 in) RU, U type NC700S/SA/SD 760 mm (29.9 in) KO type NC700XA 825 mm (32.5 in)
  • Page 12 dummyhead dummyhead GENERAL INFORMATION ITEM SPECIFICATIONS ENGINE Cylinder arrangement 2 cylinders in-line, slant angle 55° Bore and stroke 73.0 x 80.0 mm (2.87 x 3.15 in) Displacement 670 cm (40.9 cu-in) Compression ratio 10.7:1 Valve train Chain driven, OHC with rocker arm Intake valve opens at 1 mm (0.04 in) lift...
  • Page 13 dummyhead dummyhead GENERAL INFORMATION PGM-FI SPECIFICATIONS ITEM SPECIFICATIONS IAT sensor resistance (at 20°C/68°F) 2.2 – 2.7 kΩ ECT sensor resistance (at 40°C/104°F) 1.0 – 1.3 kΩ 11 – 13 Ω Injector resistance (at 20°C/68°F) IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Spark plug (Iridium) IFR6G-11K (NGK) Spark plug gap 1.0 –...
  • Page 14 After 4.1 liters (4.3 US qt, 3.6 Imp qt) – disassembly Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent API service classification: SG or higher (except oils labeled as energy conserving – on the circular API service label)
  • Page 15 dummyhead dummyhead GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (NC700X/XA/S/SA) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch lever freeplay 10 – 20 (3/8 – 13/16) – Clutch Spring free length 43.2 (1.70) 41.7 (1.64) Disc thickness 2.62 – 2.78 (0.103 – 0.109) 2.3 (0.09) Plate warpage –...
  • Page 16 dummyhead dummyhead GENERAL INFORMATION NC700XD/SD Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear I.D. 33.000 – 33.025 (1.2992 – 1.3002) 33.04 (1.301) 43.000 – 43.025 (1.6929 – 1.6939) 43.04 (1.694) 31.010 – 31.035 (1.2209 – 1.2218) 31.06 (1.223) 25.000 – 25.021 (0.9843 – 0.9851) 25.03 (0.985) C3, C4 31.000 –...
  • Page 17 NC700X/XA/XD 394.9 (15.55) 387.0 (15.24) length NC700S/SA/SD 357.0 (14.06) 349.9 (13.78) Tube runout – 0.20 (0.008) Recommended fork fluid Honda ULTRA CUSHION OIL SS-47 – (10W) or equivalent Fluid level NC700X/XA/XD 104 (4.1) – NC700S/SA/SD 103 (4.1) – Fluid capacity 514 ±...
  • Page 18 dummyhead dummyhead GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 – Brake disc thickness 4.8 – 5.2 (0.19 – 0.20) 4.0 (0.16) Brake disc warpage – 0.30 (0.012) Master cylinder I.D. 11.000 –...
  • Page 19 dummyhead dummyhead GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight 12 V – 60/55 W Position light 12 V – 5 W Brake/tail/license light 12 V – 21/5 W Turn signal light 12 V – 21 W x 4 Instrument light Turn signal indicator High beam indicator Neutral indicator...
  • Page 20 dummyhead dummyhead GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt (Include SH flange bolt) 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
  • Page 21 dummyhead dummyhead GENERAL INFORMATION MAINTENANCE THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Air cleaner housing cover screw 1.1 (0.1, 0.8) Spark plug 22 (2.2, 16) Valve adjusting screw lock nut 14 (1.4, 10) Apply engine oil to the threads and seating surface.
  • Page 22 dummyhead dummyhead GENERAL INFORMATION COOLING SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Water hose band screw – – See page 8-9 See page 8-10 See page 8-14 Fan motor shroud mounting bolt 8.4 (0.9, 6.2) Fan motor mounting screw 2.7 (0.3, 2.0) Cooling fan mounting nut 1.0 (0.1, 0.7)
  • Page 23 dummyhead dummyhead GENERAL INFORMATION DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Solenoid valve stopper plate bolt 12 (1.2, 9) Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ±...
  • Page 24 dummyhead dummyhead GENERAL INFORMATION CRANKCASE/TRANSMISSION/BALANCER THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Mainshaft bearing set plate bolt 12 (1.2, 9) Apply locking agent to the threads. Coating width; 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip Shift drum bearing set plate bolt 12 (1.2, 9)
  • Page 25 dummyhead dummyhead GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Handlebar holder bolt 22 (2.2, 16) Handlebar switch housing screw 2.5 (0.3, 1.8) Front master cylinder holder bolt 12 (1.2, 9) Handlebar weight mounting screw 10 (1.0, 7) ALOC screw;...
  • Page 26 dummyhead dummyhead GENERAL INFORMATION HYDRAULIC BRAKE THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Brake caliper bleed valve 5.4 (0.6, 4.0) (NC700X/S) Brake caliper bleed valve 5.4 (0.6, 4.0) (NC700XA/XD/SA/SD) Master cylinder reservoir cover 1.5 (0.2, 1.1) screw Rear brake reservoir mounting bolt 10 (1.0, 7) Brake pad pin...
  • Page 27 dummyhead dummyhead GENERAL INFORMATION LIGHTS/METERS/SWITCHES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Turn signal light mounting screw 2.5 (0.3, 1.8) Combination meter mounting 1.0 (0.1, 0.7) screw Combination meter back cover 0.3 (0.03, 0.2) mounting screw (NC700S/SA/SD) EOP switch PT 1/8 18 (1.8, 13)
  • Page 28 dummyhead dummyhead GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Liquid sealant Oil pan mating surface See page 9-12 (Three Bond 1207B or Right crankcase cover mating surface See page 11-6 equivalent) CKP sensor wire grommet Linear solenoid valve wire grommet (NC700XD/SD) Alternator wire grommet Alternator cover mating surface See page 13-7...
  • Page 29 Seat lock cable inside Luggage box lid lock cable inside Throttle cable A, B inside Clutch cable inside (NC700X/XA/S/SA) Parking brake cable inside (NC700XD/SD) Honda bond A, Cemedine Handlebar grip rubber inside #540 or equivalent Brake pad retainer mating surface Silicone grease Front brake lever sliding surface and lever-to-master piston 0.10 g (0.004 oz)
  • Page 30 dummyhead dummyhead GENERAL INFORMATION CABLE & HARNESS ROUTING NC700X/XA: CLUTCH SWITCH WIRE BRAKE LIGHT SWITCH CONNECTOR RIGHT HANDLEBAR LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE NC700XD: THROTTLE CABLE A BRAKE LIGHT SWITCH CONNECTOR RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLE B LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE...
  • Page 31 dummyhead dummyhead GENERAL INFORMATION NC700S/SA: CLUTCH SWITCH WIRE BRAKE LIGHT SWITCH CONNECTOR RIGHT HANDLEBAR LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE NC700SD: BRAKE LIGHT SWITCH CONNECTOR RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLE A THROTTLE CABLE B LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE 1-26...
  • Page 32 dummyhead dummyhead GENERAL INFORMATION NC700X/XA/XD: POSITION FRONT LEFT TURN SIGNAL LIGHT LIGHT WIRE 3P (ORANGE) CONNECTOR FRONT RIGHT TURN SIGNAL LIGHT 3P (BLUE) CONNECTOR FRONT SUB HARNESS FRONT SUB HARNESS 6P (BROWN) CONNECTOR NC700S/SA/SD: FRONT LEFT TURN SIGNAL LIGHT 3P (ORANGE) CONNECTOR POSITION LIGHT WIRES FRONT SUB HARNESS...
  • Page 33 dummyhead dummyhead GENERAL INFORMATION NC700X: MAIN WIRE HARNESS COMBINATION METER 16P (GRAY) CONNECTOR Front side THROTTLE CABLES BRAKE HOSE CLUTCH CABLE RIGHT HANDLEBAR LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE LEFT HANDLEBAR SWITCH 10P (GRAY) CONNECTOR IMMOBILIZER RECEIVER WIRE IGNITION SWITCH 2P (BROWN) CONNECTOR FRONT SUB HARNESS 6P (BROWN) CONNECTOR...
  • Page 34 dummyhead dummyhead GENERAL INFORMATION NC700XA: MAIN WIRE HARNESS COMBINATION METER 16P (GRAY) CONNECTOR Front side THROTTLE CABLES FRONT BRAKE HOSE A (to ABS MODULATOR) CLUTCH CABLE RIGHT HANDLEBAR LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE LEFT HANDLEBAR SWITCH 10P (GRAY) CONNECTOR IMMOBILIZER RECEIVER WIRE IGNITION SWITCH...
  • Page 35 dummyhead dummyhead GENERAL INFORMATION NC700XD: COMBINATION METER 16P (GRAY) CONNECTOR MAIN WIRE HARNESS FRONT BRAKE HOSE A (to ABS MODULATOR) Front side THROTTLE CABLES PARKING BRAKE CABLE LEFT HANDLEBAR RIGHT HANDLEBAR SWITCH WIRE SWITCH WIRE LEFT HANDLEBAR SWITCH 3P (BLACK) CONNECTOR IMMOBILIZER RECEIVER WIRE IGNITION SWITCH...
  • Page 36 dummyhead dummyhead GENERAL INFORMATION NC700S: RIGHT HANDLEBAR SWITCH IGNITION SWITCH 8P (BLUE) CONNECTOR 2P (BROWN) CONNECTOR FRONT SUB HARNESS LEFT HANDLEBAR SWITCH 6P (BROWN) CONNECTOR 10P (GRAY) CONNECTOR IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR MAIN WIRE HARNESS HEADLIGHT BRAKE HOSE 3P (BLACK) CONNECTOR NC700SA: RIGHT HANDLEBAR SWITCH IGNITION SWITCH...
  • Page 37 dummyhead dummyhead GENERAL INFORMATION NC700SD: RIGHT HANDLEBAR SWITCH IGNITION SWITCH 8P (BLUE) CONNECTOR 2P (BROWN) CONNECTOR FRONT SUB HARNESS 6P (BROWN) CONNECTOR LEFT HANDLEBAR SWITCH 10P (GRAY) CONNECTOR IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR MAIN WIRE HARNESS RIGHT HANDLEBAR SWITCH HEADLIGHT 7P (GREEN) CONNECTOR 3P (BLACK) CONNECTOR LEFT HANDLEBAR SWITCH...
  • Page 38 dummyhead dummyhead GENERAL INFORMATION NC700SA: CLUTCH SWITCH THROTTLE CABLE A CONNECTORS FRONT BRAKE HOSE A (to ABS MODULATOR) CLUTCH CABLE THROTTLE CABLE B LEFT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR IGNITION SWITCH WIRE SWITCH WIRE NC700SD: THROTTLE CABLE B FRONT BRAKE HOSE A (to ABS MODULATOR) THROTTLE CABLE A...
  • Page 39 dummyhead dummyhead GENERAL INFORMATION NC700X/XA: CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE COMBINATION METER 16P (GRAY) CONNECTOR TURN SIGNAL/HAZARD RELAY No.1 IGNITION COIL LEFT HANDLEBAR SWITCH 10P (GRAY) CONNECTOR IGNITION SWITCH 2P (BROWN) CONNECTOR FRONT SUB HARNESS 6P (BROWN) CONNECTOR IGNITION SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE 1-34...
  • Page 40 dummyhead dummyhead GENERAL INFORMATION NC700XD: LEFT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH PARKING BRAKE CABLE 10P (GRAY) CONNECTOR COMBINATION METER 16P (GRAY) CONNECTOR TURN SIGNAL/HAZARD RELAY No.1 IGNITION COIL LEFT HANDLEBAR SWITCH 3P (BLACK) CONNECTOR IGNITION SWITCH 2P (BROWN) CONNECTOR FRONT SUB HARNESS 6P (BROWN) CONNECTOR IGNITION SWITCH WIRE...
  • Page 41 dummyhead dummyhead GENERAL INFORMATION NC700S/SA: CLUTCH CABLE IAT SENSOR 2P (BLACK) CONNECTOR TURN SIGNAL/HAZARD RELAY No.2 IGNITION COIL MAIN WIRE HARNESS No.1 IGNITION COIL No.1 SPARK PLUG WIRE BATTERY BOX DRAIN HOSE 1-36...
  • Page 42 dummyhead dummyhead GENERAL INFORMATION NC700SD: PARKING BRAKE CABLE IAT SENSOR 2P (BLACK) CONNECTOR TURN SIGNAL/HAZARD RELAY No.2 IGNITION COIL MAIN WIRE HARNESS No.1 IGNITION COIL No.1 SPARK PLUG WIRE BATTERY BOX DRAIN HOSE 1-37...
  • Page 43 dummyhead dummyhead GENERAL INFORMATION NC700X: THROTTLE CABLE A RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLE B BRAKE HOSE RIGHT HANDLEBAR SWITCH 8P (BLUE) CONNECTOR THROTTLE CABLE B IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR THROTTLE CABLE A THROTTLE CABLE A THROTTLE CABLE B RIGHT HANDLEBAR SWITCH WIRE BRAKE HOSE...
  • Page 44 dummyhead dummyhead GENERAL INFORMATION NC700XA: THROTTLE CABLE B THROTTLE CABLE A RIGHT HANDLEBAR SWITCH 8P (BLUE) CONNECTOR RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE A IMMOBILIZER RECEIVER (to ABS MODULATOR) 4P (BLACK) CONNECTOR FRONT BRAKE HOSE A (to ABS MODULATOR) THROTTLE CABLE B THROTTLE CABLE A THROTTLE...
  • Page 45 dummyhead dummyhead GENERAL INFORMATION NC700XD: THROTTLE CABLE A FRONT BRAKE HOSE A RIGHT HANDLEBAR SWITCH (to ABS MODULATOR) 8P (BLUE) CONNECTOR THROTTLE CABLE B RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH 6P (BLACK) CONNECTOR FRONT BRAKE HOSE A (to ABS MODULATOR) THROTTLE CABLE B IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR...
  • Page 46 dummyhead dummyhead GENERAL INFORMATION NC700X: CLUTCH CABLE BRAKE HOSE 1-41...
  • Page 47 dummyhead dummyhead GENERAL INFORMATION NC700XA: CLUTCH CABLE FRONT BRAKE HOSE A (to ABS MODULATOR) Parallel FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE D (from ABS MODULATOR) BRAKE SUB HOSE C (from DELAY VALVE) 1-42...
  • Page 48 dummyhead dummyhead GENERAL INFORMATION NC700XD: PARKING BRAKE CABLE FRONT BRAKE HOSE A (to ABS MODULATOR) Parallel FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE D (from ABS MODULATOR) BRAKE SUB HOSE C (from DELAY VALVE) 1-43...
  • Page 49 dummyhead dummyhead GENERAL INFORMATION NC700S: LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE A CLUTCH CABLE THROTTLE CABLE B CLUTCH SWITCH WIRE IGNITION COIL PRIMARY WIRES BRAKE HOSE No.2 IGNITION COIL SIPHON HOSE RESERVE TANK OVERFLOW HOSE HORN WIRES SENSOR 1P (BLACK) CONNECTOR 1-44...
  • Page 50 dummyhead dummyhead GENERAL INFORMATION NC700SA: THROTTLE CABLE A LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE B CLUTCH CABLE FRONT WHEEL SPEED SENSOR 2P (BLUE) CONNECTOR CLUTCH SWITCH WIRE IGNITION COIL PRIMARY WIRES FRONT BRAKE HOSE A (to ABS MODULATOR) FRONT BRAKE HOSE D (from ABS MODULATOR) No.2 IGNITION COIL SIPHON HOSE...
  • Page 51 dummyhead dummyhead GENERAL INFORMATION NC700SD: PARKING BRAKE CABLE FRONT WHEEL SPEED SENSOR 2P (BLUE) CONNECTOR THROTTLE CABLE A IGNITION COIL PRIMARY WIRES THROTTLE CABLE B FRONT BRAKE HOSE A (to ABS MODULATOR) FRONT BRAKE HOSE D (from ABS MODULATOR) No.2 IGNITION COIL SIPHON HOSE RESERVE TANK OVERFLOW HOSE...
  • Page 52 dummyhead dummyhead GENERAL INFORMATION NC700X/XA/XD: SEAT LOCK CABLE LUGGAGE BOX LID LOCK CABLE NC700X/XA/XD: TURN SIGNAL/HAZARD RELAY TURN SIGNAL/HAZARD RELAY 4P CONNECTOR IGNITION COIL PRIMARY WIRE SEAT LOCK CABLE No.1 IGNITION COIL 1-47...
  • Page 53 dummyhead dummyhead GENERAL INFORMATION NC700S/SA/SD: LUGGAGE BOX LID LOCK CABLE No.2 IGNITION COIL NC700S/SA/SD: SIDESTAND SWITCH LUGGAGE BOX LID LOCK CABLE 3P (GREEN) CONNECTOR FUEL PUMP 1P (BLACK) CONNECTOR SEAT LOCK CABLE 1-48...
  • Page 54 dummyhead dummyhead GENERAL INFORMATION NC700S/SA/SD: LUGGAGE BOX LID LOCK CABLE TURN SIGNAL/HAZARD RELAY No.2 IGNITION COIL No.1 IGNITION COIL JUNCTION B 14P (ORANGE) CONNECTOR JUNCTION G 14P (ORANGE) CONNECTOR 1-49...
  • Page 55 dummyhead dummyhead GENERAL INFORMATION NC700X/XA: IAT SENSOR 2P (BLACK) CONNECTOR JUNCTION B TURN SIGNAL/HAZARD RELAY 14P (ORANGE) CONNECTOR JUNCTION G 14P (ORANGE) CONNECTOR No.2 IGNITION COIL IGNITION COIL PRIMARY WIRES LEFT HANDLEBAR SWITCH 10P (GRAY) CONNECTOR STARTER RELAY SWITCH IGNITION SWITCH IGNITION COIL 2P (BROWN) CONNECTOR PRIMARY WIRES...
  • Page 56 dummyhead dummyhead GENERAL INFORMATION NC700XD: IAT SENSOR 2P (BLACK) CONNECTOR JUNCTION B TURN SIGNAL/HAZARD RELAY 14P (ORANGE) CONNECTOR JUNCTION G 14P (ORANGE) CONNECTOR No.2 IGNITION COIL IGNITION COIL PRIMARY WIRES LEFT HANDLEBAR SWITCH 10P (GRAY) CONNECTOR STARTER RELAY SWITCH LEFT HANDLEBAR SWITCH 3P (BLACK) CONNECTOR IGNITION COIL PRIMARY WIRES...
  • Page 57 dummyhead dummyhead GENERAL INFORMATION NC700X/XA/S/SA: FAN MOTOR 3P (GRAY) CONNECTOR AIR CLEANER HOUSING DRAIN HOSE FUEL FEED HOSE RADIATOR LOWER WATER HOSE No.1 SPARK PLUG WIRE BATTERY BOX DRAIN HOSE 1-52...
  • Page 58 dummyhead dummyhead GENERAL INFORMATION NC700XD/SD: FAN MOTOR 3P (GRAY) CONNECTOR AIR CLEANER HOUSING DRAIN HOSE FUEL FEED HOSE RADIATOR LOWER WATER HOSE No.1 SPARK PLUG WIRE BATTERY BOX DRAIN HOSE SHIFT PEDAL ANGLE SENSOR 3P (BLACK) CONNECTOR (Optional) 1-53...
  • Page 59 dummyhead dummyhead GENERAL INFORMATION NC700X/XA: RADIATOR UPPER WATER HOSE CLUTCH CABLE SIPHON HOSE FUEL FEED HOSE No.2 SPARK PLUG WIRE ECT SENSOR 2P CONNECTOR RESERVE TANK SENSOR WIRE OVERFLOW HOSE HORN WIRES SENSOR 1P (BLACK) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR 1-54...
  • Page 60 dummyhead dummyhead GENERAL INFORMATION NC700XD: RADIATOR UPPER WATER HOSE PARKING BRAKE CABLE SIPHON HOSE FUEL FEED HOSE No.2 SPARK PLUG WIRE ECT SENSOR 2P CONNECTOR RESERVE TANK SENSOR WIRE OVERFLOW HOSE HORN WIRES SENSOR 1P (BLACK) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR 1-55...
  • Page 61 dummyhead dummyhead GENERAL INFORMATION NC700S/SA: Upper side RADIATOR UPPER CLUTCH CABLE WATER HOSE SIPHON HOSE FUEL FEED HOSE No.2 SPARK PLUG WIRE ECT SENSOR 2P CONNECTOR RESERVE TANK SENSOR WIRE OVERFLOW HOSE HORN WIRES SENSOR 1P (BLACK) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR...
  • Page 62 dummyhead dummyhead GENERAL INFORMATION NC700SD: Upper side PARKING BRAKE CABLE RADIATOR UPPER WATER HOSE SIPHON HOSE FUEL FEED HOSE No.2 SPARK PLUG WIRE ECT SENSOR 2P CONNECTOR RESERVE TANK SENSOR WIRE OVERFLOW HOSE HORN WIRES SENSOR 1P (BLACK) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR...
  • Page 63 dummyhead dummyhead GENERAL INFORMATION NC700XD/SD: MAIN WIRE HARNESS No.2 CLUTCH EOP SENSOR 3P (GRAY) CONNECTOR CLUTCH LINE EOP SENSOR SHIFT SPINDLE ANGLE SENSOR WIRE 3P (BLACK) CONNECTOR MAIN WIRE HARNESS No.1 CLUTCH EOP SENSOR 3P (GRAY) CONNECTOR 1-58...
  • Page 64 dummyhead dummyhead GENERAL INFORMATION NC700X/XA: OPTION 6P CONNECTOR VS SENSOR 3P (BLACK) CONNECTOR NEUTRAL SWITCH WIRE ALTERNATOR WIRE SIDESTAND SWITCH WIRE NEUTRAL SWITCH CONNECTOR SIDESTAND SWITCH WIRE BATTERY BOX DRAIN HOSE NEUTRAL FUEL TANK SWITCH WIRE DRAIN HOSE B SIDESTAND SWITCH WIRE FUEL TANK DRAIN HOSE B 1-59...
  • Page 65 dummyhead dummyhead GENERAL INFORMATION NC700XD/SD: FUEL TANK DRAIN HOSE B SIDESTAND SWITCH WIRE TR SENSOR WIRE MAIN WIRE HARNESS MAIN WIRE HARNESS SIDESTAND SWITCH WIRE TR SENSOR WIRE SHIFT PEDAL ANGLE SENSOR 3P (BLACK) CONNECTOR (Optional) NEUTRAL SWITCH TR SENSOR SIDESTAND SWITCH WIRE BATTERY BOX DRAIN HOSE...
  • Page 66 dummyhead dummyhead GENERAL INFORMATION NC700X: CRANKCASE BREATHER HOSE THROTTLE CABLES No.2 SPARK PLUG WIRE IACV 4P (BLACK) CONNECTOR No.1 SPARK PLUG WIRE SENSOR UNIT 5P (BLACK) CONNECTOR Upper Upper side side Right Left side side INJECTOR 2P (GRAY) CONNECTORS BATTERY BOX DRAIN HOSE ECT SENSOR FUEL FEED HOSE...
  • Page 67 dummyhead dummyhead GENERAL INFORMATION NC700XA/XD: CRANKCASE BREATHER HOSE THROTTLE CABLES No.2 SPARK PLUG WIRE IACV 4P (BLACK) CONNECTOR No.1 SPARK PLUG WIRE SENSOR UNIT 5P (BLACK) CONNECTOR Upper Upper side side Right Left side side INJECTOR 2P (GRAY) CONNECTORS BATTERY BOX DRAIN HOSE ECT SENSOR FUEL FEED HOSE...
  • Page 68 dummyhead dummyhead GENERAL INFORMATION NC700S: CRANKCASE BREATHER HOSE MAIN WIRE THROTTLE CABLES No.2 SPARK PLUG WIRE HARNESS IACV 4P (BLACK) CONNECTOR SENSOR UNIT Upper 5P (BLACK) CONNECTOR side CLUTCH CABLE Upper No.1 SPARK PLUG WIRE side Upper side Right side Left side INJECTOR...
  • Page 69 dummyhead dummyhead GENERAL INFORMATION NC700SA: CRANKCASE BREATHER HOSE MAIN WIRE THROTTLE CABLES No.2 SPARK PLUG WIRE HARNESS IACV 4P (BLACK) CONNECTOR Upper SENSOR UNIT side 5P (BLACK) CONNECTOR CLUTCH CABLE Upper No.1 SPARK PLUG WIRE side Upper side Right side Left side INJECTOR...
  • Page 70 dummyhead dummyhead GENERAL INFORMATION NC700SD: CRANKCASE BREATHER HOSE MAIN WIRE THROTTLE CABLES No.2 SPARK PLUG WIRE HARNESS IACV 4P (BLACK) CONNECTOR Upper SENSOR UNIT side 5P (BLACK) CONNECTOR PARKING BRAKE CABLE Upper No.1 SPARK PLUG WIRE side Upper side Right side Left side...
  • Page 71 dummyhead dummyhead GENERAL INFORMATION NC700X: FUEL TANK DRAIN HOSE A REAR BRAKE LIGHT SWITCH 3P (BLACK) CONNECTOR OPTION 6P CONNECTOR SEAT LOCK CABLE FUEL PUMP 1P (BLACK) CONNECTOR SIDESTAND SWITCH 3P (GREEN) CONNECTOR GROUND TERMINALS NC700S: REAR BRAKE LIGHT SWITCH 3P (BLACK) CONNECTOR FUEL TANK DRAIN HOSE A OPTION...
  • Page 72 dummyhead dummyhead GENERAL INFORMATION NC700XA: FRONT BRAKE PIPE C (to FRONT BRAKE CALIPER) ABS MODULATOR 25P CONNECTOR FUEL TANK DRAIN HOSE A FRONT BRAKE PIPE B (from FRONT MASTER CYLINDER) BRAKE SUB PIPE A (to DELAY VALVE) BRAKE SUB PIPE B (to FRONT BRAKE CALIPER) DELAY VALVE SEAT LOCK CABLE...
  • Page 73 dummyhead dummyhead GENERAL INFORMATION NC700XD: SHIFT SPINDLE ANGLE SENSOR 3P (GRAY) CONNECTOR FUEL TANK DRAIN HOSE A ABS MODULATOR 25P CONNECTOR FRONT BRAKE PIPE C (to FRONT BRAKE CALIPER) BRAKE SUB PIPE A (to DELAY VALVE) LINEAR SOLENOID VALVE 4P (GREEN) CONNECTOR SEAT LOCK CABLE FUEL PUMP 1P (BLACK) CONNECTOR...
  • Page 74 dummyhead dummyhead GENERAL INFORMATION NC700SA: FRONT BRAKE PIPE C (to FRONT BRAKE CALIPER) ABS MODULATOR 25P CONNECTOR FUEL TANK DRAIN HOSE A BRAKE SUB PIPE A OPTION (to DELAY VALVE) 6P CONNECTOR BRAKE SUB PIPE B (to FRONT BRAKE CALIPER) SEAT LOCK CABLE FUEL PUMP 1P (BLACK) CONNECTOR...
  • Page 75 dummyhead dummyhead GENERAL INFORMATION NC700SD: ABS MODULATOR 25P CONNECTOR FRONT BRAKE PIPE C SHIFT SPINDLE ANGLE SENSOR (to FRONT BRAKE CALIPER) 3P (GRAY) CONNECTOR BRAKE SUB PIPE A (to DELAY VALVE) FUEL TANK DRAIN HOSE A LINEAR SOLENOID VALVE 4P (GREEN) CONNECTOR OPTION 6P CONNECTOR SEAT LOCK CABLE...
  • Page 76 dummyhead dummyhead GENERAL INFORMATION NC700X: OPTION 33P (BLACK) CONNECTOR 6P CONNECTOR VS SENSOR 3P (BLACK) CONNECTOR FUEL TANK BREATHER HOSE REAR BRAKE LIGHT SWITCH 3P (BLACK) CONNECTOR GROUND TERMINALS CLUTCH CABLE NC700S: VS SENSOR OPTION WIRE 33P (BLACK) CONNECTOR 3P (BLACK) CONNECTOR FUEL TANK BREATHER HOSE REAR BRAKE LIGHT SWITCH...
  • Page 77 dummyhead dummyhead GENERAL INFORMATION NC700XA: REAR WHEEL SPEED SENSOR 2P (GRAY) CONNECTOR REAR BRAKE PIPE B 33P (BLACK) CONNECTOR (REAR MASTER CYLINDER to ABS MODULATOR) REAR BRAKE LIGHT SWITCH 3P (BLACK) CONNECTOR REAR BRAKE PIPE D (PCV to REAR BRAKE CALIPER) REAR BRAKE PIPE C (to PCV) FUEL TANK...
  • Page 78 dummyhead dummyhead GENERAL INFORMATION NC700XD: 33P (GRAY) CONNECTOR 33P (BLACK) CONNECTOR REAR BRAKE LIGHT SWITCH REAR BRAKE PIPE B 3P (BLACK) CONNECTOR (REAR MASTER CYLINDER to ABS MODULATOR) JUNCTION D REAR WHEEL SPEED SENSOR 24P CONNECTOR 2P (GRAY) CONNECTOR REAR BRAKE PIPE D (PCV to REAR BRAKE CALIPER) REAR BRAKE PIPE C (to PCV)
  • Page 79 dummyhead dummyhead GENERAL INFORMATION NC700SA: REAR WHEEL SPEED SENSOR 2P (GRAY) CONNECTOR REAR BRAKE PIPE B 33P (BLACK) CONNECTOR (REAR MASTER CYLINDER to ABS MODULATOR) REAR BRAKE LIGHT SWITCH 3P (BLACK) CONNECTOR REAR BRAKE PIPE D (PCV to REAR BRAKE CALIPER) REAR BRAKE PIPE C (to PCV) FUEL TANK...
  • Page 80 dummyhead dummyhead GENERAL INFORMATION NC700SD: 33P (GRAY) CONNECTOR 33P (BLACK) CONNECTOR REAR BRAKE PIPE B REAR BRAKE LIGHT SWITCH (REAR MASTER CYLINDER to ABS MODULATOR) 3P (BLACK) CONNECTOR JUNCTION D REAR WHEEL SPEED SENSOR 24P CONNECTOR 2P (GRAY) CONNECTOR REAR BRAKE PIPE D (PCV to REAR BRAKE CALIPER) REAR BRAKE PIPE C (to PCV)
  • Page 81 dummyhead dummyhead GENERAL INFORMATION NC700X/S: BANK ANGLE SENSOR SIDESTAND SWITCH 2P (BLACK) CONNECTOR 3P (GREEN) CONNECTOR FUEL PUMP 1P (BLACK) CONNECTOR FUEL FEED HOSE GROUND TERMINALS FUEL PUMP UNIT 3P (BLACK) CONNECTOR MAIN WIRE HARNESS ALTERNATOR WIRE NC700XA/SA: BANK ANGLE SENSOR SIDESTAND SWITCH 2P (BLACK) CONNECTOR 3P (GREEN) CONNECTOR...
  • Page 82 dummyhead dummyhead GENERAL INFORMATION NC700XD/SD: BANK ANGLE SENSOR SIDESTAND SWITCH 2P (BLACK) CONNECTOR 3P (GREEN) CONNECTOR REAR WHEEL SPEED SENSOR FUEL PUMP 2P (GRAY) CONNECTOR 1P (BLACK) CONNECTOR FUEL FEED HOSE JUNCTION D GROUND TERMINALS 24P CONNECTOR TR SENSOR 3P (BLACK) CONNECTOR MAIN WIRE HARNESS FUEL PUMP UNIT 3P (BLACK) CONNECTOR...
  • Page 83 dummyhead dummyhead GENERAL INFORMATION NC700X/XA: FUEL TANK DRAIN HOSE A FUEL TANK BREATHER HOSE Front side FUEL TANK DRAIN HOSE B FUEL FEED HOSE FUEL TANK DRAIN HOSE A SEAT LOCK CABLE SEAT LOCK CABLE FUEL TANK BREATHER HOSE 1-78...
  • Page 84 dummyhead dummyhead GENERAL INFORMATION NC700XD: VS SENSOR 3P (BLACK) CONNECTOR INNER MAINSHAFT SENSOR 3P (BLACK) CONNECTOR EOT SENSOR 2P (BLACK) CONNECTOR OUTER MAINSHAFT SENSOR 3P (BLACK) CONNECTOR FUEL TANK DRAIN HOSE A FUEL TANK BREATHER HOSE Front side FUEL TANK DRAIN HOSE B FUEL FEED HOSE FUEL TANK DRAIN HOSE A SEAT LOCK CABLE...
  • Page 85 dummyhead dummyhead GENERAL INFORMATION NC700S/SA: FUEL TANK DRAIN HOSE A FUEL TANK BREATHER HOSE Front side FUEL TANK DRAIN HOSE B FUEL FEED HOSE FUEL TANK DRAIN HOSE A SEAT LOCK CABLE SEAT LOCK CABLE FUEL TANK BREATHER HOSE 1-80...
  • Page 86 dummyhead dummyhead GENERAL INFORMATION NC700SD: VS SENSOR 3P (BLACK) CONNECTOR INNER MAINSHAFT SENSOR 3P (BLACK) CONNECTOR EOT SENSOR 2P (BLACK) CONNECTOR OUTER MAINSHAFT SENSOR 3P (BLACK) CONNECTOR FUEL TANK DRAIN HOSE A FUEL TANK BREATHER HOSE Front side FUEL TANK DRAIN HOSE B FUEL FEED HOSE FUEL TANK DRAIN HOSE A SEAT LOCK CABLE...
  • Page 87 dummyhead dummyhead GENERAL INFORMATION NC700X/S: ALTERNATOR REAR BRAKE LIGHT SWITCH WIRE 3P (BLACK) CONNECTOR REAR BRAKE HOSE REGULATOR/RECTIFIER 2P (BLACK) CONNECTOR NC700XA/XD/SA/SD: ALTERNATOR REAR BRAKE LIGHT SWITCH WIRE 3P (BLACK) CONNECTOR REAR BRAKE HOSE A (to ABS MODULATOR) REAR WHEEL SPEED SENSOR WIRE REGULATOR/RECTIFIER REAR BRAKE HOSE E 2P (BLACK) CONNECTOR...
  • Page 88 dummyhead dummyhead GENERAL INFORMATION NC700X/S: REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE NC700XA/SA: REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE A (to ABS MODULATOR) REAR BRAKE HOSE E (from PCV) REAR WHEEL SPEED SENSOR WIRE 1-83...
  • Page 89 dummyhead dummyhead GENERAL INFORMATION NC700XD/SD: REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE E (from PCV) REAR WHEEL SPEED SENSOR WIRE REAR BRAKE HOSE A (to ABS MODULATOR) PARKING BRAKE CABLE NC700X/XA/XD/S/SA/SD: REAR LEFT TURN SIGNAL LIGHT 2P (ORANGE) CONNECTOR MAIN WIRE HARNESS REAR RIGHT TURN SIGNAL LIGHT 2P (LIGHT BLUE) CONNECTOR...
  • Page 90 dummyhead dummyhead GENERAL INFORMATION NC700X/XA/XD/S/SA/SD: Upper side Right Upper side side Front side Right side 180 ± 22.5° Lower side INDEX MARK Left side Front side Front Left side side 30 ± 22.5° Front side Upper side 1-85...
  • Page 91 Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems (page 1-87) to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
  • Page 92 dummyhead dummyhead GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a three-way catalytic converter and PGM-FI system. The exhaust emission control system is separate from the crankcase emission control system. THREE-WAY CATALYTIC CONVERTER This motorcycle also equipped with a three-way catalytic converter. The three-way catalytic converter is in the exhaust system.
  • Page 93 dummyhead dummyhead GENERAL INFORMATION ECM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION (NC700X/XA/S/SA) This motorcycle is equipped with the ECM-to-combination meter two-way serial communication system. ECM sends the following information to combination meter: – Engine speed signal – HISS indicator signal, MIL signal, Engine oil pressure indicator signal, High coolant temperature indicator signal Combination meter sends the following information to the ECM.
  • Page 94 dummyhead dummyhead GENERAL INFORMATION PCM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION (NC700XD/SD) This motorcycle is equipped with the PCM-to-combination meter two-way serial communication system. The PCM sends the following information to combination meter: – High coolant temperature indicator signal – Engine oil pressure indicator signal –...
  • Page 95 dummyhead dummyhead GENERAL INFORMATION DUAL CLUTCH TRANSMISSION The dual clutch transmission on this motorcycle uses new dual clutch assembly and its hydraulic system is improved. The dual clutch assembly consists of the primary driven gear assembly, two clutch guides and hydraulic clutch assemblies. The linear solenoid valves are located inside the right crankcase cover and inner mainshaft has to oil passages instead of the oil feed pipes.
  • Page 96: Frame/Body Panels/Exhaust System

    dummytext 2. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS CENTER COVER (NC700X/XA/XD) ··········· 2-16 (NC700X/XA) ·················································2-2 LUGGAGE BOX LID ··································· 2-17 BODY PANEL LOCATIONS (NC700XD)·····················································2-3 LUGGAGE BOX LID/ HINGE ASSEMBLY ···································· 2-19 BODY PANEL LOCATIONS (NC700S/SA) ·················································2-4 LUGGAGE BOX ·········································· 2-19 BODY PANEL LOCATIONS WINDSCREEN ············································...
  • Page 97 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (NC700X/XA) FRAME/BODY PANELS/EXHAUST SYSTEM [16] [13] [14] [10] [18] [20] [17] [21] [19] [12] [26] [15] [11] [24] [22] [23] [25] Pillion seat page 2-7 [10] Air duct page 2-13 [19] Front under cover page 2-25 Single seat page 2-7...
  • Page 98 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (NC700XD) [1] [2] [14] [13] [10] [16] [15] [18] [28] [20] [17] [21] [19] [12] [27] [25] [22] [11] [24] [23] [26] Pillion seat page 2-7 [11] Shroud page 2-14 [21] Front center cowl page 2-26 Single seat page 2-7...
  • Page 99 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (NC700S/SA) E, ED, F, KO, RU type shown: [15] [10] [17] [13] [16] [18] [11] [12] [22] [19] [21] [14] [20] Pillion seat page 2-7 Rear fender B page 2-12 [17] Headlight cover page 2-27 Single seat page 2-7...
  • Page 100 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (NC700SD) E, ED, F, KO, RU type shown: [1] [2] [13] [14] [15] [10] [17] [24] [16] [18] [11] [12] [23] [21] [19] [22] [20] Pillion seat page 2-7 [10] Side cowl page 2-13 [19] Lower cowl...
  • Page 101 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels and exhaust system. • Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. •...
  • Page 102 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM PILLION SEAT REMOVAL/INSTALLATION Open the pillion seat [1] using the ignition key. Remove the nuts [2], collars [3] and pillion seat. Remove the grommets [4] from the pillion seat stay. Installation is in the reverse order of removal. Apply grease to the pillion seat catch hook sliding area if necessary.
  • Page 103 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM GRAB RAIL REMOVAL/INSTALLATION Open the pillion seat using the ignition key. Remove the clip [1], washer [2], spring [3] and pillion seat hinge [4] from the pillion seat stay. Right grab rail: Remove the caps [5] from the mounting socket bolts [6]. Remove the mounting socket bolts, washers [7] and grab rails [8] while holding the collars [9].
  • Page 104 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SEAT COWL REMOVAL/INSTALLATION Remove the following: – Single seat (page 2-7) – Grab rail (page 2-8) Remove the socket bolts [1] and trim clips [2]. Release the seat cowl front side slits [3] and tabs [4] from the side cover tabs [5] and slits [6]. Remove the seat cowl assembly [7] by releasing the its rear side tabs [8] and slits [9] from the rear fender B slits [10] and tabs [11].
  • Page 105 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER MUD GUARD (U type) REMOVAL/INSTALLATION Remove the screw [1], socket bolts [2] and rear fender mud guard [3]. BRAKE/TAIL/LICENSE LIGHT/TAIL LIGHT COVER REMOVAL/INSTALLATION Remove the rear fender mud guard (U type) (page 2- E, ED, F, KO, RU type shown: [3]/[4]/[5] 10).
  • Page 106 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the reflector mounting nut [1] and reflector [2]. Remove the screw [3], nuts [4], washers [5] and socket bolts [6] and separate the tail light covers [7] and brake/ tail/license light [8]. Remove the turn signal light mounting screw [9], setting plate [10] and turn signal light [11]. Remove the mounting rubber [12].
  • Page 107 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER A REMOVAL/INSTALLATION Remove the following: – Pillion seat (page 2-7) – Mud guard (page 2-11) Remove the clip [1], washer [2], spring [3] and pillion seat hinge [4] from the pillion seat stay. Remove the rubber holder [5] from the rear fender A tabs.
  • Page 108 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM AIR DUCT (NC700X/XA/XD) REMOVAL/INSTALLATION Open the luggage box lid using the ignition key. Remove the trim clip [1] and screw [2]. Release the air duct tabs [3] from the slits by pulling it rearward and remove the air duct [4]. Installation is in the reverse order of removal.
  • Page 109 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM RIGHT SIDE COWL REMOVAL/INSTALLATION Remove the left side cowl (page 2-13). Remove the trim clip [1] and socket bolts [2]. Remove the right side cowl [3] by releasing the side cowl tabs [4] from the luggage box hinge bracket and side cover.
  • Page 110 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws [1]. Release the shroud tabs [2] from the side cover slits [3] and remove the shroud [4] from the side cover [5]. Assembly is in the reverse order of disassembly. SHELTER/SIDE COVER (NC700S/SA/SD) REMOVAL/INSTALLATION Remove the following: –...
  • Page 111 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws [1]. Release the shelter tab [2] from the side cover slit [3] and remove the shelter [4] from the side cover [5]. Assembly is in the reverse order of disassembly. CENTER COVER (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the air duct (page 2-13).
  • Page 112 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws [1] and seat lock assembly from the center cover [2]. Remove the screws [3] and center inner cover [4]. Remove the clip [5], cable guide [6] and seat lock [7]. Assembly is in the reverse order of disassembly. Align the seat lock tab [8] with the clip and cable guide cutouts [9].
  • Page 113 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Remove the luggage box assembly screws [1]. Release the tabs [2] and remove the luggage box lids B [3] from the luggage box lid A [4]. Installation is in the reverse order of removal. TORQUE: Luggage box lid assembly screw: 0.9 N·m (0.1 kgf·m, 0.7 lbf·ft) Luggage box lid lock plate mounting screw:...
  • Page 114 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM LUGGAGE BOX LID/HINGE ASSEMBLY REMOVAL/INSTALLATION Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the shelter/side cover (NC700S/SA/SD) (page 2-15). Remove the screw [1] and disconnect the band [2]. Remove the socket bolts [3] and bolts [4] and luggage box lid/hinge assembly [5].
  • Page 115 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION (NC700S/SA/SD) Remove the shelter/side cover (page 2-15). Remove the socket bolts [1], cable guide [2] and seat lock assembly [3]. Release the luggage box lid lock cable [4]. Release the following: – Turn signal/hazard relay [5] from the luggage box tab –...
  • Page 116 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY (NC700X/XA/XD) Remove the following: – Luggage box lid (page 2-17) – Maintenance lid (page 21-6) Remove the screw [1] and band [2]. Remove the trim clips [3], owners manual lid [4] and luggage box lid hinge cover [5]. Remove the socket bolts [6] and luggage box lid catch [7].
  • Page 117 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY (NC700S/SA/SD) Remove the following: – Luggage box lid (page 2-18) – Maintenance lid (page 21-6) Remove the screw [1] and band [2]. Remove the trim clips [3] and owners manual lid [4]. Remove the socket bolts [5] and luggage box lid catch [6]. Remove the socket bolts and luggage box lid hinge assembly.
  • Page 118 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN REMOVAL/INSTALLATION (NC700X/XA/XD) Remove the socket bolts [1], washers [2] and windscreen [3]. Remove the special nuts [4] and cushion rubbers [5] if necessary. Installation is in the reverse order of removal. If you wish the windscreen position upward, you can choose high position. –...
  • Page 119 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT SIDE COWL (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the shroud/side cover (page 2-14). Remove the trim clips [1], socket bolt [2] and bolts [3]. Disconnect the front turn signal light 3P connector [4] and remove the front side cowl [5]. Installation is in the reverse order of removal.
  • Page 120 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT UNDER COVER (NC700X/XA/ REMOVAL/INSTALLATION Remove the trim clips [1] and screw [2]. Release the tabs [3] and remove the front under cover [4]. Installation is in the reverse order of removal. INNER UPPER COVER (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the front side cowl (page 2-24).
  • Page 121 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM HEADLIGHT/FRONT CENTER COWL (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the following: – Meter stay (page 2-24) – Front under cover (page 2-25) – Inner upper cover (page 2-25) Release the front turn signal light 3P connectors [1] from the wire bands [2]. Disconnect the headlight 3P (Black) connector [3] and front sub harness 6P (Brown) connector [4].
  • Page 122 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM HEADLIGHT/HEADLIGHT STAY (NC700S/SA/SD) REMOVAL/INSTALLATION Remove the socket bolts [1] and collars [2]. Release the headlight stay tabs [3] from the grommet [4]. Disconnect the headlight 3P (Black) connector [5], front sub harness 6P (Brown) connector [6] and remove the headlight/headlight stay [7].
  • Page 123 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the bolts [1], hose guide [2], socket bolts [3], washers [4] and front fender [5] from the fork legs. Remove the flange collars (E, ED, F, KO, RU type) [6], reflector (U type) [7], grommets [8], front fender brace [9] and collars [10] from the front fender.
  • Page 124 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION (NC700XD/ Remove the socket bolts [1]. Release the bosses [2] from the grommets [3] and remove the lower cowl [4]. Installation is in the reverse order of removal. DISASSEMBLY/ASSEMBLY Remove the screws [1]. Release the tabs [2] from the slits [3] and separate the left lower cowl [4], right lower cowl [5] and center lower cowl [6].
  • Page 125 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION (NC700XD/ Remove the lower cowl (page 2-29). Remove the bolts [1] and left rear cover [2]. Remove the drive chain guide plate [3] from the left rear cover. Installation is in the reverse order of removal. RIGHT ENGINE SIDE COVER (NC700XD/SD) REMOVAL/INSTALLATION...
  • Page 126 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM BATTERY BOX REMOVAL/INSTALLATION Remove the following: – Battery (page 21-6) – Luggage box (page 2-19) Remove the bolts [1] and ignition coil stay [2] from the battery box [3]. Release the following: – Fuse box [4] –...
  • Page 127 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM CENTER CROSS PLATE REMOVAL/INSTALLATION Remove the luggage box (page 2-19). Disconnect the sidestand switch 3P (Green) connector [1] and remove it from the ECM box [2]. Release the fuel pump 1P (Black) connector [3] from the ECM box. Remove the bolts [4] and ECM box from the center cross plate [5].
  • Page 128 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Remove the muffler mounting nut [1], bolt [2] and washer [3]. Remove the muffler [4] and gasket [5]. [2]/[3] Remove the muffler cover socket bolt. Remove the muffler cover by releasing its slits from the muffler bosses. Installation is in the reverse order of removal.
  • Page 129 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE REMOVAL Remove the lower cowl (page 2-28). Disconnect the O sensor 1P (Black) connector [1]. Release the O sensor wire from the clamp [2] and radiator reserve tank guide [3]. Remove the bolt [1] and disconnect the ground wire [2]. [1]/[2] Loosen the exhaust pipe mounting nut [3].
  • Page 130 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Install the muffler, then loosely install the muffler mounting bolt, washer, nut and band bolt (page 2-32). Tighten the exhaust pipe joint nuts [1] to the specified torque in numerical order by stamped number on the exhaust pipe joint [2] in 2 or 3 steps.
  • Page 131 dummyhead dummyhead MEMO...
  • Page 132: Maintenance

    dummytext 3. MAINTENANCE SERVICE INFORMATION ·····························3-2 DRIVE CHAIN ············································· 3-16 MAINTENANCE SCHEDULE························3-3 DRIVE CHAIN SLIDER ······························· 3-20 FUEL LINE·····················································3-5 BRAKE FLUID ············································ 3-21 THROTTLE OPERATION······························3-5 BRAKE PADS WEAR ································· 3-22 AIR CLEANER···············································3-7 BRAKE SYSTEM ········································ 3-23 CRANKCASE BREATHER ···························3-8 BRAKE LIGHT SWITCH ····························· 3-24 SPARK PLUG················································3-8 BRAKE LOCK OPERATION (NC700XD/SD) ············································...
  • Page 133 dummyhead dummyhead MAINTENANCE SERVICE INFORMATION MAINTENANCE GENERAL • Place the motorcycle on level surface before starting any work. • Gasoline is extremely flammable and is explosive under certain conditions. • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion.
  • Page 134 * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 1.
  • Page 135 * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 1.
  • Page 136 dummyhead dummyhead MAINTENANCE FUEL LINE INSPECTION Check the quick connect fitting [1] for looseness. Check the fuel feed hose [2] for deterioration, damage or leakage. Check the quick connect fittings for dirt, and clean if necessary. Replace the fuel pump packing if necessary (page 7- 13).
  • Page 137 dummyhead dummyhead MAINTENANCE Throttle grip freeplay can be adjusted at either end of NC700X/XA/S/SA: the throttle cable. Minor adjustment is made with the upper adjuster at throttle housing adjuster. Release the dust cover (NC700XD/SD) [1]. Loosen the lock nut [2] and turning the adjuster [3]. Tighten the lock nut while holding the adjuster and reposition the dust cover properly on the adjuster.
  • Page 138 dummyhead dummyhead MAINTENANCE AIR CLEANER REMOVAL/INSTALLATION (NC700X/ XA/XD) Remove the center cover but do not disconnect the seat lock cable and luggage box lid lock cable (page 2-16). Remove the maintenance lid (page 21-6). Disconnect the IAT sensor 2P (Black) connector [1]. Remove the air cleaner housing cover screws [2] and air cleaner housing cover [3].
  • Page 139 dummyhead dummyhead MAINTENANCE CRANKCASE BREATHER Check the crankcase breather hose [1] for deterioration, Service more damage or loose connection. Make sure that the hoses frequently when are not kinked, pinched or cracked. ridden in rain, at full throttle, or after the Replace the crankcase breather hose if necessary.
  • Page 140 dummyhead dummyhead MAINTENANCE INSPECTION Check following replace necessary (recommended spark plug: page 3-9) • Insulator [1] for damage • Center electrode [2] and side electrode [3] for wear • Burning condition, coloration If the electrodes are contaminated with accumulated This motorcycle's objects or dirt, replace the spark plug.
  • Page 141 dummyhead dummyhead MAINTENANCE VALVE CLEARANCE INSPECTION • Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F). • After the valve clearance inspection, check the engine idle speed (page 3-15). • Inspection and adjustment of the valve clearance can be serviced with the engine installed in the frame.
  • Page 142 dummyhead dummyhead MAINTENANCE Make sure that the "1" mark [1] on the cam sprocket is No.1 Cylinder: No.1 CYLINDER: No.2 CYLINDER: aligned with the upper cylinder head index line [2]. Make sure that the "2" mark [3] on the cam sprocket is No.2 Cylinder: aligned with the upper cylinder head index line.
  • Page 143 Install the oil filler cap/dipstick. Other viscosities RECOMMENDED ENGINE OIL: shown in the chart Honda "4-stroke motorcycle oil" or an equivalent may be used when API classification: SG or higher (except oils the average labeled as energy conserving on the circular API...
  • Page 144 dummyhead dummyhead MAINTENANCE ENGINE OIL CHANGE Warm up the engine. Stop the engine and remove the oil filler cap/dipstick [1]. Place an oil pan under the engine to catch the engine oil, then remove the engine oil drain bolt [1]/sealing washer [2].
  • Page 145 dummyhead dummyhead MAINTENANCE Check that the oil filter boss protrusion from the crankcase is specified length as shown. SPECIFIED LENGTH: 16.5 ± 0.5 mm (0.65 ± 0.02 in) If the oil filter boss is removed, apply locking agent to the oil filter boss threads (page 3-2). 16.5 ±...
  • Page 146 dummyhead dummyhead MAINTENANCE ENGINE IDLE SPEED • Inspect the idle speed after all other engine maintenance items have been performed and are within specifications. • Before checking the idle speed, inspect the following items. – No DTC and MIL blinking –...
  • Page 147 dummyhead dummyhead MAINTENANCE COOLING SYSTEM Check the radiator air passages for clogging or damage. Straighten bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20 % of the radiating surface.
  • Page 148 dummyhead dummyhead MAINTENANCE ADJUSTMENT Loosen the rear axle nut [1]. Loosen the lock nuts [2] and turn the adjusting nuts [3] until the correct drive chain slack is obtained. Make sure the index lines [4] on both adjusting plates are aligned with the rear end of the axle slots [5] in the swingarm.
  • Page 149 dummyhead dummyhead MAINTENANCE SPROCKET INSPECTION Remove the left rear cover (page 2-29). Inspect the drive and driven sprocket teeth for wear [1] or damage [2], replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition [3], or new replacement chain will wear rapidly.
  • Page 150 dummyhead dummyhead MAINTENANCE REPLACEMENT This motorcycle uses a drive chain with a staked master link. Fully slacken the drive chain (page 3-17). Remove the drive chain using the special tool. 1 LINK When using the special tool, follow the manufacturer's instruction.
  • Page 151 dummyhead dummyhead MAINTENANCE Make sure that the pins are staked properly by measuring the diameter of the staked area using a slide caliper [1]. DIAMETER OF THE STAKED AREA: DID: 5.40 – 5.60 mm (0.213 – 0.220 in) RK: 5.25 – 5.65 mm (0.207 – 0.222 in) After staking, check the staked area of the master link for cracks.
  • Page 152 dummyhead dummyhead MAINTENANCE BRAKE FLUID Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. • Do not mix different types of fluid, as they are not compatible with each other. •...
  • Page 153 dummyhead dummyhead MAINTENANCE Remove the rear brake reservoir mounting bolt [1] and reservoir [2]. [10] [12] Remove the cover screws [3], reservoir cover [4], set plate [5] and diaphragm [6]. Temporarily install the reservoir and mounting bolt to the reservoir stay lower hole [7] using a 6 mm nut [8]. Align the reservoir tab [9] with the reservoir stay cut out [10].
  • Page 154 dummyhead dummyhead MAINTENANCE BRAKE SYSTEM INSPECTION This model is equipped with a Combi Brake System. NC700XA/XD/SA/ Check the front and rear brake operation as follows: Support the motorcycle securely and raise the front wheel [1] off the ground. Apply the brake pedal [2]. Make sure the front wheel does not turn while the brake pedal is applied.
  • Page 155 dummyhead dummyhead MAINTENANCE If the brake pedal [1] is adjusted to the lower position [2], make sure that the clearance between the lower end of the push rod and the brake pedal does not fall below 1 mm (0.04 in). If the brake pedal is adjusted to the higher position [3], make sure that the lower end of the push rod thread [4] 1 mm...
  • Page 156 dummyhead dummyhead MAINTENANCE ADJUSTMENT Parking brake lever position can be adjusted at the upper end of the parking brake cable and at the parking brake caliper adjuster bolt. Minor adjustment is made with the upper adjuster. Release the dust cover [1]. Adjust the lever position by loosening the lock nut [2], and turning the adjuster [3].
  • Page 157 dummyhead dummyhead MAINTENANCE Adjust the headlight aim horizontally by turning the NC700X/XA/XD: horizontal beam adjusting screw [1]. A clockwise rotation moves the beam toward the right and counterclockwise rotation moves the beam toward the left. NC700S/SA/SD: CLUTCH SYSTEM (NC700X/XA/S/SA) Measure the clutch lever freeplay at the end of the 10 –...
  • Page 158 dummyhead dummyhead MAINTENANCE Major adjustment is made with the lower adjusting nut [1] at the clutch lifter arm. Loosen the lock nut [2] and turn the adjusting nut to adjust the freeplay. Tighten the lock nut while holding the adjusting nut. If proper freeplay cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch (page 11-7).
  • Page 159 dummyhead dummyhead MAINTENANCE Remove the sidestand springs [1]. Remove the sidestand pivot nut [2], bolt [3] and sidestand [4]. Apply grease to the sidestand pivot bolt sliding surface. Install the sidestand and sidestand pivot bolt. Tighten the sidestand pivot bolt to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Loosen the sidestand pivot bolt 45 –...
  • Page 160 dummyhead dummyhead MAINTENANCE REAR SUSPENSION INSPECTION Check the action of the rear shock absorber by compressing the rear end several times. Check the entire shock absorber assembly for leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Loose, worn or damaged suspension parts impair motorcycle stability and control.
  • Page 161 dummyhead dummyhead MAINTENANCE Check the tire pressure with a tire pressure gauge when the tires are cold. RECOMMENDED TIRE PRESSURE: DRIVER ONLY: FRONT: 250 kPa (2.50 kgf/cm , 36 psi) REAR: 290 kPa (2.90 kgf/cm , 42 psi) DRIVER AND PASSENGER: FRONT: 250 kPa (2.50 kgf/cm , 36 psi) REAR: 290 kPa (2.90 kgf/cm...
  • Page 162: Pgm-Fi System

    dummytext 4. PGM-FI SYSTEM PGM-FI SYSTEM LOCATION ·······················4-2 DTC TROUBLESHOOTING ························ 4-21 PGM-FI SYSTEM DIAGRAM·························4-4 MIL TROUBLESHOOTING ························· 4-43 SERVICE INFORMATION ·····························4-6 MIL CIRCUIT TROUBLESHOOTING ········· 4-63 PGM-FI SYMPTOM FUEL CUT RELAY ······································ 4-64 TROUBLESHOOTING···································4-7 ECT SENSOR ············································· 4-64 PGM-FI CONNECTOR LOCATIONS ············4-8 BANK ANGLE SENSOR·····························...
  • Page 163 dummyhead dummyhead PGM-FI SYSTEM PGM-FI SYSTEM LOCATION PGM-FI SYSTEM NC700X/XA/S/SA: IACV IAT SENSOR SENSOR UNIT: – MAP SENSOR – TP SENSOR INJECTOR ECT SENSOR IGNITION SWITCH FUEL PUMP SENSOR EOP SWITCH CKP SENSOR BANK ANGLE SENSOR VS SENSOR SIDESTAND SWITCH...
  • Page 164 dummyhead dummyhead PGM-FI SYSTEM NC700XD/SD: IACV IAT SENSOR SENSOR UNIT: – MAP SENSOR – TP SENSOR INJECTOR ECT SENSOR IGNITION SWITCH FUEL PUMP SENSOR EOP SWITCH CKP SENSOR BANK ANGLE SENSOR VS SENSOR SIDESTAND SWITCH...
  • Page 165 dummyhead dummyhead PGM-FI SYSTEM PGM-FI SYSTEM DIAGRAM NC700X/XA/S/SA: FUEL MAIN FUSE IGNITION SWITCH ENG STOP ENGINE STOP SWITCH PUMP (BLUE) 7.5A UNIT R/Bl R/Bl Bl/R Bl/W COMBINATION METER BATTERY R/Bl Bl/W ILLUMI/STOP/HORN HISS INDICATOR 7.5A P/Bu P/Bu (BLACK) Bl/G (86) TXD/RXD (54) Bl/W...
  • Page 166 dummyhead dummyhead PGM-FI SYSTEM NC700XD/SD: FUEL MAIN FUSE IGNITION SWITCH ENG STOP ENGINE STOP SWITCH PUMP (BLUE) 7.5A UNIT R/Bl R/Bl Bl/R Bl/W COMBINATION METER BATTERY R/Bl Bl/W ILLUMI/STOP/HORN HISS INDICATOR 7.5A P/Bu P/Bu (BLACK) Bl/G (86) TXD/RXD (54) Bl/W P/Bu BANK ANGLE SENSOR Bl/Bu...
  • Page 167 dummyhead dummyhead PGM-FI SYSTEM SERVICE INFORMATION GENERAL • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. • A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before proceeding.
  • Page 168 dummyhead dummyhead PGM-FI SYSTEM PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 4-15) and begin the appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the ECM/PCM memory, do the diagnostic procedure for the symptom, in sequence listed below, until you find cause.
  • Page 169 dummyhead dummyhead PGM-FI SYSTEM PGM-FI CONNECTOR LOCATIONS NOTE 1: Remove the shroud/side cover (NC700X/XA) (page 2-14). NOTE 1: Remove the side cowl (NC700S/SA) (page 2-13). ECM 33P (BLACK) CONNECTOR (NOTE 1) NOTE 2: Remove the luggage box lid/hinge assembly (NC700XD/SD) (page 2-19). PCM 33P (GRAY) CONNECTOR (NOTE 2) PCM 33P (BLACK) CONNECTOR (NOTE 2)
  • Page 170 dummyhead dummyhead PGM-FI SYSTEM NOTE 3: Remove the ECM box (page 4-65). BANK ANGLE SENSOR 2P (BLACK) CONNECTOR (NOTE 3) NOTE 4: Remove the maintenance lid (page 21-6). NOTE 5: Remove the center cover (NC700X/XA/XD) (page 2-16). NOTE 5: Remove the luggage box (NC700S/SA/SD) (page 2-20). IAT SENSOR 2P (BLACK) CONNECTOR (NOTE 5) DLC (NOTE 4)
  • Page 171 dummyhead dummyhead PGM-FI SYSTEM NOTE 7: Remove the air cleaner housing (page 7-14). IACV 4P (BLACK) CONNECTOR (NOTE 7) SENSOR UNIT 5P (BLACK) CONNECTOR (NOTE 7) INJECTOR 2P (GRAY) CONNECTOR VS SENSOR 3P (BLACK) CONNECTOR NOTE 8: Remove the windscreen (page 2-23). COMBINATION METER 16P (GRAY) CONNECTOR (NOTE 8) 4-10...
  • Page 172 dummyhead dummyhead PGM-FI SYSTEM PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out, the original problem may be intermittent.
  • Page 173 dummyhead dummyhead PGM-FI SYSTEM CURRENT DTC/FREEZE DTC The DTC is indicated in two ways according to the failure status. • In case the ECM/PCM detects the problem at present, the MIL will come on and the MIL will start to blink as its DTC when the sidestand is lowered.
  • Page 174 dummyhead dummyhead PGM-FI SYSTEM ERASING DTC Connect the HDS pocket tester to the DLC (page 4-12). Erase the DTC with the HDS pocket tester while the engine is stopped. To erase the DTC without HDS pocket tester, refer to the following procedure. How to erase the DTC with SCS connector 1.
  • Page 175 dummyhead dummyhead PGM-FI SYSTEM Connect the ECM test harness [1] between the main wire harness [2] and ECM [3]. TOOL: ECM test harness 33P 070MZ-MCA0100 TEST HARNESS CONNECTION (NC700XD/SD) Remove the luggage box lid/hinge assembly (page 2-19). Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector [1] and PCM 33P (Gray) connector [2].
  • Page 176 dummyhead dummyhead PGM-FI SYSTEM DTC INDEX Refer Refer to (MIL Function Failure Symptom/Fail-safe function (MIL) blinks) (DTC) MAP sensor circuit low voltage (less than • Engine operates normally 1-1 (1) 0.029 V) • Pre-program value: 225 mmHg/ 4-21 • MAP sensor or its circuit malfunction 30 kPa MAP sensor circuit high voltage (more •...
  • Page 177 dummyhead dummyhead PGM-FI SYSTEM Refer Refer to (MIL Function Failure Symptom/Fail-safe function (MIL) blinks) (DTC) Bank angle sensor circuit low voltage • Engine operates normally 54-1 (less than 0.020 V) • Engine stop function does not 4-37 (54) • Bank angle sensor or its circuit operate malfunction Bank angle sensor circuit high voltage...
  • Page 178 dummyhead dummyhead PGM-FI SYSTEM SENSOR UNIT POWER LINE INSPECTION BEFORE DTC TROUBLESHOOTING • When the DTC displays 1-1, 1-2, 8-1 and 8-2, check the following before DTC troubleshooting. • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and ECM 33P (Black) connector.
  • Page 179 dummyhead dummyhead PGM-FI SYSTEM 3. Sensor Unit Power Line Open Circuit Inspection Disconnect the following: NC700X/XA/S/SA: – ECM 33P (Black) connector (NC700X/XA/S/SA) – PCM 33P (Black) connector (NC700XD/SD) [2] – PCM 33P (Gray) connector (NC700XD/SD) [3] Check for continuities between the sensor unit 5P (Black) connector [4] and ECM/PCM 33P connector.
  • Page 180 dummyhead dummyhead PGM-FI SYSTEM BEFORE MIL TROUBLESHOOTING • When the MIL blinks 1 and 8 times, check the following before MIL troubleshooting. • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and ECM 33P (Black) connector.
  • Page 181 dummyhead dummyhead PGM-FI SYSTEM 3. Sensor Unit Input Voltage Line Short Circuit Inspection Turn the ignition switch OFF. Check for continuity between the sensor unit 5P (Black) connector [1] of the wire harness side and ground. Connection: Y/R or Y/V NC700X/XA/S/SA: Yellow/red –...
  • Page 182 dummyhead dummyhead PGM-FI SYSTEM DTC TROUBLESHOOTING DTC 1-1 (MAP SENSOR LOW VOLTAGE) • If the ECM/PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch "...
  • Page 183 dummyhead dummyhead PGM-FI SYSTEM 5. MAP Sensor Inspection Replace the sensor unit with a known good one (page 7-15). Turn the ignition switch OFF. Connect the sensor unit 5P (Black) connector. Erase the DTCs (page 4-13). Turn the ignition switch ON. Check the MAP sensor with the HDS pocket tester.
  • Page 184 dummyhead dummyhead PGM-FI SYSTEM 4. MAP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wire. Disconnect the following: – ECM 33P (Black) connector (NC700X/XA/S/SA) – PCM 33P (Gray) connector (NC700XD/SD) [1] Check for continuity between the ECM/PCM 33P connector and sensor unit 5P (Black) connector [2] of the wire harness side.
  • Page 185 dummyhead dummyhead PGM-FI SYSTEM 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the ECT sensor [1] terminals. Standard: 1.0 – 1.3 kΩ (40°C/104°F) Is the resistance within 1.0 – 1.3 kΩ (40°C/ 104°F)? – Replace the ECM/PCM with a known good one, and recheck.
  • Page 186 dummyhead dummyhead PGM-FI SYSTEM 2. ECT Sensor Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 2P connector [1]. Connect the ECT sensor 2P connector terminals at the wire harness side with a jumper wire [2]. Connection: Pink/white – Green/yellow Turn the ignition switch ON.
  • Page 187 dummyhead dummyhead PGM-FI SYSTEM DTC 8-1 (TP SENSOR LOW VOLTAGE) • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and ECM 33P (Black) connector, then recheck the DTC. • NC700XD/SD: Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and PCM 33P (Gray) connector, then recheck the...
  • Page 188 dummyhead dummyhead PGM-FI SYSTEM 4. TP Sensor Output Line Open Circuit Inspection Disconnect the following: – ECM 33P (Black) connector (NC700X/XA/S/SA) – PCM 33P (Gray) connector (NC700XD/SD) [1] Check for continuity between the ECM/PCM 33P connector and sensor unit 5P (Black) connector [2] of the wire harness side.
  • Page 189 dummyhead dummyhead PGM-FI SYSTEM 3. TP Sensor Resistance Inspection Turn the ignition switch OFF. Disconnect the following: – ECM 33P (Black) connector (NC700X/XA/S/SA) – PCM 33P (Gray) connector (NC700XD/SD) [1] Measure the resistance at the ECM/PCM 33P connector of the wire harness side. Connection: Red/yellow –...
  • Page 190 dummyhead dummyhead PGM-FI SYSTEM 3. IAT Sensor Voltage Output Line Short Circuit Inspection Turn the ignition switch OFF. Check for continuity between the IAT sensor 2P (Black) connector [1] of the wire harness side and ground. Connection: Gray/blue – Ground Gr/Bu Is there continuity? –...
  • Page 191 dummyhead dummyhead PGM-FI SYSTEM 3. IAT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: – ECM 33P (Black) connector (NC700X/XA/S/SA) Gr/Bu – PCM 33P (Gray) connector (NC700XD/SD) [1] Gr/Bu Check for continuity between the ECM/PCM 33P connector and IAT sensor 2P (Black) connector [2] of the wire harness side.
  • Page 192 dummyhead dummyhead PGM-FI SYSTEM 3. VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the VS sensor 3P (Black) connector of the wire harness side. P/Bu Connection: Pink/blue (+) –...
  • Page 193 dummyhead dummyhead PGM-FI SYSTEM 6. VS Sensor Inspection Replace the VS Sensor with a known good one (page 22-18). Connect the following: – Combination meter (Gray) connector (NC700X/XA/S/SA) – PCM 33P (Gray) connector (NC700XD/SD) Erase the DTCs (page 4-13). Test-ride the motorcycle above 2,000 min (rpm).
  • Page 194 dummyhead dummyhead PGM-FI SYSTEM 3. Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF. Check for continuity between the injector 2P (Gray) connector [1] of wire harness side and ground. Connection: No.1: Pink/yellow – Ground No.2: Violet/yellow – Ground P/Y or V/Y Is there continuity? –...
  • Page 195 dummyhead dummyhead PGM-FI SYSTEM DTC 21-1 (O SENSOR) • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the O sensor 1P (Black) connector or O sensor cap and ECM 33P (Black) connector, then recheck the DTC. •...
  • Page 196 dummyhead dummyhead PGM-FI SYSTEM 4. O Sensor Line Open Circuit Inspection 2 Disconnect the O sensor cap [1]. Check for continuity between the O sensor cap and sensor 1P (Black) connector [2] of the sensor side. Connection: Black – Black Is there continuity? –...
  • Page 197 dummyhead dummyhead PGM-FI SYSTEM 2. IACV Short Circuit Inspection Turn the ignition switch OFF. Disconnect the IACV 4P (Black) connector [1]. Check for continuities between the IACV 4P (Black) connector of the wire harness side and ground. Connection: Yellow/green – Ground Gray/red –...
  • Page 198 dummyhead dummyhead PGM-FI SYSTEM DTC 33-2 (EEPROM) • If the ECM/PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Recheck DTC Erase the DTCs (page 4-13). Turn the ignition switch ON and engine stop switch "...
  • Page 199 dummyhead dummyhead PGM-FI SYSTEM 3. Bank Angle Sensor Output Line Short Circuit Inspection Disconnect the following: – ECM 33P (Black) connector (NC700X/XA/S/SA) – PCM 33P (Gray) connector (NC700XD/SD) Check for continuity between the bank angle sensor 2P (Black) connector [1] of the wire harness side Bl/Bu and ground.
  • Page 200 dummyhead dummyhead PGM-FI SYSTEM 2. Bank Angle Sensor Power Input Voltage Inspection Turn the ignition switch OFF. Disconnect the bank angle sensor 2P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the bank angle sensor Bl/W connector of the wire harness side and ground.
  • Page 201 dummyhead dummyhead PGM-FI SYSTEM DTC 84-1 (CPU IN THE PCM MALFUNCTION) (NC700XD/SD) • If the PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 4-13). Check the DTC with the HDS pocket tester.
  • Page 202 dummyhead dummyhead PGM-FI SYSTEM 3. Combination Meter Serial Line Open Circuit Inspection Turn the ignition switch OFF. Check for continuity between the combination meter 16P (Gray) connector [1] and ECM/PCM 33P connector [2] of the wire harness side. Connection: Red/blue – Red/blue TOOL: R/Bu Test probe...
  • Page 203 dummyhead dummyhead PGM-FI SYSTEM Rotate and hold the throttle grip [1] to the fully open position. Turn the ignition switch ON while holding the throttle grip at the fully open position over 10 seconds. The ECM enters the communication diagnostic mode.
  • Page 204 dummyhead dummyhead PGM-FI SYSTEM 2. EOP Switch Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: – EOP switch 1P (Gray) connector [1] – ECM 33P (Black) connector (NC700X/XA/S/SA) – PCM 33P (Gray) connector (NC700XD/SD) [2] Check for continuity between the EOP switch 1P (Gray) connector and ECM/PCM 33P connector of the wire harness side.
  • Page 205 dummyhead dummyhead PGM-FI SYSTEM 2. MAP Sensor Output Voltage Inspection 1 Turn the ignition switch ON and engine stop switch " ". Measure the voltage at the test harness terminals. Connection: NC700X/XA/S/SA: 32 (+) – 22 (–) 32 or B32 22 or B22 NC700XD/SD: B32 (+) –...
  • Page 206 dummyhead dummyhead PGM-FI SYSTEM 5. MAP Sensor Output Line Open Circuit Inspection Check for continuity between the ECM test harness and sensor unit 5P (Black) connector [1] of the wire harness side. Connection: NC700X/XA/S/SA: 32 – Violet/red NC700XD/SD: 32 or B32 B32 –...
  • Page 207 dummyhead dummyhead PGM-FI SYSTEM 2. ECT Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 2P connector [1]. Turn the ignition switch ON. Measure the voltage at the ECT sensor 2P connector of the wire harness side. Connection: Pink/white (+) –...
  • Page 208 dummyhead dummyhead PGM-FI SYSTEM 5. ECT Sensor Output Line Short Circuit Inspection Check for continuity between the ECT sensor 2P connector [1] of the wire harness side and ground. Connection: Pink/white – Ground Is there continuity? – Short circuit in the Pink/white wire –...
  • Page 209 dummyhead dummyhead PGM-FI SYSTEM 4. TP Sensor Output Line Open Circuit Inspection Check for continuity between the sensor unit 5P (Black) connector [1] of the wire harness side and ECM test harness. Connection: NC700X/XA/S/SA: 33 – Red/yellow NC700XD/SD: 33 or B33 B33 –...
  • Page 210 dummyhead dummyhead PGM-FI SYSTEM 2. IAT Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the IAT sensor 2P (Black) connector of the wire harness side. Gr/Bu Connection: Gray/blue (+) –...
  • Page 211 dummyhead dummyhead PGM-FI SYSTEM 5. IAT Sensor Output Line Short Circuit Inspection Check for continuity between the IAT sensor 2P (Black) connector [1] of the wire harness side and ground. Connection: Gray/blue – Ground Is there continuity? Gr/Bu – Short circuit in the Gray/blue wire –...
  • Page 212 dummyhead dummyhead PGM-FI SYSTEM 4. VS Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the combination meter 16P (Gray) connector [1]. Check for continuity between the VS sensor 3P (Black) connector [2] and combination meter 16P (Gray) connector of the wire harness side.
  • Page 213 dummyhead dummyhead PGM-FI SYSTEM 2. VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the VS sensor 3P (Black) connector of the wire harness side. P/Bu Connection: Pink/blue (+) –...
  • Page 214 dummyhead dummyhead PGM-FI SYSTEM MIL 12 BLINKS (No.1 INJECTOR) • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the injector 2P (Gray) connector and ECM 33P (Black) connector, then recheck the MIL blinking. • NC700XD/SD: Before starting the inspection, check for loose or poor contact on the injector 2P (Gray) connector and PCM 33P (Gray) connector, then recheck the MIL blinking.
  • Page 215 dummyhead dummyhead PGM-FI SYSTEM 4. Injector Signal Line Open Circuit Inspection Connect the ECM test harness to the ECM/PCM 33P connector(s). – NC700X/XA/S/SA (page 4-13) – NC700XD/SD (page 4-14) 5 or B5 Check for continuity between the ECM test harness and injector 2P (Gray) connector [1] of the wire harness side.
  • Page 216 dummyhead dummyhead PGM-FI SYSTEM 2. O Sensor Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the O sensor 1P (Black) connector [1]. Check for continuity between the O sensor 1P (Black) connector of the wire harness side and ground.
  • Page 217 dummyhead dummyhead PGM-FI SYSTEM 5. O Sensor Inspection Replace the O sensor with a known good one (page 4-69). Disconnect the ECM test harness and connect the ECM/PCM connector(s). Erase the DTCs (page 4-13). Start the engine and warm up the engine up to coolant temperature is 80°C (176°F).
  • Page 218 dummyhead dummyhead PGM-FI SYSTEM 2. IACV Short Circuit Inspection Check for continuities between the IACV 4P (Black) connector [1] of the wire harness side and ground. Connection: Gray/red – Ground Yellow/green – Ground Violet/white – Ground Pink/black – Ground Gr/R P/Bl Is there continuity? –...
  • Page 219 dummyhead dummyhead PGM-FI SYSTEM MIL 54 BLINKS (BANK ANGLE SENSOR) • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the bank angle sensor 2P (Black) connector and ECM 33P (Black) connector, then recheck the MIL blinking. •...
  • Page 220 dummyhead dummyhead PGM-FI SYSTEM 3. Bank Angle Sensor Output Line Open Circuit Inspection Connect the ECM test harness to the ECM/PCM 33P connector(s). – NC700X/XA/S/SA (page 4-13) – NC700XD/SD (page 4-14) Check for continuity between the ECM test harness and bank angle sensor 2P (Black) connector [1] of Bl/Bu the wire harness side.
  • Page 221 dummyhead dummyhead PGM-FI SYSTEM MIL 86 BLINKS (METER COMMUNICATION MALFUNCTION) • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the combination meter 16P (Gray) connector and ECM 33P (Black) connector, then recheck the MIL blinking. • NC700XD/SD: Before starting the inspection, check for loose or poor contact on the combination meter 16P (Gray) connector and PCM 33P (Gray) connector, then...
  • Page 222 dummyhead dummyhead PGM-FI SYSTEM Rotate and hold the throttle grip [1] to the fully open position. Turn the ignition switch ON while holding the throttle grip at the fully open position over 10 seconds. ECM/PCM enters communication diagnostic mode. Measure the voltage at the combination meter 16P (Gray) connector [1] of the wire harness side and ground.
  • Page 223 dummyhead dummyhead PGM-FI SYSTEM MIL 87 BLINKS (EOP SWITCH MALFUNCTION) • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the combination meter 16P (Gray) connector, EOP switch 1P (Gray) connector and ECM 33P (Black) connector, then recheck the MIL blinking.
  • Page 224 dummyhead dummyhead PGM-FI SYSTEM MIL CIRCUIT TROUBLESHOOTING • If the ECM/PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (NC700XD/ SD) (page 12-120) Check that the MIL comes on for 2 seconds and goes NC700X/XA/S/SA: off when the ignition switch is turned ON and engine stop switch "...
  • Page 225 dummyhead dummyhead PGM-FI SYSTEM FUEL CUT RELAY INSPECTION Remove the maintenance lid (page 21-6). Open the fuse/relay box cover and remove the fuel cut relay [1]. Connect a ohmmeter to the fuel cut relay [1] terminals. Connect a 12 V battery to the fuel cut relay terminals as shown.
  • Page 226 dummyhead dummyhead PGM-FI SYSTEM BANK ANGLE SENSOR REMOVAL/INSTALLATION Remove the luggage box (page 2-19). Remove the bolts [1] and ECM box [2] from the frame. Disconnect the bank angle sensor 2P (Black) connector [1]. Remove the bank angle sensor mounting bolts [2] and bank angle sensor [3].
  • Page 227 dummyhead dummyhead PGM-FI SYSTEM SYSTEM INSPECTION WITH HDS POCKET TESTER Connect the HDS pocket tester (page 4-12). Remove the bank angle sensor (page 4-65). 60° BANK ANGLE POSITION Connect the bank angle sensor 2P (Black) connector. Place the bank angle sensor is horizontal as shown. Turn the ignition switch ON and engine stop switch "...
  • Page 228 dummyhead dummyhead PGM-FI SYSTEM ECM (NC700X/XA/S/SA)/PCM (NC700XD/SD) REMOVAL/INSTALLATION (NC700X/ XA/S/SA) Remove the shroud/side cover (NC700X/XA) (page 2- 14). Remove the side cowl (NC700S/SA) (page 2-13). Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector [1]. Release the band [2] from the ECM and remove the ECM from the ECM box.
  • Page 229 dummyhead dummyhead PGM-FI SYSTEM ECM/PCM POWER/GROUND LINE INSPECTION • NC700X/XA/S/SA: Before starting the inspection, check for loose or poor contact on the ECM 33P (Black) connector and recheck the MIL blinking. • NC700XD/SD: Before starting the inspection, check for loose or poor contact on the PCM 33P (Gray) connector and recheck the MIL blinking.
  • Page 230 dummyhead dummyhead PGM-FI SYSTEM 2. ECM/PCM Ground Line Inspection Turn the ignition switch OFF. Check for continuities between the ECM/PCM 33P connector [1] of the wire harness side and ground. Connection: Green/orange – Ground Green – Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? –...
  • Page 231 dummyhead dummyhead PGM-FI SYSTEM INSTALLATION Install and hand tighten the O sensor [1]. Tighten the O sensor to the specified torque. TORQUE: 24.5 N·m (2.5 kgf·m, 18 lbf·ft) Connect the O sensor cap [1]. • Take care not to tilt the O sensor cap when connecting the cap to the O sensor.
  • Page 232: Ignition System

    dummytext 5. IGNITION SYSTEM SYSTEM LOCATION·····································5-2 IGNITION SYSTEM INSPECTION ················ 5-6 SYSTEM DIAGRAM ······································5-3 IGNITION TIMING ········································· 5-9 SERVICE INFORMATION ·····························5-4 IGNITION COIL ··········································· 5-10 TROUBLESHOOTING···································5-5 CKP SENSOR ············································· 5-11...
  • Page 233 dummyhead dummyhead IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM NC700X/XA/S/SA: IGNITION SWITCH ENGINE STOP SWITCH IGNITION COILS CLUTCH SWITCH MAIN FUSE 30 A BATTERY FUSE BOX SPARK PLUGS CKP SENSOR BANK ANGLE SENSOR NEUTRAL SWITCH SIDESTAND SWITCH NC700XD/SD: ENGINE STOP SWITCH IGNITION COILS MAIN FUSE 30 A BATTERY...
  • Page 234 dummyhead dummyhead IGNITION SYSTEM SYSTEM DIAGRAM NC700X/XA/S/SA: MAIN FUSE IGNITION 30 A SWITCH 15 A R/Bl Bl/W Bl/Bu Br/Bl Y/Bu BATTERY (BLUE) Bu/Y BANK 2P (RED) ENGINE STOP ENG STOP ANGLE SWITCH 7.5 A SENSOR SENSOR Bl/R Br/Bl Bl: Black Br: Brown FUEL CUT RELAY Bu: Blue...
  • Page 235 dummyhead dummyhead IGNITION SYSTEM SERVICE INFORMATION GENERAL • The ECM/PCM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may damage the module. Always turn off the ignition switch before servicing. •...
  • Page 236 dummyhead dummyhead IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. – Faulty spark plug – Loose spark plug cap or spark plug wire connection – Water got into the spark plug cap (Leaking the ignition coil secondary voltage) •...
  • Page 237 dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. •...
  • Page 238 dummyhead dummyhead IGNITION SYSTEM Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the side cowl (NC700S/SA/SD) (page 2-13) With the ignition coil primary wire connected, connect Do not disconnect the peak voltage adaptor or Imrie tester to the ignition the ignition coil coil primary terminal [1] and ground.
  • Page 239 dummyhead dummyhead IGNITION SYSTEM Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector [1] and connect the tester probes to the connector terminals of the CKP sensor side. CONNECTION: Yellow (+) – White/yellow (–) In the same manner as at the ECM 33P (Black) connector, measure the peak voltage and compare it to the voltage measured at the ECM 33P (Black) connector.
  • Page 240 dummyhead dummyhead IGNITION SYSTEM Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector [1] and connect the tester probes to the connector terminals of the CKP sensor side. CONNECTION: Yellow (+) – White/yellow (–) In the same manner as at the ECM test harness, measure the peak voltage and compare it to the voltage measured at the ECM test harness.
  • Page 241 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION No.1 IGNITION COIL Remove the following: – Lower cowl (page 2-28) – Air cleaner housing (page 7-14) Disconnect the spark plug cap [1]. Release the spark plug wire [2] from the clamp [3]. Release the clamp [4] from the frame tab.
  • Page 242 dummyhead dummyhead IGNITION SYSTEM Disconnect the primary wire connectors [1] from the ignition coil. Release the clamp [2] from the frame tab. Remove the bolts [3], spacers [4] and ignition coil [5] from the ignition coil stay. Installation is in the reverse order of removal. Route the wire properly (page 1-25).
  • Page 243 dummyhead dummyhead IGNITION SYSTEM Remove the wire grommet [1] from the right crankcase cover. Remove the CKP sensor mounting bolts [2] and CKP sensor [3]. Installation is in the reverse order of removal. • Apply locking agent to the CKP sensor mounting bolt threads (page 1-23).
  • Page 244: Electric Starter

    dummytext 6. ELECTRIC STARTER SYSTEM LOCATION·····································6-2 STARTER MOTOR ······································· 6-8 SYSTEM DIAGRAM ······································6-3 STARTER RELAY SWITCH ······················· 6-10 SERVICE INFORMATION ·····························6-4 NEUTRAL DIODE (NC700X/XA/S/SA) ······· 6-12 TROUBLESHOOTING···································6-5 STARTER RELAY (NC700XD/SD) ············· 6-12...
  • Page 245 dummyhead dummyhead ELECTRIC STARTER SYSTEM LOCATION ELECTRIC STARTER NC700X/XA/S/SA: ENGINE STOP SWITCH STARTER SWITCH CLUTCH SWITCH MAIN FUSE 30 A STARTER RELAY SWITCH IGNITION SWITCH BATTERY FUSE BOX STARTER MOTOR NEUTRAL SWITCH SIDESTAND SWITCH NC700XD/SD: ENGINE STOP SWITCH STARTER SWITCH MAIN FUSE 30 A STARTER RELAY SWITCH BATTERY...
  • Page 246 dummyhead dummyhead ELECTRIC STARTER SYSTEM DIAGRAM NC700X/XA/S/SA: STARTER STARTER RELAY SWITCH MOTOR BATTERY MAIN FUSE 30 A IGNITION SWITCH CLUTCH R/Bl (GRAY) SWITCH Bl/R STARTER ENGINE STOP ENG STOP SWITCH SWITCH 7.5 A NEUTRAL DIODE Lg/R SIDESTAND Bl: Black SWITCH G: Green NEUTRAL Lg: Light green...
  • Page 247 dummyhead dummyhead ELECTRIC STARTER SERVICE INFORMATION GENERAL If the current is kept flowing through the starter motor turn it while the engine is not cranking over, the starter motor may be damaged. • The starter motor can be serviced with the engine installed in the frame. •...
  • Page 248 dummyhead dummyhead ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn (NC700X/XA/S/SA) 1. Fuse Inspection Check for blown main fuse 30 A or sub fuse 7.5 A (ENG STOP). Is the fuse blown? – Replace the fuse. – GO TO STEP 2. 2.
  • Page 249 dummyhead dummyhead ELECTRIC STARTER 7. Starter Relay Switch Continuity Inspection Remove and check the operation of the starter relay switch (page 6-11). Is there continuity? – Loose or poor contact starter relay switch connector – Faulty starter relay switch Starter motor does not turn (NC700XD/SD) 1.
  • Page 250 dummyhead dummyhead ELECTRIC STARTER 8. Starter Relay Inspection Check the starter relay (page 6-12). Is the starter relay normal? – • Loose or poor connected connector • Open circuit in the wire harness • Faulty neutral switch or its circuit •...
  • Page 251 dummyhead dummyhead ELECTRIC STARTER STARTER MOTOR REMOVAL/INSTALLATION Disconnect the battery negative cable (page 21-6). [2]/[3] Release the rubber cap [1]. Remove the starter motor terminal nut [2] and starter motor cable [3]. Remove the stater motor mounting bolts [4] and ground cable [5].
  • Page 252 dummyhead dummyhead ELECTRIC STARTER INSPECTION FRONT COVER Check the oil seal [1] in the front cover for deterioration, wear or damage. Turn the inner race of bearing [2] in the front cover with your finger. The bearings should turn smoothly and quietly. Also check that the outer race fits tightly in the front cover.
  • Page 253 dummyhead dummyhead ELECTRIC STARTER STARTER RELAY SWITCH INSPECTION Remove the maintenance lid (page 21-6). Shift the transmission into neutral. Turn the ignition switch ON and engine stop switch " ". Push the starter switch. The coil is normal if the starter relay switch [1] clicks. If you don't hear the starter relay switch "CLICK", release the starter relay switch/shock rubber from the battery box tabs [2] and inspect the starter relay switch...
  • Page 254 dummyhead dummyhead ELECTRIC STARTER GROUND LINE (NC700XD/SD) Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the Yellow/red (+) and Green/red (–) wire terminals at the starter relay switch 4P (Red) connector [1]. If the battery voltage appears only when the starter switch is pushed with the ignition switch turned ON and engine stop switch "...
  • Page 255 dummyhead dummyhead ELECTRIC STARTER NEUTRAL DIODE (NC700X/XA/S/SA) INSPECTION Remove the maintenance lid (page 21-6). Open the fuse/relay box cover and remove the neutral diode [1]. Check for continuity between the neutral diode terminals. When there is continuity, a small resistance value will register.
  • Page 256: Fuel System

    dummytext 7. FUEL SYSTEM COMPONENT LOCATION ····························7-2 AIR CLEANER HOUSING ·························· 7-14 SERVICE INFORMATION ·····························7-3 THROTTLE BODY ······································ 7-15 FUEL LINE REPLACEMENT ························7-4 INJECTOR··················································· 7-20 FUEL TANK···················································7-8 IACV ···························································· 7-22 FUEL PUMP UNIT ·······································7-10...
  • Page 257 dummyhead dummyhead FUEL SYSTEM COMPONENT LOCATION FUEL SYSTEM...
  • Page 258 dummyhead dummyhead FUEL SYSTEM SERVICE INFORMATION GENERAL • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. • Before disconnecting the fuel feed hose, relieve fuel pressure from the system (page 7-4). •...
  • Page 259 dummyhead dummyhead FUEL SYSTEM FUEL LINE REPLACEMENT FUEL PRESSURE RELIEVING Before disconnecting fuel feed hose, relieve pressure from the system as follows. 1. Turn the ignition switch OFF. 2. Remove the following: – Shroud/side cover (NC700X/XA/XD) (page 2-14) – Shelter/side cover (NC700S/SA/SD) (page 2-15) 3.
  • Page 260 dummyhead dummyhead FUEL SYSTEM 4. To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with the plastic bags [1]. QUICK CONNECT FITTING INSTALLATION FUEL PUMP SIDE Refer to fuel tank installation (page 7-8). INJECTOR SIDE •...
  • Page 261 dummyhead dummyhead FUEL SYSTEM 3. Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the fuel feed hose [1]. 4. Make sure the joint rubber [2] is in place (between the retainer tabs).
  • Page 262 dummyhead dummyhead FUEL SYSTEM FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fitting from the injector (page 7-4). Attach the fuel pressure gauge, attachments and manifold. TOOLS: Fuel pressure gauge, 0 – 100 psi 07406-0040004 Pressure gauge manifold [2] 07ZAJ-S5A0111 Hose attachment, 9 mm/9 mm [3] 07ZAJ-S5A0120 Hose attachment, 8 mm/9 mm [4] 07ZAJ-S7C0100...
  • Page 263 dummyhead dummyhead FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Relieve the fuel pressure (page 7-4). Remove the bolts [1], fuel cap [2] and fuel cap tray [3]. Release the following: – Fuel tank drain hose A [4] – Fuel tank breather hose [5] –...
  • Page 264 dummyhead dummyhead FUEL SYSTEM 5. To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with the plastic bags [1]. FUEL PUMP SIDE QUICK CONNECT FITTING INSTALLATION • Always replace the retainer and joint rubber of the quick connect fitting when the fuel feed hose is disconnected.
  • Page 265 dummyhead dummyhead FUEL SYSTEM 3. Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector [1]. 4. Make sure the joint rubber [2] is in place (between the retainer tabs [3]). 5.
  • Page 266 dummyhead dummyhead FUEL SYSTEM REMOVAL Remove the fuel tank (page 7-8). Clean around the fuel pump. Loosen the fuel pump mounting nuts [1] in a crisscross pattern in 2 or 3 steps and remove the nuts. Remove the fuel pump unit [2] and packing [3]. Be careful not to damage the fuel level sensor float arm.
  • Page 267 dummyhead dummyhead FUEL SYSTEM Remove the fuel pump [1] and O-ring [2]. Visually inspect the fuel pump filter [3] for dirt, debris or any clogging. Replace fuel pump unit as an assembly if necessary. Remove the pressure regulator [1] and O-ring [2] from the fuel filter [3].
  • Page 268 dummyhead dummyhead FUEL SYSTEM Insert the fuel pump filter edge [1] between the fuel pump and pressure regulator [2]. Install the fuel level sensor assembly [3]. Install the chamber [4]. Install a new O-ring [1] to the fuel pump stay [2]. Align Install the fuel pump unit assembly [3] to the fuel pump stay.
  • Page 269 dummyhead dummyhead FUEL SYSTEM Install the fuel pump unit [1] into the fuel tank. Be careful not to damage the fuel level sensor float arm [2]. Install and tighten the fuel pump mounting nuts [1] to the specified torque in the sequence as shown. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the fuel tank (page 7-8).
  • Page 270 dummyhead dummyhead FUEL SYSTEM Lower the radiator and disconnect the crankcase breather hose [1]. Be careful not to damage the radiator fins. Loosen the air cleaner connecting hose band screw [1]. Remove the bolts [2] and collar [3]. Disconnect connecting hose and remove the air cleaner housing [4].
  • Page 271 dummyhead dummyhead FUEL SYSTEM Loosen the insulator band screw [1] and remove the throttle body assembly [2]. DISASSEMBLY • Do not remove the sensor unit unless it is replaced. • The throttle body/sensor unit is factory pre-set. Do not disassemble in a way other than shown in this manual.
  • Page 272 dummyhead dummyhead FUEL SYSTEM ASSEMBLY For IACV installation (page 7-23). TORX SCREWS THROTTLE BODY O-RING SENSOR UNIT SETTING PLATE IACV O-RING TORX SCREWS Install a new O-ring [1] to the throttle body properly. If the O-ring is not Align installed properly, When installing the sensor unit [2] to the throttle body, the idle air will leaks align the following:...
  • Page 273 dummyhead dummyhead FUEL SYSTEM INSTALLATION Install the throttle body assembly [1] to the cylinder head. • Align the throttle body tab with the insulator groove. • Align the insulator band hole with the insulator tab. Align Align Tighten the insulator band screw to the specified range. 11 –...
  • Page 274 dummyhead dummyhead FUEL SYSTEM THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE If the sensor unit is removed, reset the throttle valve fully closed position as following. 1. Erase the DTC’s (page 4-13). 2. Turn the ignition switch OFF. 3. Short the DLC [1] terminals using a special tool. Connection: Brown –...
  • Page 275 dummyhead dummyhead FUEL SYSTEM 7. Check if the MIL blinks. If the MIL begins short blink (0.3 seconds), the throttle valve fully closed position is reset. 0.3 seconds 0.3 seconds within 10 seconds seconds MIL ON seconds MIL OFF RESET RECEIVING PATTERN SUCCESSFUL PATTERN If the MIL stays lit, the throttle valve fully closed position is not reset, repeat the reset procedure from step 1.
  • Page 276 dummyhead dummyhead FUEL SYSTEM Remove the injectors [1] from the fuel rail. Remove the O-ring [1], cushion rubber [2] and seal ring [3] from the injector [4]. Check the removed parts for wear or damage and replace them if necessary. INSTALLATION Apply engine oil to a new O-ring [1] and a new seal ring [2].
  • Page 277 dummyhead dummyhead FUEL SYSTEM Install the retainers [1] to the injector/fuel rail. Install the injector assembly [1], bolts [2] and collars [3]. Tighten the fuel rail mounting bolts securely. Connect the injector 2P (Gray) connectors [4] while aligning their grooves with the fuel rail tabs. Install the clip [5] to the fuel rail.
  • Page 278 dummyhead dummyhead FUEL SYSTEM INSTALLATION Turn the slide valve [1] clockwise until lightly seated on IACV. Install a new O-ring [1] to the IACV [2]. Align Install the IACV by aligning its groove with the slide valve housing pin. Install the setting plate [3] while aligning its cut-out with the tab on the IACV.
  • Page 279 dummyhead dummyhead MEMO...
  • Page 280: Cooling System

    dummytext 8. COOLING SYSTEM SYSTEM FLOW PATTERN···························8-2 THERMOSTAT/THERMOSTAT HOUSING ······················································ 8-7 SERVICE INFORMATION ·····························8-3 RADIATOR ···················································· 8-9 TROUBLESHOOTING···································8-4 WATER PUMP ············································ 8-12 SYSTEM TESTING········································8-5 RADIATOR RESERVE TANK····················· 8-14 COOLANT REPLACEMENT ·························8-6 FAN CONT. RELAY ···································· 8-15...
  • Page 281 dummyhead dummyhead COOLING SYSTEM SYSTEM FLOW PATTERN COOLING SYSTEM RADIATOR CAP RADIATOR RESERVE TANK RADIATOR THERMOSTAT WATER PUMP...
  • Page 282 dummyhead dummyhead COOLING SYSTEM SERVICE INFORMATION GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage.
  • Page 283 dummyhead dummyhead COOLING SYSTEM TROUBLESHOOTING Engine temperature too high • Faulty high coolant temperature indicator or ECT sensor • Thermostat stuck closed • Faulty radiator cap • Insufficient coolant • Passage blocked in radiator, hoses or water jacket • Air in system •...
  • Page 284 dummyhead dummyhead COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the screw [1] and radiator cap [2]. Test the coolant gravity using a hydrometer (see below for "Coolant gravity chart"). For maximum corrosion protection, a 1:1 solution of ethylene glycol and distilled water is recommended (page 8-6).
  • Page 285 dummyhead dummyhead COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 8-5). Wet the sealing surfaces of the cap, then install the cap onto the tester [1]. Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low.
  • Page 286 dummyhead dummyhead COOLING SYSTEM Remove the drain bolt [1], sealing washer [2] and drain the coolant. Reinstall the drain bolts with a new sealing washer. Tighten the drain bolt securely. Remove the radiator reserve tank (page 8-14). Empty the coolant and rinse the inside of the reserve tank with water.
  • Page 287 dummyhead dummyhead COOLING SYSTEM Loosen the water hose band screw [1] and disconnect Align the water bypass hose [2]. Remove the bolts [3], stay [4] and thermostat housing [5]. Remove the O-ring [1]. Remove the bolts [1] and thermostat housing cover [2]. Remove the thermostat [1] from the housing.
  • Page 288 dummyhead dummyhead COOLING SYSTEM Installation is in the reverse order of removal. • Align the thermostat air bleed hole with the rib side bolt hole. • Replace the O-ring with a new one. • Align the water bypass hose index mark with the thermostat housing tab.
  • Page 289 dummyhead dummyhead COOLING SYSTEM Remove the bolts [1] and radiator lower stay [2]. Release the radiator boss from the radiator mounting rubber [3]. SLITS Align Release the fan motor 3P (Gray) connector [1], air cleaner housing drain hose [2] and spark plug wire [3] from the radiator [4].
  • Page 290 dummyhead dummyhead COOLING SYSTEM DISASSEMBLY/ASSEMBLY Disassemble and assemble the radiator as following the illustration. RADIATOR 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) COOLING FAN 2.7 N·m (0.3 kgf·m, 2.0 lbf·ft) FAN MOTOR 8.4 N·m (0.9 kgf·m, 6.2 lbf·ft) SHROUD • Align the cooling fan and fan motor shaft flat surfaces.
  • Page 291 dummyhead dummyhead COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Check the bleed hole [1] of the water pump for signs of coolant leakage. • A small amount of coolant weeping from the bleed hole is normal. • Make sure that there are no continuous coolant leakage from the bleed hole while operating the engine.
  • Page 292 dummyhead dummyhead COOLING SYSTEM Remove and slide the water pump assembly. Remove the 6 x 35 mm bolts [1]. Reinstall the water pump assembly. Remove the 6 x 32 mm bolt [2] and sealing washer [3]. [2]/[3] Remove the following: –...
  • Page 293 dummyhead dummyhead COOLING SYSTEM Installation is in the reverse order of removal. • Replace the O-rings, gaskets and sealing washer with new ones. • Apply engine oil to the large O-ring. • Align the water pump slit with camshaft tab. •...
  • Page 294 dummyhead dummyhead COOLING SYSTEM Disconnect the siphon hose [1] and drain the coolant from the reserve tank. Installation is in the reverse order of removal. • Align the radiator reserve tank tab with stay hole. • Route the hoses properly (page 1-25). Fill the radiator reserve tank with the recommended coolant (page 3-15).
  • Page 295 dummyhead dummyhead MEMO...
  • Page 296: Lubrication System

    dummytext 9. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ············9-2 OIL PUMP (NC700X/XA/S/SA) ····················· 9-6 SERVICE INFORMATION ·····························9-4 OIL PUMP (NC700XD/SD) ···························· 9-8 TROUBLESHOOTING···································9-5 OIL STRAINER ··········································· 9-11 OIL PRESSURE INSPECTION ·····················9-6...
  • Page 297 dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM NC700X/XA/S/SA: ROCKER ARM SHAFT CAMSHAFT PISTON EOP SWITCH OIL FILTER CARTRIDGE PRESSURE RELIEF VALVE CRANKSHAFT OIL PUMP OIL STRAINER MAINSHAFT COUNTERSHAFT...
  • Page 298 dummyhead dummyhead LUBRICATION SYSTEM NC700XD/SD: ROCKER ARM SHAFT CAMSHAFT EOP SWITCH OIL FILTER CARTRIDGE PISTON PRESSURE RELIEF VALVES EOP SENSOR CRANKSHAFT CLUTCH OIL PUMP ENGINE OIL PUMP OIL STRAINER MAINSHAFT COUNTERSHAFT LINEAR SOLENOID VALVE...
  • Page 299 After 4.1 liters (4.3 US qt, 3.6 Imp qt) – disassembly Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent API service classification: SG or higher (except oils labeled as energy conserving – on the circular API service label)
  • Page 300 dummyhead dummyhead LUBRICATION SYSTEM TROUBLESHOOTING Oil level too low • Oil consumption • External oil leak • Worn piston rings • Improperly installed piston rings • Worn cylinders • Worn valve stem seals • Worn valve guide Low oil pressure •...
  • Page 301 dummyhead dummyhead LUBRICATION SYSTEM OIL PRESSURE INSPECTION Remove the following: – Lower cowl (page 2-28) – Engine oil filter cartridge (page 3-13) Apply engine oil to the O-ring and install the oil pressure attachment [1] onto the oil filter boss. TOOL: Oil pressure gauge attachment 070MJ-0010101...
  • Page 302 dummyhead dummyhead LUBRICATION SYSTEM Remove the O-rings [1] and dowel pins [2]. Align Installation is in the reverse order of removal. • Replace the O-rings with a new one. • Align the oil pump shaft tab with the balancer shaft slit.
  • Page 303 dummyhead dummyhead LUBRICATION SYSTEM Measure the pump body clearance. BODY CLEARANCE: SERVICE LIMIT: 0.35 mm (0.014 in) Measure the side clearance using a straight edge and SIDE CLEARANCE: feeler gauge. SERVICE LIMIT: 0.12 mm (0.005 in) OIL PUMP (NC700XD/SD) REMOVAL/INSTALLATION Remove the right crankcase cover (page 12-97).
  • Page 304 dummyhead dummyhead LUBRICATION SYSTEM DISASSEMBLY Remove the bolts [1] and oil pump cover [2]. Remove the clutch oil pump inner rotor [1] and outer rotor [2]. Remove the drive pin [1], oil pump plate [2] and dowel pins [3]. Remove the oil pump shaft [1], drive pin [2], engine oil pump inner rotor [3] and outer rotor [4].
  • Page 305 dummyhead dummyhead LUBRICATION SYSTEM INSPECTION Engine oil pump: Temporarily install the inner rotor, TIP CLEARANCE: outer rotor, drive pin and oil pump shaft into the oil pump body. Clutch oil pump: Temporarily install the inner rotor, outer rotor, drive pin and oil pump shaft into the oil pump cover.
  • Page 306 dummyhead dummyhead LUBRICATION SYSTEM ASSEMBLY Assembly is in the reverse order of disassembly. Dip all parts in clean engine oil. CLUTCH OIL PUMP OIL PUMP PLATE INNER ROTOR DRIVE PIN CLUTCH OIL PUMP OUTER ROTOR DOWEL PIN DRIVE PIN OIL PUMP BODY ENGINE OIL PUMP OUTER ROTOR DOWEL PIN...
  • Page 307 dummyhead dummyhead LUBRICATION SYSTEM Remove the oil strainer [1] and seal ring [2]. Clean the oil strainer screen and check for damage, replace it if necessary. INSTALLATION Apply engine oil to a new seal ring [1] and install it onto Align the oil strainer [2].
  • Page 308: Cylinder Head/Valves

    dummytext 10. CYLINDER HEAD/VALVES COMPONENT LOCATION ··························10-2 ROCKER ARM ············································ 10-8 SERVICE INFORMATION ···························10-3 CAM CHAIN TENSIONER ························ 10-11 TROUBLESHOOTING·································10-4 CAMSHAFT··············································· 10-13 CYLINDER COMPRESSION TEST·············10-5 CYLINDER HEAD ····································· 10-16 CYLINDER HEAD COVER··························10-5 10-1...
  • Page 309 dummyhead dummyhead CYLINDER HEAD/VALVES COMPONENT LOCATION CYLINDER HEAD/VALVES 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 56 N·m (5.7 kgf·m, 41 lbf·ft) 4.0 N·m (0.4 kgf·m, 3.0 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 29 N·m (3.0 kgf·m, 21 lbf·ft) 10-2...
  • Page 310 dummyhead dummyhead CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL • This section covers service of the cylinder head, valves, camshaft and rocker arm. • The rocker arm services can be done with the engine installed in the frame. The cylinder head, valves and camshaft service requires engine removal.
  • Page 311 dummyhead dummyhead CYLINDER HEAD/VALVES TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rod stethoscope. • If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for a seized piston ring (page 15-16).
  • Page 312 dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Remove the following: – Shroud/side cover (NC700X/XA/XD) (page 2-14) – Shelter/side cover (NC700S/SA/SD) (page 2-15) – Lower cowl (page 2-28) Warm the engine to normal operating temperature. Stop the engine and remove the all spark plug caps and spark plugs (page 3-8).
  • Page 313 dummyhead dummyhead CYLINDER HEAD/VALVES Release the fan motor 3P (Gray) connector [1], air cleaner housing drain hose [2] and spark plug wire [3] from the radiator. Lower the radiator and disconnect the crankcase breather hose [1]. Be careful not to damage the radiator fins. Remove the cylinder head cover socket bolts [1] and [1]/[2] mounting rubbers [2].
  • Page 314 dummyhead dummyhead CYLINDER HEAD/VALVES Installation is in the reverse order of removal. • Replace the cylinder head cover packing with a new one. • Check the mounting rubbers [1] are in good condition, replace them if necessary. • Install the mounting rubbers with their "UP" mark [2] facing up.
  • Page 315 dummyhead dummyhead CYLINDER HEAD/VALVES ROCKER ARM REMOVAL Remove the cylinder head cover (page 10-5). Remove the camshaft maintenance cap [1] and O-ring [2]. Remove the crankshaft hole cap (page 3-10). Turn the crankshaft counterclockwise and align the " " mark [1] on the cam sprocket with the lower cylinder head index line [2].
  • Page 316 dummyhead dummyhead CYLINDER HEAD/VALVES DISASSEMBLY/ASSEMBLY Remove the washers [1] and rocker arms from the rocker arm shaft [2]. Apply molybdenum oil solution to the rocker arm sliding surface and rocker arm shaft outer surface. Install the washers and rocker arms to the rocker arm shaft.
  • Page 317 dummyhead dummyhead CYLINDER HEAD/VALVES Check the sliding surface of the rocker arm shaft for wear or damage. Check the oil hole for clog of the rocker arm shaft. Measure the rocker arm shaft O.D. at the rocker arm sliding area. SERVICE LIMIT: 19.961 mm (0.7859 in) Calculate the rocker arm-to-shaft clearance.
  • Page 318 dummyhead dummyhead CYLINDER HEAD/VALVES Apply engine oil to a new O-ring [1] and install it to the camshaft maintenance cap [2]. Temporarily Install the camshaft maintenance cap to the cylinder head. If the engine is removed from the frame, tighten the camshaft maintenance cap to the specified torque.
  • Page 319 dummyhead dummyhead CYLINDER HEAD/VALVES REMOVAL/INSTALLATION Remove the thermostat housing (page 8-7). Release the cam chain tension (page 10-11). Remove the cam chain tensioner bolts [1] and sealing washers [2]. Remove the cam chain tensioner [3]. [1]/[2] Install the cam chain tensioner [1] while aligning tensioner end with the groove in the crankcase.
  • Page 320 dummyhead dummyhead CYLINDER HEAD/VALVES CAMSHAFT REMOVAL Remove the engine. – NC700X/XA/S/SA (page 16-5) – NC700XD/SD (page 16-9) Loosen the water hose band screw [1] and disconnect the water bypass hose. Remove the bolts [2], water pump [3] and O-rings [4]. Remove the rocker arm (page 10-8).
  • Page 321 dummyhead dummyhead CYLINDER HEAD/VALVES Using a micrometer, measure each cam lobe height. SERVICE LIMITS: IN: 34.7697 mm (1.36888 in) EX: 34.9027 mm (1.37412 in) Measure the camshaft journals O.D. SERVICE LIMIT: 41.927 mm (1.6507 in) CYLINDER HEAD Measure the cylinder head camshaft journal I.D. SERVICE LIMIT: 42.027 mm (1.6546 in) Calculate the cylinder head-to-camshaft clearance.
  • Page 322 dummyhead dummyhead CYLINDER HEAD/VALVES INSTALLATION Apply molybdenum oil solution to the camshaft lobes, journals and thrust surfaces. Install the camshaft [1]. Align the "1T" mark on the flywheel with the index notch on the alternator cover (page 3-10). Align the "1" mark [1] on the cam sprocket with the upper index line [2] on the cylinder head and install the cam chain onto the cam sprocket.
  • Page 323 dummyhead dummyhead CYLINDER HEAD/VALVES Install and tighten the bolts [1]. Align Connect the water bypass hose [2]. • Align the water bypass hose index mark with the water pump tab. • Route the hoses properly (page 1-25). Tighten the water hose band screws to the specified range as shown.
  • Page 324 dummyhead dummyhead CYLINDER HEAD/VALVES Turn the crankshaft clockwise and align the index lines NC700X/XA/S/SA: [1] with the crankcase matting surface, while the "TOP" mark [2] is facing down. Align NC700XD/SD: Align Make sure the " " mark [1] on the cam sprocket facing the lower cylinder head index line [2].
  • Page 325 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the 6 mm bolts [1]. Remove the cylinder head special bolts [1]. Loosen the cylinder head special bolts in a crisscross pattern in 2 or 3 steps. Remove the cylinder head [2]. • Attach a piece of wire to the cam chain to prevent it from falling into the crankcase.
  • Page 326 dummyhead dummyhead CYLINDER HEAD/VALVES DISASSEMBLY Remove the following: – Cylinder head (page 10-16) – Spark plug (page 3-8) – Injector (page 7-20) – Camshaft (page 10-13) Loosen the insulator band screws [1] and remove the insulator [2]. Remove the valve spring cotters using the special tool as shown.
  • Page 327 dummyhead dummyhead CYLINDER HEAD/VALVES Check the cylinder head for warpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.10 mm (0.004 in) VALVE SPRING Measure the free length of the valve spring. SERVICE LIMIT: 48.1 mm (1.89 in) Replace the springs if they are shorter than the service limits.
  • Page 328 dummyhead dummyhead CYLINDER HEAD/VALVES Measure and record each valve guide I.D. SERVICE LIMIT: 5.04 mm (0.198 in) Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.075 mm (0.0030 in) EX: 0.085 mm (0.0033 in) If the stem-to-guide clearance is out of standard, Reface the valve determine if a new guide with standard dimensions...
  • Page 329 dummyhead dummyhead CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve seats. Tap the valves and seats using a rubber hose or other hand-lapping tool [1].
  • Page 330 dummyhead dummyhead CYLINDER HEAD/VALVES VALVE SEAT REFACING Valve seat cutters/grinders or equivalent valve seat Follow the refacing refacing equipment are recommended to correct worn manufacturer's valve seats. operating instructions. If the contact area is too high on the valve, the seat must be lowered using a 32°...
  • Page 331 dummyhead dummyhead CYLINDER HEAD/VALVES ASSEMBLY INSULATOR COTTERS RETAINER VALVE SPRING STEM SEAL SPRING SEAT VALVE GUIDE INTAKE VALVE EXHAUST VALVE Install the valve spring seats [1]. Apply engine oil to new stem seals [2] inside and install them. Apply molybdenum oil solution to the valve stem sliding surface and stem end.
  • Page 332 dummyhead dummyhead CYLINDER HEAD/VALVES Install the valve cotters using the special tool as shown. TOOL: Valve spring compressor 07757-0010000 • To prevent loss of tension, do not compress the valve spring more than necessary. • Grease the cotters to ease installation. Tap the valve stems gently with plastic hammer and shaft as shown to seat the cotters firmly.
  • Page 333 dummyhead dummyhead CYLINDER HEAD/VALVES Install the cam chain guide [1]. • Align the cam chain guide end with the groove in the crankcase. • Align the cam chain guide tabs with the grooves in the crankcase. Align Align Install the dowel pins [1] and new gasket [2]. Route the cam chain through the cylinder head and install the cylinder head [1] onto the cylinder.
  • Page 334 dummyhead dummyhead CYLINDER HEAD/VALVES Turn the crankshaft clockwise and align the index lines NC700X/XA/S/SA: [1] with the crankcase matting surface, while the "TOP" mark [2] is facing down. Align NC700XD/SD: Align Install the cam sprocket to the camshaft while installing Align cam chain [1] onto the cam sprocket.
  • Page 335 dummyhead dummyhead CYLINDER HEAD/VALVES Apply engine oil to a new O-ring [1] and install it to the camshaft maintenance cap [2]. Temporarily Install the camshaft maintenance cap to the cylinder head. If the engine is removed from the frame, tighten the camshaft maintenance cap to the specified torque.
  • Page 336: Clutch/Gearshift Linkage (Nc700X/Xa/S/Sa)

    dummytext 11. CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) COMPONENT LOCATION ··························11-2 CLUTCH ······················································ 11-7 SERVICE INFORMATION ···························11-3 PRIMARY DRIVE GEAR/CKP SENSOR ROTOR······················································ 11-15 TROUBLESHOOTING·································11-4 GEARSHIFT LINKAGE ····························· 11-16 RIGHT CRANKCASE COVER ····················11-5 GEARSHIFT PEDAL ································· 11-19 11-1...
  • Page 337 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) COMPONENT LOCATION CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) 23 N·m (2.3 kgf·m, 17 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 93 N·m (9.5 kgf·m, 69 lbf·ft) 128 N·m (13.1 kgf·m, 94 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 11-2...
  • Page 338 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) SERVICE INFORMATION GENERAL • This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame. • Engine oil viscosity and level have an effect on clutch disengagement. Oil additives also effect clutch performance and are not recommended.
  • Page 339 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) TROUBLESHOOTING Clutch lever is too hard to pull in • Damaged, kinked or dirty clutch cable • Improperly routed clutch cable • Damaged clutch lifter mechanism • Faulty clutch lifter bearing • Clutch lifter piece installed improperly Clutch slips when accelerating •...
  • Page 340 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) RIGHT CRANKCASE COVER REMOVAL/INSTALLATION Remove the following: – Right shroud/side cover (NC700X/XA) (page 2-14) – Maintenance lid (page 21-6) Drain the engine oil (page 3-13). Disconnect the CKP sensor 2P (Red) connector [1] and release the CKP sensor harness. Release the reserve tank overflow hose [1] from the stay [2].
  • Page 341 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Remove the dowel pins [1]. Clean off any sealant from the right crankcase cover mating surfaces. Installation is in the reverse order of removal. • Apply liquid sealant (Three bond 1207B or equivalent) to the right crankcase cover mating surface as shown.
  • Page 342 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Install the clutch lifter arm [1], return spring [2] and snap ring [3]. • Align the return spring hook [4] with right crankcase cover. • Align the return spring end [5] with clutch lifter arm groove.
  • Page 343 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Remove the lock washer [1] and thrust washer [2]. Remove the clutch assembly [1]. Remove the following: [2]/[3] – Clutch center [1] – Spring seat [2] – Judder spring [3] – Clutch disc B [4] –...
  • Page 344 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Remove the clutch outer guide [1]. INSPECTION CLUTCH LIFTER BEARING Turn the inner race of the clutch lifter bearing [1] with your finger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate.
  • Page 345 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) CLUTCH LIFTER ROD B Check the clutch lifter rod B for damage or abnormal wear. CLUTCH DISC Replace the clutch discs if they show signs of scoring or Replace the clutch discoloration. discs and plates as a set.
  • Page 346 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) CLUTCH OUTER/PRIMARY DRIVEN GEAR/CLUTCH OUTER GUIDE Check the slots of the clutch outer for damage or wear caused by the clutch discs. Check the primary driven gear for abnormal wear or damage. Measure the I.D. of the primary driven gear. SERVICE LIMIT: 32.09 mm (1.263 in) Replace the clutch outer assembly if necessary.
  • Page 347 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) INSTALLATION CLUTCH OUTER GUIDE CLUTCH OUTER THRUST WASHER PRESSURE PLATE CLUTCH DISC A CLUTCH DISC C CLUTCH DISC B JUDDER SPRING SPRING SEAT CLUTCH CENTER CLUTCH PLATE THRUST WASHER LOCK WASHER 12 N·m (1.2 kgf·m, 9 lbf·ft) 128 N·m (13.1 kgf·m, 94 lbf·ft) CLUTCH SPRING CLUTCH LIFTER ROD B...
  • Page 348 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Apply engine oil to the clutch discs entire surface. Install the spring seat [1], judder spring [2] and clutch disc B [3] to the clutch center [4]. Install the clutch discs C [5] and clutch plates [6] alternately, starting with the clutch plate.
  • Page 349 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Install the thrust washer [1]. Install the lock washer [2] with its "OUTSIDE" mark [3] facing out. Apply engine oil to a new clutch center lock nut threads and seating surface. Install the clutch center lock nut [1] onto the mainshaft. Hold the pressure plate with the special tool and tighten the lock nut to the specified torque.
  • Page 350 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) PRIMARY DRIVE GEAR/CKP SENSOR ROTOR REMOVAL Remove the right crankcase cover (page 11-5). Hold the primary drive gear [1] using a special tool and remove the primary drive gear mounting bolt [2] and washer [3]. TOOL: Gear holder, 2.5 [4] 07724-0010100...
  • Page 351 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Install the CKP sensor rotor [1] on the crankshaft. • Align the CKP sensor rotor wide groove with the crankshaft wide tooth. • Install the CKP sensor rotor with its "MGS" mark [2] facing out. Align Apply engine oil to the primary drive gear mounting bolt threads and seating surface.
  • Page 352 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Remove the following: – Shift drum stopper arm pivot bolt [1] – Washers [2] – Stopper arm [3] – Return spring [4] Remove the shift drum center socket bolt [5], shift drum stopper plate [6] and dowel pin [7]. [1]/[2] Remove the bolt [1] and setting plate [2].
  • Page 353 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Install the setting plate [1] and a new bolt [2]. Align the setting plate hole with the crankcase boss. Align Install the following: – Return spring [1] – Stopper arm [2] – Washers [3] – Shift drum stopper arm pivot bolt [4] •...
  • Page 354 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Install the washer [1] and gearshift spindle [2]. Align the return spring ends with the spring pin. Install the following: – Right crankcase cover (page 11-5) – Left rear cover (page 2-29) Align GEARSHIFT PEDAL REMOVAL/INSTALLATION Loosen the gearshift pedal adjuster lock nuts [1] and remove the tie-rod [2].
  • Page 355 dummyhead dummyhead MEMO...
  • Page 356: Dual Clutch Transmission (Dct) (Nc700Xd/Sd)

    dummytext 12. DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) COMPONENT LOCATION ··························12-2 RIGHT CRANKCASE COVER ·················· 12-97 SERVICE INFORMATION ···························12-3 DUAL CLUTCH ······································· 12-105 DCT SYMPTOM TROUBLESHOOTING ·····12-5 PRIMARY DRIVE GEAR/CKP SENSOR ROTOR···················································· 12-108 DCT ELECTRICAL SYSTEM LOCATION ··················································12-6 SHIFT CONTROL MOTOR/REDUCTION GEARS ····················································...
  • Page 357 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) COMPONENT LOCATION DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 23 N·m (2.3 kgf·m, 17 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 93 N·m (9.5 kgf·m, 69 lbf·ft) 12-2...
  • Page 358 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) SERVICE INFORMATION GENERAL • This section covers service of the electrical and mechanical systems of the Dual Clutch Transmission (DCT). • A faulty DCT system is often related to poorly connected or corroded connectors. Check those connections before proceeding. •...
  • Page 359 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Linear Solenoid Valve Function Procedures • If the PCM has a DTC, the function test does not work. • The function test is not for the quality check of the linear solenoid valve. •...
  • Page 360 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DCT SYMPTOM TROUBLESHOOTING Check the shift indicator "–" blinking of the combination meter (page 12-11). If the shift indicator "–" is blinking, refer to the DTC index (page 12-15) and begin the appropriate troubleshooting procedure. If there are no "–"...
  • Page 361 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DCT ELECTRICAL SYSTEM LOCATION CKP SENSOR ABS MODULATOR VS SENSOR INNER MAINSHAFT SENSOR No.2 LINEAR SOLENOID VALVE EOT SENSOR CLUTCH EOP SENSORS NEUTRAL SWITCH OUTER MAINSHAFT SENSOR SHIFT CONTROL MOTOR SHIFT SPINDLE ANGLE SENSOR TR SENSOR No.1 LINEAR SOLENOID VALVE 12-6...
  • Page 362 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DCT SYSTEM DIAGRAM FRONT BRAKE LIGHT SWITCH ILLUMI/STOP/HORN FUSE 7.5A P/Bu REAR BRAKE LIGHT SWITCH P/Bu ENG STOP MAIN FUSE 30A FUSE 7.5A R/Bl Bl/R ENGINE STOP SWITCH IGNITION SWITCH Bl/W FI FUSE 15A SUB PVB FUSE 7.5A Br/R...
  • Page 363 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DCT CONNECTOR LOCATIONS NOTE 1: Remove the shroud/side cover (NC700XD) (page 2-14). RIGHT HANDLEBAR SWITCH 6P (BLACK) CONNECTOR (NOTE 1) NOTE 2: Remove the maintenance lid (page 21-6). NOTE 3: Remove the shroud/side cover (NC700XD) (page 2-14). LEFT HANDLEBAR SWITCH 3P (BLACK) CONNECTOR (NOTE 3) CKP SENSOR...
  • Page 364 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) NOTE 5: Remove the lower cowl (page 2-29). No.2 CLUTCH EOP SENSOR 3P (GRAY) CONNECTOR (NOTE 5) CLUTCH LINE EOP SENSOR 3P (BLACK) CONNECTOR (NOTE 5) No.1 CLUTCH EOP SENSOR 3P (GRAY) CONNECTOR (NOTE 5) NOTE 6: Remove the lower cowl (page 2-29).
  • Page 365 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) NOTE 9: Remove the luggage box (page 2-19). NOTE 10: Remove the center cross plate (page 2-32). NOTE 11: Remove the shroud/side cover (NC700XD) (page 2-14). NOTE 11: Remove the side cowl (NC700SD) (page 2-13). ABS MODULATOR 25P CONNECTOR (NOTE 9) 33P (GRAY) CONNECTOR (NOTE 10)
  • Page 366 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DCT TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the shift indicator "–" does not come on, check for poor contact or loose pins at all connectors related to the circuit that you are troubleshooting. If the shift indicator "–" was on, but then went out, the original problem may be intermittent.
  • Page 367 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Shift indicator "–" Blink Pattern • If the HDS pocket tester is not available, DTC can be read from the PCM memory by the shift indicator "–" blink pattern. • The number of shift indicator "–" blinks is the equivalent of the main code of the DTC (the sub code cannot be displayed by the shift indicator "–").
  • Page 368 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Reading DTC with the shift indicator "–" 1. Turn the ignition switch OFF. Remove the maintenance lid (page 21-6). 2. Remove the DLC [1] from the battery box. Short the DLC terminals using a special tool. Connection: Brown –...
  • Page 369 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Make sure the engine stop switch is turned to " ". While pushing the shift switch (+) [1], turn the ignition switch to ON. 4. Push the shift switch (–) [1]. 5. Push the shift switch (+) [2]. 6.
  • Page 370 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC INDEX Refer Refer Symptom/Fail-safe Function Failure ("–" blinks) function "–" TP sensor abnormal voltage • Gearshift function • Loose or poor contact of the TP sensor connector works normally 8-1 (8) 12-20 4-47 •...
  • Page 371 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Refer Refer Symptom/Fail-safe Function Failure ("–" blinks) function "–" N-D shift switch malfunction • N-D shift switch does • Loose or poor contact of the N-D shift switch not operate 41-1 (41) connector 12-31 12-69 •...
  • Page 372 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Refer Refer Symptom/Fail-safe Function Failure ("–" blinks) function "–" Inner mainshaft sensor speed low • Gearshift function does • Loose or poor contact of the inner mainshaft not work sensor connector 53-1 (53) 12-43 12-79 •...
  • Page 373 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Refer Refer Symptom/Fail-safe Function Failure ("–" blinks) function "–" No.1 clutch oil pressure malfunction (at clutch initial • Gearshift function does diagnosis) not work 61-1 (61) • No.1 clutch EOP sensor malfunction • Faulty clutch oil circuit •...
  • Page 374 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Refer Refer Symptom/Fail-safe Function Failure ("–" blinks) function "–" No.2 clutch oil pressure high • Gearshift function does • No.2 clutch EOP sensor malfunction not work (while driving) 64-1 (64) • Faulty clutch oil circuit •...
  • Page 375 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC TROUBLESHOOTING DTC 8-1 (TP SENSOR ABNORMAL VOLTAGE) 1. TP Sensor System Inspection Check the TP sensor with the HDS pocket tester when the throttle is fully closed. Is Low voltage (about 0 V) or High voltage (about 5 V) indicated? –...
  • Page 376 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Clutch Line EOP Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side clutch line EOP sensor 3P (Black) connector [1] terminal and ground. Connection: Violet/green – Ground Is there continuity? –...
  • Page 377 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Clutch Line EOP Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Gray) connector. Check for continuity between the wire harness side clutch line EOP sensor 3P (Black) connector [1] and PCM 33P (Gray) connector [2] terminals.
  • Page 378 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. CKP sensor Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Gray) connector. Check for continuity between the CKP sensor 2P (Red) connector [1] and PCM 33P (Gray) connector [2] terminals. Connection: Yellow –...
  • Page 379 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Shift Spindle Angle Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector. Check for continuity between the wire harness side shift spindle angle sensor 3P (Gray) connector [1] and PCM 33P (Black) connector [2] terminals.
  • Page 380 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Spindle Angle Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the shift spindle angle sensor 3P (Gray) connector. Turn the ignition switch ON. Measure the voltage between the wire harness side shift spindle angle sensor 3P (Gray) connector [1] terminals.
  • Page 381 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Shift Control Motor Condition Inspection Remove the shift control motor (page 12-109). Connect a fully charged 12 V battery [1] to the shift control motor [2] 2P connector terminals to check the motor operation. Change the battery connection to check the reverse operation.
  • Page 382 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 24-1 (SHIFT CONTROL MOTOR DRIVE CIRCUIT) • If the PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (page 12-120) 1. Shift Control Motor Line Open Circuit Inspection Disconnect the PCM 33P (Black) connector and shift control motor 2P (Black) connector.
  • Page 383 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 27-1 (SHIFT DRUM POSITION MALFUNCTION) • If the PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (page 12-120) 1. TR Sensor System Inspection Check the TR sensor with the HDS pocket tester.
  • Page 384 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. TR Sensor Condition Inspection Check that the TR sensor is installed properly and is not damaged. Is the TR sensor in normal condition? – GO TO STEP 6. – Install the TR sensor properly. 6.
  • Page 385 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 32-1 (FAIL SAFE RELAY CIRCUIT MALFUNCTION) • Before starting the inspection, check for loose or poor contact on the PCM 33P (Black) connector and recheck the DTC. • If the PCM is replaced, perform the following: –...
  • Page 386 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. DTC Recheck Recheck the DTC with the HDS pocket tester. Is DTC 37-1 indicated? – Replace the PCM with a known good one, and recheck. – Intermittent failure DTC 41-1 (N-D SHIFT SWITCH MALFUNCTION) •...
  • Page 387 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. N-D Shift Switch Input Line Open Circuit Inspection Disconnect the PCM 33P (Black) connector. NC700XD: Check for continuity between the wire harness side right handlebar switch connector [1] and PCM 33P (Black) connector [2] terminals. Connection: Light green/black –...
  • Page 388 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 42-1 (SHIFT SWITCH MALFUNCTION) • Before starting the inspection, check for loose or poor contact on the left handlebar switch and PCM 33P connectors, then recheck the DTC. • If the PCM is replaced, perform the following: –...
  • Page 389 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Shift Switch Input Line Open Circuit Inspection Disconnect the PCM 33P (Black) connector. NC700XD: Check for continuity between the wire harness side left handlebar switch connector [1] and PCM 33P (Black) connector [2] terminals. Connection: Blue/yellow –...
  • Page 390 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. EOT Sensor Inspection Turn the ignition switch OFF. Disconnect the EOT sensor 2P (Black) connector. Turn the ignition switch ON. Check the EOT sensor with the HDS pocket tester. Is about 0 V indicated? –...
  • Page 391 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. EOT Sensor Inspection Turn the ignition switch OFF. Disconnect the EOT sensor 2P (Black) connector. Short the wire harness side EOT sensor 2P (Black) connector [1] terminals with a jumper wire [2]. Connection: Blue/green –...
  • Page 392 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 47-1 or 48-1 (No.1 or No.2 CLUTCH EOP SENSOR LOW VOLTAGE) • If the PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (page 12-120) 1.
  • Page 393 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 47-2 or 48-2 (No.1 or No.2 CLUTCH EOP SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the clutch EOP sensor 3P (Gray) and PCM 33P connectors, and recheck the DTC. •...
  • Page 394 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Clutch EOP Sensor Output Line Open Circuit Inspection Disconnect the PCM 33P (Black) connector. Check for continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] and PCM 33P (Black) connector [2] terminals. Connection: No.1 clutch EOP sensor: Yellow/green –...
  • Page 395 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Clutch Line EOP Sensor Inspection Replace the clutch line EOP sensor with a known good one (page 12-117). Erase the DTCs (page 12-13). Test-ride the motorcycle above 2,000 min (rpm) and stop the engine. Check the clutch line EOP sensor with the HDS pocket tester.
  • Page 396 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. TR Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector. Check for continuity between the wire harness side TR sensor 3P (Black) connector [1] and PCM 33P (Black) connector [2] terminals.
  • Page 397 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. TR Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the TR sensor 3P (Black) connector. Turn the ignition switch ON. Measure the voltage between the wire harness side TR sensor 3P (Black) connector [1] terminals.
  • Page 398 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Neutral Switch Inspection Replace the neutral switch with a known good one (page 22-28). Connect the PCM 33P (Gray) connector and neutral switch connector. Turn the ignition switch ON. Recheck the DTC with the HDS pocket tester. Is DTC 52-1 indicated? –...
  • Page 399 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Inner Mainshaft Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the inner mainshaft sensor 3P (Black) connector. Turn the ignition switch ON. Measure the voltage between the wire harness side inner mainshaft sensor 3P (Black) connector [1] Br/Y terminals.
  • Page 400 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. Inner Mainshaft Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33P (Gray) connector. Check for continuity between the wire harness side inner mainshaft sensor 3P (Black) connector [1] and PCM 33P (Gray) connector [2] terminals. Connection: Green/yellow –...
  • Page 401 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 54-1 (OUTER MAINSHAFT SENSOR SPEED LOW) • Before starting the inspection, check for loose or poor contact on the outer mainshaft sensor 3P (Black) and PCM 33P connectors, and recheck the DTC. •...
  • Page 402 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Outer Mainshaft Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector. Check for continuity between the wire harness side outer mainshaft sensor 3P (Black) connector [1] and PCM 33P (Black) connector [2] terminals.
  • Page 403 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 7. Outer Mainshaft Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side outer mainshaft sensor 3P (Black) connector [1] terminal and ground Connection: Pink/yellow – Ground Is there continuity? –...
  • Page 404 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. No.1 Linear Solenoid Valve Input/ground Line Open Circuit Inspection Disconnect the PCM 33P (Black) connector. Check for continuity between the wire harness side linear solenoid valve 4P (Green) connector [1] and PCM 33P (Black) connector [2] terminals. Connection: Gray/white –...
  • Page 405 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. No.2 Linear Solenoid Valve Inspection Turn the ignition switch OFF. Disconnect the linear solenoid valve 4P (Green) connector. Measure the resistance between the linear solenoid valve side 4P (Green) connector [1] terminals. Connection: Yellow –...
  • Page 406 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 58-1 (No.1 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR) • If the PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (page 12-120) 1. Clutch Condition Inspection Remove the dual clutch assembly and inspect the clutch for sticking (page 12-105).
  • Page 407 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. PCM Inspection Replace the PCM with a known good one (page 4- 67). Test-ride the motorcycle and stop the engine. Check the No.1 clutch EOP sensor with the HDS pocket tester. Is DTC 61-1, 61-2, 61-3, 61-4, 62-1 or 62-2 indicated? –...
  • Page 408 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 65-1 (FRONT AND REAR WHEEL SPEED SIGNAL MALFUNCTION) • Before starting the inspection, check that the tire sizes are correct, and the drive and driven sprockets are the specified ones. • If the PCM is replaced, perform the following: –...
  • Page 409 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 66-1 (VS SENSOR NO SIGNAL) • Before starting the inspection, check for loose or poor contact on the VS sensor 3P (Black) and PCM 33P (Black) connectors, and recheck the DTC. • If the PCM is replaced, perform the following: –...
  • Page 410 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. VS Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector. Check for continuity between the wire harness side VS sensor 3P (Black) connector [1] and PCM 33P (Black) connector [2] terminals.
  • Page 411 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. ABS Problem Code Inspection Check the ABS problem code (page 20-8). Does the ABS modulator have any problem code? – Follow the problem code index (page 20- 10). – GO TO STEP 3. 3.
  • Page 412 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Clutch Clearance Inspection Remove the No.1 clutch assembly and measure the clutch clearance (page 12-105). Is the clearance within the standard range? – Replace the PCM with a known good one, and recheck. –...
  • Page 413 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. DTC Recheck 2 Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Check the DTC with the HDS pocket tester. Is DTC 71-1 or 72-1 indicated? –...
  • Page 414 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Pedal Angle Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the shift pedal angle sensor 3P (Black) connector [1]. Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the wire harness side shift pedal angle sensor 3P (Black) connector terminals.
  • Page 415 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. Shift Pedal Angle Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side shift pedal angle sensor 3P (Black) connector [1] and ground. Connection: Yellow/violet – Ground Is there continuity? –...
  • Page 416 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) SHIFT INDICATOR TROUBLESHOOTING DTC 9 (CLUTCH LINE EOP SENSOR) • Before starting the inspection, check for loose or poor contact on the clutch line EOP sensor 3P (Black) and PCM 33P connectors, and recheck the DTC.
  • Page 417 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Clutch Line EOP Sensor Inspection Replace the clutch line EOP sensor with a known good one (page 12-117). Connect the clutch line EOP sensor 3P (Black) connector. Turn the ignition switch ON with the engine stop switch "...
  • Page 418 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. CKP Sensor Peak Voltage Inspection Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector. Turn the ignition switch ON. Crank the engine and measure the CKP sensor peak voltage between the CKP sensor 2P (Red) connector [1] terminals.
  • Page 419 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Shift Spindle Angle Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side shift spindle angle sensor 3P (Gray) connector [1] terminal and ground. Connection: Violet/red – Ground Is there continuity? –...
  • Page 420 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Control Motor Condition Inspection Remove the shift control motor (page 12-109). Connect a fully charged 12 V battery [1] to the shift control motor [2] 2P connector terminals to check the motor operation. Change the battery connection to check the reverse operation.
  • Page 421 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Control Motor Line Short Circuit Inspection Check for continuity between the wire harness side shift control motor 2P (Black) connector [1] and ground. Connection: Pink/blue – Ground Yellow/blue – Ground P/Bu Y/Bu Is there continuity? –...
  • Page 422 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. TR Sensor Condition Inspection Check that the TR sensor is installed properly and is not damage. Is the TR sensor normal condition? – GO TO STEP 4. – Install the TR sensor properly. 4.
  • Page 423 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 32 (FAIL SAFE RELAY) • Before starting the inspection, check for loose or poor contact on the PCM 33P (Black) connector and recheck the DTC. • If the PCM is replaced, perform the following: –...
  • Page 424 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. PCM (DCT Drive Circuit) Sub Power Voltage Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Measure the voltage between the test harness [1] terminals and ground. Connection: A3 (+) – Ground (–) Is there battery voltage? –...
  • Page 425 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. N-D Shift Switch Inspection Turn the ignition switch OFF. NC700XD: Check for continuity between the switch side right handlebar switch connector [1] terminals in each switch position. Connection: N switch: Light green/blue – Red D switch: Lg/Bu Black/yellow –...
  • Page 426 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. N-D Shift Switch Input Line Short Circuit Inspection Check for continuity between the test harness [1] terminals and ground. Connection: A18 – Ground A29 – Ground Is there continuity? – • Short circuit in the Light green/black wire •...
  • Page 427 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Switch Inspection Turn the ignition switch OFF. NC700XD: Check for continuity between the switch side left handlebar switch connector [1] terminals in each switch position. Connection: "+" switch: Green/blue – Yellow/red "–"...
  • Page 428 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Shift Switch Input Line Short Circuit Inspection Check for continuity between the test harness [1] terminals and ground. Connection: A7 – Ground A30 – Ground Is there continuity? – • Short circuit in the Blue/yellow wire •...
  • Page 429 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. EOT Sensor Ground Line Open Circuit Inspection Check for continuity between the wire harness side EOT sensor 2P (Black) connector [1] and test harness [2] terminals. Connection: Green/yellow – B22 Is there continuity? –...
  • Page 430 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Clutch EOP Sensor Output Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check for continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] and test harness [2] terminals.
  • Page 431 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 49 (CLUTCH LINE LOW OIL PRESSURE) • If the PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) – Clutch Initialize Learning Procedure (page 12-120) 1. Engine Oil Level Inspection Check the engine oil level (page 3-12).
  • Page 432 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 51 (TR SENSOR) • Before starting the inspection, check for loose or poor contact on the TR sensor 3P (Black) and PCM 33P connectors and recheck the DTC. • If the PCM is replaced, perform the following: –...
  • Page 433 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. TR Sensor Inspection Replace the TR sensor with a known good one (page 12-115). Connect the TR sensor 3P (Black) connector. Turn the ignition switch ON with the engine stop switch " ", lower the sidestand and check the shift indicator.
  • Page 434 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Neutral Switch Line Short Circuit Inspection Disconnect the neutral switch connector [1]. Check for continuity between the neutral switch connector terminal and ground. Connection: Light green – Ground Is there continuity? – Short circuit in the Light green wire –...
  • Page 435 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Inner Mainshaft Sensor Output Line Inspection Measure the voltage between the wire harness side inner mainshaft sensor 3P (Black) connector [1] terminal and ground. Connection: Gray/yellow (+) – Ground (–) Gr/Y Is the voltage within 4.75 – 5.25 V? –...
  • Page 436 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. Inner Mainshaft Output Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check for continuity between the wire harness side inner mainshaft sensor 3P (Black) connector [1] and test harness [2] terminals.
  • Page 437 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 54 (OUTER MAINSHAFT SENSOR SPEED LOW) • Before starting the inspection, check for loose or poor contact on the outer mainshaft sensor 3P (Black) and PCM 33P connectors, and recheck the DTC. •...
  • Page 438 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Outer Mainshaft Sensor Ground Line Open Circuit Inspection Check for continuity between the wire harness side outer mainshaft sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: Green/yellow – B22 Is there continuity? –...
  • Page 439 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 55 (No.1 LINEAR SOLENOID VALVE) • Before starting the inspection, check for loose or poor contact on the linear solenoid valve 4P (Green) and PCM 33P (Black) connectors, and recheck the DTC. •...
  • Page 440 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 56 (No.2 LINEAR SOLENOID VALVE) • Before starting the inspection, check for loose or poor contact on the linear solenoid valve 4P (Green) and PCM 33P (Black) connectors, and recheck the DTC. •...
  • Page 441 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 57 (GEARSHIFT MECHANISM/ GEAR POSITION MALFUNCTION) See page 12-66 DTC 58 (No.1 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR) • If the PCM is replaced, perform the following: – Key Registration Procedure (page 23-6) –...
  • Page 442 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. PCM Inspection Replace the PCM with a known good one (page 4- 67). Test-ride the motorcycle and stop the engine. Read the DTC with the shift indicator (page 12-13). Is DTC 61 or 62 indicated? –...
  • Page 443 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 65 (FRONT AND REAR WHEEL SPEED SENSOR SIGNAL MALFUNCTION) • Before starting the inspection, check that the tire sizes are correct, and the drive and driven sprockets are the specified ones. • If the PCM is replaced, perform the following: –...
  • Page 444 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 66 (VS SENSOR NO SIGNAL) • Before starting the inspection, check for loose or poor contact on the VS sensor 3P (Black) and PCM 33P connectors, and recheck the DTC. • If the PCM is replaced, perform the following: –...
  • Page 445 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. VS Sensor Output Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check for continuity between the wire harness side VS sensor 3P (Black) connector [1] and test harness [2] terminals.
  • Page 446 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. ABS Problem Code Inspection Check the ABS problem code (page 20-8). Does the ABS modulator have any problem code? – Follow the problem code index (page 20- 10). – GO TO STEP 3. 3.
  • Page 447 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Clutch Condition Inspection Remove the No.1 clutch assembly and measure the clutch clearance (page 12-105). Is the clearance within the standard range? – Replace the PCM with a known good one, and recheck. –...
  • Page 448 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. DTC Recheck 2 Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph) for more than 30 seconds. Stop the engine. Read the DTC with the shift indicator (page 12-13). Is DTC 71 or 72 indicated? –...
  • Page 449 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Pedal Angle Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the shift pedal angle sensor 3P (Black) connector [1]. Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the wire harness side shift pedal angle sensor 3P (Black) connector terminals.
  • Page 450 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. Shift Pedal Angle Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side shift pedal angle sensor 3P (Black) connector [1] and ground. Connection: Yellow/violet – Ground Is there continuity? –...
  • Page 451 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) AT/MT MODE SWITCH TROUBLESHOOTING If the engine can be started but AT/MT mode cannot be changed, perform this troubleshooting. • Before starting the inspection, check for loose or poor contact on the right handlebar switch and PCM 33P connectors, and recheck the AT/MT mode switch operation.
  • Page 452 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. AT/MT mode switch Input Line Open Circuit Inspection Disconnect the PCM 33P (Black) connector. NC700XD: Check for continuity between the wire harness side right handlebar switch connector [1] and PCM 33P (Black) connector [2] terminals. Connection: White/yellow –...
  • Page 453 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Disconnect the clutch EOP sensor 3P connectors [1]. [5]/[6] Remove the following: – Bolt and shift spindle angle sensor [2] – Bolt [3] and wire clip stay [4] – Bolts [5] and wire clamps [6] Remove the wire harness and shift spindle angle sensor wire from the right crankcase cover.
  • Page 454 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Remove the bolts [1] and linear solenoid valve body [2]. Remove the separate plate [1] and dowel pins [2], Remove the bolts [1] and valve body cover [2]. Remove the wire grommet [3] from the valve body cover.
  • Page 455 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Wash all the parts with a high flash point or non- flammable solvent and blow through all oil passages with compressed air to clean completely. Check the linear solenoid valves [1] and valve body [2] for scratches, scoring or damage.
  • Page 456 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the linear solenoid valves [1] and stopper plate [2] into the valve body. Apply locking agent to the threads of the stopper plate bolt [3] (page 12-4). Install the stopper plate bolt and tighten it. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Set the wire grommet [1] into the groove in the body cover [2].
  • Page 457 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Apply liquid sealant (Three bond 1207B or equivalent) [1]/[2] to the CKP sensor wire grommet and linear solenoid valve wire grommet sealing surface. Set the linear solenoid valve wire grommet [1] and CKP sensor wire grommet [2] into the groove in the right crankcase cover.
  • Page 458 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the snap ring [1] into the right crankcase cover groove with the chamfered edge facing in. Install the right crankcase cover (page 12-103). INSTALLATION Coat new O-rings [1] with engine oil and install them Do not allow dust or onto the oil joint pipe [2].
  • Page 459 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the right crankcase cover [1]. Install the bolts [2] with the hose clamp [3] and tighten them in a crisscross pattern in 2 or 3 steps. Route the wire harness and shift spindle angle sensor Align wire on the right crankcase cover properly (page 1-25).
  • Page 460 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Connect the linear solenoid valve 4P (Green) connector [1] and install it to the ABS modulator stay. Install the following: – Maintenance lid (page 21-6) – Shroud/side cover (NC700XD) (page 2-14) – Shelter/side cover (NC700SD) (page 2-15) –...
  • Page 461 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DISASSEMBLY Remove clutch guide 1 [1], clutch guide 2 [2] and washers [3] from the clutches. Remove the clutch assemblies [1] and O-rings [2] from the primary driven gear. • Do not disassemble the clutch assembly. •...
  • Page 462 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Apply engine oil to the needle bearings in the primary driven gear. The primary driven gear has the index line [1] on its flange for the installation direction. The dual clutch assembly should be installed with the index line facing the outside.
  • Page 463 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Remove the 6 mm socket bolt [1] to free the primary drive gear and sub-gear [2]. Install the right crankcase cover (page 12-103). PRIMARY DRIVE GEAR/CKP SENSOR ROTOR REMOVAL Remove the right crankcase cover (page 12-97). Hold the primary drive gear and sub-gear with a 6 mm socket bolt (page 12-105).
  • Page 464 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) SHIFT CONTROL MOTOR/REDUCTION GEARS REMOVAL Remove the following: – Guard pipe (page 2-30) – Left rear cover (page 2-30) Disconnect the shift control motor 2P (Black) connector [1]. Remove the bolts [2] and shift control motor [3]. Remove the bolt [1], wire clip stay [2] and TR sensor [3].
  • Page 465 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) INSTALLATION REDUCTION GEAR O-RING CASE COVER TR SENSOR GASKET REDUCTION GEAR C REDUCTION GEAR B REDUCTION GEAR A 12 N·m (1.2 kgf·m, 9 lbf·ft) O-RING 14 N·m (1.4 kgf·m, 10 lbf·ft) 14 N·m (1.4 kgf·m, 10 lbf·ft) SHIFT CONTROL MOTOR Apply 2 –...
  • Page 466 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the reduction gear cover [1] and bolts [2], and tighten the bolts. TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) Coat a new O-ring [1] with engine oil and install it into the groove in the TR sensor [2]. Install the TR sensor into the crankcase by aligning the flat surfaces of the sensor and shift drum end.
  • Page 467 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the shift control motor [1] and bolts [2], and tighten the bolts. TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) Connect the shift control motor 2P (Black) connector [3]. Install the following: – Guard pipe (page 2-30) –...
  • Page 468 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) – Shift drum stopper arm [1] – Stopper arm return spring [2] – Stopper arm distance collar [3] – Shift drum center dowel pins [4] – 8 x 20 mm dowel pins [5] if necessary INSPECTION Check the gearshift spindle [1] and gearshift arm [2] for wear or damage.
  • Page 469 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Hold the shift drum stopper arm [1] with a screwdriver and install the shift drum center [2] by aligning the groove [3] with the dowel pin [4]. Apply locking agent to the threads of the shift drum center bolt [1] (page 12-4).
  • Page 470 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the washer [1] onto the gearshift spindle [2] and Align insert the spindle into the crankcase while aligning the return spring ends with spring pin and the spindle arm hole with the drum shifter collar. Install the following: –...
  • Page 471 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Remove the wire band [1] and release the wires and hose from the stay [2]. Remove the bolt [1], wire clip stay [2] and TR sensor [3]. Remove the O-ring [4] from the TR sensor. Installation is in the reverse order of removal.
  • Page 472 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Remove the O-ring [1] from the shift spindle angle Align sensor [2]. Installation is in the reverse order of removal. • Replace the O-ring with a new one. • Apply engine oil to a new O-ring. •...
  • Page 473 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) EOT SENSOR REMOVAL/INSTALLATION Disconnect the EOT sensor 2P (Black) connector [1]. Remove the EOT sensor [2] and sealing washer [3] from the crankcase. Apply engine oil to the EOT sensor threads and seating surface.
  • Page 474 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. If the "S" and "D" indicators start short blinking (0.5 Successful: seconds) alternately, registration is successful. Turn the ignition switch OFF. • If the "S" and "D" indicators go OFF during the procedure, registration is unsuccessful.
  • Page 475 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. After 5 seconds, the "S" and "D" indicators will start Successful: short blinking (0.5 seconds) alternately. If so, cancellation is successful. Turn the ignition switch OFF. • If the "S" and "D" indicators go OFF during the procedure, cancellation is unsuccessful.
  • Page 476 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Turn the ignition switch ON with the engine stop switch " " while pushing the D switch [1] of the N-D shift switch. The MIL [2] will come on. Release the D switch after the MIL goes off. •...
  • Page 477 dummyhead dummyhead DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Start the engine and let it idle. The "–" [1] on the shift indicator starts blinking at interval of 2 seconds. The Clutch Initialize Learning is successful, when the "–", "D" and "S" indicators [2] go off. Stop the engine.
  • Page 478: Alternator/Starter Clutch

    dummytext 13. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ··························13-2 FLYWHEEL ················································· 13-7 SERVICE INFORMATION ···························13-4 STARTER CLUTCH ·································· 13-10 TROUBLESHOOTING·································13-4 STATOR ···················································· 13-13 ALTERNATOR COVER·······························13-5 13-1...
  • Page 479 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH NC700X/XA/S/SA: 157 N·m (16.0 kgf·m, 116 lbf·ft) 13-2...
  • Page 480 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH NC700XD/SD: 157 N·m (16.0 kgf·m, 116 lbf·ft) 13-3...
  • Page 481 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL • This section covers service of the alternator and starter clutch. All service can be done with the engine installed in the frame. • For alternator inspection (page 21-9). • For CKP sensor inspection (page 5-6). •...
  • Page 482 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL/INSTALLATION Remove the following: – Shroud/side cover (NC700X/XA/XD) (page 2-14) – Shelter/side cover (NC700S/SA/SD) (page 2-15) – Left rear cover (page 2-29) – Guard pipe (NC700XD/SD) (page 2-30) Remove the bolt [1] and rear brake reservoir stay/ reservoir [2].
  • Page 483 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Release the battery box drain hose (NC700X/XA/S/SA) NC700X/XA/S/SA: [1] from the stay. Loosen the alternator cover bolts [2] in a crisscross pattern in 2 or 3 steps, and remove the bolts and stays [3]. Remove the alternator cover [4]. The alternator cover (stator) is magnetically attracted to the flywheel, be careful during removal.
  • Page 484 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Installation is in the reverse order of removal. • Apply liquid sealant (Three bond 1207B or equivalent) to the alternator cover mating surface as shown. • Apply liquid sealant (Three bond 1207B or equivalent) to the alternator wire grommet sealing surface.
  • Page 485 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Remove the washer [1] and needle bearing [2]. Remove the woodruff key [3]. Be careful not to damage the key groove and crankshaft. INSPECTION STARTER REDUCTION GEAR/STARTER IDLE GEAR Check the starter reduction gear [1] and shaft [2] for wear or damage and replace it if necessary.
  • Page 486 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH INSTALLATION Install the woodruff key [1]. Be careful not to damage the key groove and crankshaft. Apply engine oil to the needle bearing rotating area. Install the needle bearing [2] and washer [3]. Clean any oil from the crankshaft tapered area and flywheel thoroughly.
  • Page 487 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH STARTER CLUTCH REMOVAL Remove the flywheel (page 13-7). Remove the starter driven gear [1] while turning the starter driven gear counterclockwise. Hold the flywheel [1] using the special tool and remove the starter clutch socket bolt [2]. TOOL: Flywheel holder [3] 07725-0040001...
  • Page 488 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH INSPECTION Check the starter driven gear for abnormal wear or damage. Measure the starter driven gear boss O.D. SERVICE LIMIT: 57.73 mm (2.273 in) Check the starter clutch outer [1] inner surface for abnormal wear or damage and replace them if necessary.
  • Page 489 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Apply engine oil to the starter one-way clutch [1] sliding surface. Install the starter one-way clutch to the starter clutch outer [2]. Install the starter clutch assembly [1]. Hold the flywheel [1] using the special tool. TOOL: Flywheel holder [2] 07725-0040001...
  • Page 490 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH STATOR REMOVAL Remove the alternator cover (page 13-5). Remove the alternator wire clamp bolt [1], wire clamp [2] and grommet [3] from the alternator cover. Remove the alternator stator mounting bolts [4] and stator [5]. INSTALLATION 10 N·m (1.0 kgf·m, 7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) WIRE CLAMP...
  • Page 491 dummyhead dummyhead MEMO...
  • Page 492: Crankcase/Transmission/Balancer

    dummytext 14. CRANKCASE/TRANSMISSION/BALANCER COMPONENT LOCATION ··························14-2 TRANSMISSION (NC700X/XA/S/SA) ········· 14-8 SERVICE INFORMATION ···························14-4 TRANSMISSION (NC700XD/SD)·············· 14-17 TROUBLESHOOTING·································14-6 BALANCER··············································· 14-26 CRANKCASE SEPARATION······················14-7 CRANKCASE ASSEMBLY ······················· 14-28 14-1...
  • Page 493 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER COMPONENT LOCATION CRANKCASE/TRANSMISSION/BALANCER NC700X/XA/S/SA: 39 N·m (4.0 kgf·m, 29 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) + 150° 24 N·m (2.4 kgf·m, 18 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 494 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER NC700XD/SD: 24 N·m (2.4 kgf·m, 18 lbf·ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) + 150° 39 N·m (4.0 kgf·m, 29 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 495 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER SERVICE INFORMATION GENERAL (NC700X/XA/S/SA) • The crankcase must be separated to service the following: – Transmission – Balancer – Crankshaft (page 15-5) – Piston/cylinder (page 15-14) • The following components must be removed before separating the crankcase: –...
  • Page 496 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS (NC700X/XA/S/SA) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear I.D. M5, M6, C1 28.000 – 28.021 (1.1024 – 1.1032) 28.04 (1.104) C2, C3, C4 31.000 – 31.025 (1.2205 – 1.2215) 31.04 (1.222) Gear bushing M5, M6 27.959 –...
  • Page 497 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER TORQUE VALUES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Mainshaft bearing set plate bolt 12 (1.2, 9) Apply locking agent to the threads. Coating width; 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip Shift drum bearing set plate bolt 12 (1.2, 9)
  • Page 498 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER CRANKCASE SEPARATION For Service Information for removal of necessary parts before separating the crankcase (page 14-4). Remove the cam chain [1] from the crankshaft. Remove the crankcase 8 mm bolts [1] and sealing washer [2]. [1]/[2] Place the engine upside down. Loosen the crankcase 10 mm bolt [1], 8 mm bolts [2], 8 x 45 mm bolts [3] and 6 mm bolts [4] in a crisscross pattern in 2 or 3 steps, and remove the bolts.
  • Page 499 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Remove the dowel pins [1] and oil orifices [2]. NC700X/XA/S/SA: Clean any sealant off from the crankcase mating surface. Clean the oil orifices in solvent thoroughly. Check the oil orifices for clogs, and replace them if necessary. NC700XD/SD: TRANSMISSION (NC700X/XA/S/SA) REMOVAL/DISASSEMBLY...
  • Page 500 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Remove the right mainshaft bearing [1] from the upper crankcase. Remove the mainshaft assembly [1]. Disassemble the mainshaft assembly. Clean all disassembled parts in solvent thoroughly. • Keep track of the disassembled parts (gears, bushings, washers, and snap rings) by sliding them onto a tool or a piece of wire.
  • Page 501 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Remove the shift drum [1] and shift drum bearing [2]. INSPECTION SHIFT DRUM/SHIFT FORK Check the shift fork guide pin for abnormal wear or damage. Measure the shift fork I.D. SERVICE LIMIT: 12.03 mm (0.474 in) Measure the shift fork claw thickness. SERVICE LIMIT: 5.9 mm (0.23 in) Measure the shift fork shaft O.D.
  • Page 502 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER TRANSMISSION Check the gear shifter groove [1] and gear dogs [2] for abnormal wear or damage. Check the dog holes and teeth for abnormal wear or damage. Measure the I.D. of each gear. SERVICE LIMITS: M5, M6, C1: 28.04 mm (1.104 in) C2, C3, C4: 31.04 mm (1.222 in) Measure the O.D.
  • Page 503 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER MAINSHAFT BEARING Temporarily install the right mainshaft bearing [1] onto the mainshaft. Turn the outer race of the right mainshaft bearing with your finger. The bearing should turn smoothly and quietly. Also check that the inner race of the bearing fits tightly on the mainshaft.
  • Page 504 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Apply engine oil to a new left mainshaft bearing [1]. Drive the left mainshaft bearing into the upper Drive in a new crankcase until it is fully seated using the special tools. bearing squarely with the marking TOOLS: side facing toward Driver, 15 x 280L [2]...
  • Page 505 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT NEEDLE BEARING CAP NEEDLE BEARING THRUST WASHER NEEDLE BEARING C1 GEAR (45T) LOCK WASHER THRUST WASHER SPLINE WASHER C5 GEAR (31T) C3 GEAR (32T) SNAP RING SPLINE WASHER C4 GEAR BUSHING C6 GEAR (31T) C4 GEAR (30T) C3 GEAR BUSHING SNAP RING SPLINE WASHER...
  • Page 506 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER INSTALLATION MAINSHAFT/COUNTERSHAFT Install the mainshaft assembly [1] into the upper crankcase. Apply engine oil to the right mainshaft bearing [1]. Install the right mainshaft bearing into the upper crankcase. Install the bearing into the crankcase with the marked side facing out.
  • Page 507 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER SHIFT DRUM/SHIFT FORK Apply engine oil to the shift drum bearing [1]. Install the shift drum [2] and shift drum bearing into the lower crankcase. The shift forks have the following identification marks: – "L" mark [1]: left shift fork –...
  • Page 508 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER TRANSMISSION (NC700XD/SD) REMOVAL/DISASSEMBLY MAINSHAFT/COUNTERSHAFT Separate the crankcase halves (page 14-7). Remove the countershaft assembly [1]. Remove the dowel pin [2] and countershaft bearing set ring [3]. Disassemble the countershaft assembly. Clean all disassembled parts in solvent thoroughly. •...
  • Page 509 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER SHIFT DRUM/SHIFT FORK Remove the shift drum bearing set plate bolts [1] and set plate [2]. Remove the fork shafts [1] and shift forks [2]. Remove the shift drum [1] and shift drum bearing [2]. INSPECTION SHIFT DRUM/SHIFT FORK Check the shift fork guide pin for abnormal wear or damage.
  • Page 510 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Measure the shift fork shaft O.D. SERVICE LIMIT: 11.95 mm (0.470 in) Inspect the shift drum guide grooves for abnormal wear or damage. Turn the outer race of the shift drum bearing with your finger. The bearing should turn smoothly and quietly. Replace the bearing if the outer race does not turn smoothly or quietly.
  • Page 511 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Measure the I.D. of each gear. SERVICE LIMITS: 33.04 mm (1.301 in) 43.04 mm (1.694 in) 31.06 mm (1.223 in) 25.03 mm (0.985 in) C3, C4: 31.04 mm (1.222 in) Measure the O.D. of each gear bushing. SERVICE LIMITS: 32.93 mm (1.296 in) 42.93 mm (1.690 in)
  • Page 512 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER MAINSHAFT BEARING Turn the inner race of the left mainshaft bearing [1] with your finger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the upper crankcase. Replace the bearing (page 14-21) if the inner race does not turn smoothly, quietly, or if the outer race fits loosely in the crankcase.
  • Page 513 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER TRANSMISSION ASSEMBLY Clean all parts in solvent, and dry them thoroughly. Apply engine oil to the gear teeth, rotating surface and bearing. Apply molybdenum oil solution to the spline bushing outer surfaces, bushing inner and outer surfaces, and gear shifter grooves.
  • Page 514 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT OIL SEAL COUNTERSHAFT BEARING SET RING COUNTERSHAFT C5 GEAR (31T) SNAP RING C1 GEAR BUSHING SPLINE WASHER C1 GEAR (40T) C3 GEAR BUSHING C3 GEAR (32T) SPLINE WASHER SPLINE WASHER LOCK WASHER SNAP RING C4 GEAR BUSHING THRUST WASHER C2 GEAR BUSHING C4 GEAR (30T)
  • Page 515 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER • Coat each gear with clean engine oil and check for smooth movement. CORRECT INCORRECT • Align the lock washer tabs with the spline washer grooves. • Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from the thrust load.
  • Page 516 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Install the dowel pin [1] onto the upper crankcase hole. Install the countershaft bearing set ring [2] into the countershaft bearing groove. Install the countershaft assembly [3]. • Align the needle bearing cap hole with the dowel pin. •...
  • Page 517 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Apply locking agent to the shift drum bearing set plate bolt threads (page 14-6). Install the shift drum bearing set plate [1] and bolts [2]. Tighten the bolts to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the mainshaft/countershaft (page 14-24).
  • Page 518 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Turn the inner race of the left balancer shaft bearing [1] with your finger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the lower crankcase. Replace the bearing (page 14-27) if the inner race does not turn smoothly, quietly, or if the outer race fits loosely in the lower crankcase.
  • Page 519 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER INSTALLATION Apply engine oil to the right balancer shaft bearing [1]. Install the balancer shaft [2] and right balancer shaft bearing into the lower crankcase. Install the bearing into the crankcase with the marked side facing out. Apply locking agent to the balancer shaft bearing set plate bolts threads (page 14-6).
  • Page 520 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Install the oil orifices [1] onto the upper crankcase [2]. NC700X/XA/S/SA: Install the oil orifices with its narrow hole side facing upper crankcase. NC700XD/SD: Install the dowel pins [1] onto the upper crankcase [2]. NC700X/XA/S/SA: NC700XD/SD: 14-29...
  • Page 521 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Align the balancer driven gear [1] and balancer driven [1]/[2] sub gear [2] teeth then install a 6 x 14 mm socket bolt [3] to the balancer driven gear and balancer driven sub gear holes at the lower crankcase inspection hole [4]. Apply molybdenum oil solution to the main journal bearing sliding surfaces on the lower crankcase.
  • Page 522 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Apply locking agent to the crankcase 8 x 45 mm bolt threads (page 14-6). Install and tighten the crankcase bolts to the specified torque in a crisscross pattern in 2 or 3 steps. TORQUE: Crankcase 10 mm bolt [1]: 39 N·m (4.0 kgf·m, 29 lbf·ft) Crankcase 8 mm bolt [2]: 24 N·m (2.4 kgf·m, 18 lbf·ft)
  • Page 523 dummyhead dummyhead MEMO...
  • Page 524: Crankshaft/Piston/Cylinder

    dummytext 15. CRANKSHAFT/PISTON/CYLINDER COMPONENT LOCATION ··························15-2 MAIN JOURNAL BEARING························ 15-8 SERVICE INFORMATION ···························15-3 CRANKPIN BEARING ······························ 15-11 TROUBLESHOOTING·································15-4 PISTON/CYLINDER ·································· 15-14 CRANKSHAFT ············································15-5 15-1...
  • Page 525 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER COMPONENT LOCATION CRANKSHAFT/PISTON/CYLINDER 10 N·m (1.0 kgf·m, 7 lbf·ft) + 90° 15-2...
  • Page 526 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION GENERAL This motorcycle provides cracking connecting rods. Be sure to install each part in its original position, as noted during removal. Do not reuse the improperly installed connecting rod and bearing cap, because their mating surfaces are damaged. •...
  • Page 527 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER TROUBLESHOOTING Cylinder compression is too low, hard to starting or poor performance at low speed • Leaking cylinder head gasket • Worn, stuck or broken piston ring • Worn or damaged cylinder and piston Cylinder compression too high, overheating or knocking •...
  • Page 528 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER CRANKSHAFT Separate the crankcase halves (page 14-7). SIDE CLEARANCE INSPECTION Measure the connecting rod side clearance. SERVICE LIMIT: 0.45 mm (0.018 in) If the clearance exceeds the service limit, replace the connecting rod. Recheck and if still out of limit, replace the crankshaft. REMOVAL Do not interchange the bearing inserts.
  • Page 529 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER INSPECTION Support the crankshaft on both end journals. Set a dial gauge on the crankshaft. Rotate the crankshaft two revolutions (720°) and read the runout. SERVICE LIMITS: Right side [1]: 0.03 mm (0.001 in) Left side [2]: 0.03 mm (0.001 in) Check the balancer drive gear [3] teeth for abnormal wear or damage.
  • Page 530 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Clean the mating surface of the connecting rods and crankpin bearing caps with cleaning solvent and blow them with compressed air. Apply molybdenum oil solution to the crankpin bearing sliding surfaces on the crankpin bearing caps [1]. Align Install the crankpin bearing caps.
  • Page 531 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER MAIN JOURNAL BEARING Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 15-5). BEARING INSPECTION Inspect the main journal bearing inserts [1] on the upper and lower crankcase halves for unusual wear or peeling.
  • Page 532 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Install the dowel pins [1] and oil orifices [2] onto the upper crankcase [3]. Install the oil orifices with its narrow hole side facing upper crankcase. Install the lower crankcase [1] onto the upper crankcase. Apply engine oil to the crankcase main journal bolt (reuse) threads and seating surfaces.
  • Page 533 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER If you are replacing the crankshaft, record the Numbers (1, 2 or 3) corresponding main journal O.D. code numbers [1] from on the crank weight the crank weight. are main journal O.D. codes from left If you are reusing the crankshaft, measure the crankpin to right.
  • Page 534 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER CRANKPIN BEARING Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 15-5). BEARING INSPECTION Check the bearing inserts for unusual wear or peeling.
  • Page 535 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Install the crankpin bearing caps [1]. Align Be sure to install each part in its original position, as noted during removal. Do not reuse the improperly installed connecting rod and bearing cap, because their mating surfaces are damaged. Align the I.D.
  • Page 536 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER If you are replacing the crankshaft, record the Letters (A, B, C or corresponding crankpin O.D. code letter [1]. D) on the crank weight are the If you are reusing the crankshaft, measure the crankpin crankpin O.D. O.D.
  • Page 537 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER PISTON/CYLINDER PISTON/CONNECTING ROD REMOVAL • Before piston removal, place a clean shop towel around the connecting rod to prevent damaging the cylinder sleeve. • Do not try to remove the piston/connecting rod assembly from bottom of the cylinder; the assembly will get stuck in the gap between the cylinder liner and the upper crankcase.
  • Page 538 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Clean carbon deposits from the piston ring grooves with Never use a wire a ring that will be discarded. brush; it will scratch the groove. PISTON REMOVAL Assemble the special tools as shown. TOOLS: Piston pin tool set 07PAF-0010000 –...
  • Page 539 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Place the piston assembly [1] on the special tools [2]. Be sure to position the piston flat area against the piston base head inserts as shown. Place the pilot collar [3] and insert pin/insert adjuster [4] on the piston assembly. Press the piston pin [1] out with the insert pin [2], insert [2]/[3] adjuster [3], pilot collar [4] and a hydraulic press.
  • Page 540 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Measure the piston pin bore I.D. SERVICE LIMIT: 18.023 mm (0.7096 in) Measure the O.D. of the piston pin. SERVICE LIMIT: 17.988 mm (0.7082 in) Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.035 mm (0.0014 in) Measure the diameter of the piston at 13 mm (0.5 in) from the bottom and 90°...
  • Page 541 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER CYLINDER INSPECTION Inspect the cylinder bore for wear or damage. Measure the cylinder I.D. in X and Y axis at three levels. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 73.07 mm (2.877 in) Calculate the cylinder-to-piston clearance.
  • Page 542 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Apply engine oil to the piston pin outer surface. [1]/[2] Adjust the length of the insert pin [1] and insert adjuster [2] to 44.0 mm (1.73 in). TOOLS: Piston pin tool set 07PAF-0010000 – Insert pin 07PAF-0010700 –...
  • Page 543 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings. • Apply engine oil to the piston ring sliding surface. • Avoid piston and piston ring damage during installation. 120° • Install the piston rings with the marked side facing –...
  • Page 544: Engine Removal/Installation

    dummytext 16. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ··························16-2 ENGINE REMOVAL (NC700XD/SD) ············································ 16-9 SERVICE INFORMATION ···························16-4 ENGINE INSTALLATION (NC700X/XA/S/SA) ··································· 16-15 ENGINE REMOVAL (NC700X/XA/S/SA)······································16-5 ENGINE INSTALLATION (NC700XD/SD) ·········································· 16-21 16-1...
  • Page 545 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION NC700X/XA/S/SA: 32 N·m (3.3 kgf·m, 24 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 546 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION NC700XD/SD: 32 N·m (3.3 kgf·m, 24 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 547 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • A hoist or equivalent is required to support the motorcycle when removing and installing the engine. • When removing/installing the engine, tape the frame around the engine beforehand for frame protection. • When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence. If you mistake the torque or sequence, loosen all mounting fasteners, then tighten them again to the specified torque in the correct sequence.
  • Page 548 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL (NC700X/XA/S/SA) Drain the engine oil (page 3-13). Drain the coolant (page 8-6). Fully slacken the drive chain (page 3-17). Relieve the fuel pressure and disconnect the quick connect fitting from the fuel injector side (page 7-4). Remove the following: –...
  • Page 549 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the neutral switch connector [1]. Remove the wire band [2], bolt [3] and setting plate [4]. Release the following: – Neutral switch wire [5] – Sidestand switch wire [6] – Fuel tank drain hose B [7] [3]/[4] Disconnect the VS sensor 3P (Black) connector [1].
  • Page 550 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the spark plug cap [1]. Release the spark plug wire clamp [2] from the frame. Remove the bolts [1] and stay [2] from the frame. Disconnect the EOP switch 1P (Gray) connector [3]. Disconnect the ECT sensor 2P connector [1]. Loosen the band screw and disconnect the water hose [2] from the thermostat cover.
  • Page 551 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Release the rubber cap [1]. [2]/[3] Remove the starter motor terminal nut [2] and disconnect the starter motor cable [3]. Remove the starter motor mounting bolt [4] and disconnect the ground cable [5]. Release the fuel feed hose [6] from the clamp [7]. [4]/[5] Remove the drive sprocket bolt [1], washer [2] and drive sprocket [3].
  • Page 552 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Support the engine using a jack or other adjustable The jack height Left side: Right side: support to ease of engine hanger bolts removal. must be continually adjusted to relieve Remove the upper engine hunger bolts [1] and collar stress for ease of [2].
  • Page 553 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the bolt [1] and rear brake reservoir stay/ reservoir [2]. Remove the socket bolts [3]. Lower the rear fender B [1]. Disconnect the alternator 3P (Black) connector [2]. Release the sidestand switch wire harness clamp [1]. Release the alternator wire harness [2].
  • Page 554 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the VS sensor 3P (Black) connector [1] and EOT sensor 2P (Black) connector [2]. Disconnect the injector 2P (Gray) connectors [1]. Release the clip [2] from the fuel rail. Disconnect the TR sensor 3P (Black) connector [1] and remove it from the ABS modulator stay.
  • Page 555 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the spark plug cap [1]. Release the spark plug wire clamp [2] from the frame. Remove the bolts [1] and stay [2] from the frame. Disconnect the EOP switch 1P (Gray) connector [3]. Disconnect the clutch EOP sensor 3P connectors [1]. Remove the bolts [2] and clamps [3].
  • Page 556 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the linear solenoid valve 4P (Green) connector [1] and shift spindle angle sensor 3P (Gray) connector [2] and remove them from the ABS modulator stay. Release the fuel feed hose [3] from the clamp [4]. Disconnect the following: –...
  • Page 557 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the step holder mounting socket bolts [1] and left step holder [2]. Remove the step holder mounting socket bolts [1] and right step holder [2]. Do not twist the brake hose. Support the engine using a jack or other adjustable The jack height Left side: Right side:...
  • Page 558 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the rear engine hunger nuts [1], collars [2] and Left side: Right side: bolts [3]. Carefully maneuver the engine and remove it out of the frame to the right. During engine removal, hold the engine securely and be careful not to damage the frame and engine.
  • Page 559 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Tighten the left front lower engine hunger bolt [1] to the Left side: Right side: specified torque. TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft) Tighten the right front lower engine hunger bolt [2] to the specified torque. TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft) Tighten the left upper engine hunger bolt [1] to the Left side:...
  • Page 560 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the left step holder [1] and step holder mounting socket bolts [2]. Tighten the step holder mounting socket bolts to the specified torque. TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft) Install the drive sprocket [1], washer [2] and drive sprocket bolt [3].
  • Page 561 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect the ECT sensor 2P connector [1]. Align Connect the water hose [2] to the thermostat cover. Align the water hose paint mark with the thermostat cover tab. Install the main wire harness [3] to the stay [4] and frame [5].
  • Page 562 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the spark plug wire clamp [1] to the frame. Connect the spark plug cap [2]. Connect the water hose [3] to the water pump. Tighten the water hose band screw to the specified range. 0 – 1 mm (0 –...
  • Page 563 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the following: – Fuel tank drain hose B [1] – Sidestand switch wire [2] – Neutral switch wire [3] Install the setting plate [4] and a new bolt [5]. Align Align the setting plate hole with the crankcase boss. Install the wire band [6].
  • Page 564 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect the CKP sensor 2P (Red) connector [1]. Install the following: – Throttle body (page 7-18) – Radiator (page 8-9) – Radiator reserve tank (page 8-14) – Exhaust pipe/muffler (page 2-32) – Left rear cover (page 2-29) Inspect the following: –...
  • Page 565 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Tighten the left front lower engine hunger bolt [1] to the Left side: Right side: specified torque. TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft) Tighten the right front lower engine hunger bolt [2] to the specified torque. TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft) Tighten the left upper engine hunger bolt [1] to the Left side:...
  • Page 566 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the left step holder [1] and step holder mounting socket bolts [2]. Tighten the step holder mounting socket bolts to the specified torque. TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft) Install the drive sprocket [1], washer [2] and drive sprocket bolt [3].
  • Page 567 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the fuel feed hose [1] to the clamp [2]. Connect the linear solenoid valve 4P (Green) connector [3] and shift spindle angle sensor 3P (Gray) connector [4] and install them to the ABS modulator stay. Connect the ECT sensor 2P connector [1].
  • Page 568 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect the EOP switch 1P (Gray) connector [1]. Install the stay [2] and bolts [3] to the frame. Tighten the bolts securely. Install the spark plug wire clamp [1] to the frame. Connect the spark plug cap [2]. Install the spark plug wire clamp [1] to the frame.
  • Page 569 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect the TR sensor 3P (Black) connector [1] and install it to the ABS modulator stay. Install the clip [1] to the fuel rail. Connect the injector 2P (Gray) connectors [2]. Connect the VS sensor 3P (Black) connector [1] and EOT sensor 2P (Black) connector [2].
  • Page 570 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Route the alternator wire harness [1]. Install the sidestand switch wire harness clamp [2]. Connect the alternator 3P (Black) connector [1]. Install the rear fender B [1] and socket bolts [2]. Tighten the socket bolts securely. Install the rear brake reservoir stay/reservoir [3] and bolt [4].
  • Page 571 dummyhead dummyhead MEMO...
  • Page 572: Front Wheel/Suspension/Steering

    dummytext 17. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION ··························17-2 FRONT WHEEL ········································ 17-20 SERVICE INFORMATION ···························17-8 FORK························································· 17-25 TROUBLESHOOTING·································17-9 STEERING STEM ····································· 17-33 HANDLEBAR ············································17-10 CLUTCH LEVER (NC700X/XA/S/SA)······· 17-42 17-1...
  • Page 573 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION FRONT WHEEL/SUSPENSION/STEERING NC700X: 22 N·m (2.2 kgf·m, 16 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 17-2...
  • Page 574 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING NC700XA: 22 N·m (2.2 kgf·m, 16 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 17-3...
  • Page 575 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING NC700XD: 22 N·m (2.2 kgf·m, 16 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 17-4...
  • Page 576 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING NC700S: 22 N·m (2.2 kgf·m, 16 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 17-5...
  • Page 577 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING NC700SA: 22 N·m (2.2 kgf·m, 16 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 17-6...
  • Page 578 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING NC700SD: 22 N·m (2.2 kgf·m, 16 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 17-7...
  • Page 579 NC700X/XA/XD 394.9 (15.55) 387.0 (15.24) length NC700S/SA/SD 357.0 (14.06) 349.9 (13.78) Tube runout – 0.20 (0.008) Recommended fork fluid Honda ULTRA CUSHION OIL 10W or – equivalent Fluid level NC700X/XA/XD 104 (4.1) – NC700S/SA/SD 103 (4.1) – Fluid capacity 514 ± 2.5 cm (17.4 ±...
  • Page 580 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING Hard steering • Steering stem adjusting nut too tight • Damaged steering head bearings • Insufficient tire pressure • Faulty tire Steers to one side or does not track straight • Bent fork pipe • Bent axle •...
  • Page 581 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL (NC700X/XA/S/SA) Remove the rearview mirrors [1] and wire bands [2]. Hold the handlebar weight [1] and remove the handlebar weight mounting screw [2], then remove both handlebar weights. Disconnect the clutch switch connectors [1]. Remove the bolts [2], holder [3] and clutch lever bracket [4].
  • Page 582 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Disconnect the brake light switch connectors [1]. Remove the bolts [2], holder [3] and master cylinder [4]. Keep the brake master cylinder upright to prevent air from entering the hydraulic system. Remove the screws [1]. Separate the right handlebar switch housing [2]. Remove the screws [1].
  • Page 583 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING REMOVAL (NC700XD/SD) Remove the rearview mirrors [1] and wire bands [2]. Hold the handlebar weight [1] and remove the handlebar weight mounting screw [2], then remove both handlebar weights. Disconnect the parking brake switch connectors [1]. Remove the socket bolts [2], holder [3] and parking brake lever bracket [4].
  • Page 584 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Disconnect the brake light switch connectors [1]. Remove the bolts [2], holder [3] and master cylinder [4]. Keep the brake master cylinder upright to prevent air from entering the hydraulic system. Remove the screws [1]. Separate the right handlebar switch housing [2]. Disconnect the throttle cables [1] from the throttle pipe [2], then remove the throttle pipe.
  • Page 585 Clean the inside surface of the handlebar grip and outside surface of the handlebar and throttle pipe. Apply Honda Bond A, Cemedine #540 or equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe.
  • Page 586 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the screws [1] and tighten the upper screw first, then tighten the lower screw to the specified torque. TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) Install the master cylinder [1], holder [2] ("UP" mark [3] Align facing up) and bolts [4].
  • Page 587 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the clutch lever bracket [1], holder [2] ("UP" mark Align [3] facing up) and bolts [4]. Align the end of the clutch lever bracket with the punch mark on the handlebar, and tighten the upper bolt first, then the lower bolt.
  • Page 588 Clean the inside surface of the handlebar grip and outside surface of the handlebar and throttle pipe. Apply Honda Bond A, Cemedine #540 or equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe.
  • Page 589 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the master cylinder [1], holder [2] ("UP" mark [3] Align facing up) and bolts [4]. Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first, then the lower bolt to the specified torque.
  • Page 590 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the holder [1] and socket bolts [2]. Tighten the socket bolts securely. Connect the parking brake switch connectors [3]. Install the handlebar weight [1] to both handlebars aligning each cutout. Align Hold the handlebar weight [1]. Install and tighten a new handlebar weight mounting screw [2] to the specified torque.
  • Page 591 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INNER WEIGHT REPLACEMENT Remove the throttle pipe or grip rubber from the handlebar. – NC700X/XA/S/SA (page 17-10) – NC700XD/SD (page 17-12) Straighten the retainer ring tab [1] by the screwdriver or punch. Temporarily install the handlebar weight [2] and screw, Apply lubricant then remove the inner weight assembly [3] by turning spray through the...
  • Page 592 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the brake pads (page 19-17). NC700XA/XD/SA/ NC700XA/XD/SA/SD: Remove the bolts [1] and front wheel speed sensor [2] from the caliper bracket. Check that there is no iron or other magnetic deposits between the pulser ring and front wheel speed sensor. Remove any deposits.
  • Page 593 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the outer race fits tightly in the wheel hub. Remove and discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the wheel hub.
  • Page 594 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the front wheel dust seal [1] from the left wheel hub. Assembly is in the reverse order of disassembly. • Replace the front wheel dust seals and front brake disc mounting bolts with new ones. •...
  • Page 595 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING WHEEL BEARING REPLACEMENT Install the bearing remover head [1] into the bearing [2]. From the opposite side, install the bearing remover shaft [3] and drive out the bearing from the wheel hub. Remove the distance collar and drive out the other bearing.
  • Page 596 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the front wheel speed sensor [1] and bolts [2]. NC700XA/XD/SA/ NC700XA/XD/SA/SD: Tighten the bolts securely. Check the air gap between the front wheel speed sensor and pulser ring (page 20-24). Install the brake pads (page 19-17). Install the front brake caliper/bracket assembly [1] and NC700X/S: NC700X/S:...
  • Page 597 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Loosen the top bridge pinch bolts [1]. When the fork is ready to be disassembled, loosen the fork cap [2]. Hold the fork legs [3] and loosen the bottom bridge pinch bolts [4] and lower the fork legs, then remove it. DISASSEMBLY Remove the dust seal [1] and stopper ring [2].
  • Page 598 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Set the fork slider [1] in a vise with a piece of wood or Do not over-tighten [2]/[3] soft jaws to avoid damage. the vise on the fork slider. Remove the fork socket bolt [2] and sealing washer [3]. If the fork piston turns with the socket bolt,...
  • Page 599 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the following: – Oil seal [1] – Back-up ring [2] – Guide bushing [3] INSPECTION FORK SPRING Check the fork spring for fatigue or damage. Measure the fork spring free length. SERVICE LIMITS: NC700X/XA/XD: 387.0 mm (15.24 in) NC700S/SA/SD: 349.9 mm (13.78 in) FORK PIPE/SLIDER Check the fork pipe [1] and slider [2] for score marks,...
  • Page 600 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING FORK PISTON/REBOUND SPRING/OIL LOCK PIECE Check the fork piston [1], piston ring [2] and oil lock piece [3] for wear or damage. Check the rebound spring [4] for fatigue or damage. Replace any components that are worn or damage. GUIDE BUSHING/SLIDER BUSHING/BACK-UP RING Visually inspect the slider and guide bushings [1].
  • Page 601 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY FORK PISTON RING 22 N·m (2.2 kgf·m, 16 lbf·ft) FORK PISTON DUST SEAL STOPPER RING O-RING OIL SEAL SPRING COLLAR BACK-UP RING SPRING SEAT GUIDE BUSHING SLIDER BUSHING FORK SPRING FORK SLIDER REBOUND SPRING FORK PIPE OIL LOCK PIECE SEALING WASHER 20 N·m (2.0 kgf·m, 15 lbf·ft)
  • Page 602 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the oil lock piece [1] onto the fork piston [2] end. Install the fork pipe [3] into the fork slider [4]. Set the fork slider in a vise with a piece of wood or soft Do not over-tighten jaws to avoid damage.
  • Page 603 Install the dust seal [2]. Pour the specified amount of recommended fork fluid into the fork pipe. RECOMMENDED FORK FLUID: Honda ULTRA CUSHION OIL 10W or equivalent FORK FLUID CAPACITY: NC700X/XA/XD: 514 ± 2.5 cm (17.4 ± 0.08 US oz, 18.1 ±...
  • Page 604 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the fork leg through the bottom bridge and top Route the wires and bridge while aligning top surface of fork pipe with the cables properly top surface of top bridge. (page 1-25). Tighten the bottom bridge pinch bolts [1] to the specified torque.
  • Page 605 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the ignition switch wire harness clamp [1] and NC700X/XA/XD: NC700X/XA/XD: immobilizer receiver wire harness clamp [2]. Remove the bolt [1] and brake hose clamp [2] from the NC700X: NC700X: bottom bridge. Remove the following: NC700S/SA/SD: NC700S/SA/SD: –...
  • Page 606 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the cap. Remove the steering stem nut [1]. Remove the fork legs (page 17-25). Release the following: NC700X/XA/XD: – Clutch cable (NC700X/XA) [1] – Parking brake cable (NC700XD) [1] – Left handlebar switch wire harness clamp [2] –...
  • Page 607 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Loosen the steering stem adjusting nut [1] using a special tool. TOOL: Steering stem socket [2] 07916-3710101 Hold the steering stem and remove the steering stem adjusting nut. Remove the following: – Dust seal [1] – Upper bearing inner race [2] –...
  • Page 608 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Temporarily install the steering stem nut [1] onto the steering stem [2] to prevent the threads from being damaged when removing the lower inner race [3] from the steering stem. Remove the lower inner race with a chisel or equivalent tools, being careful not to damage the steering stem.
  • Page 609 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSTALLATION LOCK NUT LOCK WASHER : BEARINGS : BEARING RACES ADJUSTING NUT : DUST SEALS UPPER DUST SEAL LOWER OUTER RACE UPPER INNER RACE UPPER BEARING LOWER BEARING UPPER OUTER RACE LOWER INNER RACE LOWER DUST SEAL NC700XA/XD/SA/SD: STEERING STEM 39 N·m (4.0 kgf·m, 29 lbf·ft)
  • Page 610 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Move the steering stem left and right, lock-to-lock five times to seat the bearings. Retighten the adjusting nut [1] to the specified torque using a special tool. TOOL: Steering stem socket [2] 07916-3710101 TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft) Install a new lock washer [1], aligning its short bent tabs with the grooves in the steering stem adjusting nut.
  • Page 611 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the top bridge [1]. Install the following: NC700X/XA/XD: – Brake hose [2] – Right handlebar switch wire harness clamp [3] – Throttle cables [4] – Left handlebar switch wire harness clamp [5] – Clutch cable (NC700X/XA) [6] –...
  • Page 612 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the wire harness from the clamps [1]. NC700X/XA/XD: NC700X/XA: Connect the ignition switch 2P (Brown) connector [2] and immobilizer receiver 4P (Black) connector [3]. Install the following: – Shroud/side cover (page 2-14) – Handlebar – NC700X/XA (page 17-14) –...
  • Page 613 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING CLUTCH LEVER (NC700X/XA/S/SA) REMOVAL/INSTALLATION Remove the clutch lever pivot nut [1] and bolt [2]. Remove the clutch lever [3] and disconnect the clutch cable [4]. Connect the clutch cable [1] to the clutch lever [2]. Install the clutch lever to the clutch lever bracket. Apply grease to the clutch lever pivot bolt sliding surface.
  • Page 614: Rear Wheel/Suspension

    dummytext 18. REAR WHEEL/SUSPENSION COMPONENT LOCATION ··························18-2 SHOCK LINKAGE····································· 18-13 SERVICE INFORMATION ···························18-4 SHOCK ABSORBER ································ 18-14 TROUBLESHOOTING·································18-5 SWINGARM ·············································· 18-16 REAR WHEEL ·············································18-6 18-1...
  • Page 615 dummyhead dummyhead REAR WHEEL/SUSPENSION COMPONENT LOCATION REAR WHEEL/SUSPENSION NC700X/XA/S/SA: NC700XA/SA shown: 44 N·m (4.5 kgf·m, 32 lbf·ft) 98 N·m (10.0 kgf·m, 72 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 98 N·m (10.0 kgf·m, 72 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft)
  • Page 616 dummyhead dummyhead REAR WHEEL/SUSPENSION NC700XD/SD: 44 N·m (4.5 kgf·m, 32 lbf·ft) 98 N·m (10.0 kgf·m, 72 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 98 N·m (10.0 kgf·m, 72 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 18-3...
  • Page 617 • After the rear wheel installation, check the brake operation by applying the brake pedal. • Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE". • Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point. • For brake system information (page 19-5).
  • Page 618 dummyhead dummyhead REAR WHEEL/SUSPENSION TROUBLESHOOTING Steers to one side or does not track straight • Drive chain adjusters not adjusted equally • Bent axle • Bent frame • Worn swingarm pivot components Rear wheel wobbling • Bent rim • Worn wheel bearing •...
  • Page 619 dummyhead dummyhead REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle using a safety stand or hoist, NC700XA/XD/SA/SD: raise the rear wheel off the ground. Remove the bolts [1] and rear wheel speed sensor [2]. NC700XA/XD/SA/ Loosen the lock nut [1], drive chain adjusting nut [2] and axle nut [3].
  • Page 620 dummyhead dummyhead REAR WHEEL/SUSPENSION INSPECTION WHEEL RIM Check the rim runout by placing the wheel in a truing stand. Spin the wheel by hand, and measure the runout using a dial indicator. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) AXLE Place the axle on V-blocks.
  • Page 621 dummyhead dummyhead REAR WHEEL/SUSPENSION Remove the dust seal [1] from the driven flange [2]. Remove the driven flange assembly. If you will disassemble the driven flange, loosen the driven sprocket nuts [3] in a crisscross pattern in 2 or 3 steps, before removing the driven flange from the left wheel hub.
  • Page 622 dummyhead dummyhead REAR WHEEL/SUSPENSION Drive out the driven flange bearing [1]. Install the bearing remover head [1] into the bearing. From the opposite side, install the bearing remover shaft [2] and drive out the bearing from the wheel hub. TOOLS: Bearing remover head, 20 mm 07746-0050600 Bearing remover shaft...
  • Page 623 dummyhead dummyhead REAR WHEEL/SUSPENSION Drive in a new right side bearing [1] squarely until it is Never install the old fully seated. bearing, once the bearing has been TOOLS: removed, the Driver [2] 07749-0010000 bearing must be Attachment, 42 x 47 mm [3] 07746-0010300 replaced with new ones.
  • Page 624 dummyhead dummyhead REAR WHEEL/SUSPENSION Apply grease to a new O-ring [1]. Install the damper rubbers [2] and the O-ring into the left wheel hub. Install the driven flange assembly [1] into the left wheel hub. Tighten the driven sprocket nuts [2] to the specified torque in a crisscross pattern in 2 or 3 steps.
  • Page 625 dummyhead dummyhead REAR WHEEL/SUSPENSION Install the brake caliper/bracket assembly [1] to the NC700XA/SA shown: swingarm. Align the bracket groove with swingarm tab. Align NC700XD/SD: Align Install the rear wheel in the swingarm aligning the brake Be careful not to disc between the brake pads. damage the brake pads.
  • Page 626 dummyhead dummyhead REAR WHEEL/SUSPENSION SHOCK LINKAGE REMOVAL/INSTALLATION Support the motorcycle using a safety stand or hoist, [5]/[6] raise the rear wheel off the ground. Remove the following: – Shock link bolt [1] and nut [2] – Shock absorber lower mounting bolt [3] and nut [4] –...
  • Page 627 dummyhead dummyhead REAR WHEEL/SUSPENSION BEARING REPLACEMENT Remove the needle bearings [1] using the special tools. TOOLS: Bearing remover set, 17 mm [2] 07936-3710300 Remover handle [3] 07936-3710100 Remover weight [4] 07741-0010201 Apply molybdenum disulfide grease to new needle Never install the old [3]/[4] bearings rotating area.
  • Page 628 dummyhead dummyhead REAR WHEEL/SUSPENSION INSPECTION Visually inspect the shock absorber for wear or damage. Check the following: – Damper rod [1] for bend or damage – Damper unit [2] for deformation or oil leaks – Rubber bumper [3] for wear or damage –...
  • Page 629 dummyhead dummyhead REAR WHEEL/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the shock absorber to mark the drilling point. Wrap the shock absorber inside a plastic bag. Support the shock absorber in a vise as shown. Through the open end of the bag, insert a drill motor 31 mm with a sharp 2 –...
  • Page 630 dummyhead dummyhead REAR WHEEL/SUSPENSION Remove the socket bolts [1] and drive chain case [2]. Remove the socket bolts [1] and brake hose guide [2]. NC700X/XA/S/SA: NC700XA/SA shown: Release the brake hose [3] and rear wheel speed sensor wire (NC700XA/SA) [4] from the brake hose guide.
  • Page 631 dummyhead dummyhead REAR WHEEL/SUSPENSION Remove the step holder mounting socket bolts [1] and right step holder [2]. Do not twist the brake hose. Remove the swingarm pivot nut [1], washer [2], pivot bolt [3] and swingarm [4]. [1]/[2]/[3] DISASSEMBLY/INSPECTION Remove the drive chain slider mounting screws [1] and [1]/[2] washers [2].
  • Page 632 dummyhead dummyhead REAR WHEEL/SUSPENSION Remove the collar [1] form the shock absorber bracket. Check the collar for wear, damage or fatigue. Check the needle bearings [2] for damage or loose fit, replace it if necessary (page 18-19). Turn the inner race of the right side pivot ball bearings with your finger.
  • Page 633 dummyhead dummyhead REAR WHEEL/SUSPENSION Drive the needle bearing [1] out of the left pivot using a hydraulic press and special tool. TOOLS: Driver, 15 x 280L [2] 07949-3710001 Pilot, 32 mm [3] 07MAD-PR90200 Remove the needle bearings [1] out of the shock absorber bracket using the special tools.
  • Page 634 dummyhead dummyhead REAR WHEEL/SUSPENSION Apply molybdenum disulfide grease to a new needle [3]/[4] bearing rotating area. Install the needle bearing [1] into the right pivot with the marked side facing out until it is fully seated using a hydraulic press and special tools as shown. TOOLS: Driver [2] 07749-0010000...
  • Page 635 dummyhead dummyhead REAR WHEEL/SUSPENSION ASSEMBLY SNAP RING DUST SEAL PIVOT COLLAR NEEDLE BEARING BEARING DISTANCE COLLAR NEEDLE BEARING NEEDLE BEARING SWINGARM DUST SEAL PIVOT COLLAR DRIVE CHAIN SLIDER WASHER NEEDLE BEARING DRIVE CHAIN ADJUSTERS 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft) COLLAR Install the collar [1] to the shock absorber bracket.
  • Page 636 dummyhead dummyhead REAR WHEEL/SUSPENSION Install the drive chain slider [1]. [4]/[5] • Align the drive chain slider slit [2] from the swingarm tab. • Align the drive chain slider tabs [3] from the swingarm holes. Install the washers [4] and drive chain slider mounting screws [5].
  • Page 637 dummyhead dummyhead REAR WHEEL/SUSPENSION Install the shock arm [1] and shock absorber lower mounting bolt [2] to the shock absorber. Install and tighten the shock absorber lower mounting nut [3] to the specified torque. TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft) Install the shock links [4] and shock link bolt [5] to the swingarm.
  • Page 638 dummyhead dummyhead REAR WHEEL/SUSPENSION Install the left step holder [1] and step holder mounting NC700X/XA/S/SA shown: socket bolts [2]. Tighten the step holder mounting socket bolts to the specified torque. TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft) Install the gearshift arm [1] to the gearshift spindle. NC700X/XA/S/SA: NC700X/XA/S/SA: Align...
  • Page 639 dummyhead dummyhead MEMO...
  • Page 640: Hydraulic Brake

    dummytext 19. HYDRAULIC BRAKE COMPONENT LOCATION ··························19-2 REAR MASTER CYLINDER ····················· 19-23 SERVICE INFORMATION ···························19-5 FRONT BRAKE CALIPER (NC700X/S) ··············································· 19-26 TROUBLESHOOTING·································19-7 FRONT BRAKE CALIPER (NC700XA/XD/SA/SD) ······························ 19-28 BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700X/S) ······························19-8 REAR BRAKE CALIPER ·························· 19-30 BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700XA/XD/SA/SD) ···········19-11 PARKING BRAKE CALIPER (NC700XD/SD) ··········································...
  • Page 641 dummyhead dummyhead HYDRAULIC BRAKE COMPONENT LOCATION HYDRAULIC BRAKE 12 N·m (1.2 kgf·m, 9 lbf·ft) NC700XA/SA shown: 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 17 N·m (1.7 kgf·m, 13 lbf·ft) NC700X/S: 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 19-2...
  • Page 642 dummyhead dummyhead HYDRAULIC BRAKE NC700X/XA/S/SA: NC700XA/SA shown: 34 N·m (3.5 kgf·m, 25 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 19-3...
  • Page 643 dummyhead dummyhead HYDRAULIC BRAKE NC700XD/SD: 10 N·m (1.0 kgf·m, 7 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 31 N·m (3.2 kgf·m, 23 lbf·ft) 19-4...
  • Page 644 dummyhead dummyhead HYDRAULIC BRAKE SERVICE INFORMATION GENERAL Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilling brake fluid will severely damage instrument lenses and painted surface.
  • Page 645 dummyhead dummyhead HYDRAULIC BRAKE TORQUE VALUES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Brake caliper bleed valve 5.4 (0.6, 4.0) (NC700X/S) Brake caliper bleed valve 5.4 (0.6, 4.0) (NC700XA/XD/SA/SD) Master cylinder reservoir cover 1.5 (0.2, 1.1) screw Rear brake reservoir mounting bolt 10 (1.0, 7) Brake pad pin...
  • Page 646 dummyhead dummyhead HYDRAULIC BRAKE TROUBLESHOOTING Brake lever/pedal soft or spongy • Air in hydraulic system • Leaking hydraulic system • Contaminated brake pad/disc • Worn caliper piston seal • Worn master cylinder piston cups • Worn brake pad/disc • Contaminated caliper •...
  • Page 647 dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700X/S) • Do not allow foreign material to enter the system when filling the reservoir. • When using a commercially available brake bleeder, follow the manufacture’s operating instructions. BRAKE FLUID DRAINING Turn the handlebar until the reservoir is parallel to the Front brake: Front: [3]/[4]...
  • Page 648 dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir with DOT 4 brake fluid from a sealed Do not mix different Front shown: container. types of fluid. There are not compatible. Connect a automatic refill system to the reservoir. If an automatic refill system is not used, add fluid when the fluid level in the reservoir is low.
  • Page 649 dummyhead dummyhead HYDRAULIC BRAKE Fill the reservoir with DOT 4 brake fluid from a sealed Do not mix different Front shown: container to the casting ledge [1]. types of fluid. There are not compatible. Install the diaphragm [1], set plate [2], reservoir cover Front brake: Front: [1]/[2]...
  • Page 650 dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700XA/XD/SA/SD) • Do not allow foreign material to enter the system when filling the reservoir. • When using a commercially available brake bleeder, follow the manufacture’s operating instructions. BRAKE FLUID DRAINING LEVER BRAKE LINE Turn the handlebar until the reservoir is parallel to the [3]/[4] ground.
  • Page 651 dummyhead dummyhead HYDRAULIC BRAKE Connect a bleed hose [1] to the front brake caliper center bleed valve [2]. Loosen the center bleed valve and pump the brake pedal until no more fluid flows out of the bleed valve. Tighten the bleed valve. Connect a bleed hose [1] to the rear brake caliper bleed valve [2].
  • Page 652 dummyhead dummyhead HYDRAULIC BRAKE LEVER BRAKE LINE Close the bleed valves. Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect an automatic refill system to the reservoir. • If an automatic refill system is not used, add brake fluid when the fluid level in the reservoir is low.
  • Page 653 dummyhead dummyhead HYDRAULIC BRAKE PEDAL (COMBI) BRAKE FLUID FILLING Add fluid and bleed any air from the pedal brake line in the sequence as follow: 1. Front brake caliper center bleed valve 2. Rear brake caliper bleed valve Fill the reservoir with DOT 4 brake fluid from a sealed container.
  • Page 654 dummyhead dummyhead HYDRAULIC BRAKE Connect a bleed hose [1] to the rear brake caliper bleed valve [2]. Repeat above steps 1. and 2. for the rear brake caliper bleed valve. Bleed the rear hydraulic system (page 19-15). PEDAL (COMBI) BRAKE AIR BLEEDING Connect a bleed hose [1] to the front brake caliper center bleed valve [2].
  • Page 655 dummyhead dummyhead HYDRAULIC BRAKE Remove the 6 mm nut [1], rear brake reservoir mounting bolt [2] and reservoir [3]. Install the diaphragm [4], set plate [5] and reservoir cover [6]. Install and tighten the cover screws [7] to the specified torque.
  • Page 656 dummyhead dummyhead HYDRAULIC BRAKE FRONT BRAKE PAD REPLACEMENT (NC700XA/XD/SA/SD) • Always replace the brake pads in pairs to assure even disc pressure. • Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise.
  • Page 657 dummyhead dummyhead HYDRAULIC BRAKE REAR BRAKE PAD REPLACEMENT • Always replace the brake pads in pairs to assure even disc pressure. • Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise. Remove the brake pad pin [1] and rear brake caliper mounting bolt [2].
  • Page 658 dummyhead dummyhead HYDRAULIC BRAKE Tighten the rear brake caliper mounting bolt [1] to the specified torque. TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) Tighten the brake pad pin [2] to the specified torque. TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft) Operate the brake pedal to seat the caliper pistons against the pads.
  • Page 659 dummyhead dummyhead HYDRAULIC BRAKE BRAKE DISC INSPECTION Visually inspect the brake discs for damage or crack. Measure the brake disc thickness using a micrometer. SERVICE LIMITS: Front: 4.0 mm (0.16 in) Rear: 4.0 mm (0.16 in) Replace the brake disc if the smallest measurement is less than the service limit.
  • Page 660 dummyhead dummyhead HYDRAULIC BRAKE Remove the bolts [1], holder [2] and master cylinder [3]. Installation is in the reverse order of removal. • Install the master cylinder holder with the "UP" mark [4] facing up. • Align the end of the master cylinder with the handlebar punch mark.
  • Page 661 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY Disassemble and assemble the front master cylinder as following the illustration. • Be careful not to damage the boot. • When removing and installing the snap ring, use the special tool. TOOL: Snap ring pliers 07914-SA50001 •...
  • Page 662 dummyhead dummyhead HYDRAULIC BRAKE INSPECTION Check the master cylinder [1] for scoring, scratches or damage. Check the master piston [2] for scoring, scratches or damage. Check the piston cups [3] for wear, deterioration or damage. Measure the master cylinder I.D. SERVICE LIMIT: 11.055 mm (0.4352 in) Measure the master piston O.D.
  • Page 663 dummyhead dummyhead HYDRAULIC BRAKE Unhook the brake light switch spring [1]. Remove the brake light switch [2] from the right step holder [3], then remove the right step holder. Remove and discard the cotter pin [1]. Remove the joint pin [2] and disconnect the push rod joint from the brake pedal.
  • Page 664 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY Disassemble and assemble the rear master cylinder as following the illustration. • Be careful not to damage the boot. • When removing and installing the snap ring, use the special tool. TOOL: Snap ring pliers 07914-SA50001 •...
  • Page 665 dummyhead dummyhead HYDRAULIC BRAKE INSPECTION Check the master cylinder [1] for scoring, scratches or damage. Check the master piston [2] for scoring, scratches or damage. Check the piston cup [3] for wear, deterioration or damage. Measure the master cylinder I.D. SERVICE LIMIT: 14.055 mm (0.5533 in) Measure the master piston O.D.
  • Page 666 • Apply silicone grease to new dust seals. • Install the pistons with the opening toward the pads. • Apply Honda Bond A, Cemedine #540 or equivalent to the brake pad retainer mating surface. • Apply 0.4 g (0.01 oz) of silicone grease to the caliper pin and bracket pin sliding surface.
  • Page 667 dummyhead dummyhead HYDRAULIC BRAKE INSPECTION Check the caliper cylinder for scoring or other damage. Measure the each caliper cylinder I.D. SERVICE LIMIT: 27.060 mm (1.0654 in) Check the caliper pistons for scratches, scoring or other damage. Measure the each caliper piston O.D. SERVICE LIMIT: 26.91 mm (1.059 in) FRONT BRAKE CALIPER (NC700XA/ XD/SA/SD)
  • Page 668 dummyhead dummyhead HYDRAULIC BRAKE Remove the brake caliper mounting bolts [1] and brake caliper/bracket assembly [2]. Installation is in the reverse order of removal. • Replace the front brake caliper mounting bolts and sealing washers with new ones. • Install the brake hose eyelet stopper against the caliper body.
  • Page 669 • Apply silicone grease to new dust seals. • Install the pistons with the opening toward the pads. • Apply Honda Bond A, Cemedine #540 or equivalent to the brake pad retainer mating surface. • Apply 0.4 g (0.01 oz) of silicone grease to the caliper pin and bracket pin sliding surface.
  • Page 670 dummyhead dummyhead HYDRAULIC BRAKE Remove the brake caliper [1] from the caliper bracket. Remove the rear wheel (page 18-6). Remove the caliper bracket from the swingarm. Installation is in the reverse order of removal. • Replace the sealing washers with new ones. •...
  • Page 671 • Apply silicone grease to new dust seal. • Install the piston with the opening toward the pads. • Apply Honda Bond A, Cemedine #540 or equivalent to the brake pad retainer mating surface. • Apply 0.4 g (0.01 oz) of silicone grease to the boot inside.
  • Page 672 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY Remove the caliper pin bolt [1]. Remove the following: – Caliper bracket [1] – Pad spring [2] – Bracket pin boot [3] – Caliper pin boot [4] – Sleeve [5] Remove the parking brake adjuster bolt lock nut [1] while holding the brake arm [2].
  • Page 673 dummyhead dummyhead HYDRAULIC BRAKE Remove the adjuster bolt/piston [1] while holding the brake shaft [2]. Remove the brake shaft. Do not disassemble the adjuster bolt/piston. Remove the dust seal [1]. Clean the caliper cylinder and brake shaft sliding surface. INSPECTION Check the caliper cylinder [1] and piston [2] for scoring, scratches or damage.
  • Page 674 dummyhead dummyhead HYDRAULIC BRAKE ASSEMBLY BRACKET DUST SEAL ADJUSTER BOLT/PISTON PAD PIN 17 N·m (1.7 kgf·m, 13 lbf·ft) PAD SPRING SLEEVE CALIPER PIN BOOT CALIPER PIN BOOT CALIPER PIN BOLT 22 N·m (2.2 kgf·m, 16 lbf·ft) LOCK NUT 17 N·m (1.7 kgf·m, 13 lbf·ft) BRAKE PADS CALIPER BODY BRAKE ARM...
  • Page 675 dummyhead dummyhead HYDRAULIC BRAKE Apply 0.4 g (0.01 oz) minimum of silicone grease to the adjuster bolt threads and piston sliding surface. Install the adjuster bolt/piston [1] while holding the brake shaft [2]. Apply 0.4 g (0.01 oz) minimum of silicone grease to the brake shaft boot lips.
  • Page 676 dummyhead dummyhead HYDRAULIC BRAKE Apply 0.4 g (0.01 oz) minimum of silicone grease of silicone grease to the bracket pin and sleeve sliding surface. Install the following: – Sleeve [1] – Caliper pin boots [2] – Bracket pin boot [3] –...
  • Page 677 dummyhead dummyhead HYDRAULIC BRAKE Installation is in the reverse order of removal. • Apply grease to the brake pedal pivot sliding area. • Replace the cotter pin with a new one. TORQUE: Step holder mounting socket bolt: 32 N·m (3.3 kgf·m, 24 lbf·ft) PARKING BRAKE LEVER (NC700XD/ REMOVAL/INSTALLATION Remove the following:...
  • Page 678 dummyhead dummyhead HYDRAULIC BRAKE Installation is in the reverse order of removal. • Align the parking brake lever bracket locating pin with the handlebar hole. • Route the cables and wire harness properly (page 1- 25). TORQUE: Parking brake adjuster bolt lock nut: 17 N·m (1.7 kgf·m, 13 lbf·ft) Parking brake cable mounting nut: 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 679 dummyhead dummyhead HYDRAULIC BRAKE Remove the ratchet B [1]. Remove the ratchet A [1] and springs [2]. ASSEMBLY Apply grease to the ratchet A teeth and sliding surface. Install the springs [1] and ratchet A [2]. Apply grease to the ratchet B teeth and sliding surface. Install the ratchet B [1] with its tab [2] facing up.
  • Page 680 dummyhead dummyhead HYDRAULIC BRAKE Apply grease to the parking brake lever sliding surface. Align Install the parking brake lever [1]. Align the parking brake lever hole with the ratchet B tab. Apply grease to the washer sliding surface. Install the washer [1] and E-clip [2]. Install the release shaft [1] and new spring pin [2] while aligning the hole of the release shaft, ratchet A and parking brake lever bracket.
  • Page 681 dummyhead dummyhead MEMO...
  • Page 682: Anti-Lock Brake System (Abs)

    dummytext 20. ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM LOCATION ··························20-2 ABS INDICATOR CIRCUIT TROUBLESHOOTING ······························ 20-12 ABS SYSTEM DIAGRAM····························20-3 ABS TROUBLESHOOTING······················ 20-15 SERVICE INFORMATION ···························20-4 WHEEL SPEED SENSOR ························ 20-24 ABS CONNECTOR LOCATIONS ···············20-5 PCV ··························································· 20-28 ABS TROUBLESHOOTING INFORMATION············································20-7 DELAY VALVE··········································...
  • Page 683 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM LOCATION ANTI-LOCK BRAKE SYSTEM (ABS) BATTERY FUSE BOX ABS MODULATOR DELAY VALVE FRONT WHEEL SPEED SENSOR REAR WHEEL SPEED SENSOR 20-2...
  • Page 684 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM DIAGRAM FUSE BOX MAIN CLOCK/TURN (30 A) (7.5A) FRONT BRAKE LIGHT SWITCH IGNITION SWITCH (BLUE) REAR BRAKE ILLUMI/ LIGHT SWITCH STOP/HORN BRAKE/TAIL LIGHT (7.5A) R/Bl P/Bu (81) ABS MODULATOR ABS MAIN (7.5A) R/Bl R/Bl (61,62)
  • Page 685 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) SERVICE INFORMATION GENERAL The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing, the excessive voltage may damage the control unit. Always turn off the ignition switch before servicing. •...
  • Page 686 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS CONNECTOR LOCATIONS NOTE 1: Remove the shroud/side cover (NC700XA/XD) (page 2-14). NOTE 1: Remove the shelter/side cover (NC700SA/SD) (page 2-15). ABS MODULATOR REAR WHEEL SPEED SENSOR 2P (GRAY) CONNECTOR (NOTE 1) NOTE 2: Remove the luggage box (page 2-19). ABS MODULATOR 25P CONNECTOR (NOTE 2) 20-5...
  • Page 687 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) NOTE 3: Remove the maintenance lid (page 21-6). FUSE BOX (NOTE 3) – ABS fuse 30 A (ABS M.) – ABS fuse 30 A (ABS SOL.) – ABS fuse 7.5 A (ABS MAIN) (NOTE 3) NOTE 4: Remove the shroud/side cover (NC700XA/XD) (page 2-14).
  • Page 688 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the associated part can be detected by reading the problem code.
  • Page 689 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE INDICATION PATTERN • The ABS indicator denotes the problem codes from 11 to 81. the ABS indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.3 seconds. When two long blinks occur, and three short blinks, that problem code is 23 (two long blinks = 20 blinks, three short blinks = 3 blinks).
  • Page 690 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 2. Turn the ignition switch ON and engine stop switch to " ". The ABS indicator [1] should come on 2 seconds (start signal) (then goes off 3.6 seconds) and starts problem code indication. 3.
  • Page 691 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR PROBLEM CODE INDEX • The ABS indicator might blink in the following cases. Correct the faulty part. – Incorrect tire pressure. – Tires not recommended for the motorcycle were installed (incorrect tire size). –...
  • Page 692 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) Detection Problem Refer Function failure Symptom/Fail-safe function Code Power circuit/Under voltage • Stops ABS operation • Input voltage (too low) • ABS fuse 7.5 A (ABS MAIN) 20-22 Power circuit/Over voltage • Stops ABS operation •...
  • Page 693 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) 1. Combination Meter Power/ground Line Inspection Check the combination meter power and ground lines (page 22-10). Are the wires normal? –...
  • Page 694 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR STAYS ON (Indicator does not go off when the motorcycle is running, Problem code is not indicated by the retrieval procedure) 1. Service Check Line Short Circuit Inspection Disconnect the ABS modulator 25P connector [1]. Check for continuity between the ABS modulator 25P connector of the wire harness side and ground.
  • Page 695 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 4. Logic Ground Line Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wire from the ABS modulator 25P connector [1]. Check for continuity between the ABS modulator 25P connector of the wire harness side and ground. Connection: Green/yellow –...
  • Page 696 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 7. Power Input Line Open Circuit Inspection Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the ABS modulator 25P connector [1] of wire harness side and ground. Connection: Red/black (+) –...
  • Page 697 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 2. Speed Sensor Condition Inspection Inspect the area around the speed sensor: Check that there is iron or other magnetic deposits between the pulser ring [1] and wheel speed sensor [2], and the pulser ring slots for obstructions. Check the installation condition of the pulser ring or wheel speed sensor for looseness.
  • Page 698 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 5. Speed Sensor Line Open Circuit Inspection Short the ABS modulator 25P connector [1] Bu/Y terminals of the wire harness side with a jumper wire [2]. Connection: Blue/yellow – White/yellow TOOL: Test probe 07ZAJ-RDJA110 Check for continuity between the terminals of the Bu/Y wire harness side front wheel speed sensor 2P...
  • Page 699 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 2. Speed Sensor Condition Inspection Inspect the area around the speed sensor: Check that there is iron or other magnetic deposits between the pulser ring [1] and wheel speed sensor [2], and the pulser ring slots for obstructions. Check installation condition of the pulser ring or wheel speed sensor for looseness.
  • Page 700 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 5. Speed Sensor Line Open Circuit Inspection Short the ABS modulator 25P connector [1] terminals of the wire harness side with a jumper wire [2]. Connection: Blue – White TOOL: Test probe 07ZAJ-RDJA110 Check for continuity between the terminals of the wire harness side rear wheel speed sensor 2P (Gray) connector [3].
  • Page 701 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 51, 52 or 53 (Pump Motor) 1. Fuse Inspection Check the ABS fuse 30 A (ABS M.) [1] in the fuse NC700XA/SA shown: box for blown. Is the fuse blown? – GO TO STEP 2. –...
  • Page 702 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 4. Failure Reproduction Connect the ABS modulator 25P connector. Erase the problem code (page 20-9). Test ride the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20-8) and recheck the ABS indicator [1]. Does the ABS indicator indicate the code "51, 52 or 53"? –...
  • Page 703 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 3. Relay Power Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 25P connector [1]. Measure the voltage between the ABS modulator 25P connector of the wire harness side and ground. Connection: Black/white (+) –...
  • Page 704 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 2. Power Input Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 25P connector [1]. With the ABS fuse 7.5 A (ABS MAIN) removed, check for continuity between the ABS modulator 25P connector of the wire harness side and ground.
  • Page 705 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 71 (Tire Size) • Check the following and correct the faulty part. – Incorrect tire pressure. – Tires not recommended for the motorcycle were installed (incorrect tire size). – Deformation of the wheel or tire. 1.
  • Page 706 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR REPLACEMENT Refer to procedure for the pulser ring removal/ installation. – Front pulser ring (page 17-22) – Rear pulser ring (page 18-7) FRONT WHEEL SPEED SENSOR REMOVAL/ INSTALLATION Remove the bolts [1] and radiator lower stay [2]. Release the radiator boss from the radiator mounting rubber [3].
  • Page 707 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) Remove the side cowl (page 2-13). NC700SA/SD: NC700SA/SD: Remove the front wheel speed sensor 2P (Blue) connector [1] from the side cover and disconnect the connector. Release the sensor wire from the guide [2]. Release the sensor wire [1] from the clamps [2].
  • Page 708 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) Disconnect the rear wheel speed sensor 2P (Gray) connector [1]. Release the rear wheel speed sensor 2P (Gray) connector from the ECM box [2]. Release the clamp [3]. Remove the socket bolts [1] and brake hose guide [2]. Release the brake hose [3] and rear wheel speed sensor wire [4] from the brake hose guide.
  • Page 709 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) REMOVAL/INSTALLATION Drain the brake fluid from the lever/pedal brake line hydraulic systems (page 19-11). Remove the luggage box (page 2-19). Loosen the brake pipe joint nuts [1] and disconnect the brake pipe from the PCV [2]. Remove the PCV mounting bolt (long) [3], PCV mounting bolt (short) [4] and PCV.
  • Page 710 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS MODULATOR REMOVAL/INSTALLATION (NC700XA/ Be careful not to bend or damage the brake pipes during assembly or removal. Remove the following: NC700XA shown: – Delay valve (page 20-28) – PCV (page 20-28) Pull up the lock lever [1] and disconnect the ABS modulator 25P connector [2].
  • Page 711 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) Remove the ABS modulator mounting bolts [1] and ABS modulator [2] from the ABS modulator stay [3]. Installation is in the reverse order of removal. • Apply brake fluid to the joint nut threads and sliding surface.
  • Page 712 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) REMOVAL/INSTALLATION (NC700XD/ Be careful not to bend or damage the brake pipes during assembly or removal. Remove the following: – Delay valve (page 20-28) – PCV (page 20-28) Remove the linear solenoid valve 4P (Green) connector [1] and shift spindle angle sensor 3P (Gray) connector [2] from the ABS modulator stay.
  • Page 713 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) Remove the ABS modulator mounting bolts [1] and ABS modulator [2] from the ABS modulator stay [3]. Installation is in the reverse order of removal. • Apply brake fluid to the joint nut threads and sliding surface.
  • Page 714: Battery/Charging System

    dummytext 21. BATTERY/CHARGING SYSTEM SYSTEM LOCATION···································21-2 BATTERY ···················································· 21-6 SYSTEM DIAGRAM ····································21-2 CHARGING SYSTEM INSPECTION ·········· 21-7 SERVICE INFORMATION ···························21-3 REGULATOR/RECTIFIER ·························· 21-8 TROUBLESHOOTING·································21-5 ALTERNATOR CHARGING COIL ·············· 21-9 21-1...
  • Page 715 dummyhead dummyhead BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY/CHARGING SYSTEM BATTERY MAIN FUSE 30 A REGULATOR/RECTIFIER ALTERNATOR SYSTEM DIAGRAM MAIN FUSE 30 A REGULATOR/RECTIFIER BATTERY ALTERNATOR G: Green R: Red Y: Yellow 21-2...
  • Page 716 dummyhead dummyhead BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 717 dummyhead dummyhead BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Type YTZ12S Capacity 12 V – 11 Ah Current leakage 1.2 mA maximum Voltage Fully charged 13.0 – 13.2 V (20°C/68°F) Needs Below 12.4 V charging Charging current Normal 1.1 A/5 – 10 h Quick 5.5 A/1 h Alternator...
  • Page 718 dummyhead dummyhead BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 21-6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent Is the battery good condition? –...
  • Page 719 dummyhead dummyhead BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Open the luggage box lid using the ignition key. Remove the screws [1] and maintenance lid [2]. Remove the battery holder band [3]. Always turn the ignition switch OFF Disconnect the battery negative (–) cable [4] first, then before removing the disconnect the battery positive (+) cable [5].
  • Page 720 dummyhead dummyhead BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Remove the maintenance lid (page 21-6). Turn the ignition switch OFF, disconnect the negative (–) cable [1] from the battery. Connect the ammeter (+) probe [2] to the negative (–) cable and the ammeter (–) probe [3] to the battery (–) terminal.
  • Page 721 dummyhead dummyhead BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER REMOVAL/INSTALLATION Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the shelter/side cover (NC700S/SA/SD) (page 2-15). Remove the bolt [1] and rear brake reservoir stay/ reservoir [2]. Remove the socket bolts [3]. Align Lower the rear fender B [1]. Remove the bolts [2] and regulator/rectifier [3].
  • Page 722 dummyhead dummyhead BATTERY/CHARGING SYSTEM GROUND LINE INSPECTION Turn the ignition switch OFF. Disconnect the regulator/rectifier 2P (Black) connector [1] (page 21-8). Check for continuity between the regulator/rectifier 2P (Black) connector at the wire side and ground. CONNECTION: Green – Ground There should be continuity at all times.
  • Page 723 dummyhead dummyhead MEMO...
  • Page 724: Lights/Meters/Switches

    dummytext 22. LIGHTS/METERS/SWITCHES SYSTEM LOCATION···································22-2 ENGINE OIL PRESSURE INDICATOR/EOP SWITCH····················································· 22-19 SERVICE INFORMATION ···························22-3 FUEL LEVEL SENSOR····························· 22-21 TROUBLESHOOTING·································22-4 PARKING BRAKE INDICATOR/SWITCH (NC700XD/SD) ·········································· 22-22 HEADLIGHT ················································22-5 IGNITION SWITCH···································· 22-24 TURN SIGNAL LIGHT·································22-6 HANDLEBAR SWITCHES ························ 22-25 POSITION LIGHT ········································22-7 BRAKE LIGHT SWITCH ···························...
  • Page 725 dummyhead dummyhead LIGHTS/METERS/SWITCHES SYSTEM LOCATION LIGHTS/METERS/SWITCHES NC700X/XA/S/SA: FRONT BRAKE LIGHT SWITCH HORN ECT SENSOR CLUTCH SWITCH FUEL LEVEL SENSOR IGNITION SWITCH TURN SIGNAL/ HAZARD RELAY EOP SWITCH NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH VS SENSOR SIDESTAND SWITCH NC700XD/SD: FRONT BRAKE LIGHT SWITCH HORN PARKING BRAKE SWITCH ECT SENSOR...
  • Page 726 dummyhead dummyhead LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL • Note the following when replacing the halogen headlight bulb. – Wear clean gloves while replacing the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail.
  • Page 727 dummyhead dummyhead LIGHTS/METERS/SWITCHES TROUBLESHOOTING SPEED SENSOR/SPEEDOMETER (NC700X/XA/S/SA) The speedometer operation is abnormal 1. Fuse Inspection Check for blown main fuse or sub fuse. Is the fuse blown? – Replace the fuse. – GO TO STEP 2. 2. Battery Inspection Make sure the battery is fully charged and in good condition. Is the battery in good condition? –...
  • Page 728 dummyhead dummyhead LIGHTS/METERS/SWITCHES HEADLIGHT For headlight unit removal/installation. – NC700X/XA/XD (page 2-26) – NC700S/SA/SD (page 2-27) BULB REPLACEMENT (NC700X/XA/ Disconnect the headlight 3P (Black) connector [1]. Remove the dust cover [2]. Unhook the bulb retainer [3] and remove the headlight bulb [4].
  • Page 729 dummyhead dummyhead LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screws [1] and turn signal light lens [2]. While pushing in the bulb [3], turn it counterclockwise to remove it. Replace the bulb with a new one. Check the packing [4] is installed in position and is in good condition, replace it with a new one if necessary.
  • Page 730 dummyhead dummyhead LIGHTS/METERS/SWITCHES REAR Remove the tail light cover (page 2-10). Remove the turn signal light mounting screw [1], setting plate [2] and turn signal light [3]. Remove the mounting rubber [4]. Installation is in the reverse order of removal. Route the wires properly (page 1-25).
  • Page 731 dummyhead dummyhead LIGHTS/METERS/SWITCHES BRAKE/TAIL/LICENSE LIGHT For brake/tail/license light removal/installation (page 2- 10). BULB REPLACEMENT Remove the tail light cover (page 2-10). Turn the bulb socket [1] counterclockwise and remove While pushing in the bulb [2], turn it counterclockwise to remove it. Replace the bulb with a new one.
  • Page 732 dummyhead dummyhead LIGHTS/METERS/SWITCHES SYSTEM INSPECTION (NC700XD/SD) Check for loose or poor contact terminals at the combination meter 16P (Gray) connector. When the ignition switch is turned ON with the engine stop switch " ", the combination meter will show the entire digital display and the tachometer segments [1] will reduce from full scale to zero.
  • Page 733 dummyhead dummyhead LIGHTS/METERS/SWITCHES Remove the dust cover [1]. [1]/[2] Disconnect combination meter (Gray) connector [2]. Remove the combination meter mounting screws [3], washer [4] and combination meter [5]. Installation is in the reverse order of removal. TORQUE: Combination meter mounting screw: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) Combination meter back cover mounting screw: 0.3 N·m (0.03 kgf·m, 0.2 lbf·ft)
  • Page 734 dummyhead dummyhead LIGHTS/METERS/SWITCHES GROUND LINE Check for continuity at the combination meter 16P (Gray) connector [1] of the wire harness side and ground. CONNECTION: Green/red – Ground There should be continuity. If there is no continuity, check for open circuit in Green/ red wire.
  • Page 735 dummyhead dummyhead LIGHTS/METERS/SWITCHES MIL AND ENGINE OIL PRESSURE INDICATOR ARE STAY ON, TACHOMETER, HIGH COOLANT TEMPERATURE INDICATOR AND HISS INDICATOR DOES NOT COME ON AND SHIFT INDICATOR "–" (NC700XD/SD) IS BLINKING (when the ignition switch turned ON) • Check the following items before starting the inspection: –...
  • Page 736 dummyhead dummyhead LIGHTS/METERS/SWITCHES Check for continuity between the combination meter 16P (Gray) connector [1] of the wire harness side and ground. Connection: Red/blue – Ground Is there continuity? R/Bu – Short circuit in Red/blue wire – GO TO STEP 2. 2.
  • Page 737 dummyhead dummyhead LIGHTS/METERS/SWITCHES 4. ECM Serial Line Output Voltage Inspection Turn the ignition switch OFF. Disconnect the combination meter 16P (Gray) connector. Connect the ECM/PCM 33P connector. Remove the maintenance lid (page 21-6). Remove the DLC [1] from the battery box. Short the DLC terminals using a special tool.
  • Page 738 dummyhead dummyhead LIGHTS/METERS/SWITCHES Push the A button, then hour digits [1] start blinking. The combination meter enter the clock setting mode. Push the B button until the desired hour [1] and AM/PM are displayed. Push and hold to advance the hour fast. Push the A button, then the minute digits [1] start blinking.
  • Page 739 dummyhead dummyhead LIGHTS/METERS/SWITCHES SPEEDOMETER/VS SENSOR SYSTEM INSPECTION (NC700X/XA/S/ Perform the combination meter system inspection NC700X/XA: NC700S/SA: (page 22-8). Remove the windscreen (page 2-23). Remove the dust cover [1]. If the system fails the inspection, shift the transmission into neutral, the combination meter 16P (Gray) connector [2] is connected, then turn the ignition switch Measure the voltage at the combination meter 16P (Gray) connector [1] of the wire harness side.
  • Page 740 dummyhead dummyhead LIGHTS/METERS/SWITCHES Turn the ignition switch ON with the engine stop switch " ". Measure the voltage at the combination meter 16P (Gray) connector [1] of the wire harness side. CONNECTION: Pink/green (+) – Green/red (–) Slowly turn the rear wheel by hand. There should be 0 to 5 V pulse voltage.
  • Page 741 dummyhead dummyhead LIGHTS/METERS/SWITCHES VS SENSOR REMOVAL/ INSTALLATION Disconnect the VS sensor 3P (Black) connector [1]. Remove the bolt [2] and VS sensor [3]. Remove the O-ring [4]. Installation is in the reverse order of removal. • Replace the O-ring with a new one. •...
  • Page 742 dummyhead dummyhead LIGHTS/METERS/SWITCHES ECT SENSOR UNIT INSPECTION Remove the ECT sensor (page 4-64). Suspend the ECT sensor [1] in a pan of coolant (50 – 50 mixture) on an electric heating element and measure the resistance through the sensor as the coolant heats •...
  • Page 743 dummyhead dummyhead LIGHTS/METERS/SWITCHES EOP SWITCH LINE INSPECTION Turn the ignition switch OFF. Disconnect the EOP switch 1P (Gray) connector [1]. Check for continuity between the EOP switch connector terminal and ground. CONNECTION: Light green – Ground – If there is continuity, the Light green wire has a short circuit.
  • Page 744 dummyhead dummyhead LIGHTS/METERS/SWITCHES FUEL LEVEL SENSOR FUEL LEVEL SENSOR INSPECTION Remove the fuel pump unit (page 7-11). Connect the ohmmeter to the fuel pump unit 3P (Black) connector [1] terminals. CONNECTION: Red/black – Black/white Inspect the resistance of the float [2] at the top and bottom positions.
  • Page 745 dummyhead dummyhead LIGHTS/METERS/SWITCHES PARKING BRAKE INDICATOR/SWITCH (NC700XD/SD) SYSTEM INSPECTION If the parking brake indicator [1] does not operate properly, check combination meter system inspection (page 22-9). If the combination meter system inspection is OK, check the parking brake switch line as follows: Turn the ignition switch OFF.
  • Page 746 dummyhead dummyhead LIGHTS/METERS/SWITCHES PARKING BRAKE SWITCH REMOVAL/ INSTALLATION Remove the parking brake lever holder cover [1]. Disconnect the parking brake switch connectors [1]. Remove the parking brake switch screw [2], parking brake switch [3] and switch spring [4]. Installation is in the reverse order of removal. •...
  • Page 747 dummyhead dummyhead LIGHTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Remove the shroud/side cover (NC700X/XA/XD) (page NC700X/XA: NC700S/SA/SD: 2-14). Remove the headlight/headlight stay (NC700S/SA/SD) (page 2-27). Disconnect the ignition switch 2P (Brown) connector [1]. Check for continuity between the wire terminals of the ignition switch connector in each switch position. Refer to the wiring diagram for the terminals and switch status: –...
  • Page 748 dummyhead dummyhead LIGHTS/METERS/SWITCHES HANDLEBAR SWITCHES RIGHT HANDLEBAR SWITCH Remove the shroud/side cover (NC700X/XA/XD) (page NC700X/XA: NC700S/SA: 2-14). Remove the headlight/headlight stay (NC700S/SA/SD) (page 2-27). Disconnect the following: – Right handlebar switch 8P (Blue) connector [1] – Right handlebar switch 6P (Black) connector (NC700XD) [2] –...
  • Page 749 dummyhead dummyhead LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors and check for continuity between the terminals. There should be continuity with the brake lever applied, and there should be no continuity with the brake lever released.
  • Page 750 dummyhead dummyhead LIGHTS/METERS/SWITCHES NEUTRAL SWITCH INSPECTION (NC700X/XA/S/SA) Make sure that the neutral indicator [1] come on with the ignition switch turned ON and transmission is in neutral. If the neutral indicator does not come on, inspect as follows: Remove the left rear cover (page 2-29). Disconnect the neutral switch connector [1].
  • Page 751 dummyhead dummyhead LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION (NC700X/ XA/S/SA) Drain the engine oil (page 3-13). [2]/[3] Remove the left rear cover (page 2-29). Disconnect the neutral switch connector [1]. Remove the neutral switch [2] and sealing washer [3]. Install the neutral switch with a new sealing washer. Tighten the neutral switch to the specified torque.
  • Page 752 dummyhead dummyhead LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the shelter/side cover (NC700S/SA/XD) (page 2-15) Disconnect the sidestand switch 3P (Green) connector [1]. Remove the sidestand switch wire clamp [2]. Remove the wire band [1] and sidestand switch wire NC700X/XA/S/SA: NC700XD/SD: clamp [2].
  • Page 753 dummyhead dummyhead LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the lower cowl (page 2-28). Disconnect the wire connectors [1] from the horn [2]. Remove the bolt [3] and horn. Installation is in the reverse order of removal. • Install the horn against the frame stopper [4]. •...
  • Page 754 dummyhead dummyhead LIGHTS/METERS/SWITCHES 2. Ground Line Open Circuit Inspection Check for continuity between the 4P connector [1] terminal and ground. Connection: Green – Ground Is there continuity? – GO TO STEP 3. – Open circuit in the Green wire 3. Turn Signal/hazard Switch Line Open Circuit Inspection Connect the 4P connector [1] terminals with a jumper wire.
  • Page 755 dummyhead dummyhead LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the center cover (NC700X/XA/XD) (page 2- 16). Remove the side cowl (NC700S/SA/SD) (page 2-13). Release the turn signal/hazard relay [1] from the luggage box. Disconnect the turn signal/hazard relay 4P connector [2] and remove the turn signal/hazard relay. Installation is in the reverse order of removal.
  • Page 756: Immobilizer System (Hiss)

    dummytext 23. IMMOBILIZER SYSTEM (HISS) SYSTEM LOCATION···································23-2 TROUBLESHOOTING ································ 23-8 SYSTEM DIAGRAM ····································23-2 HISS INDICATOR ····································· 23-10 SERVICE INFORMATION ···························23-3 ECM (NC700X/XA/S/SA)/ PCM (NC700XD/SD) ································· 23-11 KEY REGISTRATION PROCEDURES ·······23-3 IMMOBILIZER RECEIVER························ 23-12 DIAGNOSTIC CODE INDICATION ·············23-6 23-1...
  • Page 757: System Location

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) SYSTEM LOCATION IMMOBILIZER SYSTEM (HISS) ENGINE STOP SWITCH IGNITION SWITCH/ IMMOBILIZER RECEIVER MAIN FUSE 30 A BATTERY ECM/PCM BANK ANGLE SENSOR FUSE BOX CKP SENSOR SYSTEM DIAGRAM CLOCK/TURN MAIN 30 A 7.5 A HISS INDICATOR ENGINE STOP SWITCH Bl/R...
  • Page 758: Service Information

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION GENERAL • When checking the immobilizer system (HISS), follow the steps in the troubleshooting flow chart (page 23-8). • Keep the immobilizer key away from the other vehicle's immobilizer key when using it. The jamming of the key code signal may occur and the proper operation of the system will be obstructed.
  • Page 759 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 8. Repeat the steps 6 and 7 when you continuously register the other new key. The ECM/PCM can store up to four key codes. (The four keys can be registered.) 9. Turn the ignition switch OFF, remove the inspection adaptor and connect the CKP sensor 2P (Red) connector. 10.Turn the ignition switch ON with the registered key.
  • Page 760 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 14.Disconnect the red clip of the inspection adaptor from the battery positive (+) terminal for two seconds or more, then connect it again. The indicator remains on for approx. two seconds then it blinks four times repeatedly. •...
  • Page 761: Diagnostic Code Indication

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) When the ECM/PCM is faulty: 1. Obtain a new ECM/PCM and two new transponder keys. 2. Grind the keys in accordance with the shape of the original key (or use the key number plate when all key have been lost). 3.
  • Page 762 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE When the system (ECM/PCM) enters the diagnostic mode from the normal mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE ECM/PCM data is Faulty ECM/PCM Replace the ECM/PCM. abnormal. 10 sec. Code signals Faulty immobilizer Follow the troubleshooting (page cannot send or receiver or wire 23-8).
  • Page 763: Troubleshooting

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) TROUBLESHOOTING The immobilizer indicator comes on for approx. two seconds then it goes off, when the ignition switch is turned ON with the properly registered key and the HISS functions normally. If there is any problem or the properly registered key is not used, the indicator will remains on.
  • Page 764 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 2. First Transponder Key Inspection Turn the ignition switch ON with the spare transponder key and check the immobilizer indicator. The indicator should came on for 2 seconds then go off. Is the indicator go off? –...
  • Page 765: Hiss Indicator

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) HISS INDICATOR INSPECTION If the MIL and engine oil pressure indicator are stay on and tachometer, high coolant temperature indicator and HISS indicator does not come on and shift indicator "–" (NC700XD/SD) is blinking, inspect the TXD/RXD line. Remove the windscreen (page 2-23).
  • Page 766 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) ECM (NC700X/XA/S/SA)/PCM (NC700XD/SD) INSPECTION Remove the shroud/side cover (NC700X/XA) (page 2- NC700X/XA/S/SA: NC700X/XA/S/SA: 14). Remove the side cowl (NC700S/SA) (page 2-13). Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector [1]. Perform the following inspections at the wire harness side connector of the ECM.
  • Page 767: Immobilizer Receiver

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) GROUND LINE INSPECTION Check for continuity between the ECM/PCM 33P connector [1] terminals and ground. CONNECTION: Green/orange – Ground Green – Ground TOOL: Test probe 07ZAJ-RDJA110 There should be continuity at all times. CKP SENSOR LINE INSPECTION Disconnect the CKP sensor 2P (Red) connector [1] (page 23-6).
  • Page 768 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) POWER INPUT LINE INSPECTION Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the immobilizer receiver 4P (Black) connector [1] terminal and ground at the wire side. CONNECTION: Yellow/red (+) – Ground (–) There should be approx.
  • Page 769 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) Check for continuity between the ECM/PCM 33P connector [1] terminal and ground at the wire side. CONNECTION: Blue – Ground TOOL: Test probe 07ZAJ-RDJA110 There should be no continuity. REMOVAL/INSTALLATION Remove the top bridge (page 17-33). Remove the screws [1] and the immobilizer receiver [2].
  • Page 770: Wiring Diagram

    dummytext 24. WIRING DIAGRAM NC700X························································24-2 NC700S ······················································· 24-5 NC700XA ·····················································24-3 NC700SA····················································· 24-6 NC700XD ·····················································24-4 NC700SD····················································· 24-7 24-1...
  • Page 771: Index

    INDEX dummytext INDEX ABS CONNECTOR LOCATIONS ·································20-5 CRANKCASE ASSEMBLY ········································· 14-28 ABS INDICATOR CIRCUIT TROUBLESHOOTING ···20-12 CRANKCASE BREATHER············································· 3-8 ABS INDICATOR PROBLEM CODE INDEX ··············20-10 CRANKCASE SEPARATION ······································· 14-7 ABS MODULATOR ·····················································20-29 CRANKPIN BEARING ················································ 15-11 ABS SYSTEM DIAGRAM ·············································20-3 CRANKSHAFT ·····························································...
  • Page 772 dummytext INDEX HEADLIGHT ································································· 22-5 REAR MASTER CYLINDER······································· 19-23 HEADLIGHT AIM·························································· 3-25 REAR WHEEL ······························································ 18-6 HEADLIGHT COVER (NC700S/SA/SD) ······················ 2-27 REGULATOR/RECTIFIER············································ 21-8 HEADLIGHT/FRONT CENTER COWL RIGHT CRANKCASE COVER (NC700X/XA/XD)·························································· 2-26 CLUTCH/GEARSHIFT LINKAGE HEADLIGHT/HEADLIGHT STAY (NC700S/SA/SD) ···· 2-27 (NC700X/XA/S/SA) ·················································· 11-5 HIGH COOLANT TEMPERATURE INDICATOR/ECT DUAL CLUTCH TRANSMISSION (DCT) SENSOR ····································································...
  • Page 773 dummytext INDEX ELECTRIC STARTER ················································6-2 ELECTRIC STARTER················································ 6-5 IGNITION SYSTEM ····················································5-2 FRAME/BODY PANELS/EXHAUST SYSTEM ·········· 2-6 IMMOBILIZER SYSTEM (HISS)·······························23-2 FRONT WHEEL/SUSPENSION/STEERING ··········· 17-9 LIGHTS/METERS/SWITCHES·································22-2 HYDRAULIC BRAKE ··············································· 19-7 SYSTEM TESTING·························································8-5 IGNITION SYSTEM ··················································· 5-5 TACHOMETER ···························································22-18 IMMOBILIZER SYSTEM (HISS) ······························ 23-8 TECHNICAL FEATURES··············································1-87 LIGHTS/METERS/SWITCHES ································...

Table of Contents