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Honda NC700 2012, Service Manual

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Honda NC700 2012 Service Manual Download Page 339

11-4

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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

 • Clutch lifter sticking
 • Worn clutch disc
 • Weak clutch springs
 • No clutch lever freeplay
 • Engine oil mixed with molybdenum or graphite additive

Clutch will not disengage or motorcycle creeps with clutch disengaged

 • Excessive clutch lever freeplay
 • Clutch plate warped
 • Engine oil level too high, improper engine oil viscosity or additive used
 • Loose clutch center lock nut
 • Damaged clutch lifter mechanism
 • Clutch lifter rod installed improperly
 • Worn clutch outer slot and clutch center grooves
 • Improper clutch operation

Hard to shift

 • Misadjusted clutch cable
 • Improper clutch operation
 • Improper engine oil viscosity
 • Damaged or bent shift fork
 • Bent shift fork shaft
 • Bent shift fork claw
 • Loose shift drum stopper plate bolt
 • Damaged shift drum stopper plate
 • Damaged shift drum guide grooves
 • Damaged or bent gearshift spindle

Transmission jumps out of gear

 • Worn shift drum stopper arm
 • Weak or broken shift drum stopper arm return spring
 • Loose shift drum stopper plate bolt
 • Damaged shift drum stopper plate
 • Bent shift fork shaft
 • Damaged or bent shift forks
 • Worn gear engagement dogs or slots

Gearshift pedal will not return

 • Weak or broken gearshift spindle return spring
 • Damaged or bent gearshift spindle

Summary of Contents for NC700 2012

Page 1: ...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 gri...

Page 2: ...this message is to help prevent damage to your vehicle other property or the environment Honda Motor Co Ltd SERVICE PUBLICATION OFFICE Date of Issue February 2012 Your safety and the safety of others is very important To help you make informed decisions we have provided safety messages and other information throughout this manual Of course it is not practical or possible to warn you about all the ...

Page 3: ...NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan 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 Mo...

Page 4: ... NC700X XA S SA 11 DUAL CLUTCH TRANSMISSION DCT NC700XD SD 12 ALTERNATOR STARTER CLUTCH 13 CRANKCASE TRANSMISSION BALANCER 14 CRANKSHAFT PISTON CYLINDER 15 ENGINE REMOVAL INSTALLATION 16 FRONT WHEEL SUSPENSION STEERING 17 REAR WHEEL SUSPENSION 18 HYDRAULIC BRAKE 19 ANTI LOCK BRAKE SYSTEM ABS 20 BATTERY CHARGING SYSTEM 21 LIGHTS METERS SWITCHES 22 IMMOBILIZER SYSTEM HISS 23 WIRING DIAGRAM 24 INDEX ...

Page 5: ...MEMO dummyhead dummyhead ...

Page 6: ...xt 1 GENERAL INFORMATION SERVICE RULES 1 2 MODEL IDENTIFICATION 1 3 SPECIFICATIONS 1 6 TORQUE VALUES 1 15 LUBRICATION SEAL POINTS 1 23 CABLE HARNESS ROUTING 1 25 EMISSION CONTROL SYSTEMS 1 86 TECHNICAL FEATURES 1 87 ...

Page 7: ...ollowing abbreviations are used to identify the respective parts or systems DESTINATION CODE Throughout this manual the following codes are used to identify individual types for each region Abbrev term Full term ABS NC700XA XD SA SD Anti lock Brake System CKP sensor Crankshaft Position sensor DCT NC700XD SD Dual Clutch Transmission DLC Data Link Connector DTC Diagnostic Trouble Code ECM NC700X XA ...

Page 8: ...ENTIFICATION NC700XA shown NC700SA shown This manual covers following types of NC700 models Be sure to refer to the procedure for the appropriate version of the NC700 TYPE NC700X NC700S NC700X NC700XA NC700XD NC700S NC700SA NC700SD Standard brake ABS DCT ...

Page 9: ...e 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 The throttle body identification number 1 is stamped on the lower left side of the throttle body as shown 1 1 1 1 ...

Page 10: ...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 The Emission Control Information Label KO type 2 is located on the left side of the rear frame 1 1 1 ...

Page 11: ...rb weight E ED F RU U type NC700X 214 kg 472 lbs NC700XA 218 kg 481 lbs NC700XD 228 kg 503 lbs NC700S 211 kg 465 lbs NC700SA 215 kg 474 lbs NC700SD 225 kg 496 lbs KO type NC700XA 220 kg 485 lbs Maximum weight capacity E ED F RU U type 209 kg 461 lbs KO type 189 kg 417 lbs FRAME Frame type Diamond Front suspension Telescopic fork Front axle travel NC700X XA XD 137 mm 5 4 in NC700S SA SD 107 mm 4 2 ...

Page 12: ...C700X XA S SA Multi plate wet NC700XD SD 2 Multi plate wet clutches Clutch operation system NC700X XA S SA Cable operating NC700XD SD Automatic Transmission Constant mesh 6 speeds Primary reduction NC700X XA S SA 1 731 71 41 NC700XD SD 1 921 73 38 Final reduction NC700X XA S SA 2 687 43 16 NC700XD SD 2 437 39 16 Gear ratio NC700X XA S SA 1st 2 812 45 16 2nd 1 894 36 19 3rd 1 454 32 22 4th 1 200 30...

Page 13: ...brush length 12 0 13 0 0 47 0 51 6 5 0 26 ITEM SPECIFICATIONS Throttle body identification number GQ3UA Idle speed 1 200 100 min 1 rpm Throttle grip freeplay 2 6 mm 1 16 1 4 in Fuel pressure at idle 343 kPa 3 5 kgf cm2 50 psi Fuel pump flow at 12 V 230 cm3 7 8 US oz 8 1 Imp oz minimum 10 seconds ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1 69 liters 1 79 US qt 1 49 Imp qt At draining...

Page 14: ...clearance 0 15 0 006 Body clearance 0 15 0 21 0 006 0 008 Side clearance 0 04 0 09 0 002 0 004 ITEM STANDARD SERVICE LIMIT Cylinder compression at 470 min 1 rpm 1 775 kPa 18 1 kgf cm2 257 psi Valve clearance IN 0 17 0 02 0 007 0 001 EX 0 28 0 02 0 011 0 001 Rocker arm rocker arm shaft Rocker arm I D 20 012 20 030 0 7879 0 7886 20 041 0 7890 Rocker arm shaft O D 19 972 19 993 0 7863 0 7871 19 961 0...

Page 15: ...nsor resistance 20 C 68 F 2 5 2 8 kΩ ITEM STANDARD SERVICE LIMIT Starter driven gear boss O D 57 749 57 768 2 2736 2 2743 57 73 2 273 Starter clutch outer I D 74 412 74 442 2 9296 2 9308 74 46 2 931 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 O D M5 M6 27 959 27 980 1 1007 1 1016 27...

Page 16: ...1 965 0 8643 0 8648 21 94 0 864 Bushing to shaft clearance M5 0 015 0 049 0 0006 0 0019 0 09 0 004 M6 0 016 0 053 0 0006 0 0021 0 10 0 004 C1 0 020 0 054 0 0008 0 0021 0 08 0 003 C2 0 020 0 054 0 0008 0 0021 0 08 0 003 Shift fork fork shaft Fork I D 12 000 12 018 0 4724 0 4731 12 03 0 474 Claw thickness 5 93 6 00 0 233 0 236 5 9 0 23 Shift fork shaft O D 11 957 11 968 0 4707 0 4712 11 95 0 470 ITE...

Page 17: ...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 NC700X XA XD 514 2 5 cm3 17 4 0 08 US oz 18 1 0 09 Imp oz NC700S SA SD 518 2 5 cm3 17 5 0 08 US oz 18 2 0 09 Imp oz ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2 0 0 08 Cold tire pressure Driver only 290 kPa 2 90 kgf cm2 42 psi Drive...

Page 18: ...30 1 0650 27 060 1 0654 Caliper piston O D NC700XA XD SA SD Piston A 22 585 22 618 0 8892 0 8905 22 56 0 888 Piston B 26 918 26 968 1 0598 1 0617 26 91 1 059 Rear 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 14 000 14 043 0 5512 0 5529 14 055 0 5533 Master piston O D 13 957 13 984 0 5495 0 5506 13 945 0 5490 Caliper c...

Page 19: ...gh beam indicator LED Neutral indicator LED Engine oil pressure indicator LED High coolant temperature indicator LED MIL LED HISS indicator LED ABS indicator NC700XA XD SA SD LED Parking brake indicator NC700XD SD LED Fuse Main fuse 30 A PGM FI fuse 15 A Sub fuse 15 A x 2 7 5 A x 4 ABS fuse NC700XA XD SA SD 30 A x 2 7 5 A DCT fuse NC700XD SD 30 A 7 5 A ECT sensor resistance 40 C 104 F 1 0 1 3 kΩ 1...

Page 20: ...ange bolt and nut 39 4 0 29 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Seat cowl assembly screw 2 4 0 9 0 1 0 7 Brake tail license light mounting socket bolt 1 6 10 1 0 7 Reflector mounting nut 1 5 1 7 0 2 1 3 Turn signal light mounting screw 4 6 2 5 0 3 1 8 Luggage box lid assembly screw 9 4 0 9 0 1 0 7 Luggage box lid lock plate mounting screw 2 6 4 0 0 4 3 0 Luggage box lid mountin...

Page 21: ... cover screw 4 4 1 5 0 2 1 1 Rear brake reservoir mounting bolt 1 6 10 1 0 7 Rear master cylinder push rod lock nut 1 8 17 1 7 13 Parking brake adjuster bolt lock nut NC700XD SD 1 8 17 1 7 13 Sidestand pivot bolt 1 10 See page 3 27 Apply grease to the sliding surface Sidestand pivot nut 1 10 39 4 0 29 U nut Sidestand switch bolt 1 6 10 1 0 7 ALOC bolt replace with a new one ITEM Q TY THREAD TORQUE...

Page 22: ...aft maintenance cap 1 36 4 0 0 4 3 0 See page 10 11 See page 10 28 Cam chain tensioner bolt 2 6 12 1 2 9 Cam sprocket bolt 1 10 56 5 7 41 Apply engine oil to the threads and seating surface Water hose band screw 6 See page 10 16 Insulator band screw 1 5 See page 10 25 Cylinder head special bolt 6 9 44 4 5 32 Apply molybdenum oil solution to the threads and seating surface ITEM Q TY THREAD TORQUE R...

Page 23: ...ter bolt 1 8 23 2 3 17 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 Drum shifter guide plate bolt 2 6 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 Clutch line EOP sensor 3 10 19 6 2 0 14 EOT sensor 1 10 14 1 4 10 Apply engine oil to the threads and seatin...

Page 24: ...mm bolt 1 10 39 4 0 29 Crankcase 8 mm bolt 3 8 24 2 4 18 Crankcase 8 x 45 mm bolt 1 8 24 2 4 18 Apply locking agent to the threads Coating width 6 5 1 0 mm 0 26 0 04 in from tip Crankcase 6 mm bolt 8 6 12 1 2 9 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Crankpin bearing cap bolt 4 6 10 1 0 7 90 See page 15 7 See page 15 12 Replace with a new one Apply engine oil to the threads and sea...

Page 25: ... 2 8 30 3 1 22 ALOC bolt replace with a new one Steering stem adjusting nut 1 26 23 2 3 17 See page 17 38 Apply engine oil to the threads Steering stem adjusting lock nut 1 26 See page 17 38 Steering stem nut 1 24 103 10 5 76 See page 17 38 Clutch lever pivot bolt NC700X XA S SA 1 6 1 0 0 1 0 7 Apply grease to the sliding surface Clutch lever pivot nut NC700X XA S SA 1 6 6 0 0 6 4 4 ITEM Q TY THRE...

Page 26: ...locking agent to the threads Rear master cylinder push rod lock nut 1 8 17 1 7 13 Front brake caliper pin 1 8 22 2 2 16 Apply locking agent to the threads Apply 0 4 g 0 01 oz silicone grease to the sliding surface Front brake caliper bracket pin 1 8 12 1 2 9 Apply locking agent to the threads Apply 0 4 g 0 01 oz silicone grease to the sliding surface Front brake caliper mounting bolt 2 8 30 3 1 22...

Page 27: ...ition switch mounting bolt 2 8 25 2 5 18 One way bolt replace with a new one Neutral switch 1 10 12 1 2 9 Parking brake switch screw NC700XD SD 1 4 1 2 0 1 0 9 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Cam chain tensioner set plate bolt 1 6 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 Camshaft cap 1 20 30 3 ...

Page 28: ...ft fork guide area and guide pin Shift fork shaft outer surface Main journal bearing sliding surface Crankpin bearing sliding surface Crankshaft thrust surface Engine oil Oil filter cartridge O ring Oil filler cap O ring Timing hole cap O ring Crankshaft hole cap O ring Clutch oil filter cover O ring NC700XD SD Oil joint pipe O ring NC700XD SD Clutch oil guide collar O rings NC700XD SD Oil straine...

Page 29: ... step sliding area Cable lubricant 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 540 or equivalent Handlebar grip rubber inside Brake pad retainer mating surface Silicone grease Front brake lever sliding surface and lever to master piston contacting area 0 10 g 0 004 ...

Page 30: ... NC700X XA NC700XD RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE CLUTCH SWITCH WIRE BRAKE LIGHT SWITCH CONNECTOR RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE BRAKE LIGHT SWITCH CONNECTOR RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLE B THROTTLE CABLE A ...

Page 31: ...NC700SD RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE CLUTCH SWITCH WIRE BRAKE LIGHT SWITCH CONNECTOR RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE BRAKE LIGHT SWITCH CONNECTOR RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLE A THROTTLE CABLE B ...

Page 32: ...GNAL LIGHT 3P ORANGE CONNECTOR FRONT RIGHT TURN SIGNAL LIGHT 3P BLUE CONNECTOR POSITION LIGHT WIRE FRONT SUB HARNESS 6P BROWN CONNECTOR FRONT SUB HARNESS FRONT LEFT TURN SIGNAL LIGHT 3P ORANGE CONNECTOR FRONT RIGHT TURN SIGNAL LIGHT 3P BLUE CONNECTOR FRONT SUB HARNESS 6P BROWN CONNECTOR POSITION LIGHT WIRES ...

Page 33: ...RNESS 6P BROWN CONNECTOR HEADLIGHT 3P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 10P GRAY CONNECTOR IGNITION SWITCH 2P BROWN CONNECTOR THROTTLE CABLES IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR SWITCH WIRE BRAKE HOSE MAIN WIRE HARNESS Front side MAIN WIRE HARNESS Front side COMBINATION METER 16P GRAY CONNECTOR ...

Page 34: ...WN CONNECTOR HEADLIGHT 3P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 10P GRAY CONNECTOR IGNITION SWITCH 2P BROWN CONNECTOR THROTTLE CABLES IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE A to ABS MODULATOR MAIN WIRE HARNESS Front side MAIN WIRE HARNESS Front side COMBINATION METER 16P GRAY CONNECTOR ...

Page 35: ...LIGHT 3P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 3P BLACK CONNECTOR IGNITION SWITCH 2P BROWN CONNECTOR THROTTLE CABLES IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE A to ABS MODULATOR Front side MAIN WIRE HARNESS Front side COMBINATION METER 16P GRAY CONNECTOR MAIN WIRE HARNESS LEFT HANDLEBAR SWITCH 10P GRAY CONNECTOR ...

Page 36: ...LIZER RECEIVER 4P BLACK CONNECTOR RIGHT HANDLEBAR SWITCH 8P BLUE CONNECTOR BRAKE HOSE FRONT SUB HARNESS 6P BROWN CONNECTOR HEADLIGHT 3P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 10P GRAY CONNECTOR IGNITION SWITCH 2P BROWN CONNECTOR MAIN WIRE HARNESS IMMOBILIZER RECEIVER 4P BLACK CONNECTOR RIGHT HANDLEBAR SWITCH 8P BLUE CONNECTOR FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE D from ABS MODULATOR BRAKE...

Page 37: ...VER 4P BLACK CONNECTOR RIGHT HANDLEBAR SWITCH 8P BLUE CONNECTOR FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE D from ABS MODULATOR BRAKE SUB HOSE C from DELAY VALVE RIGHT HANDLEBAR SWITCH 7P GREEN CONNECTOR LEFT HANDLEBAR SWITCH 7P GREEN CONNECTOR RIGHT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER WIRE CLUTCH CABLE THROTTLE CABLE A THROTTLE CABLE B FRONT BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE IGNITI...

Page 38: ...ROTTLE CABLE A THROTTLE CABLE B FRONT BRAKE HOSE A to ABS MODULATOR LEFT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE CLUTCH SWITCH CONNECTORS RIGHT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER WIRE PARKING BRAKE CABLE THROTTLE CABLE A THROTTLE CABLE B FRONT BRAKE HOSE A to ABS MODULATOR LEFT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE ...

Page 39: ... LEFT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH 10P GRAY CONNECTOR IGNITION SWITCH 2P BROWN CONNECTOR TURN SIGNAL HAZARD RELAY No 1 IGNITION COIL IGNITION SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE COMBINATION METER 16P GRAY CONNECTOR FRONT SUB HARNESS 6P BROWN CONNECTOR ...

Page 40: ...EBAR SWITCH 10P GRAY CONNECTOR IGNITION SWITCH 2P BROWN CONNECTOR TURN SIGNAL HAZARD RELAY No 1 IGNITION COIL IGNITION SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE COMBINATION METER 16P GRAY CONNECTOR FRONT SUB HARNESS 6P BROWN CONNECTOR PARKING BRAKE CABLE LEFT HANDLEBAR SWITCH 3P BLACK CONNECTOR ...

Page 41: ...head dummyhead GENERAL INFORMATION NC700S SA CLUTCH CABLE TURN SIGNAL HAZARD RELAY No 1 IGNITION COIL No 2 IGNITION COIL No 1 SPARK PLUG WIRE BATTERY BOX DRAIN HOSE IAT SENSOR 2P BLACK CONNECTOR MAIN WIRE HARNESS ...

Page 42: ...d dummyhead GENERAL INFORMATION NC700SD PARKING BRAKE CABLE TURN SIGNAL HAZARD RELAY No 1 IGNITION COIL No 2 IGNITION COIL No 1 SPARK PLUG WIRE BATTERY BOX DRAIN HOSE IAT SENSOR 2P BLACK CONNECTOR MAIN WIRE HARNESS ...

Page 43: ...HANDLEBAR SWITCH WIRE BRAKE HOSE IMMOBILIZER RECEIVER 4P BLACK CONNECTOR RIGHT HANDLEBAR SWITCH 8P BLUE CONNECTOR IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR SWITCH WIRE CLUTCH CABLE THROTTLE CABLE A THROTTLE CABLE A THROTTLE CABLE A THROTTLE CABLE B THROTTLE CABLE B BRAKE HOSE ...

Page 44: ...VER WIRE RIGHT HANDLEBAR SWITCH WIRE CLUTCH CABLE FRONT BRAKE HOSE D from ABS MODULATOR BRAKE SUB HOSE C from DELAY VALVE FRONT BRAKE HOSE A to ABS MODULATOR FRONT BRAKE HOSE A to ABS MODULATOR FRONT WHEEL SPEED SENSOR 2P BLUE CONNECTOR THROTTLE CABLE B THROTTLE CABLE A THROTTLE CABLE A THROTTLE CABLE A THROTTLE CABLE B THROTTLE CABLE B FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE D from ABS MOD...

Page 45: ... SWITCH WIRE PARKING BRAKE CABLE FRONT BRAKE HOSE D from ABS MODULATOR BRAKE SUB HOSE C from DELAY VALVE FRONT BRAKE HOSE A to ABS MODULATOR FRONT BRAKE HOSE A to ABS MODULATOR FRONT WHEEL SPEED SENSOR 2P BLUE CONNECTOR THROTTLE CABLE B THROTTLE CABLE A THROTTLE CABLE A THROTTLE CABLE A THROTTLE CABLE B THROTTLE CABLE B FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE D from ABS MODULATOR BRAKE SUB ...

Page 46: ...1 41 dummyhead dummyhead GENERAL INFORMATION NC700X CLUTCH CABLE BRAKE HOSE ...

Page 47: ...dummyhead dummyhead GENERAL INFORMATION NC700XA FRONT BRAKE HOSE D from ABS MODULATOR FRONT WHEEL SPEED SENSOR WIRE CLUTCH CABLE BRAKE SUB HOSE C from DELAY VALVE FRONT BRAKE HOSE A to ABS MODULATOR Parallel ...

Page 48: ...yhead dummyhead GENERAL INFORMATION NC700XD FRONT BRAKE HOSE D from ABS MODULATOR FRONT WHEEL SPEED SENSOR WIRE BRAKE SUB HOSE C from DELAY VALVE FRONT BRAKE HOSE A to ABS MODULATOR PARKING BRAKE CABLE Parallel ...

Page 49: ...TION NC700S CLUTCH CABLE BRAKE HOSE THROTTLE CABLE B THROTTLE CABLE A SIPHON HOSE RESERVE TANK OVERFLOW HOSE HORN WIRES O2 SENSOR 1P BLACK CONNECTOR No 2 IGNITION COIL IGNITION COIL PRIMARY WIRES LEFT HANDLEBAR SWITCH WIRE CLUTCH SWITCH WIRE ...

Page 50: ...K OVERFLOW HOSE No 2 IGNITION COIL IGNITION COIL PRIMARY WIRES FRONT BRAKE HOSE D from ABS MODULATOR FRONT WHEEL SPEED SENSOR WIRE BRAKE SUB HOSE C from DELAY VALVE FRONT BRAKE HOSE A to ABS MODULATOR CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE CLUTCH SWITCH WIRE FRONT WHEEL SPEED SENSOR 2P BLUE CONNECTOR Parallel ...

Page 51: ...HON HOSE RESERVE TANK OVERFLOW HOSE No 2 IGNITION COIL IGNITION COIL PRIMARY WIRES FRONT BRAKE HOSE D from ABS MODULATOR FRONT WHEEL SPEED SENSOR WIRE BRAKE SUB HOSE C from DELAY VALVE FRONT BRAKE HOSE A to ABS MODULATOR PARKING BRAKE CABLE FRONT WHEEL SPEED SENSOR 2P BLUE CONNECTOR Parallel ...

Page 52: ...myhead GENERAL INFORMATION NC700X XA XD NC700X XA XD SEAT LOCK CABLE LUGGAGE BOX LID LOCK CABLE SEAT LOCK CABLE TURN SIGNAL HAZARD RELAY IGNITION COIL PRIMARY WIRE No 1 IGNITION COIL TURN SIGNAL HAZARD RELAY 4P CONNECTOR ...

Page 53: ...ead dummyhead GENERAL INFORMATION NC700S SA SD NC700S SA SD LUGGAGE BOX LID LOCK CABLE No 2 IGNITION COIL SEAT LOCK CABLE SIDESTAND SWITCH 3P GREEN CONNECTOR FUEL PUMP 1P BLACK CONNECTOR LUGGAGE BOX LID LOCK CABLE ...

Page 54: ...mmyhead dummyhead GENERAL INFORMATION NC700S SA SD LUGGAGE BOX LID LOCK CABLE DLC JUNCTION B 14P ORANGE CONNECTOR JUNCTION G 14P ORANGE CONNECTOR TURN SIGNAL HAZARD RELAY No 1 IGNITION COIL No 2 IGNITION COIL ...

Page 55: ...ON COIL PRIMARY WIRES IGNITION SWITCH 2P BROWN CONNECTOR DLC JUNCTION B 14P ORANGE CONNECTOR JUNCTION G 14P ORANGE CONNECTOR No 2 IGNITION COIL IGNITION COIL PRIMARY WIRES MAIN WIRE HARNESS CKP SENSOR 2P RED CONNECTOR STARTER MOTOR CABLE GROUND CABLE FUEL FEED HOSE STARTER RELAY SWITCH FUSE BOX LEFT HANDLEBAR SWITCH 10P GRAY CONNECTOR ...

Page 56: ... IGNITION SWITCH 2P BROWN CONNECTOR DLC JUNCTION B 14P ORANGE CONNECTOR JUNCTION G 14P ORANGE CONNECTOR No 2 IGNITION COIL IGNITION COIL PRIMARY WIRES MAIN WIRE HARNESS CKP SENSOR 2P RED CONNECTOR STARTER MOTOR CABLE GROUND CABLE FUEL FEED HOSE STARTER RELAY SWITCH FUSE BOX LEFT HANDLEBAR SWITCH 3P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 10P GRAY CONNECTOR ...

Page 57: ... 52 dummyhead dummyhead GENERAL INFORMATION NC700X XA S SA FUEL FEED HOSE BATTERY BOX DRAIN HOSE No 1 SPARK PLUG WIRE AIR CLEANER HOUSING DRAIN HOSE RADIATOR LOWER WATER HOSE FAN MOTOR 3P GRAY CONNECTOR ...

Page 58: ...GENERAL INFORMATION NC700XD SD FUEL FEED HOSE BATTERY BOX DRAIN HOSE No 1 SPARK PLUG WIRE AIR CLEANER HOUSING DRAIN HOSE RADIATOR LOWER WATER HOSE FAN MOTOR 3P GRAY CONNECTOR SHIFT PEDAL ANGLE SENSOR 3P BLACK CONNECTOR Optional ...

Page 59: ...XA CLUTCH CABLE No 2 SPARK PLUG WIRE RADIATOR UPPER WATER HOSE SIPHON HOSE O2 SENSOR WIRE O2 SENSOR 1P BLACK CONNECTOR HORN WIRES RESERVE TANK OVERFLOW HOSE ECT SENSOR 2P CONNECTOR FUEL FEED HOSE EOP SWITCH 1P GRAY CONNECTOR EOP SWITCH 1P GRAY CONNECTOR ...

Page 60: ...o 2 SPARK PLUG WIRE RADIATOR UPPER WATER HOSE SIPHON HOSE O2 SENSOR WIRE O2 SENSOR 1P BLACK CONNECTOR HORN WIRES RESERVE TANK OVERFLOW HOSE ECT SENSOR 2P CONNECTOR FUEL FEED HOSE EOP SWITCH 1P GRAY CONNECTOR EOP SWITCH 1P GRAY CONNECTOR PARKING BRAKE CABLE ...

Page 61: ... 2 SPARK PLUG WIRE RADIATOR UPPER WATER HOSE SIPHON HOSE O2 SENSOR WIRE O2 SENSOR 1P BLACK CONNECTOR HORN WIRES RESERVE TANK OVERFLOW HOSE ECT SENSOR 2P CONNECTOR FUEL FEED HOSE EOP SWITCH 1P GRAY CONNECTOR EOP SWITCH 1P GRAY CONNECTOR CLUTCH CABLE Upper side ...

Page 62: ...ARK PLUG WIRE RADIATOR UPPER WATER HOSE SIPHON HOSE O2 SENSOR WIRE O2 SENSOR 1P BLACK CONNECTOR HORN WIRES RESERVE TANK OVERFLOW HOSE ECT SENSOR 2P CONNECTOR FUEL FEED HOSE EOP SWITCH 1P GRAY CONNECTOR EOP SWITCH 1P GRAY CONNECTOR PARKING BRAKE CABLE Upper side ...

Page 63: ...d GENERAL INFORMATION NC700XD SD MAIN WIRE HARNESS MAIN WIRE HARNESS SHIFT SPINDLE ANGLE SENSOR WIRE CLUTCH LINE EOP SENSOR 3P BLACK CONNECTOR No 1 CLUTCH EOP SENSOR 3P GRAY CONNECTOR No 2 CLUTCH EOP SENSOR 3P GRAY CONNECTOR ...

Page 64: ...ERY BOX DRAIN HOSE FUEL TANK DRAIN HOSE B SIDESTAND SWITCH WIRE NEUTRAL SWITCH CONNECTOR ALTERNATOR WIRE VS SENSOR 3P BLACK CONNECTOR OPTION 6P CONNECTOR NEUTRAL SWITCH WIRE SIDESTAND SWITCH WIRE NEUTRAL SWITCH WIRE SIDESTAND SWITCH WIRE FUEL TANK DRAIN HOSE B ...

Page 65: ...SWITCH WIRE TR SENSOR WIRE NEUTRAL SWITCH SIDESTAND SWITCH WIRE BATTERY BOX DRAIN HOSE MAIN WIRE HARNESS Upper side MAIN WIRE HARNESS TR SENSOR SHIFT CONTROL MOTOR 2P BLACK CONNECTOR FUEL TANK DRAIN HOSE B TR SENSOR WIRE SIDESTAND SWITCH WIRE MAIN WIRE HARNESS SHIFT PEDAL ANGLE SENSOR 3P BLACK CONNECTOR Optional ...

Page 66: ...OTOR CABLE GROUND CABLE THROTTLE CABLES ECT SENSOR 2P CONNECTOR FUEL FEED HOSE INJECTOR 2P GRAY CONNECTORS BATTERY BOX DRAIN HOSE SENSOR UNIT 5P BLACK CONNECTOR No 2 SPARK PLUG WIRE No 1 SPARK PLUG WIRE CRANKCASE BREATHER HOSE WATER BYPASS HOSE Left side Right side Upper side Upper side ...

Page 67: ... MOTOR CABLE GROUND CABLE THROTTLE CABLES ECT SENSOR 2P CONNECTOR FUEL FEED HOSE INJECTOR 2P GRAY CONNECTORS BATTERY BOX DRAIN HOSE SENSOR UNIT 5P BLACK CONNECTOR No 2 SPARK PLUG WIRE CRANKCASE BREATHER HOSE WATER BYPASS HOSE Left side Right side Upper side Upper side No 1 SPARK PLUG WIRE ...

Page 68: ...LE THROTTLE CABLES ECT SENSOR 2P CONNECTOR FUEL FEED HOSE INJECTOR 2P GRAY CONNECTORS BATTERY BOX DRAIN HOSE SENSOR UNIT 5P BLACK CONNECTOR No 2 SPARK PLUG WIRE CRANKCASE BREATHER HOSE WATER BYPASS HOSE Left side Right side Upper side Upper side CLUTCH CABLE MAIN WIRE HARNESS No 1 SPARK PLUG WIRE Upper side ...

Page 69: ...LE THROTTLE CABLES ECT SENSOR 2P CONNECTOR FUEL FEED HOSE INJECTOR 2P GRAY CONNECTORS BATTERY BOX DRAIN HOSE SENSOR UNIT 5P BLACK CONNECTOR No 2 SPARK PLUG WIRE CRANKCASE BREATHER HOSE WATER BYPASS HOSE Left side Right side Upper side Upper side CLUTCH CABLE MAIN WIRE HARNESS No 1 SPARK PLUG WIRE Upper side ...

Page 70: ...THROTTLE CABLES ECT SENSOR 2P CONNECTOR FUEL FEED HOSE INJECTOR 2P GRAY CONNECTORS BATTERY BOX DRAIN HOSE SENSOR UNIT 5P BLACK CONNECTOR No 2 SPARK PLUG WIRE CRANKCASE BREATHER HOSE WATER BYPASS HOSE Left side Right side Upper side Upper side MAIN WIRE HARNESS No 1 SPARK PLUG WIRE Upper side PARKING BRAKE CABLE ...

Page 71: ...LS SIDESTAND SWITCH 3P GREEN CONNECTOR OPTION 6P CONNECTOR FUEL PUMP 1P BLACK CONNECTOR REAR BRAKE LIGHT SWITCH 3P BLACK CONNECTOR FUEL TANK DRAIN HOSE A SEAT LOCK CABLE GROUND TERMINALS SIDESTAND SWITCH 3P GREEN CONNECTOR OPTION 6P CONNECTOR FUEL PUMP 1P BLACK CONNECTOR REAR BRAKE LIGHT SWITCH 3P BLACK CONNECTOR ...

Page 72: ...REEN CONNECTOR OPTION 6P CONNECTOR ABS MODULATOR 25P CONNECTOR FRONT BRAKE PIPE B from FRONT MASTER CYLINDER FRONT BRAKE PIPE C to FRONT BRAKE CALIPER BRAKE SUB PIPE B to FRONT BRAKE CALIPER BRAKE SUB PIPE A to DELAY VALVE DELAY VALVE REAR BRAKE PIPE B from REAR MASTER CYLINDER REAR BRAKE PIPE C to PCV FUEL PUMP 1P BLACK CONNECTOR ...

Page 73: ...LATOR 25P CONNECTOR FRONT BRAKE PIPE B from FRONT MASTER CYLINDER FRONT BRAKE PIPE C to FRONT BRAKE CALIPER BRAKE SUB PIPE B to FRONT BRAKE CALIPER BRAKE SUB PIPE A to DELAY VALVE DELAY VALVE REAR BRAKE PIPE B from REAR MASTER CYLINDER REAR BRAKE PIPE C to PCV FUEL PUMP 1P BLACK CONNECTOR LINEAR SOLENOID VALVE 4P GREEN CONNECTOR SHIFT SPINDLE ANGLE SENSOR 3P GRAY CONNECTOR ...

Page 74: ...ONNECTOR OPTION 6P CONNECTOR ABS MODULATOR 25P CONNECTOR FRONT BRAKE PIPE B from FRONT MASTER CYLINDER FRONT BRAKE PIPE C to FRONT BRAKE CALIPER BRAKE SUB PIPE B to FRONT BRAKE CALIPER BRAKE SUB PIPE A to DELAY VALVE DELAY VALVE REAR BRAKE PIPE B from REAR MASTER CYLINDER REAR BRAKE PIPE C to PCV FUEL PUMP 1P BLACK CONNECTOR OPTION WIRE ...

Page 75: ...25P CONNECTOR FRONT BRAKE PIPE B from FRONT MASTER CYLINDER FRONT BRAKE PIPE C to FRONT BRAKE CALIPER BRAKE SUB PIPE B to FRONT BRAKE CALIPER BRAKE SUB PIPE A to DELAY VALVE DELAY VALVE REAR BRAKE PIPE B from REAR MASTER CYLINDER REAR BRAKE PIPE C to PCV FUEL PUMP 1P BLACK CONNECTOR LINEAR SOLENOID VALVE 4P GREEN CONNECTOR SHIFT SPINDLE ANGLE SENSOR 3P GRAY CONNECTOR OPTION WIRE ...

Page 76: ...BLACK CONNECTOR FUEL TANK BREATHER HOSE GROUND TERMINALS OPTION 6P CONNECTOR VS SENSOR 3P BLACK CONNECTOR CLUTCH CABLE ECM 33P BLACK CONNECTOR REAR BRAKE LIGHT SWITCH 3P BLACK CONNECTOR FUEL TANK BREATHER HOSE GROUND TERMINALS OPTION 6P CONNECTOR VS SENSOR 3P BLACK CONNECTOR CLUTCH CABLE OPTION WIRE OPTION WIRE ...

Page 77: ...to REAR BRAKE CALIPER REAR BRAKE PIPE C to PCV PCV DELAY VALVE REAR BRAKE PIPE D PCV to REAR BRAKE CALIPER GROUND TERMINAL FRONT BRAKE PIPE B from FRONT MASTER CYLINDER FRONT BRAKE PIPE C to FRONT BRAKE CALIPER BRAKE SUB PIPE B to FRONT BRAKE CALIPER BRAKE SUB PIPE A to DELAY VALVE REAR BRAKE PIPE B from REAR MASTER CYLINDER GROUND TERMINAL REAR BRAKE PIPE B REAR MASTER CYLINDER to ABS MODULATOR F...

Page 78: ... D PCV to REAR BRAKE CALIPER GROUND TERMINAL FRONT BRAKE PIPE B from FRONT MASTER CYLINDER FRONT BRAKE PIPE C to FRONT BRAKE CALIPER BRAKE SUB PIPE B to FRONT BRAKE CALIPER BRAKE SUB PIPE A to DELAY VALVE REAR BRAKE PIPE B from REAR MASTER CYLINDER GROUND TERMINAL REAR BRAKE PIPE B REAR MASTER CYLINDER to ABS MODULATOR FRONT BRAKE PIPE C ABS MODULATOR to FRONT BRAKE CALIPER Upper side PCM 33P BLAC...

Page 79: ...to REAR BRAKE CALIPER REAR BRAKE PIPE C to PCV PCV DELAY VALVE REAR BRAKE PIPE D PCV to REAR BRAKE CALIPER GROUND TERMINAL FRONT BRAKE PIPE B from FRONT MASTER CYLINDER FRONT BRAKE PIPE C to FRONT BRAKE CALIPER BRAKE SUB PIPE B to FRONT BRAKE CALIPER BRAKE SUB PIPE A to DELAY VALVE REAR BRAKE PIPE B from REAR MASTER CYLINDER GROUND TERMINAL REAR BRAKE PIPE B REAR MASTER CYLINDER to ABS MODULATOR F...

Page 80: ... D PCV to REAR BRAKE CALIPER GROUND TERMINAL FRONT BRAKE PIPE B from FRONT MASTER CYLINDER FRONT BRAKE PIPE C to FRONT BRAKE CALIPER BRAKE SUB PIPE B to FRONT BRAKE CALIPER BRAKE SUB PIPE A to DELAY VALVE REAR BRAKE PIPE B from REAR MASTER CYLINDER GROUND TERMINAL REAR BRAKE PIPE B REAR MASTER CYLINDER to ABS MODULATOR FRONT BRAKE PIPE C ABS MODULATOR to FRONT BRAKE CALIPER Upper side PCM 33P BLAC...

Page 81: ...MP UNIT 3P BLACK CONNECTOR BANK ANGLE SENSOR 2P BLACK CONNECTOR ALTERNATOR WIRE MAIN WIRE HARNESS FUEL FEED HOSE FUEL PUMP 1P BLACK CONNECTOR GROUND TERMINALS SIDESTAND SWITCH 3P GREEN CONNECTOR REAR WHEEL SPEED SENSOR 2P GRAY CONNECTOR FUEL PUMP UNIT 3P BLACK CONNECTOR BANK ANGLE SENSOR 2P BLACK CONNECTOR ALTERNATOR WIRE MAIN WIRE HARNESS FUEL FEED HOSE ...

Page 82: ...ONNECTOR GROUND TERMINALS SIDESTAND SWITCH 3P GREEN CONNECTOR REAR WHEEL SPEED SENSOR 2P GRAY CONNECTOR FUEL PUMP UNIT 3P BLACK CONNECTOR BANK ANGLE SENSOR 2P BLACK CONNECTOR ALTERNATOR WIRE MAIN WIRE HARNESS FUEL FEED HOSE JUNCTION D 24P CONNECTOR TR SENSOR 3P BLACK CONNECTOR ...

Page 83: ... dummyhead GENERAL INFORMATION NC700X XA FUEL TANK DRAIN HOSE A SEAT LOCK CABLE FUEL TANK DRAIN HOSE B FUEL FEED HOSE FUEL TANK BREATHER HOSE FUEL TANK DRAIN HOSE A Front side FUEL TANK BREATHER HOSE SEAT LOCK CABLE ...

Page 84: ...K CABLE FUEL TANK DRAIN HOSE B FUEL FEED HOSE FUEL TANK BREATHER HOSE FUEL TANK DRAIN HOSE A Front side FUEL TANK BREATHER HOSE SEAT LOCK CABLE OUTER MAINSHAFT SENSOR 3P BLACK CONNECTOR INNER MAINSHAFT SENSOR 3P BLACK CONNECTOR VS SENSOR 3P BLACK CONNECTOR EOT SENSOR 2P BLACK CONNECTOR ...

Page 85: ... dummyhead GENERAL INFORMATION NC700S SA FUEL TANK DRAIN HOSE A SEAT LOCK CABLE FUEL TANK DRAIN HOSE B FUEL FEED HOSE FUEL TANK BREATHER HOSE FUEL TANK DRAIN HOSE A Front side FUEL TANK BREATHER HOSE SEAT LOCK CABLE ...

Page 86: ...K CABLE FUEL TANK DRAIN HOSE B FUEL FEED HOSE FUEL TANK BREATHER HOSE FUEL TANK DRAIN HOSE A Front side FUEL TANK BREATHER HOSE SEAT LOCK CABLE OUTER MAINSHAFT SENSOR 3P BLACK CONNECTOR INNER MAINSHAFT SENSOR 3P BLACK CONNECTOR VS SENSOR 3P BLACK CONNECTOR EOT SENSOR 2P BLACK CONNECTOR ...

Page 87: ...OR RECTIFIER 2P BLACK CONNECTOR ALTERNATOR 3P BLACK CONNECTOR REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE A to ABS MODULATOR REAR BRAKE HOSE E PCV to REAR BRAKE CALIPER REGULATOR RECTIFIER 2P BLACK CONNECTOR ALTERNATOR 3P BLACK CONNECTOR REAR WHEEL SPEED SENSOR WIRE REAR BRAKE LIGHT SWITCH WIRE ...

Page 88: ... dummyhead GENERAL INFORMATION NC700X S NC700XA SA REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE REAR BRAKE HOSE A to ABS MODULATOR REAR BRAKE HOSE E from PCV REAR WHEEL SPEED SENSOR WIRE REAR BRAKE LIGHT SWITCH WIRE ...

Page 89: ...E HOSE A to ABS MODULATOR REAR BRAKE HOSE E from PCV REAR WHEEL SPEED SENSOR WIRE REAR BRAKE LIGHT SWITCH WIRE PARKING BRAKE CABLE REAR LEFT TURN SIGNAL LIGHT 2P ORANGE CONNECTOR REAR RIGHT TURN SIGNAL LIGHT 2P LIGHT BLUE CONNECTOR MAIN WIRE HARNESS BRAKE TAIL LICENSE LIGHT 3P CONNECTOR ...

Page 90: ...ead dummyhead GENERAL INFORMATION NC700X XA XD S SA SD Front side Left side Right side Right side Lower side Front side Left side Front side Front side Upper side Upper side Upper side 30 22 5 INDEX MARK 180 22 5 ...

Page 91: ...hotochemical smog when subject to sunlight 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 Blow by gas is returned to ...

Page 92: ...o its sale or delivery to the ultimate customer or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing of the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or p...

Page 93: ... 1 signal to the combination meter These signals are forwarded to the combination meter or ECM by asynchronous communication via one wire This wire is called the TXD RXD line serial communication line WHEN THERE IS A PROBLEM IN THE TXD RXD LINE When an open or short circuit occurs in the TXD RXD line the combination meter indicate the following MIL 1 come on Engine oil pressure indicator 2 come on...

Page 94: ...ation meter and PCM via one wire This wire is called the TXD RXD line serial communication line WHEN THE SERIAL COMMUNICATION IS ABNORMAL If there is any problem in the TXD RXD line the combination meter shows following MIL 1 and engine oil pressure indicator 2 stay on Shift indicator 3 is blinking Tachometer high coolant temperature indicator and HISS indicator do not come on TXD RXD line trouble...

Page 95: ... The linear solenoid valves are located inside the right crankcase cover and inner mainshaft has to oil passages instead of the oil feed pipes For linear solenoid valve location page 12 100 For clutch operating oil flow page 9 3 The transmission shift mechanism and electric shift control system are same as the conventional dual clutch transmission No 1 CLUTCH ASSEMBLY PRIMARY DRIVEN GEAR ASSEMBLY ...

Page 96: ... 13 SIDE COWL NC700S SA SD 2 13 SHROUD SIDE COVER NC700X XA XD 2 14 SHELTER SIDE COVER NC700S SA SD 2 15 CENTER COVER NC700X XA XD 2 16 LUGGAGE BOX LID 2 17 LUGGAGE BOX LID HINGE ASSEMBLY 2 19 LUGGAGE BOX 2 19 WINDSCREEN 2 23 FRONT SIDE COWL NC700X XA XD 2 24 METER STAY NC700X XA XD 2 24 FRONT UNDER COVER NC700X XA XD 2 25 INNER UPPER COVER NC700X XA XD 2 25 HEADLIGHT FRONT CENTER COWL NC700X XA X...

Page 97: ... 28 5 Seat cowl page 2 9 14 Luggage box lid page 2 17 23 Lower cowl page 2 28 6 Tail light cover page 2 10 15 Luggage box page 2 19 24 Left rear cover page 2 29 7 Mud guard page 2 11 16 Windscreen page 2 23 25 Battery box page 2 31 8 Rear fender A page 2 12 17 Front side cowl page 2 24 26 Center cross plate page 2 32 9 Rear fender B page 2 12 18 Meter stay page 2 24 18 Meter stay 16 Windscreen 3 G...

Page 98: ...de cover page 2 30 6 Tail light cover page 2 10 16 Windscreen page 2 23 7 Mud guard page 2 11 17 Front side cowl page 2 24 26 Guard pipe page 2 30 8 Rear fender A page 2 12 18 Meter stay page 2 24 27 Battery box page 2 31 9 Rear fender B page 2 12 19 Front under cover page 2 25 28 Center cross plate page 2 32 10 Air duct page 2 13 20 Inner upper cover page 2 25 18 Meter stay 16 Windscreen 3 Grab r...

Page 99: ... page 2 15 20 Left rear cover page 2 29 5 Seat cowl page 2 9 13 Luggage box lid page 2 18 21 Battery box page 2 31 6 Tail light cover page 2 10 14 Luggage box page 2 20 22 Center cross plate page 2 32 7 Mud guard page 2 11 15 Windscreen page 2 23 23 Rear fender mud guard U type page 2 10 8 Rear fender A page 2 12 16 Headlight stay page 2 27 15 Windscreen 3 Grab rail 6 Tail light cover 8 Rear fende...

Page 100: ...Luggage box page 2 20 22 Guard pipe page 2 30 6 Tail light cover page 2 10 15 Windscreen page 2 23 23 Battery box page 2 31 7 Mud guard page 2 11 16 Headlight stay page 2 27 24 Center cross plate page 2 32 8 Rear fender A page 2 12 17 Headlight cover page 2 27 25 Rear fender mud guard U type page 2 10 9 Rear fender B page 2 12 18 Front fender page 2 28 1 Pillion seat 2 Single seat 3 Grab rail 4 Ce...

Page 101: ...TING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Seat cowl assembly screw 2 4 0 9 0 1 0 7 Brake tail license light mounting socket bolt 1 6 10 1 0 7 Reflector mounting nut 1 5 1 7 0 2 1 3 Turn signal light mounting screw 4 6 2 5 0 3 1 8 Luggage box li...

Page 102: ...rom the single seat Install the grommets and collars to the single seat Install the single seat by inserting its hook 5 into the seat bracket 6 under the luggage box hinge bracket Install and tighten the mounting bolts securely Close the pillion seat REMOVAL INSTALLATION NC700S SA SD Open the pillion seat using the ignition key Remove the mounting socket bolts 1 and washers 2 Remove the single sea...

Page 103: ...t to let the collars fall into the seat cowl Remove the collars from the grab rail If necessary remove the clips 10 washers 11 and pillion seat hinge from the right grab rail Installation is in the reverse order of removal CENTER SEAT COWL REMOVAL INSTALLATION Open the pillion seat using the ignition key Remove the socket bolts 1 Pull up the center seat cowl rear end and release the center seat co...

Page 104: ... 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 Installation is in the reverse order of removal DISASSEMBLY ASSEMBLY Remove the center seat cowl page 2 8 Remove the seat cowl assembly screws 1 and separate the right and left seat cowls 2 Assembly is in the reverse order of disassembly 2 8 2 3 4 9 6 5 7 10 ...

Page 105: ...light 2P Light blue connector 3 Rear left turn signal light 2P Orange connector 4 Brake tail license light 3P connector 5 Remove the brake tail license light mounting socket bolt 1 and collar 2 Remove the socket bolts E ED F KO RU type 3 and brake tail license light assembly 4 and release the wire harnesses from the rear fender A Installation is in the reverse order of removal Route the wire harne...

Page 106: ...isassembly Align the tail light cover tabs with the brake tail license light slots Align the reflector tab 13 with the left tail light cover hole 14 MUD GUARD REMOVAL INSTALLATION Remove the brake tail license light assembly page 2 10 Remove the socket bolts 1 nuts 2 collars 3 and mud guard 4 If necessary remove the brake tail license light assembly mounting collars 5 and grommets 6 Installation i...

Page 107: ...ses Installation is in the reverse order of removal Route the wire harness properly page 1 25 REAR FENDER B REMOVAL INSTALLATION Remove the following Rear fender A page 2 12 Shroud side cover NC700X XA XD page 2 14 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 Release the tab 4 from the frame Release the main wire ha...

Page 108: ...ng it rearward and remove the air duct 4 Installation is in the reverse order of removal SIDE COWL NC700S SA SD LEFT SIDE COWL REMOVAL INSTALLATION Remove the single seat page 2 7 Open the luggage box lid using the ignition key Remove the trim clip 1 and socket bolts 2 Remove the left side cowl 3 by releasing the side cowl tabs 4 from the right side cowl and side cover Installation is in the rever...

Page 109: ...hinge bracket and side cover Remove the screw 5 and center cover 6 Installation is in the reverse order of removal SHROUD SIDE COVER NC700X XA XD REMOVAL INSTALLATION Remove the following Seat cowl page 2 9 Air duct page 2 13 Remove the trim clips 1 screw 2 and socket bolts 3 Remove the shroud side cover 4 by releasing the side cover tabs 5 from the grommet 6 and step holder 7 Installation is in t...

Page 110: ...AL INSTALLATION Remove the following Seat cowl page 2 9 Side cowl page 2 13 Right side Release the front wheel speed sensor 2P Blue connector NC700SA SD 1 from the side cover Remove the trim clip 2 and socket bolts 3 Remove the shelter side cover 4 by releasing the side cover tabs 5 from the grommet 6 and step holder 7 Installation is in the reverse order of removal Route the seat lock cable 8 to ...

Page 111: ...the air duct page 2 13 Remove the trim clips 1 and socket bolts 2 Lift the center cover 3 and remove the trim clip screws 4 right cable under cover 5 and left cable under cover 6 Be careful not to damage the center cover cable under cover and cable by lifting the center cover too far Disconnect the seat lock cable 7 and luggage box lid lock cable 8 from the center cover and remove it Installation ...

Page 112: ...y Align the seat lock tab 8 with the clip and cable guide cutouts 9 LUGGAGE BOX LID REMOVAL INSTALLATION NC700X XA XD Open the luggage box lid using the ignition key Remove the luggage box assembly screw long 1 and disconnect the band 2 Remove the following Luggage box lid mounting socket bolts 3 Luggage box lid lock plate mounting screw 4 Luggage box lid assembly screws 5 Inner luggage box lid 6 ...

Page 113: ...k plate mounting screw 4 Luggage box lid assembly screws 5 Inner luggage box lid 6 Luggage box lid lock plate 7 Center luggage box lid 8 Left luggage box lid 9 Right luggage box lid 10 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 4 0 N m 0 4 kgf m 3 0 lbf ft Luggage box lid mounting sock...

Page 114: ...tallation is in the reverse order of removal LUGGAGE BOX REMOVAL INSTALLATION NC700X XA XD Remove the following Shroud side cover page 2 14 Center cover page 2 16 Release the following Turn signal hazard relay 1 from the luggage box tab Seat lock cable 2 from the luggage box cable guides Option 6P connector 3 from the luggage box Remove the bolts 4 socket bolts 5 and luggage box 6 Installation is ...

Page 115: ...t lock assembly 3 Release the luggage box lid lock cable 4 Release the following Turn signal hazard relay 5 from the luggage box tab Option 6P connector 6 from the luggage box Remove the bolts 7 socket bolts 8 and luggage box 9 Installation is in the reverse order of removal For luggage box lid removal installation page 2 18 Route the cable properly page 1 25 6 2 4 1 3 7 5 4 9 8 ...

Page 116: ...e the socket bolts 6 and luggage box lid catch 7 Remove the socket bolts and luggage box lid hinge assembly Remove the luggage box lid hinge nut 8 washers 9 hinge bolt 10 and hinge 11 from the hinge bracket 12 Assembly is in the reverse order of disassembly Align the luggage box lid catch holes 13 with the luggage box tabs 14 Apply grease to the luggage box lid catch sliding area TORQUE Luggage bo...

Page 117: ...h 6 Remove the socket bolts and luggage box lid hinge assembly Remove the luggage box lid hinge nut 7 washers 8 hinge bolt 9 and hinge 10 from the hinge bracket 11 Assembly is in the reverse order of disassembly Align the luggage box lid catch hole 12 with the luggage box tab 13 Align the hinge bracket holes 14 with the luggage box tabs 15 Apply grease to the luggage box lid catch sliding area TOR...

Page 118: ...rse order of removal If you wish the windscreen position upward you can choose high position High position Install the special nuts to the upper holes Low position Install the special nuts to the lower holes REMOVAL INSTALLATION NC700S SA SD Remove the socket bolts 1 plastic washers 2 rubbers 3 and windscreen 4 Remove the special nuts 5 if necessary Installation is in the reverse order of removal ...

Page 119: ...t side cowl 5 Installation is in the reverse order of removal Route the wire harness properly page 1 25 METER STAY NC700X XA XD REMOVAL INSTALLATION Remove the following Windscreen page 2 23 Front side cowl page 2 24 Disconnect the combination meter 16P Gray connector 1 Remove the bolts 2 and meter stay 3 Installation is in the reverse order of removal For combination meter removal installation pa...

Page 120: ...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 Remove the trim clips 1 Release the tabs 2 and remove the inner upper cover 3 Installation is in the reverse order of removal 1 2 3 4 1 3 1 2 ...

Page 121: ... 3P Black connector 3 and front sub harness 6P Brown connector 4 Remove the bolts 5 Release the headlight boss 6 from the frame grommet 7 and remove the front center cowl headlight 8 Installation is in the reverse order of removal Route the wire harness properly page 1 25 DISASSEMBLY ASSEMBLY Remove the bolts 1 and front center cowl 2 from the headlight unit 3 Remove the socket bolts 4 and headlig...

Page 122: ... 3P Blue connector 2 Remove the bolts 3 washers 4 and headlight stays 5 from the headlight unit 6 Assembly is in the reverse order of disassembly HEADLIGHT COVER NC700S SA SD REMOVAL INSTALLATION Remove the headlight headlight stay page 2 27 Remove the following Bolt 1 Main wire harness clamp 2 Bolts 3 Brake hose clamp NC700S 4 Washer NC700SA SD 5 Wire band NC700SD 6 Release the following Front su...

Page 123: ...lector U type 7 grommets 8 front fender brace 9 and collars 10 from the front fender Installation is in the reverse order of removal Route the wire harness and hoses properly page 1 25 LOWER COWL REMOVAL INSTALLATION NC700X XA S SA 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 10 2 9 6 8 1 5 8 3 3 4 3 ...

Page 124: ...bly is in the reverse order of disassembly Align the left and right lower cowl holes 7 with center lower cowl bosses 8 LEFT REAR COVER REMOVAL INSTALLATION NC700X XA S SA Remove the gearshift arm pinch bolt 1 and gearshift arm 2 Remove the bolts 3 and left rear cover 4 Remove the drive chain guide plate 5 and collar 6 from the left rear cover Installation is in the reverse order of removal Align t...

Page 125: ...lower cowl page 2 29 Remove the socket bolts 1 and right engine side cover 2 Installation is in the reverse order of removal GUARD PIPE NC700XD SD REMOVAL INSTALLATION Remove the lower cowl page 2 29 Release the shift pedal angle sensor 3P Black connector Optional 1 from the guard pipe 2 and clamp 3 Remove the bolts 4 nuts 5 and guard pipe Release the fuel tank drain hose B 6 and battery box drain...

Page 126: ...or harness 6 Battery negative cable 7 Main wire harness 8 Junction B 14P Orange connector 9 Junction G 14P Orange connector 10 DLC 11 Battery positive cable 12 Remove the socket bolts 13 and battery box while releasing the grommets 14 from the frame bosses 15 Disconnect the battery box drain hose 16 Remove the grommet from the battery box Installation is in the reverse order of removal Route the c...

Page 127: ...le sensor 2P Black connector 6 Release the fuel tank drain hose A 7 from the ECM box Remove the wire band NC700S SA SD 8 and seat lock cable NC700S SA SD 9 from the center cross plate Remove the ABS modulator stay mounting bolts 10 and collars 11 Remove the bolts 12 and ground terminals 13 Remove the center cross plate to the left Installation is in the reverse order of removal Route the wire harn...

Page 128: ...ing its slits from the muffler bosses Installation is in the reverse order of removal Replace the gasket with a new one Align the muffler band tab with the muffler upper right slit 2 3 4 1 5 TORQUE Muffler cover socket bolt 10 N m 1 0 kgf m 7 lbf ft Muffler band bolt 17 5 N m 1 8 kgf m 13 lbf ft MUFFLER MOUNTING NUT GASKET 17 5 N m 1 8 kgf m 13 lbf ft WASHER MUFFLER MOUNTING BOLT RIGHT 10 N m 1 0 ...

Page 129: ...move the exhaust pipe joint nuts 4 Remove the exhaust pipe mounting nut bolt 5 washers 6 and exhaust pipe 7 Remove the exhaust pipe gasket 8 INSTALLATION Install a new exhaust pipe gasket 1 to the exhaust port of the cylinder head Install the exhaust pipe and exhaust pipe joint nuts 2 but do not tighten yet Install the exhaust pipe mounting bolt 1 washers 2 and nut 3 but do not tighten yet Install...

Page 130: ...ank guide 2 Route the O2 sensor wire properly page 1 25 Connect the O2 sensor 1P Black connector 3 Tighten the muffler mounting nut and band bolt securely page 2 32 Install the lower cowl page 2 28 STUD BOLT REPLACEMENT Remove the exhaust pipe muffler page 2 32 Thread two nuts onto the stud and tighten them together and use a wrench on them to turn the stud bolt out Install new stud bolts into the...

Page 131: ...MEMO dummyhead dummyhead ...

Page 132: ...LTER 3 13 CLUTCH OIL FILTER NC700XD SD 3 14 ENGINE IDLE SPEED 3 15 RADIATOR COOLANT 3 15 COOLING SYSTEM 3 16 DRIVE CHAIN 3 16 DRIVE CHAIN SLIDER 3 20 BRAKE FLUID 3 21 BRAKE PADS WEAR 3 22 BRAKE SYSTEM 3 23 BRAKE LIGHT SWITCH 3 24 BRAKE LOCK OPERATION NC700XD SD 3 24 HEADLIGHT AIM 3 25 CLUTCH SYSTEM NC700X XA S SA 3 26 SIDESTAND 3 27 SUSPENSION 3 28 NUTS BOLTS FASTENERS 3 29 WHEELS TIRES 3 29 STEER...

Page 133: ...d seating surface Camshaft maintenance cap 1 36 4 0 0 4 3 0 See page 3 12 Timing hole cap 1 14 10 1 0 7 Apply grease to the threads Crankshaft hole cap 1 30 15 1 5 11 Apply grease to the threads Engine oil drain bolt 1 12 30 3 1 22 Engine oil filter cartridge 1 20 26 2 7 19 Apply engine oil to the threads Oil filter boss 1 20 See page 3 14 Apply locking agent to the threads Coating width 6 5 1 0 m...

Page 134: ...g in unusually wet or dusty areas 3 Service more frequently when riding in rain or at full throttle 4 Replacement requires mechanical skill FREQUENCY ODOMETER READING NOTE 1 ANNUAL CHECK REGULAR REPLACE REFER TO PAGE x 1 000 km 1 12 24 36 48 ITEMS NOTE x 1 000 mi 0 6 8 16 24 32 FUEL LINE I I I I I 3 5 THROTTLE OPERATION I I I I I 3 5 AIR CLEANER NOTE 2 R R 3 7 CRANKCASE BREATHER NOTE 3 C C C C C 3...

Page 135: ...eas 3 Service more frequently when riding in rain or at full throttle 4 Replacement requires mechanical skill FREQUENCY ODOMETER READING NOTE 1 ANNUAL CHECK REGULAR REPLACE REFER TO PAGE x 1 000 km 1 12 24 36 48 ITEMS NOTE x 1 000 mi 0 6 8 16 24 32 FUEL LINE I I I I I 3 5 THROTTLE OPERATION I I I I I 3 5 AIR CLEANER NOTE 2 R R 3 7 CRANKCASE BREATHER NOTE 3 C C C C C 3 8 SPARK PLUG I R 3 8 VALVE CL...

Page 136: ...n Check that the throttle opens and automatically closes in all steering positions If the throttle grip does not return properly lubricate the throttle cable and overhaul and lubricate the throttle grip housing If the throttle grip still do not return properly replace the throttle cable With the engine idling turn the handlebar all the way to the right and left to ensure that the idle speed does n...

Page 137: ...oosen 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 Recheck the throttle operation Major adjustment is made with the lower adjuster nut at the throttle body Loosen the lock nut 1 and turn the adjuster nut 2 Tighten the lock nut while holding the adjuster nut Recheck the throttle operation 2 3 NC700X ...

Page 138: ... Check that the condition of the packings 6 replace them if necessary REMOVAL INSTALLATION NC700S SA SD Remove the following Side cowl page 2 13 Maintenance lid page 21 6 Remove the air cleaner housing cover screws 1 Remove the air cleaner housing cover 2 to the left side and disconnect the IAT sensor 2P Black connector 3 Release the air cleaner housing cover tabs 4 and remove the air cleaner elem...

Page 139: ...ousing drain hose and drain the deposits into a suitable container Reinstall the drain plug securely SPARK PLUG REMOVAL INSTALLATION Remove the lower cowl page 2 28 Disconnect the spark plug caps 1 Clean around the spark plug base with compressed air before removing the spark plug and be sure that no debris is allowed to enter the combustion chamber Remove the spark plug 1 using the equipped spark...

Page 140: ...e illustration To prevent damaging the iridium center electrode use a wire type feeler gauge to check the spark plug gap Check the spark plug gap between the center and side electrodes with a wire type feeler gauge 1 Make sure that the Φ 1 0 mm 0 04 in plug gauge does not insert between the gap If the gauge can be inserted into the gap replace the plug with a new one This motorcycle s spark plug i...

Page 141: ...nstalled in the frame Remove the cylinder head cover page 10 5 Remove the timing hole cap 1 crankshaft hole cap 2 and O rings 3 Remove the camshaft maintenance cap 1 and O ring 2 No 1 Cylinder Rotate the crankshaft counterclockwise and align the 1T mark 1 on the flywheel with the index notch 2 on the alternator cover Rotate the crankshaft counterclockwise and align the 2T mark 3 on the flywheel wi...

Page 142: ...t 1 and apply engine oil to the adjusting screw threads and seating surface Adjust by turning the adjusting screw 2 until there is a slight drag on the feeler gauge 3 Hold the adjusting screw and tighten the lock nut to the specified torque After tightening the lock nut recheck the valve clearance Apply engine oil to a new O ring 1 and install it to the camshaft maintenance cap 2 Temporarily Insta...

Page 143: ... Stop the engine and wait 2 3 minutes Remove the oil filler cap dipstick 1 and wipe it clean Reinstall the oil filler cap dipstick but do not screw it Remove the oil filler cap dipstick and check the oil level If the level is below or near the lower level 2 on the dipstick fill the recommended engine oil to the upper level 3 Check that the O ring 4 is in good condition replace it if necessary Appl...

Page 144: ...ine with the recommended engine oil page 3 12 Install the oil filler cap dipstick 1 Check the engine oil level page 3 12 Make sure there are no oil leaks ENGINE OIL FILTER Drain the engine oil page 3 13 Remove the oil filter cartridge 1 using the special tool 1 TORQUE 30 N m 3 1 kgf m 22 lbf ft 1 2 ENGINE OIL CAPACITY NC700X XA S SA 3 1 liters 3 3 US qt 2 7 Imp qt at draining 3 4 liters 3 6 US qt ...

Page 145: ...3 12 CLUTCH OIL FILTER NC700XD SD Replace the engine oil filter when the clutch oil filter is replaced Drain the engine oil page 3 13 Remove the lower cowl page 2 29 Remove the following Bolts 1 Clutch oil filter cover 2 Spring 3 Clutch oil filter 4 O ring 5 Install a new clutch oil fitter with the OUTSIDE mark 6 facing out Installation is in the reverse order of removal Replace the O ring with a ...

Page 146: ... freeplay page 3 5 IACV operation page 7 22 RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature The level should be between the UPPER and LOWER level lines with the motorcycle in an upright position If necessary add recommended coolant Remove the lower cowl page 2 28 Remove the reserve tank cap 1 and add the coolant to the UPPER leve...

Page 147: ... hose band screws page 8 10 DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Never inspect and adjust the drive chain while the engine is running Turn the ignition switch OFF support the motorcycle on its sidestand and shift the transmission into neutral Check the slack in the drive chain lower run midway between the sprockets NC700X XA XD Excessive chain slack 60 mm 2 4 in or more may damage the frame NC...

Page 148: ...hain cleaner designed specifically for O ring chains or a neutral detergent Use a soft brush if the drive chain is dirty Do not use a steam cleaner high pressure cleaner wire brush volatile solvent such as gasoline and benzene abrasive cleaner or a chain cleaner NOT designed specifically for O ring chains to clean the drive chain Inspect the drive chain for possible damage or wear Replace any driv...

Page 149: ... 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 Check the attaching bolts and nuts on the drive and driven sprockets If any are loose torque them Install the left rear cover page 2 29 1 2 3 TORQUE Drive sprocket bolt 1 54 N m 5 5 kgf m 40 lbf ft Driven sprocket nut 2 108 N m 11 0 kgf m 80 lbf ft 1 2 ...

Page 150: ...a new master link 1 with new O rings 2 from the inside of the drive chain and install a new plate 3 and O rings with the identification mark facing the outside Assemble the master link O rings and plate Make sure that the master link pins 1 are installed properly Measure the master link pin length projected from the plate Stake the master link pins TOOL Drive chain tool set 07HMH MR10103 STANDARD ...

Page 151: ...ck the staked area of the master link for cracks If there is any cracking replace the master link O rings and plate DRIVE CHAIN SLIDER Check the drive chain slider for wear or damage The drive chain slider must be replaced if it is worn to the wear indicator 1 page 18 16 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 1 1 1 ...

Page 152: ...evel is low check the entire system for leaks page 3 23 FRONT BRAKE Turn the handlebar to the left so that the reservoir is level and check the front brake fluid level through the sight glass If the level is near the LOWER level line 1 fill the recommended brake fluid Remove the following Screws 2 Reservoir cover 3 Set plate 4 Diaphragm 5 Fill the reservoir with DOT 4 brake fluid from a sealed con...

Page 153: ...rear brake reservoir mounting bolt Align the reservoir tab with the reservoir stay upper hole 12 Tighten the rear brake reservoir mounting bolt to the specified torque BRAKE PADS WEAR FRONT BRAKE PADS Check the brake pads for wear Replace the brake pads if either pad is worn to the bottom of wear limit grooves 1 For brake pad replacement NC700X S page 19 16 NC700XA XD SA SD page 19 17 REAR BRAKE P...

Page 154: ...pedal is applied Firmly apply the brake lever or pedal and check that no air has entered the system If the lever or pedal feels soft or spongy when operated bleed the air from the system For brake air bleeding NC700X S page 19 9 NC700XA XD SA SD page 19 12 Inspect the brake hose 1 and fittings for deterioration cracks and signs of leakage Tighten any loose fittings Replace hoses and fittings as re...

Page 155: ...ake light switch 1 so that the brake light comes on just prior to the brake actually being engaged If the light fails to come on adjust the switch so that the light comes on at the proper time Hold the switch body and turn the adjuster 2 Do not turn the switch body BRAKE LOCK OPERATION NC700XD SD INSPECTION Support the motorcycle using a safety stand or hoist raise the rear wheel off the ground Tu...

Page 156: ...r bolt Major adjustment is made with the parking brake caliper adjuster bolt 1 Loosen the lock nut 2 Turn the adjuster bolt clockwise until bolt resistance is felt brake pads contact with the brake disc Then turn the adjuster bolt 1 4 turn counterclockwise and tighten the lock nut to the specified torque while holding the adjuster bolt Recheck the parking brake operation HEADLIGHT AIM Support the ...

Page 157: ...ever The adjuster may be damaged if it is positioned too far out leaving minimal thread engagement Minor adjustment is made with the upper adjuster at the clutch lever Loosen the lock nut 1 and turn the adjuster 2 If the adjuster is threaded out near its limit and the correct freeplay cannot be obtained turn the adjuster all the way in and back out one turn Tighten the lock nut while holding the a...

Page 158: ... spring 1 for damage or loss of tension Check the sidestand 2 assembly for freedom of movement and lubricate the sidestand pivot if necessary Check the sidestand ignition cut off system Sit astride the motorcycle and raise the sidestand Start the engine with the transmission in neutral then with the clutch lever fully squeezed shift the transmission into gear Move the sidestand full down The engin...

Page 159: ...stand switch groove with the frame pin Align the sidestand switch tab with the sidestand hole Install and tighten a new sidestand switch bolt 2 to the specified torque SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brake and compressing the front suspension several times Check the entire assembly for signs of leaks damage or loose fasteners Replace dama...

Page 160: ...eel side to side Replace the bearings if any looseness to noted For swingarm service page 18 16 NUTS BOLTS FASTENERS Check that all chassis nuts screws and bolts are tightened to their correct torque values page 1 15 Check that all cotter pins safety clips hose clamps and cable stays are in place and properly secured WHEELS TIRES Support the motorcycle using a safety stand or hoist raise the front...

Page 161: ...les do not interfere with the handlebar rotation Check for steering stem bearings by grabbing the fork legs and attempting to move the front fork forward to backward If the handlebar moves unevenly binds or has vertical movement inspect the steering head bearings page 17 33 RECOMMENDED TIRE PRESSURE DRIVER ONLY FRONT 250 kPa 2 50 kgf cm2 36 psi REAR 290 kPa 2 90 kgf cm2 42 psi DRIVER AND PASSENGER...

Page 162: ...SHOOTING 4 7 PGM FI CONNECTOR LOCATIONS 4 8 PGM FI TROUBLESHOOTING INFORMATION 4 11 DTC INDEX 4 15 SENSOR UNIT POWER LINE INSPECTION 4 17 DTC TROUBLESHOOTING 4 21 MIL TROUBLESHOOTING 4 43 MIL CIRCUIT TROUBLESHOOTING 4 63 FUEL CUT RELAY 4 64 ECT SENSOR 4 64 BANK ANGLE SENSOR 4 65 ECM NC700X XA S SA PCM NC700XD SD 4 67 O2 SENSOR 4 69 ...

Page 163: ...TEM PGM FI SYSTEM PGM FI SYSTEM LOCATION NC700X XA S SA IGNITION SWITCH INJECTOR BANK ANGLE SENSOR DLC O2 SENSOR SENSOR UNIT MAP SENSOR TP SENSOR CKP SENSOR IACV ECT SENSOR FUEL PUMP ECM SIDESTAND SWITCH IAT SENSOR VS SENSOR EOP SWITCH ...

Page 164: ... dummyhead PGM FI SYSTEM NC700XD SD IGNITION SWITCH INJECTOR BANK ANGLE SENSOR DLC O2 SENSOR SENSOR UNIT MAP SENSOR TP SENSOR CKP SENSOR IACV ECT SENSOR FUEL PUMP PCM SIDESTAND SWITCH IAT SENSOR VS SENSOR EOP SWITCH ...

Page 165: ...Y G Y Br W R Bu Gr R P Bl V W Y G G 5 INJ1 4 INJ2 1 IG1 7 FLR ECM 17 16 15 3 IACV1B IACV2B Bl Br Bu G Gr Lg O Black Brown Blue Green Gray Light green Orange P R V W Y PINK Red Violet White Yellow DTC MIL number Short terminals for reading DTC MIL Engine does not start when detecting DTC MIL 1 12 23 22 11 33 ECM 33P CONNECTOR ECM side of male terminals 21 7 87 29 12 86 13 CKP SENSOR CLUTCH SWITCH S...

Page 166: ... V W Y G G B5 INJ1 B4 INJ2 B1 IG1 B7 FLR B17 B16 B15 B3 IACV1B IACV2B Bl Br Bu G Gr Lg O Black Brown Blue Green Gray Light green Orange P R V W Y PINK Red Violet White Yellow DTC MIL number Short terminals for reading DTC MIL Engine does not start when detecting DTC MIL 1 12 23 22 11 33 PCM 33P BLACK CONNECTOR PCM side of male terminals 1 12 23 22 11 33 PCM 33P GRAY CONNECTOR PCM side of male term...

Page 167: ...e O rings Replace them with new ones upon reassembly Use a digital tester for PGM FI system inspection The following color codes are used throughout this section SPECIFICATIONS TORQUE VALUES Bl Black Bu Blue Gr Gray O Orange R Red W White Br Brown G Green Lg Light green P Pink V Violet Y Yellow ITEM SPECIFICATIONS IAT sensor resistance at 20 C 68 F 2 2 2 7 kΩ ECT sensor resistance at 40 C 104 F 1 ...

Page 168: ...7 5 A ENG STOP Engine stalls hard to start rough idling 1 Inspect the engine idle speed page 3 15 2 Inspect the IACV page 7 22 3 Inspect the fuel supply system page 7 4 4 Inspect the battery charging system page 21 7 5 Inspect the ignition system page 5 6 Restricted fuel feed hose Contaminated deteriorated fuel Intake air leak Faulty MAP sensor Restricted fuel tank breather hose Afterburn when eng...

Page 169: ... NOTE 1 Remove the shroud side cover NC700X XA page 2 14 NOTE 1 Remove the side cowl NC700S SA page 2 13 NOTE 2 Remove the luggage box lid hinge assembly NC700XD SD page 2 19 ECM 33P BLACK CONNECTOR NOTE 1 PCM 33P GRAY CONNECTOR NOTE 2 PCM 33P BLACK CONNECTOR NOTE 2 ...

Page 170: ...Remove the center cover NC700X XA XD page 2 16 NOTE 5 Remove the luggage box NC700S SA SD page 2 20 NOTE 6 Remove the lower cowl page 2 28 BANK ANGLE SENSOR 2P BLACK CONNECTOR NOTE 3 IAT SENSOR 2P BLACK CONNECTOR NOTE 5 DLC NOTE 4 ECT SENSOR 2P CONNECTOR EOP SWITCH 1P GRAY CONNECTOR NOTE 6 O2 SENSOR 1P BLACK CONNECTOR NOTE 6 ...

Page 171: ...Remove the air cleaner housing page 7 14 NOTE 8 Remove the windscreen page 2 23 SENSOR UNIT 5P BLACK CONNECTOR NOTE 7 IACV 4P BLACK CONNECTOR NOTE 7 INJECTOR 2P GRAY CONNECTOR VS SENSOR 3P BLACK CONNECTOR COMBINATION METER 16P GRAY CONNECTOR NOTE 8 ...

Page 172: ...the hyphen are the sub code they detail the specific symptom of the component or function failure For example in the case of the TP sensor DTC 08 1 TP sensor voltage lower than the specified value DTC 08 2 TP sensor voltage higher than the specified value The MAP ECT TP and IAT sensor diagnosis will be made according to the voltage output of the affected sensor If a failure occurs the ECM PCM dete...

Page 173: ... engine stop switch check the DTC and freeze data Freeze data indicates the engine conditions when the first malfunction was detected ECM PCM reset The HDS pocket tester can reset the ECM PCM data including the DTC freeze data and some learning memory After the ECM PCM reset perform the TP sensor reset procedure page 7 19 DTC READOUT Start the engine and check the MIL 1 When the ignition switch is...

Page 174: ...not the MIL will not start blinking Note that the self diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking CIRCUIT INSPECTION INSPECTION AT ECM PCM CONNECTOR Always clean around and keep any foreign material away from the ECM PCM 33P connector s before disconnecting it A faulty PGM FI system is often related to poorly connected or corroded termina...

Page 175: ... 33P Black connector 1 and PCM 33P Gray connector 2 Connect the ECM test harness 1 between the main wire harness 2 and PCM 3 TEST HARNESS TERMINAL LAYOUT The ECM PCM 33P connector 1 terminals are numbered as shown in this illustration The ECM test harness terminals are same layout as for the ECM PCM 33P connector terminals as shown TOOL ECM test harness 33P 070MZ MCA0100 1 2 3 2 1 TOOL ECM test ha...

Page 176: ...lfunction Poor engine acceleration Pre program value 0 4 27 9 1 9 IAT sensor circuit low voltage less than 0 049 V IAT sensor or its circuit malfunction Engine operates normally Pre program value 35 C 95 F 4 28 4 48 9 2 9 IAT sensor circuit high voltage more than 4 946 V Loose or poor contact of the IAT sensor connector IAT sensor or its circuit malfunction Engine operates normally Pre program val...

Page 177: ...tes normally Engine stop function does not operate 4 38 84 1 84 CPC in the PCM malfunction Faulty PCM Gearshift system stops 4 40 4 59 86 1 86 Meter communication malfunction Open or short circuit in the TXD RXD wire Faulty combination meter Engine operates normally 4 40 4 60 87 1 87 EOP switch high voltage more than 1 001 V Loose or poor contact of the EOP switch connector Open circuit in the EOP...

Page 178: ...urn the ignition switch OFF Disconnect the sensor unit 5P Black connector 1 Turn the ignition switch ON and engine stop switch Measure the voltage at the wire harness side If the voltage within 4 75 5 25 V YES Turn the ignition switch OFF Connect the sensor unit 5P Black connector and start the DTC troubleshooting page 4 21 NO GO TO STEP 2 2 Sensor Unit Input Voltage Line Short Circuit Inspection ...

Page 179: ...P Black connector 4 and ECM PCM 33P connector Is there continuity YES Replace the ECM PCM with a known good one and recheck NO Open circuit in the Yellow red wire Open circuit in the Yellow violet wire Open circuit in the Green yellow wire Connection NC700X XA S SA Yellow red Yellow red Green yellow Green yellow NC700XD SD Yellow violet Yellow violet Green yellow Green yellow TOOL Test probe 07ZAJ...

Page 180: ... test harness to the ECM PCM 33P connector s NC700X XA S SA page 4 13 NC700XD SD page 4 14 Turn the ignition switch ON and engine stop switch Measure the voltage at the ECM test harness terminals Is the voltage within 4 75 5 25 V YES GO TO STEP 2 NO GO TO STEP 3 2 Sensor Unit Power Input Voltage Inspection 2 Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector 1 Turn the igni...

Page 181: ... 4 Sensor Unit Input Voltage Line Open Circuit Inspection Check for continuities between the ECM test harness 1 and sensor unit 5P Black connector 2 of the wire harness side Is there continuity YES Intermittent failure NO Open circuit in the Yellow red wire Open circuit in the Yellow violet wire Open circuit in the Green yellow wire Connection NC700X XA S SA Yellow red Ground NC700XD SD Yellow vio...

Page 182: ... unit power line normal YES GO TO STEP 3 NO Replace or repair the abnormal circuit 3 MAP Sensor Output Voltage Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector 1 Turn the ignition switch ON Measure the voltage at the sensor unit 5P Black connector of the wire harness side Is the voltage within 4 75 5 25 V YES GO TO STEP 5 NO GO TO STEP 4 4 MAP Sensor Output Lin...

Page 183: ...ion 1 Turn the ignition switch ON and engine stop switch Check the MAP sensor with the HDS pocket tester Is about 5 V indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the sensor unit 5P Black connector 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 17 Is the sensor unit power line normal YES GO TO STEP 3 NO Replace or repair the ab...

Page 184: ...ire DTC 7 1 ECT 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 ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the ECT sensor with the HDS pocket tester Is about 0 V indicated YES GO TO STEP 2 NO Intermittent failure 2 ECT Sensor Inspection T...

Page 185: ... and recheck DTC 7 2 ECT SENSOR HIGH VOLTAGE NC700X XA S SA Before starting the inspection check for loose or poor contact on the ECT sensor 2P connector and ECM 33P Black connector then recheck the DTC NC700XD SD Before starting the inspection check for loose or poor contact on the ECT sensor 2P connector and PCM 33P Gray connector then recheck the DTC If the ECM PCM is replaced perform the follo...

Page 186: ...pen Circuit Inspection Turn the ignition switch OFF Remove the jumper wire Disconnect the following ECM 33P Black connector NC700X XA S SA 1 PCM 33P Gray connector NC700XD SD 1 Check for continuities between the ECM PCM 33P connector and ECT sensor 2P connector 2 of the wire harness side Is there continuity YES Replace the ECM PCM with a known good one and recheck NO Open circuit in the Pink white...

Page 187: ...TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester with the throttle fully closed Is about 0 V indicated YES Intermittent failure NO GO TO STEP 2 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 17 Is the sensor unit power line normal YES GO TO STEP 3 NO Replace or repair the abnormal c...

Page 188: ...er Is DTC 8 1 indicated YES Replace the ECM PCM with a known good one and recheck NO Faulty original sensor unit TP sensor DTC 8 2 TP SENSOR HIGH 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 TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor...

Page 189: ...n 4 75 5 25 V YES Replace the ECM PCM with a known good one and recheck NO Open circuit in the Green yellow wire Open circuit in the Yellow red wire DTC 9 1 IAT 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 IAT Sensor System Inspection Turn the ignition switch ON and engine stop...

Page 190: ...sor 2P Black connector and PCM 33P Gray connector then recheck the DTC 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 IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the IAT sensor with the HDS pocket tester Is about 5 V indicated YES GO TO STEP 2 NO Intermitte...

Page 191: ...XD SD Before starting the inspection check for loose or poor contact on the VS sensor 3P Black and PCM 33P Black connector then recheck the DTC 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 VS Sensor System Inspection Erase the DTCs page 4 13 Test ride the motorcycle above 2 000 min 1 rpm Stop the...

Page 192: ...circuit in the Pink green wire NO GO TO STEP 5 5 VS Sensor Signal Line Open Circuit Inspection NC700X XA S SA 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 NC700XD SD Disconnect the PCM 33P Gray connector 3 Check for continuity between the VS sensor 3P Black con...

Page 193: ...e DTC 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 DTC 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 Injector System Inspection Erase the DTCs page 4 13 Turn the ignition switch ON and engine...

Page 194: ...Faulty injector 5 Injector Signal Line Open Circuit Inspection Disconnect the following ECM 33P Black connector NC700X XA S SA 1 PCM 33P Gray connector NC700XD SD 1 Check for continuity between the ECM PCM 33P connector and injector 2P Gray connector 2 of the wire harness side Is there continuity YES Replace the ECM PCM with a known good one and recheck NO Open circuit in the Pink yellow wire Open...

Page 195: ...rature is 80 C 176 F Test ride the motorcycle and check the O2 sensor with the HDS pocket tester Is the DTC 21 1 indicated YES GO TO STEP 2 NO Intermittent failure 2 O2 Sensor Short Circuit Inspection Turn the ignition switch OFF Disconnect the O2 sensor 1P Black connector 1 Check for continuity between the O2 sensor 1P Black connector of the wire harness side and ground Is there continuity YES Sh...

Page 196: ... 21 1 indicated YES Replace the ECM PCM with a known good one and recheck NO Faulty original O2 sensor and or O2 sensor cord DTC 29 1 IACV NC700X XA S SA Before starting the inspection check for loose or poor contact on the IACV 4P 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 IACV 4P Black connecto...

Page 197: ...onnector and IACV 4P Black connector 2 of the wire harness side Is there continuity YES GO TO STEP 4 NO Open circuit in the Yellow green or Gray red wire Open circuit in the Violet white or Pink black wire 4 IACV Resistance Inspection Measure the resistance at the IACV 4P Black connector 1 at the motor side Is the resistance within 110 150 Ω 25 C 77 F YES Replace the ECM PCM with a known good one ...

Page 198: ...rform 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 Check the bank angle sensor with the HDS pocket tester Is about 0 V indicated YES GO TO STEP 2 NO Intermittent failure 2 Bank Angle Sensor Power Input Line Short Circuit Inspection Turn the ign...

Page 199: ...pocket tester Is DTC 54 1 indicated YES Replace the ECM PCM with a known good one and recheck NO Faulty original bank angle sensor DTC 54 2 BANK ANGLE SENSOR HIGH VOLTAGE 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 DTC NC700XD SD Before starting the inspection check for loose ...

Page 200: ...CM 33P Gray connector NC700XD SD Check for continuity between the bank angle sensor 2P Black connector 1 of the wire harness side and ground Is there continuity YES Short circuit in the Black blue wire NO GO TO STEP 4 4 Bank Angle Sensor Output Line Open Circuit Inspection Check for continuity between the ECM PCM 33P connector 1 and bank angle sensor 2P Black connector 2 of the wire harness side I...

Page 201: ... the combination meter 16P Gray connector and PCM 33P Gray connector then recheck the DTC 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 Check the meter communication with the HDS pocket tester Is the DTC 86 1 i...

Page 202: ...ombination meter enters the communication diagnostic mode Measure the voltage at the ECM PCM 33P connector 1 of the wire harness side and ground Does the standard voltage exist YES GO TO STEP 5 NO Inspect the combination meter page 22 8 5 ECM Serial Line Output Voltage Inspection Turn the ignition switch OFF Disconnect the combination meter 16P Gray connector Connect the following ECM 33P Black co...

Page 203: ...ck 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 DTC NC700XD SD Before starting the inspection check for loose or poor contact on the combination meter 16P Gray connector EOP switch 1P Gray connector and PCM 33P Gray connector then recheck the DTC If the ECM PCM is replaced perform the following Key R...

Page 204: ... 1P Gray connector ECM 33P Black connector NC700X XA S SA PCM 33P Gray connector NC700XD SD Erase the DTCs page 4 13 Turn the ignition switch ON Check the EOP switch with the HDS Is the DTC 87 1 indicated YES Replace the ECM PCM with a known good one and recheck NO Faulty original EOP switch MIL TROUBLESHOOTING MIL 1 BLINK MAP SENSOR If the ECM PCM is replaced perform the following Key Registratio...

Page 205: ... the voltage at the sensor unit 5P Black connector of the wire harness side Is the voltage within 4 75 5 25 V YES Faulty sensor unit MAP sensor NO GO TO STEP 4 4 MAP Sensor Output 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 Is there continuity YES Short circuit in the Violet red wir...

Page 206: ...e or poor contact on the ECT sensor 2P connector and PCM 33P Gray connector then recheck the MIL blinking 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 ECT Sensor Output Voltage 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 Tur...

Page 207: ... resistance within 1 0 1 3 kΩ 40 C 104 F YES Replace the ECM PCM with a known good one and recheck NO Faulty ECT sensor 4 ECT Sensor Line Open Circuit Inspection Turn the ignition switch OFF Check for continuities between the ECM test harness and ECT sensor 2P connector 1 of the wire harness side Are there continuities YES GO TO STEP 5 NO Open circuit in the Pink white wire Open circuit in the Gre...

Page 208: ...t Voltage Inspection Turn the ignition switch ON and engine stop switch Measure the TP sensor output voltage at the ECM test harness terminals Is there standard voltage YES Intermittent failure NO GO TO STEP 3 3 TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector 1 Check for continuity between the sensor unit 5P Black connector ...

Page 209: ...ontact on the IAT sensor 2P Black connector and PCM 33P Gray connector then recheck the MIL blinking 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 IAT Sensor Output Voltage 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 Turn the...

Page 210: ...ls Is the resistance within 2 2 2 7 kΩ 20 C 68 F YES Replace the ECM PCM with a known good one and recheck NO Faulty IAT sensor 4 IAT Sensor Line Open Circuit Inspection Turn the ignition switch OFF Check for continuity between the IAT sensor 2P Black connector 1 of the wire harness side and ECM test harness Is there continuity YES GO TO STEP 5 NO Open circuit in the Gray blue wire Open circuit in...

Page 211: ... Sensor Pulse Inspection Support the motorcycle securely and raise the rear wheel off the ground Turn the ignition switch ON and engine stop switch Measure the voltage between the combination meter 16P Gray connector 1 and ground while slowly turning the rear wheel by hand Is the indicated voltage at the standard value YES Inspect the combination meter page 22 8 NO GO TO STEP 3 3 VS Sensor Input V...

Page 212: ...SD Before starting the inspection check for loose or poor contact on the VS sensor 3P Black connector and PCM 33P Black connector then recheck the MIL blinking If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 VS Sensor Pulse Inspection Support the motorcycle securely and raise the rear wheel off the ground Connect ...

Page 213: ... harness Is there continuity YES GO TO STEP 4 NO Open circuit in the Pink green wire 4 VS Sensor Signal Line Short Circuit Inspection Check for continuity between the VS sensor 3P Black connector 1 of the wire harness side and ground Is there continuity YES Short circuit in the Pink green wire NO GO TO STEP 5 5 VS Sensor Inspection Replace the VS sensor with a known good one page 22 18 Erase the D...

Page 214: ...nector 1 Turn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P Gray connector of the wire harness side and ground Does the standard voltage exist YES GO TO STEP 2 NO Open circuit in the Black wire 2 Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF Check for continuity between the injector 2P Gray connector 1 of the wire harness sid...

Page 215: ...r or O2 sensor cap and ECM 33P Black connector then recheck the MIL blinking NC700XD SD Before starting the inspection check for loose or poor contact on the O2 sensor 1P Black connector or O2 sensor cap and PCM 33P Gray connector then recheck the MIL blinking If the ECM PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure NC700XD SD page ...

Page 216: ... s NC700X XA S SA page 4 13 NC700XD SD page 4 14 Check for continuity between the ECM test harness and O2 sensor 1P Black connector 1 of the wire harness side Is there continuity YES GO TO STEP 4 NO Open circuit in the White green wire 4 O2 Sensor Line Open Circuit Inspection 2 Disconnect the O2 sensor cap 1 Check for continuity between the O2 sensor cap and O2 sensor 1P Black connector 2 of the s...

Page 217: ... for loose or poor contact on the IACV 4P Black 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 IACV 4P Black connector and PCM 33P Gray connector then recheck the MIL blinking If the ECM PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure...

Page 218: ... NC700XD SD page 4 14 Check for continuities between the ECM test harness and IACV 4P Black connector 1 of the wire harness side Is there continuity YES Replace the ECM PCM with a known good one and recheck NO Open circuit in the Yellow green or Gray red wire Open circuit in the Violet white or Pink black wire Connection Gray red Ground Yellow green Ground Violet white Ground Pink black Ground V W...

Page 219: ...ltage Inspection Turn the ignition switch OFF Disconnect the bank angle sensor 2P Black connector 1 Turn the ignition switch ON and engine stop switch Measure the voltage at the bank angle sensor 2P Black connector of the wire harness side and ground Does the standard voltage exist YES GO TO STEP 2 NO Open circuit in the Black white wire 2 Bank Angle Sensor Output Line Short Circuit Inspection Tur...

Page 220: ...angle sensor page 4 66 Is the bank angle sensor operation normal YES Replace the ECM PCM with a known good one and recheck No Faulty bank angle sensor MIL 84 BLINKS 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 Turn the ignition switch ON...

Page 221: ... page 4 14 Disconnect the following ECM 33P Black connector NC700X XA S SA PCM 33P Gray connector NC700XD SD Turn the ignition switch ON and engine stop switch while pushing and holding combination meter A button 1 and B button 2 over 10 seconds The combination meter enter the communication diagnostic mode Measure the voltage at the ECM test harness terminal and ground Does the standard voltage ex...

Page 222: ...sition over 10 seconds The ECM PCM enters the communication diagnostic mode Measure the voltage at the combination meter 16P Gray connector 1 of the wire harness side and ground Does the standard voltage exist YES Inspect the combination meter page 22 8 NO Replace the ECM PCM with a known good one and recheck 1 Connection Red blue Ground Standard 8 V or more Every 5 seconds 1 R Bu ...

Page 223: ...00XD SD page 12 120 1 EOP Switch 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 Disconnect the EOP switch 1P Gray connector 1 Check for continuity between the ECM test harness and the EOP switch 1P Gray connector of the wire harness side Is there continuity YES GO TO STEP 2 NO Open circuit in the Light g...

Page 224: ...icator 5 is blinking and the tachometer high coolant temperature indicator and HISS indicator do not come on inspect the TXD RXD line page 22 11 If the MIL stays on check as follows Turn the ignition switch OFF Remove the following Shroud side cover NC700X XA page 2 14 Side cowl NC700S SA page 2 13 Luggage box lid hinge assembly NC700XD SD page 2 19 Disconnect the following ECM 33P Black connector...

Page 225: ... is connected If there is no continuity only when the 12 V battery is connected replace the fuel cut relay ECT SENSOR REMOVAL INSTALLATION Drain the coolant page 8 6 Disconnect the ECT sensor 2P connector 1 Remove the ECT sensor 2 and O ring 3 Install a new O ring onto the ECT sensor and install them Tighten the ECT sensor to the specified torque Connect the ECT sensor 2P connector Fill the coolin...

Page 226: ...d 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 Installation is in the reverse order of removal Install the bank angle sensor with its UP mark 1 facing up 2 1 2 1 3 TORQUE Bank angle sensor mounting bolt 10 N m 1 0 kgf m 7 lbf ft 1 ...

Page 227: ... S SA page 4 13 NC700XD SD page 4 14 Remove the bank angle sensor page 4 65 Connect the bank angle sensor 2P Black connector Place the bank angle sensor horizontal as shown Turn the ignition switch ON and engine stop switch Measure the output voltage at the ECM test harness 1 terminals Incline the bank angle sensor approximately 60 to the left or right with keeping the ignition switch ON and engin...

Page 228: ...n is in the reverse order of removal If the ECM is replaced perform the Key Registration Procedures page 23 6 REMOVAL INSTALLATION 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 Release the band 3 from the PCM and remove the PCM from the ECM box Installation is in the reverse order of...

Page 229: ...ink 1 ECM PCM Power Input Voltage Inspection Remove the following Shroud side cover NC700X XA page 2 14 Side cowl NC700S SA page 2 13 Luggage box lid hinge assembly NC700XD SD page 2 19 Disconnect the following ECM 33P Black connector NC700X XA S SA 1 PCM 33P Gray connector NC700XD SD 2 Turn the ignition switch ON and engine stop switch Measure the voltage at the ECM PCM 33P connector 1 of the wir...

Page 230: ...r materials in the O2 sensor air hole The O2 sensor may be damaged if dropped Replace it with a new one if dropped Handle the O2 sensor with care Do not service the O2 sensor while it is hot REMOVAL Remove the lower cowl page 2 28 Release the O2 sensor wire from the clamp 1 and radiator reserve tank guide 2 Remove the radiator reserve tank page 8 14 Disconnect the O2 sensor cap 3 Remove the O2 sen...

Page 231: ... the O2 sensor cap 1 Take care not to tilt the O2 sensor cap when connecting the cap to the O2 sensor Do not turn the O2 sensor cap after connecting it Install the radiator reserve tank page 8 14 Install the O2 sensor wire to the clamp 2 and radiator reserve tank guide 3 Install the lower cowl page 2 28 TORQUE 24 5 N m 2 5 kgf m 18 lbf ft 1 2 3 1 ...

Page 232: ...5 1 5 dummytext 5 IGNITION SYSTEM SYSTEM LOCATION 5 2 SYSTEM DIAGRAM 5 3 SERVICE INFORMATION 5 4 TROUBLESHOOTING 5 5 IGNITION SYSTEM INSPECTION 5 6 IGNITION TIMING 5 9 IGNITION COIL 5 10 CKP SENSOR 5 11 ...

Page 233: ...BATTERY NEUTRAL SWITCH CKP SENSOR CLUTCH SWITCH MAIN FUSE 30 A ECM FUSE BOX ENGINE STOP SWITCH SIDESTAND SWITCH SPARK PLUGS BANK ANGLE SENSOR IGNITION COILS IGNITION SWITCH BATTERY NEUTRAL SWITCH CKP SENSOR MAIN FUSE 30 A PCM FUSE BOX ENGINE STOP SWITCH SIDESTAND SWITCH SPARK PLUGS BANK ANGLE SENSOR IGNITION COILS ...

Page 234: ... Bl W Br Bl Bl Bu Bu Y G G O Br Bl Y Bu G W G R W Y Y Y CLUTCH SWITCH Bl Bl Lg Br Br Bu Y Y Bu G W Y SPARK PLUG To NEUTRAL INDICATOR 8P BLUE 10P 14P GRAY W Y FUEL CUT RELAY Bl Br Bl Y Bu G W Y BATTERY MAIN FUSE 30 A Bl R IGNITION SWITCH ENGINE STOP SWITCH BANK ANGLE SENSOR CKP SENSOR No 2 IGNITION COIL SPARK PLUG PCM Bl R Bl Bl Black Br Brown Bu Blue G Green Lg Light green O Orange R Red W White Y...

Page 235: ... Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug For ECM PCM service page 4 67 Refer to following components informations Ignition switch page 22 24 Engine stop switch page 22 25 Bank angle sensor page 4 65 Sidestand switch page 22 28 Neutral switch page 22 27 The following color codes are used throughout this section SPEC...

Page 236: ...rcuit or loose connection in Green orange wire at the ECM PCM 5 An open circuit or loose connection in Blue yellow or Yellow blue wire between the ignition coil and ECM PCM 6 Faulty sidestand switch neutral diode NC700X XA S SA or neutral switch 7 Loose or poor connection or an open circuit in No 6 related wires Sidestand switch line Green white and Green Neutral switch line NC700X XA S SA Green r...

Page 237: ...tal multimeter 2 or use the Imrie diagnostic tester IGNITION COIL PRIMARY PEAK VOLTAGE Check all system connections before performing this inspection Loose connectors can cause incorrect readings If the system is disconnected incorrect peak voltage might be measured Check the cylinder compression and check that the spark plug is installed correctly in the cylinder head Disconnect the spark plug ca...

Page 238: ...he spark plugs are installed correctly in the cylinder head Disconnect the ECM 33P Black connector 1 page 4 67 Connect the peak voltage tester or adaptor probes to the ECM 33P Black connector terminals of the wire harness side Shift the transmission into neutral Turn the ignition switch ON and engine stop switch Crank the engine with the starter motor and measure the CKP sensor peak voltage If the...

Page 239: ...ved parts in the reverse order of removal CKP SENSOR PEAK VOLTAGE NC700XD SD Check the cylinder compression and check that the spark plugs are installed correctly in the cylinder head Disconnect the spark plug caps page 3 8 Connect the ECM test harness to the PCM 33P connectors page 4 14 Connect the peak voltage tester or adaptor probes to the ECM test harness 1 terminals Shift the transmission in...

Page 240: ...follow the checks described in the troubleshooting table page 5 5 For CKP sensor replacement page 5 11 Install the removed parts in the reverse order of removal IGNITION TIMING Warm up the engine Stop the engine and remove the timing hole cap Connect the timing light 1 to the spark plug wire Read the instructions for timing light operation Start the engine and let it idle The ignition timing is co...

Page 241: ...motor stay NC700S SA SD Remove the wire band 1 and spark plug wire 2 from the main wire harness Disconnect the primary wire connectors 1 from the ignition coil Remove the bolts 2 spacers 3 and ignition coil 4 from the ignition coil stay Installation is in the reverse order of removal Route the wire properly page 1 25 No 2 IGNITION COIL Remove the following Lower cowl page 2 28 Air cleaner housing ...

Page 242: ...A S SA Remove the right crankcase cover page 11 5 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 bolts threads page 1 23 Apply liquid sealant Three bond 1207B or equivalent to the CKP sensor wire grommet sealing surface REMOVAL INSTALLATIO...

Page 243: ... Installation is in the reverse order of removal Apply locking agent to the CKP sensor mounting bolt threads page 1 23 Apply locking agent to the right crankcase cover wire clamp bolt threads page 5 4 Apply sealant to the wire grommet seating surface and grommet mating surface TORQUE Right crankcase cover wire clamp bolt 12 N m 1 2 kgf m 9 lbf ft 1 3 2 ...

Page 244: ...ext 6 ELECTRIC STARTER SYSTEM LOCATION 6 2 SYSTEM DIAGRAM 6 3 SERVICE INFORMATION 6 4 TROUBLESHOOTING 6 5 STARTER MOTOR 6 8 STARTER RELAY SWITCH 6 10 NEUTRAL DIODE NC700X XA S SA 6 12 STARTER RELAY NC700XD SD 6 12 ...

Page 245: ...NC700XD SD STARTER MOTOR BATTERY STARTER RELAY SWITCH IGNITION SWITCH CLUTCH SWITCH NEUTRAL SWITCH FUSE BOX MAIN FUSE 30 A STARTER SWITCH ENGINE STOP SWITCH SIDESTAND SWITCH STARTER MOTOR BATTERY STARTER RELAY SWITCH IGNITION SWITCH FUSE BOX MAIN FUSE 30 A STARTER SWITCH ENGINE STOP SWITCH ...

Page 246: ... Bl NEUTRAL DIODE NEUTRAL SWITCH To NEUTRAL INDICATOR Bl Black G Green Lg Light green R Red Y Yellow W White SIDESTAND SWITCH Bl Bl Bl G R Y R R R Bl W Y Bl R Lg R Lg G R Bl Bl G W G R R Bl Y R W Y BATTERY STARTER MOTOR Bl Bl Bl Bl STARTER RELAY SWITCH MAIN FUSE 30 A Bl Black G Green R Red V Violet W White Y Yellow IGNITION SWITCH ENG STOP 7 5 A To PCM G V W STARTER SWITCH Bl W START RELAY ENGINE ...

Page 247: ... the starter motor quickly enough or supply adequate ignition current When servicing the starter system always follow the steps in the troubleshooting flow chart page 6 5 Refer to the following components information Ignition switch page 22 24 Starter switch page 22 25 Engine stop switch page 22 25 Neutral switch NC700X XA S SA page 22 27 Sidestand switch NC700X XA S SA page 22 28 Clutch switch NC...

Page 248: ...nspection Disconnect the starter relay switch connector and check the relay coil ground wire line as below for continuity 1 Green red terminal neutral diode neutral switch line with the transmission in neutral and clutch lever released 2 Green red terminal clutch switch sidestand switch in any gear except neutral and with the clutch lever pulled in and sidestand up Is there continuity YES GO TO ST...

Page 249: ...4 NO GO TO STEP 5 4 Starter Motor Inspection Turn the ignition switch OFF Apply battery voltage directly to the starter motor and check the operation Does the starter motor turn YES Poorly contacted battery positive cable or starter motor cable Faulty starter relay switch NO Faulty starter motor page 6 8 5 Relay Coil Input Line Inspection Check the relay coil input line of the starter relay switch...

Page 250: ...S GO TO STEP 2 NO Faulty clutch switch 2 Sidestand Switch Inspection Check the sidestand switch operation page 22 28 Is the sidestand switch operation normal YES Loose or poor contact connector Open circuit in wire harness NO Faulty sidestand switch Starter motor turns slowly Low battery voltage Poorly connected battery terminal cable Poorly connected starter motor cable Faulty starter motor Poorl...

Page 251: ...nd cable 5 Remove the starter motor 6 Remove the O ring 1 Installation is in the reverse order of removal Apply engine oil to a new O ring Route the cables properly page 1 25 DISASSEMBLY ASSEMBLY 4 6 2 3 1 4 5 TORQUE Starter motor terminal nut 10 N m 1 0 kgf m 7 lbf ft 1 ARMATURE TERMINAL BOLT POSITIVE BRUSHES BRUSH HOLDER SPRING NUT TERMINAL STOPPER INSULATOR REAR COVER WASHER NEGATIVE BRUSHES O ...

Page 252: ...as below Between the positive brush 2 and cable terminal 3 should be continuity Between the cable terminal and the rear cover should be No continuity Between the positive brush and rear cover should be No continuity Between positive brush and negative brush 4 should be No continuity ARMATURE Clean the metallic debris off between commutator bars 1 Check the commutator bars of the armature for disco...

Page 253: ...and engine stop switch Measure the voltage between the Yellow red wire terminal at the starter relay switch 4P Red connector 1 and ground If the battery voltage appears only when the starter switch is pushed with the ignition switch turned ON and engine stop switch the starter relay input voltage is normal GROUND LINE NC700X XA S SA Disconnect the starter relay switch 4P Red connector 1 Check for ...

Page 254: ...CK Remove the starter relay switch page 6 11 Connect a 12 V battery to the starter relay switch as shown There should be continuity between the cable terminals when the battery is connected and not continuity when the battery is disconnected REMOVAL INSTALLATION Remove the maintenance lid page 21 6 Release the starter relay switch shock rubber from the battery box tabs 1 Release the rubber cover 2...

Page 255: ...e is continuity in direction shown by the arrow the neutral diode is normal STARTER RELAY NC700XD SD INSPECTION Remove the maintenance lid page 21 6 Open the fuse relay box cover and remove the START RELAY 1 Connect an ohmmeter to the START RELAY 1 connector terminals Connect a 12 V battery to the START RELAY connector terminals as shown There should be continuity only when 12 V battery is connect...

Page 256: ... 1 7 dummytext 7 FUEL SYSTEM COMPONENT LOCATION 7 2 SERVICE INFORMATION 7 3 FUEL LINE REPLACEMENT 7 4 FUEL TANK 7 8 FUEL PUMP UNIT 7 10 AIR CLEANER HOUSING 7 14 THROTTLE BODY 7 15 INJECTOR 7 20 IACV 7 22 ...

Page 257: ...7 2 dummyhead dummyhead FUEL SYSTEM FUEL SYSTEM COMPONENT LOCATION ...

Page 258: ...nd debris from entering the throttle bore and air passages after the throttle body has been removed Clean them using a compressed air if necessary Do not loosen or tighten the white painted nut and screw of the throttle body Loosening or tightening them can cause throttle valve and idle control failure The parts of the throttle body not shown in this manual should not be disassembled For fuel leve...

Page 259: ... REMOVAL Do not bend or twist fuel feed hose FUEL PUMP SIDE Refer to fuel tank removal page 7 8 INJECTOR SIDE 1 Relieve the fuel pressure page 7 4 Check the fuel quick connect fitting 1 for dirt and clean if necessary Place a shop towel over the quick connect fitting 2 Pull and release the joint rubber 1 tabs from the retainer 3 Squeeze the retainer tabs 2 with the hand to release them from the lo...

Page 260: ...feed hose is disconnected Replace the retainer and joint rubber with the same manufacturer s item that was removed Do not bent or twist fuel feed hose 1 Insert a new retainer 1 into the connector 2 Align new retainer locking pawls with the connector grooves 2 Set a new joint rubber 1 as shown Then press the fuel feed hose into the quick connect fitting until both retainer pawls 2 lock with a CLICK...

Page 261: ... supply system page 7 6 FUEL PRESSURE NORMALIZATION 1 Connect the fuel pump 1P Black connector 1 Connect the battery negative cable page 21 6 2 Turn the ignition switch ON and engine stop switch Do not start the engine The fuel pump will run for about 2 seconds and fuel pressure will rise 3 Repeat 2 or 3 times and check that there is no leakage in the fuel supply system 4 Turn the ignition switch ...

Page 262: ...ing page 7 5 FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick connect fitting from the injector page 7 4 Place the end of the hose 1 into an approved gasoline container Temporarily connect the battery negative cable and fuel pump 1P Black connector Turn the ignition switch ON and engine stop switch Measure the amount of fuel flow The fuel pump operates for 2 seconds Repeat 5...

Page 263: ...t fitting page 7 9 Route the hose and wire properly page 1 25 FUEL PUMP SIDE QUICK CONNECT FITTING REMOVAL 1 Relieve the fuel pressure page 7 4 2 Check the fuel quick connect fitting 1 for dirt and clean if necessary Place a shop towel over the quick connect fitting 3 Pull and release the joint rubber 1 from the retainer 4 Hold the connector with one hand and squeeze the retainer tabs 2 with the o...

Page 264: ...connected Replace the retainer and joint rubber with the same manufacturer s item that was removed Do not bent or twist fuel feed hose 1 Insert a new retainer 1 into the connector 2 Align new retainer locking pawls with the connector grooves 2 Set a new joint rubber 1 as shown Then press the quick connect fitting onto the pipe until both retainer pawls 2 lock with a CLICK Align the quick connect f...

Page 265: ...ift and support the fuel tank page 7 8 Do not disconnect the quick connect fitting Disconnect the fuel pump unit 3P Black connector 1 Turn the ignition switch ON and engine stop switch Measure the voltage at the fuel pump unit 3P Black connector 1 terminals of the wire side There should be standard voltage for a few seconds If there is standard voltage replace the fuel pump unit If there is no sta...

Page 266: ...nit 2 and packing 3 Be careful not to damage the fuel level sensor float arm DISASSEMBLY INSPECTION Remove the screws 1 and Black wire terminals 2 Disconnect the Pink wire connector 3 and Blue wire connector 4 Remove the fuel pump unit assembly 1 and O ring 2 from the fuel pump stay 3 Remove the chamber 1 Release the tab 2 and remove the fuel level sensor assembly 3 from the fuel filter 4 1 3 2 3 ...

Page 267: ... as an assembly if necessary Remove the pressure regulator 1 and O ring 2 from the fuel filter 3 ASSEMBLY Replace the fuel filter 1 with a new one Install a new O ring 2 to the pressure regulator 3 Install the pressure regulator Install a new O ring 1 to the fuel pump 2 Install the fuel pump Align the Blue wire with the fuel filter groove 1 2 3 1 2 3 3 2 1 2 1 Align ...

Page 268: ...uel pump stay Align the fuel pump stay with fuel pump assembly grooves Install the screws 1 and Black wire terminals 2 Tighten the screws securely Connect the Pink wire connector 3 and Blue wire connector 4 INSTALLATION Install a new packing 1 onto the fuel pump unit 2 Always replace the packing with a new one Be careful not to pinch the dirt and debris between the fuel pump unit and packing Align...

Page 269: ...he sequence as shown Install the fuel tank page 7 8 AIR CLEANER HOUSING REMOVAL INSTALLATION Remove the air cleaner page 3 7 Remove the bolts 1 and radiator lower stay 2 Release the radiator boss from the radiator mounting rubber 3 Release the fan motor 3P Gray connector 1 air cleaner housing drain hose 2 and spark plug wire 3 from the radiator 1 2 TORQUE 12 N m 1 2 kgf m 9 lbf ft 1 1 2 3 4 5 6 1 ...

Page 270: ... the radiator mounting rubber slits facing down Align radiator lower stay slit with cylinder head tab THROTTLE BODY REMOVAL Remove the air cleaner housing page 7 14 Disconnect the sensor unit 5P Black connector 1 and IACV 4P Black connector 2 Loosen the throttle cable A adjuster lock nut 1 and adjusting nut 2 then disconnect the throttle cable A 3 from the throttle drum and cable stay Loosen the t...

Page 271: ... the throttle body It may cause incorrect throttle valve operation Do not loosen or tighten the white painted nut and screw 1 of the throttle body Loosening or tightening it can cause throttle valve and idle control failure Always clean around the throttle body before each sensor removal to prevent dirt and debris from entering the air passage For IACV removal page 7 22 Remove the sensor unit torx...

Page 272: ...Install a new O ring 1 to the throttle body properly When installing the sensor unit 2 to the throttle body align the following The TP sensor clip with the throttle valve boss The sensor unit tab with the throttle body hole Install and tighten the sensor unit torx screws 1 securely SENSOR UNIT O RING THROTTLE BODY SETTING PLATE IACV TORX SCREWS TORX SCREWS O RING 2 1 Align Align 1 ...

Page 273: ...ange Connect the throttle cables 1 to the throttle drum and throttle cable stay Route the cables properly page 1 25 Tighten the throttle cable B lock nut 2 securely Tighten the throttle cable A adjuster lock nut 3 securely Connect the sensor unit 5P Black connector 1 and IACV 4P Black connector 2 Route the wire harness properly page 1 25 Install the air cleaner housing page 7 14 Adjust the throttl...

Page 274: ...cial tool 4 Disconnect the ECT sensor 2P connector 1 Short the ECT sensor 2P connector terminals of the wire harness side with a jumper wire 2 5 Turn the ignition switch ON and engine stop switch then MIL will start blinking Disconnect the jumper wire while the MIL blinking within 10 seconds 6 After disconnection of the jumper wire the MIL 1 start to short blinking Connection Brown Green TOOL SCS ...

Page 275: ...2P Gray connectors 1 Remove the clip 2 from the fuel rail Remove the bolts 3 collars 4 and injector assembly 5 Remove the retainers 1 from the injector fuel rail If the MIL begins short blink 0 3 seconds the throttle valve fully closed position is reset If the MIL stays lit the throttle valve fully closed position is not reset repeat the reset procedure from step 1 MIL ON MIL OFF 0 1 seconds 1 2 s...

Page 276: ... engine oil to a new O ring 1 and a new seal ring 2 Install the cushion rubber 3 until it is fully seated Align the cushion rubber cut out with the injector connector Install the seal ring to the injector 4 being careful not to damage them Install the O ring to the injector Install the injectors 1 to the fuel rail 2 being careful not to damage the O ring Align the injector body with the fuel rail ...

Page 277: ...The IACV is installed on the throttle body and is operated by the step motor When the ignition switch is turned ON and engine stop switch the IACV operates for a few seconds Check the step motor operating beep sound with the ignition switch turned ON and engine stop switch Disconnect the IACV 4P Black connector 1 Remove the IACV setting plate torx screws 2 and setting plate 3 Remove the IACV 4 and...

Page 278: ...to the IACV 2 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 Install and tighten the IACV setting plate torx screws 4 securely Connect the IACV 4P Black connector 5 Install the air cleaner housing page 7 14 1 5 2 3 Align 4 1 Align ...

Page 279: ...MEMO dummyhead dummyhead ...

Page 280: ...SYSTEM SYSTEM FLOW PATTERN 8 2 SERVICE INFORMATION 8 3 TROUBLESHOOTING 8 4 SYSTEM TESTING 8 5 COOLANT REPLACEMENT 8 6 THERMOSTAT THERMOSTAT HOUSING 8 7 RADIATOR 8 9 WATER PUMP 8 12 RADIATOR RESERVE TANK 8 14 FAN CONT RELAY 8 15 ...

Page 281: ...8 2 dummyhead dummyhead COOLING SYSTEM COOLING SYSTEM SYSTEM FLOW PATTERN WATER PUMP RADIATOR RADIATOR CAP RADIATOR RESERVE TANK THERMOSTAT ...

Page 282: ...ding you Always let the engine and radiator cool down before removing the radiator cap ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1 69 liters 1 79 US qt 1 49 Imp qt At draining 1 41 liters 1 49 US qt 1 24 Imp qt Reserve tank 0 13 liter 0 14 US qt 0 11 Imp qt Radiator cap relief pressure 108 137 kPa 1 1 1 4 kgf cm2 16 20 psi Thermostat Begin to open 80 84 C 176 183 F Fully open 95 C 2...

Page 283: ...ses or water jacket Air in system Faulty cooling fan motor Faulty FAN CONT RELAY Faulty water pump Engine temperature too low Faulty high coolant temperature indicator or ECT sensor Thermostat stuck open Faulty FAN CONT RELAY Coolant leak Faulty water pump mechanical seal Deteriorated O rings Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or...

Page 284: ... 997 10 1 018 1 017 1 017 1 016 1 015 1 014 1 013 1 011 1 009 1 007 1 005 15 1 028 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 016 1 014 1 012 20 1 036 1 035 1 034 1 033 1 031 1 029 1 027 1 025 1 023 1 021 1 019 25 1 045 1 044 1 043 1 042 1 040 1 038 1 036 1 034 1 031 1 028 1 025 30 1 053 1 052 1 051 1 049 1 047 1 045 1 043 1 041 1 038 1 035 1 032 35 1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049...

Page 285: ...ure for at least 6 seconds COOLANT REPLACEMENT PREPARATION The effectiveness of coolant 1 decreases with the accumulation of rust or if there is a change in the mixing proportion during usage Therefore for best performance change the coolant regularly as specified in the maintenance schedule Mix only distilled low mineral water 2 with the antifreeze 3 REPLACEMENT AIR BLEEDING When filling the syst...

Page 286: ...line Bleed air from the system as follows 1 Shift the transmission into neutral Start the engine and let it idle for 2 3 minutes 2 Snap the throttle 3 or 4 times to bleed air from the system 3 Stop the engine and add coolant up to the filler neck if necessary Install the radiator cap 4 Check the level of coolant in the reserve tank and fill to the upper level if it is low After installation check ...

Page 287: ...ater hose band screw 1 and disconnect 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 2 5 1 4 3 Align 1 2 1 1 Align ...

Page 288: ...otection Keep flammable materials away from the electric heating element Do not let the thermostat or thermometer 1 touch the pan or you will get false reading Heat the water with an electric heating element to operating temperature for 5 minutes Suspend the thermostat 2 in heated water to check its operation Replace the thermostat if the valve stays open at room temperature or if it responds at t...

Page 289: ...3P Gray connector and remove the radiator Be careful not to damage the radiator fins Installation is in the reverse order of removal Tighten the water hose band screws to the specified range as shown Route the wire harness and hoses properly page 1 25 Make sure the radiator mounting rubber slits facing down Align radiator lower stay slit with cylinder head tab Fill the recommended coolant mixture ...

Page 290: ...flat surfaces Apply locking agent to the cooling fan mounting nut threads RADIATOR COOLING FAN SHROUD FAN MOTOR 2 7 N m 0 3 kgf m 2 0 lbf ft 1 0 N m 0 1 kgf m 0 7 lbf ft 8 4 N m 0 9 kgf m 6 2 lbf ft TORQUE Fan motor shroud mounting bolt 8 4 N m 0 9 kgf m 6 2 lbf ft Fan motor mounting screw 2 7 N m 0 3 kgf m 2 0 lbf ft Cooling fan mounting nut 1 0 N m 0 1 kgf m 0 7 lbf ft ...

Page 291: ... continuous coolant leakage from the bleed hole while operating the engine Replace the water pump as an assembly if necessary REMOVAL INSTALLATION Remove the lower cowl page 2 28 Drain the coolant page 8 6 Loosen the water hose band screw 1 and disconnect the radiator lower water hose 2 and water bypass hose 3 Remove the following 6 x 50 mm bolt 1 6 x 32 mm bolt 2 Loosen the 6 x 32 mm bolt 3 and 6...

Page 292: ...he water pump assembly Remove the 6 x 32 mm bolt 2 and sealing washer 3 Remove the following Water pump cover 1 Gasket 2 Plate 3 Remove the gasket 1 and dowel pins 2 from the water pump body Remove the water pump body 1 and O rings 2 from the cylinder head Do not disassemble the water pump body 1 2 3 2 3 1 2 1 2 1 2 Align ...

Page 293: ...r neck and bleed the air page 8 6 DISASSEMBLY ASSEMBLY When engine removed remove the water pump assembly Remove the following 6 x 32 mm bolts 1 Sealing washer 2 Water pump cover 3 Gasket 4 Plate 5 Gasket 6 Dowel pins 7 Water pump body 8 Assembly is in the reverse order of disassembly Do not disassemble the water pump body Replace the gasket and sealing washer with new ones RADIATOR RESERVE TANK R...

Page 294: ...ve tank with the recommended coolant page 3 15 FAN CONT RELAY INSPECTION Remove the maintenance lid page 21 6 Open the fuse relay box cover and remove the FAN CONT RELAY 1 Connect an ohmmeter to the FAN CONT RELAY 1 connector terminals Connect a 12 V battery to the FAN CONT RELAY connector terminals as shown There should be continuity only when 12 V battery is connected If there is no continuity o...

Page 295: ...MEMO dummyhead dummyhead ...

Page 296: ...9 dummytext 9 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 9 2 SERVICE INFORMATION 9 4 TROUBLESHOOTING 9 5 OIL PRESSURE INSPECTION 9 6 OIL PUMP NC700X XA S SA 9 6 OIL PUMP NC700XD SD 9 8 OIL STRAINER 9 11 ...

Page 297: ...d LUBRICATION SYSTEM LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM NC700X XA S SA CAMSHAFT PISTON CRANKSHAFT OIL FILTER CARTRIDGE OIL STRAINER PRESSURE RELIEF VALVE OIL PUMP COUNTERSHAFT MAINSHAFT EOP SWITCH ROCKER ARM SHAFT ...

Page 298: ...BRICATION SYSTEM NC700XD SD CAMSHAFT PISTON CRANKSHAFT OIL FILTER CARTRIDGE OIL STRAINER CLUTCH OIL PUMP COUNTERSHAFT MAINSHAFT EOP SWITCH ROCKER ARM SHAFT PRESSURE RELIEF VALVES EOP SENSOR LINEAR SOLENOID VALVE ENGINE OIL PUMP ...

Page 299: ... 3 1 liters 3 3 US qt 2 7 Imp qt After draining filter change 3 4 liters 3 6 US qt 3 0 Imp qt After disassembly 3 7 liters 3 9 US qt 3 3 Imp qt NC700XD SD After draining 3 2 liters 3 4 US qt 2 8 Imp qt After draining filter change 3 4 liters 3 6 US qt 3 0 Imp qt After disassembly 4 1 liters 4 3 US qt 3 6 Imp qt Recommended engine oil Honda 4 stroke motorcycle oil or an equivalent API service class...

Page 300: ...trainer Faulty oil pump Internal oil leak Incorrect oil being used No oil pressure Oil level too low Oil pressure relief valve stuck open Damaged oil pump Internal oil leak High oil pressure Oil pressure relief valve stuck closed Clogged oil filter oil gallery or metering orifice Incorrect oil being used Oil contamination Oil or filter not changed often enough Worn piston rings Oil emulsification ...

Page 301: ...mal operating temperature approximately 80 C 176 F and increase the engine speed to 6 000 min 1 rpm and read the oil pressure Stop the engine and remove the tools Install the following Engine oil filter cartridge page 3 13 Lower cowl page 2 28 OIL PUMP NC700X XA S SA REMOVAL INSTALLATION Remove the right crankcase cover page 11 5 Remove the bolts 1 and oil pump 2 TOOL Oil pressure gauge attachment...

Page 302: ...aft 5 drive pin 6 outer rotor 7 and inner rotor 8 from the oil pump body 9 Clean all disassembled parts thoroughly Assembly is in the reverse order of disassembly Dip all parts in clean engine oil INSPECTION If any portion of the oil pump is worn beyond the service limit replace the oil pump as an assembly Temporarily install the outer and inner rotors into the oil pump body Temporarily install th...

Page 303: ...TALLATION Remove the right crankcase cover page 12 97 Remove the bolts 1 and oil pump 2 Remove the O rings 1 and dowel pins 2 Installation is in the reverse order of removal Replace the O rings with new ones Align the oil pump shaft end with the balancer shaft groove SERVICE LIMIT 0 35 mm 0 014 in BODY CLEARANCE SERVICE LIMIT 0 12 mm 0 005 in SIDE CLEARANCE 1 2 1 2 Align ...

Page 304: ...ve 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 1 2 2 1 2 3 1 4 1 3 2 ...

Page 305: ...il pump cover Measure the rotor tip clearance Measure the pump body clearance Measure the side clearance using a straight edge and feeler gauge Engine oil pump SERVICE LIMIT 0 20 mm 0 008 in Clutch oil pump STANDARD 0 15 mm 0 006 in TIP CLEARANCE Engine oil pump SERVICE LIMIT 0 35 mm 0 014 in Clutch oil pump STANDARD 0 15 0 21 mm 0 006 0 008 in BODY CLEARANCE Engine oil pump SERVICE LIMIT 0 12 mm ...

Page 306: ...gine oil page 3 13 Remove the exhaust pipe muffler page 2 32 Loosen the bolts 1 in a crisscross pattern in 2 or 3 steps and remove the bolts and oil pan 2 DRIVE PIN OIL PUMP PLATE OIL PUMP BODY ENGINE OIL PUMP OUTER ROTOR ENGINE OIL PUMP INNER ROTOR OIL PUMP SHAFT DRIVE PIN DOWEL PIN OIL PUMP COVER DOWEL PIN CLUTCH OIL PUMP OUTER ROTOR CLUTCH OIL PUMP INNER ROTOR 1 2 ...

Page 307: ... while aligning the oil strainer boss with the crankcase groove Clean the oil pan mating surface thoroughly Apply liquid sealant Three Bond 1207B or equivalent to the oil pan mating surface as shown Do not apply more liquid sealant than necessary Install the oil pan 1 and bolts 2 Tighten the bolts in a crisscross pattern in 2 or 3 steps Install the exhaust pipe muffler page 2 32 Fill the engine wi...

Page 308: ...CYLINDER HEAD VALVES COMPONENT LOCATION 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 4 CYLINDER COMPRESSION TEST 10 5 CYLINDER HEAD COVER 10 5 ROCKER ARM 10 8 CAM CHAIN TENSIONER 10 11 CAMSHAFT 10 13 CYLINDER HEAD 10 16 ...

Page 309: ...d CYLINDER HEAD VALVES CYLINDER HEAD VALVES COMPONENT LOCATION 10 N m 1 0 kgf m 7 lbf ft 29 N m 3 0 kgf m 21 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 ...

Page 310: ...27 1 37491 1 38436 34 9027 1 37412 Runout 0 04 0 002 Camshaft journal O D 41 935 41 950 1 6510 1 6516 41 927 1 6507 Valve valve guide Valve stem O D IN 4 975 4 990 0 1959 0 1965 4 965 0 1955 EX 4 965 4 980 0 1955 0 1961 4 955 0 1951 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 5 04 0 198 Stem to guide clearance IN 0 010 0 037 0 0004 0 0015 0 075 0 0030 EX 0 020 0 047 0 0008 0 0019 0 085 0 0033 ...

Page 311: ...alve seating Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Worn cylinder piston or piston rings page 15 16 Compression too high overheating or knocking Excessive carbon build up on piston crown or on combustion chamber Excessive smoke Cylinder head Worn valve stem or valve guide Damaged stem seal Worn cylinder piston or piston rings page 15 ...

Page 312: ...pen the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising The maximum reading is usually reached within 4 7 seconds Low compression can be caused by Blown cylinder head gasket Improper valve clearance adjustment Valve leakage Worn piston ring or cylinder High compression can be caused by Carbon deposits in combustion chamber or on piston head CYL...

Page 313: ...nd disconnect the crankcase breather hose 1 Be careful not to damage the radiator fins Remove the cylinder head cover socket bolts 1 and mounting rubbers 2 Be careful not to damage the radiator fins Remove the cylinder head cover 1 from the cylinder head Be careful not to damage the radiator fins Remove the cylinder head cover packing 2 from the cylinder head cover 1 3 2 1 1 2 1 2 ...

Page 314: ...ge 1 25 Make sure the radiator mounting rubber slits facing down Align radiator lower stay slit with cylinder head tab DISASSEMBLY ASSEMBLY Remove the breather plate mounting bolts 1 Remove the breather plate 1 and gasket 2 Assembly is in the reverse order of disassembly Replace the breather plate gasket with a new one Apply locking agent to the breather plate mounting bolt threads page 10 3 TORQU...

Page 315: ... 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 Remove the rocker arm shaft bolts 1 Remove the rocker arm assembly 1 Be careful not to let the dowel pin 2 fall into the crankcase Remove the dowel pin from the rocker arm shaft 2 1 1 2 1 1 2 ...

Page 316: ...Install the washers and rocker arms to the rocker arm shaft Rocker arm identification tips PWC A mark exhaust rocker arm A 3 White paint mark Intake rocker arm S 4 No mark Intake rocker arm P 5 PWC B mark exhaust rocker arm B 6 INSPECTION Check the sliding surface of each rocker arm for wear or damage Check the oil hole for clog of each rocker arm Measure the rocker arm I D 6 1 2 5 4 3 6 1 5 4 3 S...

Page 317: ...does not align turn the crankshaft counterclockwise and align it Install the dowel pin 1 to the rocker arm shaft Install the rocker arm assembly 2 Align boss 3 and dowel pin with the cylinder head holes 4 Make sure the washers 5 are installed in correct position Be careful not to let the dowel pin fall into the crankcase Apply engine oil to the rocker arm shaft bolts threads and seating surface In...

Page 318: ...nstall the following Cylinder head cover page 10 5 Crankshaft hole cap page 3 12 CAM CHAIN TENSIONER CAM CHAIN INSPECTION Remove the cylinder head cover page 10 5 Measure the cam chain tensioner wedge B 1 length Replace the cam chain with a new one if the projection exceeds the service limit For the cam chain replacement remove the following Cam sprocket page 10 13 Primary drive gear NC700X XA S S...

Page 319: ... cam chain tension page 10 12 Install the thermostat housing page 8 7 INSPECTION Remove the cam chain tensioner page 10 12 Check the cam chain tensioner 1 for wear or damage Replace the cam chain tensioner if necessary Remove the cam chain guide page 10 16 Check the cam chain guide 2 for wear or damage Replace the cam chain guide if necessary APPLYING CAM CHAIN TENSION Remove the O D 2 mm pin 1 fr...

Page 320: ... 1 by holding the flywheel mounting bolt and remove it Remove the cam sprocket bolt and cam sprocket 2 by removing the cam chain 3 from the cam sprocket Attach a piece of wire to the cam chain to prevent it from falling into the crankcase Remove the camshaft 1 INSPECTION CAMSHAFT Check the cam and journal surfaces of the camshaft for scoring scratches or evidence of insufficient lubrication Suppor...

Page 321: ...LINDER HEAD Measure the cylinder head camshaft journal I D Calculate the cylinder head to camshaft clearance CAM SPROCKET Check the cam sprocket teeth for wear or damage SERVICE LIMITS IN 34 7697 mm 1 36888 in EX 34 9027 mm 1 37412 in SERVICE LIMIT 41 927 mm 1 6507 in SERVICE LIMIT 42 027 mm 1 6546 in SERVICE LIMIT 0 10 mm 0 004 in ...

Page 322: ...am sprocket onto the camshaft by aligning the groove with the pin Apply engine oil to the cam sprocket bolt threads and seating surface Install the cam sprocket bolt 1 Hold the flywheel mounting bolt and tighten the cam sprocket bolt to the specified torque Apply the cam chain tension page 10 12 Install the rocker arm page 10 10 Apply engine oil to a new large O ring 1 and install it to the water ...

Page 323: ...Tighten the water hose band screws to the specified range as shown Install the engine NC700X XA S SA page 16 15 NC700XD SD page 16 21 CYLINDER HEAD REMOVAL Remove the following Engine NC700X XA S SA page 16 5 NC700XD SD page 16 9 Cylinder head cover page 10 5 Right crankcase cover NC700X XA S SA page 11 5 NC700XD SD page 12 97 Remove the camshaft maintenance cap 1 and O ring 2 1 Align 2 0 1 mm 0 0...

Page 324: ...ad index line 3 turn the crankshaft clockwise one full turn 360 and realign the mark with the lower cylinder head index line Remove the cam chain tensioner page 10 12 Insert the gear holder 1 between the primary drive gear and driven gear Remove the cam sprocket bolt 2 Remove the cam sprocket 3 by removing the cam chain 4 from the cam sprocket Attach a piece of wire to the cam chain to prevent it ...

Page 325: ...n 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 Do not strike the cylinder too hard and do not damage the mating surface with a screwdriver Remove the gasket 1 dowel pins 2 and cam chain guide 3 Remove the partition plate 1 Check the partition plate for deterioration or damage 1 1 2 3 2 1 1 ...

Page 326: ...t loss of tension do not compress the valve springs more than necessary to remove the cotters Remove the following Spring retainer 1 Valve spring 2 Valve 3 Stem seal 4 Valve spring seat 5 Mark all parts during disassembly so they can be placed back in their original locations INSPECTION CYLINDER HEAD Remove carbon deposits from the combustion chambers 1 Avoid damaging the gasket surface Check the ...

Page 327: ...moves smoothly in the guide Inspect each valve for bending burning or abnormal stem wear Measure and record each valve stem O D Ream the guides to remove any carbon deposits before checking clearances Insert the reamer 1 from the combustion chamber side of the cylinder head and always rotate the reamer clockwise SERVICE LIMIT 0 10 mm 0 004 in SERVICE LIMIT 48 1 mm 1 89 in SERVICE LIMITS IN 4 965 m...

Page 328: ... cylinder head and drive out the valve guides from combustion chamber side of the cylinder head Drive in the valve guides to the specified depth from the top of the cylinder head Let the cylinder head cool to room temperature Use cutting oil on the reamer during this operation Ream new valve guides after installation Insert the reamer 1 from the combustion chamber side of the cylinder head and alw...

Page 329: ... width and even all around the circumference If the seat width is not within specification reface the valve seat page 10 23 Inspect the valve seat face for Uneven seat width Replace the valve and reface the valve seat Damaged face Replace the valve and reface the valve seat The valves cannot be ground If a valve face is burned or badly worn or if it contacts the seat unevenly replace the valve Con...

Page 330: ... the proper width Make sure that all pitting and irregularities are removed Refinish if necessary After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure Excessive lapping pressure may deform or damage the seat Change the angle of lapping tool 1 frequently to prevent uneven seat wear Do not allow lapping compound to enter the guides After lapping wash...

Page 331: ...e stem sliding surface and stem end Insert the valve 3 into the valve guide while turning it slowly to avoid damage to the stem seal Install the valve springs 4 with the tightly wound coils facing the combustion chamber Install the valve spring retainer 5 RETAINER VALVE GUIDE INTAKE VALVE VALVE SPRING SPRING SEAT INSULATOR COTTERS EXHAUST VALVE STEM SEAL 5 4 1 3 2 COMBUSTION CHAMBER SIDE 4 ...

Page 332: ...ort the cylinder head above the work bench surface to prevent possible valve damage Install the insulator 1 while aligning its slit with cylinder head tab Tighten the band screw 2 to the specified range Install the following Camshaft page 10 15 Injector page 7 21 Spark plug page 3 8 Cylinder head page 10 25 INSTALLATION Install the partition plate 1 to the No 1 cylinder intake side Install the par...

Page 333: ...pins 1 and new gasket 2 Route the cam chain through the cylinder head and install the cylinder head 1 onto the cylinder Apply molybdenum oil solution to the cylinder head special bolts 2 threads and seating surface Install and tighten the cylinder head special bolts in a crisscross pattern in 2 or 3 steps to the specified torque Install and tighten the 6 mm bolts 1 1 Align Align 1 2 TORQUE 44 N m ...

Page 334: ...t Align the cam sprocket slit with camshaft pin Align the cam sprocket mark with cylinder head lower index line Apply engine oil to the cam sprocket bolt threads and seating surface Install the cam sprocket bolt 3 Insert the gear holder 4 between the primary drive gear and driven gear then tighten the cam sprocket bolt to the specified torque Install the cam chain tensioner page 10 12 NC700XD SD N...

Page 335: ...e engine is installed on the frame insert a feeler gauge 0 1 mm 1 between the camshaft maintenance cap and cylinder head Tighten the camshaft maintenance cap securely Remove the feeler gauge Further tighten the camshaft maintenance cap at 30 One concave area 2 size is equivalent with 30 Install the following Cylinder head cover page 10 5 Right crankcase cover NC700X XA S SA page 11 5 NC700XD SD pa...

Page 336: ...GEARSHIFT LINKAGE NC700X XA S SA COMPONENT LOCATION 11 2 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 4 RIGHT CRANKCASE COVER 11 5 CLUTCH 11 7 PRIMARY DRIVE GEAR CKP SENSOR ROTOR 11 15 GEARSHIFT LINKAGE 11 16 GEARSHIFT PEDAL 11 19 ...

Page 337: ...TCH GEARSHIFT LINKAGE NC700X XA S SA CLUTCH GEARSHIFT LINKAGE NC700X XA S SA COMPONENT LOCATION 128 N m 13 1 kgf m 94 lbf ft 12 N m 1 2 kgf m 9 lbf ft 93 N m 9 5 kgf m 69 lbf ft 12 N m 1 2 kgf m 9 lbf ft 23 N m 2 3 kgf m 17 lbf ft ...

Page 338: ...57 Mainshaft O D at clutch outer guide 21 967 21 980 0 8648 0 8654 21 95 0 864 Clutch outer guide to mainshaft clearance 0 011 0 049 0 0004 0 0019 0 08 0 003 Primary driven gear I D 32 000 32 025 1 2598 1 2608 32 09 1 263 Primary driven gear to clutch outer guide clearance 0 025 0 066 0 0010 0 0026 0 10 0 004 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Clutch center lock nut 1 18 128 1...

Page 339: ...Loose clutch center lock nut Damaged clutch lifter mechanism Clutch lifter rod installed improperly Worn clutch outer slot and clutch center grooves Improper clutch operation Hard to shift Misadjusted clutch cable Improper clutch operation Improper engine oil viscosity Damaged or bent shift fork Bent shift fork shaft Bent shift fork claw Loose shift drum stopper plate bolt Damaged shift drum stopp...

Page 340: ...the CKP sensor 2P Red connector 1 and release the CKP sensor harness Release the reserve tank overflow hose 1 from the stay 2 Remove the bolt 3 and stay Remove the bolts 1 and clutch cable guide 2 then disconnect the clutch cable 3 from the clutch lifter arm 4 Loosen the right crankcase cover bolts 1 in a crisscross pattern in 2 or 3 steps and remove the bolts and sealing washer 2 Remove the right...

Page 341: ... sensor wire grommet sealing surface Replace the sealing washer with a new one Route the cables and wire harness properly page 1 25 Adjust the clutch lever freeplay page 3 26 Fill the engine with the recommended engine oil and check that there are no oil leaks page 3 12 CLUTCH LIFTER ARM REMOVAL INSTALLATION Remove the clutch lifter rod A 1 Remove the snap ring 2 clutch lifter arm 3 and return spr...

Page 342: ...face Install the clutch lifter rod A 6 CLUTCH REMOVAL Remove the right crankcase cover page 11 5 Remove the clutch lifter rod B 1 Loosen the clutch lifter plate bolts 2 in a crisscross pattern in 2 or 3 steps and remove the bolts lifter plate bearing 3 and clutch springs 4 Unstake the clutch center lock nut 1 Be careful not to damage the mainshaft threads Hold the clutch pressure plate with the sp...

Page 343: ...he lock washer 1 and thrust washer 2 Remove the clutch assembly 1 Remove the following Clutch center 1 Spring seat 2 Judder spring 3 Clutch disc B 4 Seven clutch plates 5 Six clutch discs C 6 Clutch disc A 7 Pressure plate 8 Remove the thrust washer 1 2 1 1 1 2 3 4 5 6 7 8 1 ...

Page 344: ...that the outer race of the bearing fits tightly in the pressure plate Replace the clutch lifter bearing if the inner race does not turn smoothly quietly or if the outer race fits loosely in the lifter plate CLUTCH SPRING Replace the clutch springs as a set Measure the clutch spring free length CLUTCH CENTER Check the grooves 1 of the clutch center for damage or wear caused by the clutch plates Rep...

Page 345: ...c CLUTCH PLATE Replace the clutch discs and plates as a set Check the plates for discoloration Check the plate warpage on a surface plate using a feeler gauge JUDDER SPRING SPRING SEAT Check the judder spring and spring seat for deformation warpage or damage A damaged or warped spring seat will cause the judder spring to be pressed unevenly A damaged judder spring also causes the weak contact betw...

Page 346: ...driven gear Replace the clutch outer assembly if necessary Measure the O D and I D of the clutch outer guide Calculate the primary driven gear to clutch outer guide clearance MAINSHAFT Measure the mainshaft O D at clutch outer guide sliding surfaces Calculate the clutch outer guide to mainshaft clearance SERVICE LIMIT 32 09 mm 1 263 in SERVICE LIMITS O D 31 92 mm 1 257 in I D 22 03 mm 0 867 in SER...

Page 347: ...ide 1 to the mainshaft Install the thrust washer 1 to the clutch outer 12 N m 1 2 kgf m 9 lbf ft 128 N m 13 1 kgf m 94 lbf ft CLUTCH OUTER GUIDE CLUTCH OUTER PRESSURE PLATE THRUST WASHER JUDDER SPRING CLUTCH CENTER THRUST WASHER LOCK WASHER CLUTCH SPRING SPRING SEAT LIFTER PLATE CLUTCH LIFTER BEARING CLUTCH LIFTER ROD B CLUTCH DISC C CLUTCH DISC B CLUTCH PLATE CLUTCH DISC A 1 1 ...

Page 348: ...utch plates 6 alternately starting with the clutch plate Install the clutch disc A 7 and pressure plate 8 Install the clutch center assembly 1 to the clutch outer 2 Align the clutch disc A C tabs with clutch outer slits 3 Align the clutch disc B tabs with clutch outer shallow slots 4 Install the clutch assembly 1 to the clutch outer guide 6 7 5 3 2 1 4 8 CLUTCH DISC A 7 30 CLUTCH DISC B 5 3 5 9 mm...

Page 349: ... torque Stake the clutch center lock nut 1 into the mainshaft groove Be careful not to damage the mainshaft threads Install the clutch springs 1 lifter plate bearing 2 and clutch lifter plate bolts 3 Tighten the clutch lifter plate bolts to the specified torque in a crisscross pattern in 2 or 3 steps Apply engine oil to the clutch lifter rod B sliding surface Install the clutch lifter rod B 4 Inst...

Page 350: ...and washer 3 Remove the gear holder Remove the CKP sensor rotor 5 and primary drive gear INSPECTION Check the primary drive gear 1 for wear or damage Check the CKP sensor rotor 2 for wear or damage INSTALLATION Install the primary drive gear 1 on the crankshaft Align the primary drive gear wide groove with the crankshaft wide tooth Install the primary drive gear with its OUT mark 2 facing out TOOL...

Page 351: ...rface Install the washer 1 and primary drive gear mounting bolt 2 Hold the primary drive gear using a special tool and tighten the primary drive gear mounting bolt to the specified torque Remove the gear holder Install the right crankcase cover page 11 5 GEARSHIFT LINKAGE REMOVAL Remove the following Left rear cover page 2 29 Right crankcase cover page 11 5 Clean the gearshift spindle 1 Remove the...

Page 352: ...m stopper plate 6 and dowel pin 7 Remove the bolt 1 and setting plate 2 Remove the gearshift spindle oil seal 3 INSPECTION Check the gearshift spindle for bend wear or damage Check the return springs for fatigue or damage INSTALLATION Install the gearshift spindle oil seal 1 as shown Install the oil seal with its marked side facing out Apply grease to the oil seal lips 5 1 2 3 4 6 7 2 3 1 1 0 4 1 ...

Page 353: ...spring hook 5 with stopper arm cut out Install the stopper arm with its MGS mark 6 facing out Hold the stopper arm 1 with a screwdriver Install the dowel pin 2 into the shift drum hole Install the shift drum stopper plate 3 while aligning its slit with the dowel pins Apply locking agent to the shift drum center socket bolt threads page 11 3 Install and tighten the shift drum center socket bolt 1 t...

Page 354: ... pedal pivot bolt 3 and gearshift pedal 4 Remove the dust seals 1 Installation is in the reverse order of removal Apply grease to the gearshift pedal pivot and dust seal lips Apply grease to the gearshift pedal tie rod ball joint area Adjust the tie rod length so that the distance between the ball joint ends is standard length as shown After adjustment tighten the gearshift pedal adjuster lock nut...

Page 355: ...MEMO dummyhead dummyhead ...

Page 356: ...UBLESHOOTING 12 20 SHIFT INDICATOR TROUBLESHOOTING 12 61 MODE SHIFT INDICATOR CIRCUIT TROUBLESHOOTING 12 95 AT MT MODE SWITCH TROUBLESHOOTING 12 96 RIGHT CRANKCASE COVER 12 97 DUAL CLUTCH 12 105 PRIMARY DRIVE GEAR CKP SENSOR ROTOR 12 108 SHIFT CONTROL MOTOR REDUCTION GEARS 12 109 GEARSHIFT LINKAGE 12 112 MAINSHAFT SENSOR 12 115 TR SENSOR 12 115 SHIFT SPINDLE ANGLE SENSOR 12 116 CLUTCH EOP SENSOR 1...

Page 357: ...2 2 dummyhead dummyhead DUAL CLUTCH TRANSMISSION DCT NC700XD SD DUAL CLUTCH TRANSMISSION DCT NC700XD SD COMPONENT LOCATION 23 N m 2 3 kgf m 17 lbf ft 93 N m 9 5 kgf m 69 lbf ft 12 N m 1 2 kgf m 9 lbf ft ...

Page 358: ...ration of both systems Before starting any troubleshooting check the following items and refer to the appropriate troubleshooting MIL blinks or DTC for the PGM FI system page 4 12 Shift indicator blinks or DTC for the DCT system page 12 11 Symptom of the DCT system operation page 12 5 TXD RXD line page 22 11 Refer to the PGM FI Troubleshooting Information for the CIRCUIT INSPECTION information pag...

Page 359: ...T sensor resistance 20 C 68 F 2 5 2 8 kΩ ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Solenoid valve stopper plate bolt 1 6 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 Right crankcase cover wire clamp bolt 2 6 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...

Page 360: ...dition and follow the symptom troubleshooting described below CLUTCH SLIPS AND MOTORCYCLE DOES NOT ACCELERATE Check the clutch clearance page 12 106 EXCESSIVE NOISE OR VIBRATION AROUND THE DCT SYSTEM Inspect the following components Clutch clearance Dual clutch needle bearings for wear or damage Primary drive sub gear for wear or damage Primary driven gear for wear or damage Each fasteners are tig...

Page 361: ...ELECTRICAL SYSTEM LOCATION CLUTCH EOP SENSORS INNER MAINSHAFT SENSOR No 2 LINEAR SOLENOID VALVE OUTER MAINSHAFT SENSOR SHIFT SPINDLE ANGLE SENSOR No 1 LINEAR SOLENOID VALVE TR SENSOR NEUTRAL SWITCH SHIFT CONTROL MOTOR EOT SENSOR ABS MODULATOR DLC CKP SENSOR PCM VS SENSOR ...

Page 362: ...Y IGNITION HOLD RELAY GEARSHIFT MECHANISM No 1 LINEAR SOLENOID VALVE No 2 LINEAR SOLENOID VALVE SHIFT CONTROL MOTOR No 1 CLUTCH SLIPS No 2 CLUTCH SLIPS No 1 CLUTCH OIL PRESSURE MAINSHAFT COUNTERSHAFT SPEED RATIO No 2 CLUTCH OIL PRESSURE SHIFT SWITCH SIDESTAND SWITCH N D SHIFT SWITCH SHIFT PEDAL ANGLE SENSOR OPTIONAL AT MT MODE SWITCH DLC DOWN UP UP DOWN TP SENSOR SFTPANG LG SG R Bl R Bl R Bl W Bl ...

Page 363: ...ce lid page 21 6 NOTE 3 Remove the shroud side cover NC700XD page 2 14 NOTE 4 Remove the headlight headlight stay NC700SD page 2 27 RIGHT HANDLEBAR SWITCH 6P BLACK CONNECTOR NOTE 1 LEFT HANDLEBAR SWITCH 3P BLACK CONNECTOR NOTE 3 DLC NOTE 2 CKP SENSOR 2P RED CONNECTOR NOTE 2 LEFT HANDLEBAR SWITCH 7P GREEN CONNECTOR NOTE 4 RIGHT HANDLEBAR SWITCH 7P GREEN CONNECTOR NOTE 4 ...

Page 364: ...LUTCH LINE EOP SENSOR 3P BLACK CONNECTOR NOTE 5 No 1 CLUTCH EOP SENSOR 3P GRAY CONNECTOR NOTE 5 No 2 CLUTCH EOP SENSOR 3P GRAY CONNECTOR NOTE 5 NEUTRAL SWITCH NOTE 7 TR SENSOR NOTE 7 SHIFT CONTROL MOTOR 2P BLACK CONNECTOR NOTE 7 SHIFT PEDAL ANGLE SENSOR 3P BLACK CONNECTOR NOTE 6 OUTER MAINSHAFT SENSOR 3P BLACK CONNECTOR INNER MAINSHAFT SENSOR 3P BLACK CONNECTOR NOTE 8 VS SENSOR 3P BLACK CONNECTOR ...

Page 365: ...the shroud side cover NC700XD page 2 14 NOTE 11 Remove the side cowl NC700SD page 2 13 NOTE 12 Remove the center cross plate page 2 32 ABS MODULATOR 25P CONNECTOR NOTE 9 SHIFT SPINDLE ANGLE SENSOR 3P GRAY CONNECTOR NOTE 11 PCM 33P BLACK CONNECTOR NOTE 10 PCM 33P GRAY CONNECTOR NOTE 10 LINEAR SOLENOID VALVE 4P GREEN CONNECTOR NOTE 11 TR SENSOR 3P BLACK CONNECTOR NOTE 12 ...

Page 366: ...ROUBLESHOOTING page 12 5 SYSTEM DESCRIPTION SELF DIAGNOSIS SYSTEM The DCT system is equipped with the self diagnostic system When any abnormality occurs in the DCT system the PCM have the shift indicator 1 blinking and stores a DTC in its erasable memory for the relevant system failure FAIL SAFE FUNCTION The DCT system is provided with a fail safe function to secure a minimum running capability ev...

Page 367: ...icator blink pattern will indicate the current DTC If the PCM does not detect any current but has a problem stored in its memory the shift indicator will not light and blink If it is necessary to retrieve the past problem readout the stored DTC by following the DTC readout procedure page 12 12 HDS POCKET TESTER INFORMATION Refer to the PGM FI system page 4 12 The front wheel speed sensor signal ca...

Page 368: ...oting index page 12 15 If the PCM has no DTC in its memory the shift indicator will start blinking page 12 14 4 Release the shift switch ERASING DTC Connect the HDS pocket tester to the DLC page 4 12 Erase the DTC with the HDS while the engine is stopped To erase the DTC without HDS refer to the following procedure How to erase the DTC without HDS 1 Turn the ignition switch OFF Remove the maintena...

Page 369: ...Push the shift switch 2 6 The self diagnostic memory is erased if the shift indicator goes off and starts blinking as shown Note that the self diagnostic memory cannot be erased if the ignition switch is turned to OFF before the shift indicator starts blinking 7 Turn the ignition switch OFF 8 Remove the special tool from the DLC 1 1 1 2 2 ON OFF 3 sec Pattern repeated 2 sec 2 sec 2 sec 1 cycle 3 s...

Page 370: ...erating gearshift mechanism Gearshift mechanism malfunction Shift spindle angle sensor malfunction Gearshift function does not work while driving Only shifted into 1st gear 12 25 12 64 23 1 23 Shift spindle operation malfunction while operating gearshift mechanism Gearshift mechanism malfunction Shift spindle angle sensor malfunction Gearshift function does not work while driving Only shifted into...

Page 371: ... not work 12 37 12 74 48 2 48 No 2 clutch EOP sensor high voltage Loose or poor contact of the No 2 clutch EOP sensor connector No 2 clutch EOP sensor or its circuit malfunction Faulty PCM Gearshift function does not work 12 38 49 1 49 Clutch line low oil pressure when clutch engage Engine oil level low Faulty oil pump Faulty clutch oil circuit Clutch line EOP sensor malfunction Faulty PCM Engine ...

Page 372: ...linear solenoid valve current failure Loose or poor contact of the No 1 linear solenoid valve connector No 2 linear solenoid valve or its circuit malfunction No 2 linear solenoid valve drive circuit in the PCM malfunction Faulty PCM Gearshift function does not work 12 49 12 85 56 2 56 No 2 linear solenoid valve driver in the PCM failure Loose or poor contact of the No 2 linear solenoid valve conne...

Page 373: ...hift function does not work while driving Engine does not operate 12 51 12 86 62 2 62 No 1 clutch oil pressure high Prevention of motorcycle creeps No 1 clutch EOP sensor malfunction Faulty clutch oil circuit No 1 linear solenoid valve malfunction Faulty PCM Gearshift function does not work while driving Engine does not operate 63 1 63 No 2 clutch oil pressure malfunction at clutch initial diagnos...

Page 374: ...etic interference at front wheel speed sensor Faulty ABS modulator Faulty pulser ring Faulty PCM Gearshift function does not work 12 55 12 90 68 1 68 No 1 clutch operation malfunction clutch slips VS sensor or its circuit malfunction Faulty No 1 clutch Faulty PCM Gearshift function does not work 12 56 12 91 69 1 69 No 2 clutch operation malfunction clutch slips VS sensor or its circuit malfunction...

Page 375: ...Inspection Connect the HDS pocket tester and start the engine Check the clutch line EOP sensor with the HDS pocket tester Is about 0 V indicated YES GO TO STEP 2 NO Intermittent failure 2 Clutch Line EOP Sensor Inspection Stop the engine Disconnect the clutch line EOP sensor 3P Black connector Turn the ignition switch ON Check the clutch line EOP sensor with the HDS pocket tester Is about 0 V indi...

Page 376: ... is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 Clutch Line EOP Sensor System Inspection Check the clutch line EOP sensor with the HDS pocket tester Is about 5 V indicated YES GO TO STEP 2 NO Intermittent failure 2 Clutch Line EOP Sensor Inspection Turn the ignition switch OFF Disconnect the clutch line EOP sensor 3P Black ...

Page 377: ...NSOR NO SIGNAL Before starting the inspection check for loose or poor contact on the CKP sensor 2P Red and PCM 33P Gray connectors then recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 CKP sensor Peak Voltage Inspection Disconnect the CKP sensor 2P Red connector Turn the ignition switch ON with the ...

Page 378: ...M is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 Shift Spindle Angle Sensor System Inspection Check the shift spindle angle sensor with the HDS pocket tester Is about 0 V indicated YES GO TO STEP 2 NO Intermittent failure 2 Shift Spindle Angle Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF Disconnect...

Page 379: ... 5 5 Shift Spindle Angle Sensor Inspection Replace the shift spindle angle sensor with a known good one page 12 116 Connect the shift spindle angle sensor 3P Gray connector and PCM 33P Black connector Turn the ignition switch ON Check the shift spindle angle sensor with the HDS pocket tester Is about 0 V indicated YES Replace the PCM with a known good one and recheck NO Faulty original shift spind...

Page 380: ...hift spindle angle sensor with the HDS pocket tester Is about 5 V indicated YES Replace the PCM with a known good one and recheck NO Faulty shift spindle angle sensor DTC 22 1 SHIFT SPINDLE OPERATION MALFUNCTION AFTER OPERATING GEARSHIFT MECHANISM 1 Shift Spindle Angle Sensor System Inspection Check the shift spindle angle sensor with the HDS pocket tester Is Low voltage about 0 V or High voltage ...

Page 381: ... spindle angle sensor shaft check the shift spindle angle sensor voltage with the HDS pocket tester Does the voltage vary properly YES GO TO STEP 5 NO Faulty shift spindle angle sensor 5 Shift Spindle Angle Sensor Condition Inspection Check that the shift spindle angle sensor is installed properly Is the shift spindle angle sensor in normal condition YES GO TO STEP 6 NO Install the shift spindle a...

Page 382: ... Motor Line Short Circuit Inspection Check for continuity between the wire harness side shift control motor 2P Black connector 1 terminals and ground Is there continuity YES Short circuit in the Pink blue wire Short circuit in the Yellow blue wire NO GO TO STEP 3 3 Shift Control Motor Inspection Remove the shift control motor page 12 109 Connect a fully charged 12 V battery 1 to the shift control ...

Page 383: ...YES GO TO STEP 3 NO Install the shift control motor and reduction gears properly or replace faulty parts 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 Does the shift control motor...

Page 384: ... the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 DTC Recheck Erase the DTCs page 12 13 Check the DTC with the HDS pocket tester Is DTC 32 1 or 37 1 indicated YES DTC 32 1 indicated page 12 30 DTC 37 1 indicated page 12 30 NO GO TO STEP 2 2 Shift Control Motor Line Open Circuit Inspection Disconnect the PCM 33P Black connector and shift control ...

Page 385: ...and starter relay switch 4P Red connector Blown PVB fuse 30 A 2 DTC Recheck Recheck the DTC with the HDS pocket tester Is DTC 32 1 indicated YES Replace the PCM with a known good one and recheck NO Intermittent failure DTC 37 1 IGNITION HOLD RELAY 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 per...

Page 386: ...lebar switch 6P Black connector NC700XD 1 Right handlebar switch 7P Green connector NC700SD 2 Turn the ignition switch ON with the engine stop switch Measure the voltage between the wire harness side right handlebar switch connector terminal and ground Is the voltage within 4 75 5 25 V YES GO TO STEP 2 NO Open circuit in the Yellow red wire 2 N D Shift Switch Inspection Turn the ignition switch OF...

Page 387: ...e Open circuit in the Black yellow wire 4 N D Shift Switch Input Line Short Circuit Inspection Check for continuity between the wire harness side PCM 33P Black connector 1 terminals and ground Is there continuity YES Short circuit in the Light green black wire Short circuit in the Black yellow wire NO Replace the PCM with a known good one and recheck Connection Light green black A18 Black yellow A...

Page 388: ...C700SD 2 Turn the ignition switch ON with the engine stop switch Measure the voltage between the wire harness side left handlebar switch connector terminal and ground Is the voltage within 4 75 5 25 V YES GO TO STEP 2 NO Open circuit in the Yellow red wire 2 Shift Switch Inspection Turn the ignition switch OFF Check for continuity between the switch side left handlebar switch connector 1 terminals...

Page 389: ...P Black connector 1 terminals and ground Is there continuity YES Short circuit in the Blue yellow wire Short circuit in the Light green red wire NO Replace the PCM with a known good one and recheck DTC 44 1 EOT 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 EOT Sensor System Inspection Check th...

Page 390: ...r 4 EOT Sensor Input Line Short Circuit Inspection Check the continuity between the wire harness side 2P Black connector 1 terminal and ground Is there continuity YES Short circuit in the Blue green wire NO Replace the PCM with a known good one and recheck DTC 44 2 EOT SENSOR HIGH VOLTAGE Before starting the inspection check for loose or poor contact on the EOT sensor 2P Black and PCM 33P connecto...

Page 391: ...Check for continuity between the wire harness side EOT sensor 2P Black connector 1 and PCM 33P Black connector 2 terminals Is there continuity YES GO TO STEP 4 NO Open circuit in the Blue green wire 4 EOT Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33P Gray connector Check for continuity between the wire harness side EOT sensor 2P Black connector 1 and PCM 33P Gray connector 2 te...

Page 392: ...DS pocket tester Is about 0 V indicated YES GO TO STEP 3 NO Faulty clutch EOP sensor 3 Clutch EOP Sensor Input Line Open Circuit Inspection Measure the voltage between the wire harness side clutch EOP sensor 3P Gray connector 1 terminals Is the voltage within 4 75 5 25 V YES GO TO STEP 4 NO Open circuit in the Yellow red wire 4 Clutch EOP Sensor Output Line Short Circuit Inspection Turn the igniti...

Page 393: ...nnect the clutch EOP sensor 3P Gray connector Short the wire harness side clutch EOP sensor 3P Gray connector 1 terminals with a jumper wire 2 Turn the ignition switch ON Check the clutch EOP sensor with the HDS pocket tester Is about 0 V indicated YES Faulty clutch EOP sensor NO GO TO STEP 3 3 Clutch EOP Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the PCM 33...

Page 394: ...tialize Learning Procedure page 12 120 1 Clutch Line EOP Sensor System Inspection Check the clutch line EOP sensor with the HDS pocket tester Is Low voltage about 0 V or High voltage about 5 V indicated YES About 0 V while engine running See DTC 9 1 page 12 20 About 5 V See DTC 9 2 page 12 21 NO GO TO STEP 2 2 Engine Oil Level Inspection Check the engine oil level page 3 12 Is the engine oil level...

Page 395: ... oil pump Internal oil leak in the clutch oil line NO Faulty original PCM DTC 51 1 TR SENSOR LOW VOLTAGE 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 Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 TR Sensor System Inspection Ch...

Page 396: ...he Black pink wire NO GO TO STEP 5 5 TR Sensor Inspection Replace the TR sensor with a known good one page 12 115 Connect the TR sensor 3P Black connector and PCM 33P Black connector Turn the ignition switch ON Check the TR sensor with the HDS pocket tester Is the voltage about 0 V YES Replace the PCM with a known good one and recheck NO Faulty original TR sensor DTC 51 2 TR SENSOR HIGH VOLTAGE If...

Page 397: ...iginal TR sensor DTC 52 1 NEUTRAL SWITCH STUCK OFF Before starting the inspection check for loose or poor contact on the neutral switch and PCM 33P Gray connectors and recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 DTC Recheck Recheck the DTC with the HDS pocket tester Is DTC 52 1 indicated YES GO...

Page 398: ...terminal and ground Is there continuity YES Short circuit in the Light green wire NO GO TO STEP 2 2 Neutral Switch Inspection Replace the neutral switch with a known good one page 22 28 Connect the neutral switch connector Check the DTC with the HDS pocket tester Is DTC 52 2 indicated YES Replace the PCM with a known good one and recheck NO Faulty original neutral switch DTC 53 1 INNER MAINSHAFT S...

Page 399: ...sure the voltage between the wire harness side 3P Black connector 1 terminal and ground Is the voltage within 4 75 5 25 V YES GO TO STEP 8 NO GO TO STEP 6 4 Inner 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 inner mainshaft sensor 3P Black connector 1 and PCM 33P Black conn...

Page 400: ...als Is there continuity YES GO TO STEP 7 NO Open circuit in the Gray yellow wire 7 Inner Mainshaft Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side inner mainshaft sensor 3P Black connector 1 terminal and ground Is there continuity YES Short circuit in the Gray yellow wire NO GO TO STEP 8 8 Inner Mainshaft Sensor Inspection Turn the ignition switch OFF...

Page 401: ... pocket tester Is DTC 54 1 indicated YES GO TO STEP 2 NO Intermittent failure 2 Outer Mainshaft Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the outer mainshaft sensor 3P Black connector Turn the ignition switch ON Measure the voltage between the wire harness side outer mainshaft sensor 3P Black connector 1 terminals Is there about battery voltage YES GO TO STEP 3 NO GO ...

Page 402: ...side outer mainshaft sensor 3P Black connector 1 and PCM 33P Gray connector 2 terminals Is there continuity YES Replace the PCM with a known good one and recheck NO Open circuit in the Green yellow wire 6 Outer Mainshaft 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 outer mainshaft s...

Page 403: ...outer mainshaft sensor DTC 55 1 55 2 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 If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 DTC Recheck Recheck the DTC with the HDS pocket teste...

Page 404: ...connector 1 terminals and ground Is there continuity YES Short circuit in the Gray white wire Short circuit in the Blue white wire NO Replace the PCM with a known good one and recheck DTC 56 1 56 2 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 If the PCM is replaced pe...

Page 405: ... terminals Is the continuity normal YES GO TO STEP 4 NO Open circuit in the Pink white wire Open circuit in the Brown white wire 4 No 2 Linear Solenoid Valve Input ground Line Short Circuit Inspection Check for continuity between the wire harness side linear solenoid valve 4P Green connector 1 terminals and ground Is there continuity YES Short circuit in the Pink white wire Short circuit in the Br...

Page 406: ... 2 CLUTCH DOES NOT DISENGAGE WHEN SHIFTING GEAR See page 12 51 DTC 61 1 61 2 61 3 61 4 62 1 62 2 No 1 CLUTCH OIL PRESSURE MALFUNCTION If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 DTC Recheck Recheck the DTC with the HDS pocket tester Is DTC 47 1 47 2 55 1 or 55 2 indicated YES DTC 47 1 is indicated page 12 37 D...

Page 407: ...C 48 1 48 2 56 1 or 56 2 indicated YES DTC 48 1 is indicated page 12 37 DTC 48 2 is indicated page 12 38 DTC 56 1 is indicated page 12 49 DTC 56 2 is indicated page 12 49 NO GO TO STEP 2 2 No 2 Clutch EOP Sensor Inspection Replace the No 2 clutch EOP sensor with a known good one page 12 117 Erase the DTCs page 12 13 Test ride the motorcycle and stop the engine Check the No 2 clutch EOP sensor with...

Page 408: ...sor air gap page 20 24 Is the air gap correct YES GO TO STEP 3 NO Check each part for deformation and looseness and correct accordingly Recheck the air gap 3 Front Wheel Speed Sensor Condition Inspection Inspect the area around the front wheel speed sensor Check that there is no iron or other magnetic deposits between the pulser ring and wheel speed sensor and check the pulser ring slots for obstr...

Page 409: ...C with the HDS pocket tester Is DTC 66 1 indicated YES GO TO STEP 2 NO Intermittent failure 2 VS Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the VS sensor 3P Black connector Turn the ignition switch ON Measure the voltage between the wire harness side VS sensor 3P Black connector 1 terminals Is there battery voltage YES GO TO STEP 3 NO Open circuit in the Pink blue wire...

Page 410: ...wn good one page 22 18 Erase the DTCs page 12 13 Test ride the motorcycle and stop the engine Check the DTC with the HDS pocket tester Is DTC 66 1 indicated YES Replace the PCM with a known good one and recheck NO Faulty original VS sensor DTC 67 1 FRONT WHEEL SPEED SENSOR NO SIGNAL Before starting the inspection check for loose or poor contact on the front wheel speed sensor 2P Blue ABS modulator...

Page 411: ... Speed Sensor Line Short Circuit Inspection Check for continuity between the wire harness side PCM 33P Black connector 1 and ground Is there continuity YES Short circuit in the Violet red wire NO Replace the PCM with a known good one and recheck DTC 68 1 No 1 CLUTCH OPERATION MALFUNCTION CLUTCH SLIPS If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initializ...

Page 412: ...e engine Check the DTC with the HDS pocket tester Is DTC 66 1 indicated YES Refer to DTC 66 1 troubleshooting page 12 54 NO GO TO STEP 2 2 Clutch Condition Inspection Remove the No 2 clutch assembly and measure the clutch clearance page 12 105 Is the clearance within the standard range YES Replace the PCM with a known good one and recheck NO Faulty No 2 clutch assembly DTC 71 1 72 1 INNER OUTER MA...

Page 413: ...d recheck NO Intermittent failure DTC 1 1 SHIFT PEDAL ANGLE SENSOR OPTIONAL MALFUNCTION Before starting this inspection check for loose or poor contact on the shift pedal angle sensor 3P Black connector and PCM 33P connectors and recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 DCT Shift Pedal Optiona...

Page 414: ... harness side shift pedal angle sensor 3P Black connector 2 and PCM 33P Gray connector terminals Is there continuity YES Replace the PCM with a known good one and recheck NO Open circuit in Green yellow wire Open circuit in Yellow red wire 4 Shift Pedal Angle Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the PCM 33P Gray connector 1 Check for continuity between...

Page 415: ...the sensor side shift pedal angle sensor 3P Black connector 1 terminals Operate the DCT shift pedal to check that the resistance changes in accordance with the pedal operation Are the resistance inspections normal YES Replace the PCM with a known good one and recheck NO Faulty shift pedal angle sensor replace the DCT shift pedal as an assembly Connection Yellow violet Ground 1 Y V Connection Yello...

Page 416: ...line EOP sensor 3P Black connector 1 terminal and ground Is the voltage within 4 75 5 25 V YES GO TO STEP 2 NO GO TO STEP 5 2 Clutch Line EOP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Connect the ECM test harness to the PCM connectors page 4 14 Check for continuity between the wire harness side clutch line EOP sensor 3P Black connector 1 and test harness 2 terminals I...

Page 417: ... one and recheck NO Open circuit in the Yellow red wire Open circuit in the Green yellow wire DTC 19 CKP SENSOR Before starting the inspection check for loose or poor contact on the CKP sensor 2P Red and PCM 33P connectors and recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 CKP Sensor Peak Voltage ...

Page 418: ... 23 6 Clutch Initialize Learning Procedure page 12 120 1 Shift Spindle Angle Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the shift spindle angle sensor 3P Gray connector Turn the ignition switch ON with the engine stop switch Measure the voltage between the wire harness side shift spindle angle sensor 3P Blue connector 1 terminals Is the voltage within 4 75 5 25 V YES G...

Page 419: ...l shift spindle angle sensor 5 Shift Spindle Angle Sensor Power Ground Line Open Circuit Inspection Turn the ignition switch OFF Connect the ECM test harness to the PCM connectors page 4 14 Check for continuity between the wire harness side shift spindle angle sensor 3P Gray connector 1 and test harness 2 terminals Is there continuity YES Replace the PCM with a known good one and recheck NO Open c...

Page 420: ...r in normal condition YES Faulty shift spindle angle sensor NO Install the shift spindle angle sensor properly DTC 24 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 Connect the ECM test harness to the PCM connectors page 4 14 Disco...

Page 421: ...ol motor DTC 27 SHIFT DRUM POSITION 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 Reduction gear condition Check the shift control motor and reduction gears are installed properly and are not damaged Are the shift control motor and reduction gears normal condition YES GO TO STEP 2 NO Install ...

Page 422: ...ontrol motor 2P Black and PCM 33P connectors and recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 PVB Fuse Inspection Check the PVB fuse 30 A Is the PVB fuse in good condition YES GO TO STEP 2 NO Faulty PVB fuse 30 A 2 Shift Control Motor Line Open Circuit Inspection Connect the ECM test harness to ...

Page 423: ...e voltage between the test harness 1 terminals and ground Is there battery voltage YES Replace the PCM with a known good one and recheck NO Open circuit in the Yellow red wire between the PCM 33P Black connector and fuse relay box Open circuit in the Red wire between the fuse relay box and starter relay switch 4P Red connector DTC 37 IGNITION HOLD RELAY Before starting the inspection check for loo...

Page 424: ...ck for loose or poor contact on the right handlebar switch and PCM 33P Black connectors and recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 N D Shift Switch Power Input Voltage Inspection Turn the ignition switch OFF Disconnect the following Right handlebar switch 6P Black connector NC700XD 1 Right...

Page 425: ...N D Shift Switch Input Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors page 4 14 Check for continuity between the wire harness side right handlebar switch connector 1 and test harness 2 terminals Is there continuity YES GO TO STEP 4 NO Open circuit in the Light green black wire Open circuit in the Black yellow wire Connection N switch Light green blue Red D switch B...

Page 426: ...recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 Shift Switch Power Input Voltage Inspection Turn the ignition switch OFF Disconnect the following Left handlebar switch 3P Black connector NC700XD 1 Left handlebar switch 7P Green connector NC700SD 2 Turn the ignition switch ON with the engine stop sw...

Page 427: ...ft Switch Input Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors page 4 14 Check for continuity between the wire harness side left handlebar switch connector 1 and test harness 2 terminals Is there continuity YES GO TO STEP 4 NO Open circuit in the Blue yellow wire Open circuit in the Light green red wire Connection switch Green blue Yellow red switch Light green red...

Page 428: ... Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 EOT Sensor Input Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors page 4 14 Disconnect the EOT sensor 2P Black connector Check for continuity between the wire harness side EOT sensor 2P Black connector 1 and test harness 2 terminals Is there continuity YES GO TO STEP 2 NO Open circuit in the Blue...

Page 429: ...r 48 No 1 or No 2 CLUTCH EOP SENSOR 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 If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 Clutch EOP Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the clutc...

Page 430: ...known good one page 12 117 Connect the clutch EOP sensor 3P Gray connector Turn the ignition switch ON with the engine stop switch lower the sidestand and check the shift indicator Is DTC 47 or 48 indicated YES Replace the PCM with a known good one and recheck NO Faulty original clutch EOP sensor 5 Clutch EOP Sensor Power Ground Line Open Circuit Inspection Connect the ECM test harness to the PCM ...

Page 431: ...ondition YES GO TO STEP 3 NO Replace the clutch oil filter 3 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 1 rpm and stop the engine Read the DTC with the shift indicator page 12 13 Is DTC 49 indicated YES GO TO STEP 4 NO Faulty original clutch line EOP sensor 4 PCM Inspectio...

Page 432: ... side TR sensor 3P Black connector 1 terminals Is the voltage within 4 75 5 25 V YES GO TO STEP 2 NO GO TO STEP 5 2 TR 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 TR sensor 3P Black connector 1 and test harness 2 terminals Is there continuity YES GO TO STEP 3 NO Open circuit in the Black ...

Page 433: ...red wire Open circuit in the Green yellow wire DTC 52 NEUTRAL SWITCH Before starting the inspection check for loose or poor contact on the neutral switch and PCM 33P Gray connectors and recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 DTC Recheck Turn the ignition switch ON with the engine stop swit...

Page 434: ...and recheck NO Faulty original neutral switch DTC 53 INNER MAINSHAFT SENSOR SPEED LOW Before starting the inspection check for loose or poor contact on the inner mainshaft sensor 3P Black and PCM 33P connectors and recheck the DTC If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 Inner Mainshaft Sensor Input Voltage...

Page 435: ...heck for continuity between the wire harness side inner mainshaft sensor 3P Black connector 1 and test harness 2 terminals Is there continuity YES GO TO STEP 4 NO Open circuit in the Brown yellow wire 4 Inner Mainshaft Sensor Ground Line Open Circuit Inspection Check for continuity between the wire harness side inner mainshaft sensor 3P Black connector 1 and test harness 2 terminals Is there conti...

Page 436: ...ine Short Circuit Inspection Check for continuity between the wire harness side inner mainshaft sensor 3P Black connector 1 terminal and ground Is there continuity YES Short circuit in the Gray yellow wire NO GO TO STEP 7 7 Inner Mainshaft Sensor Inspection Replace the inner mainshaft sensor with a known good one page 12 115 Erase the DTCs page 12 13 Test ride the motorcycle and read the DTC with ...

Page 437: ... wire harness side outer mainshaft sensor 3P Black connector 1 terminals Is there about battery voltage YES GO TO STEP 2 NO GO TO STEP 3 2 Outer Mainshaft Sensor Output Line Inspection Measure the voltage between the wire harness side outer mainshaft sensor 3P Black connector 1 terminal and ground Is the voltage within 4 75 5 25 V YES GO TO STEP 7 NO GO TO STEP 5 3 Outer Mainshaft Sensor Input Lin...

Page 438: ...rness 2 terminals Is there continuity YES GO TO STEP 6 NO Open circuit in the Pink yellow wire 6 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 Is there continuity YES Short circuit in the Pink yellow wire NO GO TO STEP 7 7 Outer Mainshaft Sensor Inspection Replace the ou...

Page 439: ...lve 2 No 1 Linear Solenoid Valve Input ground Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors page 4 14 Check for continuity between the wire harness side linear solenoid valve 4P Green connector 1 and test harness 2 terminals Is there continuity YES GO TO STEP 3 NO Open circuit in the Gray white wire Open circuit in the Blue white wire 3 No 1 Linear Solenoid Valve ...

Page 440: ...No 2 Linear Solenoid Valve Input ground Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors page 4 14 Check for continuity between the wire harness side linear solenoid valve 4P Green connector 1 and test harness 2 terminals Is there continuity YES GO TO STEP 3 NO Open circuit in the Pink white wire Open circuit in the Brown white wire 3 No 2 Linear Solenoid Valve Input...

Page 441: ...n the oil passage NO Replace the PCM with a known good one and recheck DTC 59 No 2 CLUTCH DOES NOT DISENGAGE WHEN SHIFTING GEAR See page 12 86 DTC 61 62 No 1 CLUTCH OIL PRESSURE MALFUNCTION If the PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 1 DTC Recheck Turn the ignition switch ON with the engine stop switch lower the...

Page 442: ...ith the engine stop switch lower the sidestand and check the shift indicator Is DTC 48 or 56 indicated YES DTC 48 indicated page 12 74 DTC 56 indicated page 12 85 NO GO TO STEP 2 2 No 2 Clutch EOP Sensor Inspection Replace the No 2 clutch EOP sensor with a known good one page 12 117 Erase the DTCs page 12 13 Test ride the motorcycle and stop the engine Read the DTC with the shift indicator page 12...

Page 443: ...age 20 24 Is the air gap correct YES GO TO STEP 3 NO Check each part for deformation and looseness and correct accordingly Recheck the air gap 3 Speed Sensor Condition Inspection Inspect the area around the front wheel speed sensor Check that there is no iron or other magnetic deposits between the pulser ring and wheel speed sensor and check the pulser ring slots for obstructions Check installatio...

Page 444: ...cator page 12 13 Is DTC 66 indicated YES GO TO STEP 2 NO Intermittent failure 2 VS Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the VS sensor 3P Black connector Turn the ignition switch ON Measure the voltage between the wire harness side VS sensor 3P Black connector 1 terminals Is there battery voltage YES GO TO STEP 3 NO Open circuit in the Pink blue wire Open circuit ...

Page 445: ...e page 22 18 Erase the DTCs page 12 13 Test ride the motorcycle and stop the engine Read the DTC with the shift indicator page 12 13 Is DTC 66 indicated YES Replace the PCM with a known good one and recheck NO Faulty original VS sensor DTC 67 FRONT WHEEL SPEED SENSOR NO SIGNAL Before starting the inspection check for loose or poor contact on the front wheel speed sensor 2P Blue ABS modulator 25P a...

Page 446: ... Open circuit in the Violet red wire 4 Front Wheel Speed Sensor Line Short Circuit Inspection Check for continuity between the test harness 1 terminal and ground Is there continuity YES Short circuit in the Violet red wire NO Replace the PCM with a known good one and recheck DTC 68 No 1 CLUTCH OPERATION MALFUNCTION CLUTCH SLIPS If the PCM is replaced perform the following Key Registration Procedur...

Page 447: ...r page 12 13 Is DTC 66 indicated YES Refer to DTC 66 troubleshooting page 12 89 NO GO TO STEP 2 2 Clutch Condition Inspection Remove the No 2 clutch assembly and measure the clutch clearance page 12 105 Is the clearance within the standard range YES Replace the PCM with a known good one and recheck NO Faulty No 2 clutch assembly DTC 71 72 INNER OUTER MAINSHAFT COUNTERSHAFT SPEED RATIO FAILURE If t...

Page 448: ...od one and recheck NO Intermittent failure DTC 1 SHIFT PEDAL ANGLE SENSOR OPTIONAL MALFUNCTION Before starting this inspection check for loose or poor contact on the shift pedal angle sensor 3P Black connector and PCM 33P Gray connector and recheck the MIL If the PCM is replaced perform the following procedure Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure page 12 120 DC...

Page 449: ...nnectors page 4 14 Check for continuity between the shift pedal angle sensor 3P Black connector 1 and test harness 2 terminals Is there continuity YES Replace the PCM with a known good one and recheck NO Open circuit in Green yellow wire Open circuit in Yellow red wire 4 Shift Pedal Angle Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Connect the ECM test harness to the PC...

Page 450: ...ce the PCM with a known good one and recheck NO Faulty shift pedal angle sensor replace the DCT shift pedal as an assembly MODE SHIFT INDICATOR CIRCUIT TROUBLESHOOTING If the mode indicator does not operate check that the combination meter shows following when the ignition switch is turned ON with the engine stop switch MIL 1 and engine oil pressure indicator 2 stay on Shift indicator 3 is blinkin...

Page 451: ... 1 Right handlebar switch 7P Green connector NC700SD 2 Turn the ignition switch ON with the engine stop switch Measure the voltage between the wire harness side right handlebar switch connector terminal and ground Is there battery voltage YES GO TO STEP 2 NO Open circuit in the Black white wire between the right handlebar switch connector and fuse relay box FI fuse 2 AT MT mode switch Inspection T...

Page 452: ...and recheck NO Open circuit in the White yellow wire RIGHT CRANKCASE COVER REMOVAL Drain the engine oil page 3 13 Remove the following Maintenance lid page 21 6 Shroud side cover NC700XD page 2 14 Shelter side cover NC700SD page 2 15 Right engine side cover page 2 30 Disconnect the linear solenoid valve 4P Green connector 1 and remove it from the ABS modulator stay Disconnect the CKP sensor 2P Red...

Page 453: ...assages Remove the bolts 1 and hose clamp 2 Remove the right crankcase cover 3 Remove the oil joint pipe 1 and dowel pins 2 Remove the O rings from the joint pipe Remove the seal rings 3 from the mainshaft end LINEAR SOLENOID VALVE BODY DISASSEMBLY Keep dust and dirt away from all the parts Be careful not to damage the mating surfaces of the valve body components Remove the right crankcase cover p...

Page 454: ...lve 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 Remove the bolt 1 linear solenoid valves 2 and stopper plate 3 from the valve body Remove the stopper plate from the linear solenoid valves 2 1 1 2 3 2 1 3 1 2 ...

Page 455: ... 2 for scratches scoring or damage LINEAR SOLENOID VALVE BODY ASSEMBLY Clean all the parts with compressed air Make sure that there is no dust or lint on any parts Coat linear solenoid valves 1 with engine oil Set the stopper plate 2 into the grooves in the solenoid valves 2 1 WIRE CLAMP VALVE BODY COVER LINEAR SOLENOID VALVES VALVE BODY STOPPER PLATE SEPARATE PLATE DOWEL PIN 12 N m 1 2 kgf m 9 lb...

Page 456: ...ten it Set the wire grommet 1 into the groove in the body cover 2 Install the valve body cover onto the valve body and tighten the bolts securely Check the oil filter screen 1 and packing 2 for damage and replace them if necessary Install the dowel pins 3 and separate plate 4 onto the right crankcase cover Install the valve body 1 and bolts 2 and tighten the bolts in the sequence as shown TORQUE 1...

Page 457: ...Install the wire clamp 4 and tighten bolts Install the right crankcase cover page 12 103 OIL GUIDE COLLAR REMOVAL INSTALLATION Remove the right crankcase cover page 12 97 Remove the snap ring 1 from the right crankcase cover Remove the oil guide collar 1 from the right crankcase cover with the special tool Remove the O rings from the oil guide collar Coat new O rings 1 with engine oil and install ...

Page 458: ... passages Coat new O rings 1 with engine oil and install them onto the oil joint pipe 2 Install the oil joint pipe into the oil pump Install the dowel pins 1 Apply engine oil to new seal rings 2 and install them into the mainshaft grooves Push in the seal rings to seat them into the grooves Clean the right crankcase cover mating surfaces thoroughly Apply liquid sealant Three Bond 1207B or equivale...

Page 459: ...l it onto the shift spindle angle sensor 2 Install the shift spindle angle sensor by aligning the flat surfaces of the sensor and spindle Install the following Wire clamps 1 and bolts 2 Wire clip stay 3 and bolt 4 Install the shift spindle angle sensor bolt 5 and tighten it Connect the clutch EOP sensor 3P connectors 6 Connector with no mark to the upper sensor connector with P mark to the middle ...

Page 460: ...15 Right engine side cover page 2 30 Fill the engine with the recommended engine oil and check that there are no oil leaks page 3 12 DUAL CLUTCH REMOVAL Remove the right crankcase cover page 12 97 Align the gear teeth of the primary drive gear and sub gear 1 by prying the gears through the holes 2 and hold them with a 6 mm socket bolt 3 Remove the ball bearing 1 Remove the dual clutch assembly 2 f...

Page 461: ...shaft are the same parts CLUTCH CLEARANCE INSPECTION Set a dial indicator on the end plate 1 with the plate bottomed Measure the clearance by lifting the end plate against the snap ring and record it Perform this inspection at three points in 120 apart If the measured value exceeds the service limit replace the clutch assembly ASSEMBLY Coat new O rings 1 with engine oil and install them into the g...

Page 462: ...eth with the clutch disc tabs Turn over the dual clutch assembly while holding clutch guide 1 Apply engine oil to the needle bearings in the primary driven gear Line up the clutch disc tabs with the two wide grooves 1 aligned as shown Install the washer 2 onto the clutch assembly Install clutch guide 2 3 into the clutch by aligning the gear teeth with the clutch disc tabs INSTALLATION Apply engine...

Page 463: ...sub gear 5 from the crankshaft INSTALLATION Install the primary drive gear sub gear 1 and CKP sensor rotor 2 onto the crankshaft by aligning their wide grooves with the wide tooth Apply engine oil to the primary drive gear bolt threads and seating surface Install the washer 1 and primary drive gear bolt 2 Install the special tool between the primary drive and driven gears and tighten the primary d...

Page 464: ... 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 Remove the bolts 1 and reduction gear cover 2 Remove the dowel pins 1 and gasket 2 Remove the reduction gears 3 1 2 3 2 3 1 2 1 2 3 1 ...

Page 465: ...ase Then install reduction gear C 2 so the punch marks 3 on the gear and shift spindle line up as shown Install reduction gear A 4 Install the dowel pins 1 and a new gasket 2 O RING 14 N m 1 4 kgf m 10 lbf ft 14 N m 1 4 kgf m 10 lbf ft 12 N m 1 2 kgf m 9 lbf ft TR SENSOR O RING REDUCTION GEAR CASE COVER GASKET REDUCTION GEAR A REDUCTION GEAR B REDUCTION GEAR C SHIFT CONTROL MOTOR SPECIFIED GREASE ...

Page 466: ...o 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 Install the wire clip stay 1 and TR sensor bolt 2 and tighten the bolt Coat a new O ring 1 with engine oil and install it into the groove in the shift control motor 2 TORQUE 14 N m 1 4 kgf m 10 lbf ft 1 2 2 1 Align TORQUE 12 N m 1 2 kgf m 9 lbf ft 1 2 1 2 ...

Page 467: ... page 2 30 Left rear cover page 2 30 GEARSHIFT LINKAGE REMOVAL Remove the following Shift control motor reduction gears page 12 109 Dual clutch page 12 105 Gearshift spindle 1 Washer 2 Drum shifter collar 1 Bolts 2 Drum shifter guide plate drum shifter assembly 3 Guide plate distance collar 1 Stopper arm side collar 2 Shift drum center bolt 3 Shift drum center 4 TORQUE 14 N m 1 4 kgf m 10 lbf ft 3...

Page 468: ...ndle 1 and gearshift arm 2 for wear or damage Check the return spring 3 for fatigue or damage Check the drum shifter guide plate 1 drum shifter 2 ratchet pawls 3 and plungers 4 for wear or damage Check the plunger springs 5 for fatigue or damage INSTALLATION Install the following 8 x 20 mm dowel pins 1 Shift drum center dowel pins 2 Stopper arm distance collar 3 Stopper arm return spring 4 Shift d...

Page 469: ...tall the stopper arm side collar 2 and guide plate distance collar 3 Install the plunger springs 1 plungers 2 and ratchet pawls 3 into the drum shifter 4 and set them in the drum shifter guide plate 5 Install the drum shifter guide plate drum shifter assembly 1 Apply locking agent to the threads of the guide plate bolts 2 page 12 4 Install the guide plate bolts and tighten them Install the drum sh...

Page 470: ...ainshaft sensor Remove the luggage box page 2 19 Disconnect the outer mainshaft sensor 3P Black connector 1 from the outer mainshaft sensor 2 Disconnect the inner mainshaft sensor 3P Black connector 3 from the inner mainshaft sensor 4 Remove the bolt 5 and mainshaft sensor Remove the O ring 6 from the mainshaft sensor Installation is in the reverse order of removal Replace the O ring with a new on...

Page 471: ... shift drum end SHIFT SPINDLE ANGLE SENSOR REMOVAL INSTALLATION Remove the following Shroud side cover NC700XD page 2 14 Side cowl NC700SD page 2 13 Right engine side cover page 2 30 Disconnect the shift spindle angle sensor 3P Gray connector 1 and remove it from the ABS modulator stay Remove the bolts 1 and clamps 2 Remove the bolts 3 and wire clip stay 4 Remove the shift spindle angle sensor wir...

Page 472: ... sensor Remove the clutch EOP sensor and O rings from the right crankcase cover Coat a new O ring 1 with engine oil and install it into the right crankcase cover Install the clutch EOP sensor 2 and tighten it Connect the 3P connector to the proper sensor Each sensor wires has the following identification mark near the connector 1 No 1 clutch lower EOP sensor P Clutch line middle EOP sensor No mark...

Page 473: ...registration The registration will fail if any of the following condition presents during the procedure The vehicle is moved The engine is started The transmission is in gear The shift pedal is operated incorrectly The shift pedal angle sensor 3P black connector is disconnected 1 Install the shift pedal to the vehicle and connect the shift pedal angle sensor 3P black connector 2 Turn the ignition ...

Page 474: ...E SENSOR MALFUNCTION will be indicated The cancellation will fail if any of the following condition presents during the procedure The vehicle is moved The engine is started The transmission is in gear The shift switch is operated incorrectly The shift pedal angle sensor 3P black connector is connected 1 Remove the shift pedal from the vehicle and disconnect the shift pedal angle sensor 3P black co...

Page 475: ... DCT system have no DTC Engine idle speed is normal Transmission is in neutral and cooling fan stops Do not operate the throttle during clutch initialize learning 1 Warm up the engine to the normal operating temperature engine oil temperature 50 110 C 122 230 F and stop it If the PCM is replaced with a new one the D and S indicators 1 come on to indicate that the clutch initialize learning is nece...

Page 476: ... the N switch Push the D switch Push the N switch When only the dual clutch assembly is replaced The PCM is ready to clutch initialize learning when the D and S indicators 2 lights and the 3 is displayed on the shift indicator and blinks at interval of 2 seconds When the PCM is replaced The PCM is ready to clutch initialize learning when the is displayed on the shift indicator and blinks at interv...

Page 477: ...ing is successful when the D and S indicators 2 go off Stop the engine The clutch initialize learning is unsuccessful if the starts blinking at interval of 0 5 second or it goes off and the D and S indicators stay on Perform the initialize learning procedure from step 2 again 5 Stop the engine 6 Restart the engine push the D switch of the N D shift switch and check that the D indicator comes on 1 ...

Page 478: ...13 1 13 dummytext 13 ALTERNATOR STARTER CLUTCH COMPONENT LOCATION 13 2 SERVICE INFORMATION 13 4 TROUBLESHOOTING 13 4 ALTERNATOR COVER 13 5 FLYWHEEL 13 7 STARTER CLUTCH 13 10 STATOR 13 13 ...

Page 479: ...13 2 dummyhead dummyhead ALTERNATOR STARTER CLUTCH ALTERNATOR STARTER CLUTCH COMPONENT LOCATION NC700X XA S SA 157 N m 16 0 kgf m 116 lbf ft ...

Page 480: ...13 3 dummyhead dummyhead ALTERNATOR STARTER CLUTCH NC700XD SD 157 N m 16 0 kgf m 116 lbf ft ...

Page 481: ...ANDARD SERVICE LIMIT Starter driven gear boss O D 57 749 57 768 2 2736 2 2743 57 73 2 273 Starter clutch outer I D 74 412 74 442 2 9296 2 9308 74 46 2 931 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Flywheel mounting bolt 1 12 157 16 0 116 Left hand thread Apply engine oil to the threads and seating surface Starter clutch socket bolt 6 8 30 3 1 22 Apply locking agent to the threads Coa...

Page 482: ...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 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 2 1 3 3 Align 2 1 2 1 ...

Page 483: ...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 Remove the dowel pins 1 oil orifice 2 and O ring 3 Clean off any sealant from the alternator cover mating surfaces Do not loosen the alternator cover sealing bolt 1 1 3 4 3 4 NC700X XA S SA 2 NC700XD SD 2 1 1 2 3 1 ...

Page 484: ... rear brake reservoir stay with the frame tab Fill the engine with the recommended engine oil and check that there are no oil leaks page 3 12 FLYWHEEL REMOVAL Remove the alternator cover page 13 5 Remove the starter idle gear shaft 1 and starter idle gear 2 Remove the starter reduction gear shaft 3 and starter reduction gear 4 Hold the flywheel 1 using the special tool and loosen the flywheel moun...

Page 485: ...ge and replace it if necessary Check the starter idle gear 3 and shaft 4 for wear or damage and replace it if necessary NEEDLE BEARING Check the needle bearing 1 for abnormal wear or damage Replace it if necessary STARTER CLUTCH OPERATION Check the operation of the one way clutch by turning the starter driven gear 1 You should be able to turn the starter driven gear counterclockwise smoothly but t...

Page 486: ...ting bolt threads and seating surface Install the washer 1 and flywheel mounting bolt 2 Hold the flywheel 3 using the special tool and tighten the flywheel mounting bolt to the specified torque The flywheel mounting bolt has left hand threads Apply molybdenum oil solution to the starter reduction and idle gear shaft outer surface Install the starter reduction gear 1 and shaft 2 Install the starter...

Page 487: ...tarter 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 Remove the starter clutch assembly 1 Remove the starter one way clutch 1 from the starter clutch outer 2 1 TOOL Flywheel holder 3 07725 0040001 1 3 2 1 2 1 ...

Page 488: ...clutch outer 1 inner surface for abnormal wear or damage and replace them if necessary Measure the clutch outer I D Check the starter one way clutch 2 for abnormal wear or damage and replace them if necessary INSTALLATION SERVICE LIMIT 57 73 mm 2 273 in SERVICE LIMIT 74 46 mm 2 931 in 2 1 STARTER CLUTCH OUTER ONE WAY CLUTCH FLYWHEEL STARTER DRIVEN GEAR 30 N m 3 1 kgf m 22 lbf ft ...

Page 489: ...the special tool Apply locking agent to the starter clutch socket bolt threads page 13 4 Install and tighten the starter clutch socket bolt 3 to the specified torque Install the starter driven gear 1 into the starter clutch outer while turning the starter driven gear counterclockwise Recheck the one way clutch operation page 13 8 Install the flywheel page 13 9 2 1 1 TOOL Flywheel holder 2 07725 00...

Page 490: ...he alternator stator mounting bolts 2 to the specified torque Apply liquid sealant Three bond 1207B or equivalent to the alternator wire grommet 3 sealing surface then install it into the alternator cover groove securely Apply locking agent to the alternator wire clamp bolt threads page 13 4 Install the wire clamp 4 and alternator wire clamp bolt 5 Tighten the bolt to the specified torque Install ...

Page 491: ...MEMO dummyhead dummyhead ...

Page 492: ...KCASE TRANSMISSION BALANCER COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 4 TROUBLESHOOTING 14 6 CRANKCASE SEPARATION 14 7 TRANSMISSION NC700X XA S SA 14 8 TRANSMISSION NC700XD SD 14 17 BALANCER 14 26 CRANKCASE ASSEMBLY 14 28 ...

Page 493: ...ENT LOCATION NC700X XA S SA 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 39 N m 4 0 kgf m 29 lbf ft 20 N m 2 0 kgf m 15 lbf ft 150 12 N m 1 2 kgf m 9 lbf ft 24 N m 2 4 kgf m 18 lbf ft 24 N m 2 4 kgf m 18 lbf ft 12 N m 1 2 kgf m 9 lbf ft 24 N m 2 4 kgf m 18 lbf ft ...

Page 494: ... 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 39 N m 4 0 kgf m 29 lbf ft 24 N m 2 4 kgf m 18 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 12 N m 1 2 kgf m 9 lbf ft 24 N m 2 4 kgf m 18 lbf ft ...

Page 495: ...kcase halves apply sealant to their mating surfaces Wipe off excess sealant thoroughly GENERAL NC700XD SD 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 Engine page 16 9 Engine oil filter page 3 13 EOP switch page 22 20 Starter motor page 6 8 Cyli...

Page 496: ... 43 04 1 694 C1 31 010 31 035 1 2209 1 2218 31 06 1 223 C2 25 000 25 021 0 9843 0 9851 25 03 0 985 C3 C4 31 000 31 025 1 2205 1 2215 31 04 1 222 Gear bushing O D M5 32 955 32 980 1 2974 1 2984 32 93 1 296 M6 42 950 42 975 1 6909 1 6919 42 93 1 690 C1 30 970 30 995 1 2193 1 2203 30 94 1 218 C2 24 959 24 980 0 9826 0 9835 24 94 0 982 C3 C4 30 950 30 975 1 2185 1 2195 30 93 1 218 Gear to bushing clea...

Page 497: ... or damaged transmission gear Worn or damaged transmission bearings ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Mainshaft bearing set plate bolt 3 6 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 2 6 12 1 2 9 Apply locking agent to the threads Coating width 6 5 1 0 mm 0 26 0 04 ...

Page 498: ...kcase 8 mm bolts 1 and sealing washer 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 Loosen the crankcase main journal bolt 1 in a crisscross pattern in 2 or 3 steps and remove them Separate the lower crankcase 2 from the upper crankcase Do not ply the crankcase halves wit...

Page 499: ...age 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 Keep track of the disassembled parts gears bushings washers and snap rings by sliding them onto a tool or a piece of wire Do not expand the snap ring more than necessary for removal To remove a snap ring expa...

Page 500: ...lvent thoroughly Keep track of the disassembled parts gears bushings washers and snap rings by sliding them onto a tool or a piece of wire Do not expand the snap ring more than necessary for removal To remove a snap ring expand the snap ring and pull it off using the gear behind it SHIFT DRUM SHIFT FORK Remove the shift drum bearing set plate bolts 1 and set plate 2 Remove the fork shaft 1 and shi...

Page 501: ... fork shaft O D 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 Also check that the inner race of the bearing fits tightly on the shift drum Replace the bearing if the inner race does not turn smoothly quietly or if the inner race fits loosely on the shift drum 1 2 SERVICE L...

Page 502: ...ntershaft for abnormal wear or damage Measure the mainshaft O D at the M5 bushing Measure the countershaft O D at the C2 bushing Calculate the gear bushing to shaft clearance 1 2 SERVICE LIMITS M5 M6 C1 28 04 mm 1 104 in C2 C3 C4 31 04 mm 1 222 in SERVICE LIMITS M5 M6 27 94 mm 1 100 in C2 C3 C4 30 93 mm 1 218 in SERVICE LIMITS M5 25 04 mm 0 986 in C2 28 02 mm 1 103 in SERVICE LIMITS M5 M6 0 08 mm ...

Page 503: ... the outer race fits loosely in the crankcase COUNTERSHAFT BEARING Turn the outer race of countershaft bearing 1 with your finger The bearing should turn smoothly and quietly Also check that the bearing inner race fits tightly on the countershaft Replace the countershaft collar and bearing as an assembly if the race does not turn smoothly quietly or if the inner race fits loosely on the countersha...

Page 504: ...e and bearing Apply molybdenum oil solution to the spline bushing outer surface bushing inner and outer surface shift fork grooves Assemble the mainshaft and countershaft MAINSHAFT Drive in a new bearing squarely with the marking side facing toward the inside of the crankcase TOOLS Driver 15 x 280L 2 07949 3710001 Attachment 42 x 47 mm 3 07746 0010300 Pilot 20 mm 4 07746 0040500 2 3 4 1 M2 GEAR 19...

Page 505: ...st load Install the snap rings 1 so that the end gap aligns with the groove of the splines Make sure that the snap rings are fully seated in the shaft groove after installing them C6 GEAR 31T C3 GEAR 32T C2 GEAR 36T COUNTERSHAFT C4 GEAR 30T C4 GEAR BUSHING SPLINE WASHER SNAP RING C5 GEAR 31T THRUST WASHER C1 GEAR 45T NEEDLE BEARING THRUST WASHER NEEDLE BEARING NEEDLE BEARING CAP LOCK WASHER SPLINE...

Page 506: ...e bolts threads page 14 6 Install the mainshaft bearing set plate 1 with its OUT SIDE mark 2 facing out Install and tighten the mainshaft bearing set plate bolts 3 to the specified torque Install the dowel pin 1 onto the upper crankcase hole Install the countershaft bearing set ring 2 to the countershaft bearing groove Install the countershaft assembly 3 Align the needle bearing cap hole with the ...

Page 507: ...a and guide pin Apply molybdenum oil solution to the shift fork shaft outer surface Install the shift forks 1 into the shift drum guide grooves with the identification marks facing toward the right side of the engine and insert the fork shaft 2 Apply locking agent to the shift drum bearing set plate bolt threads page 14 6 Install the set plate 1 and shift drum bearing set plate bolts 2 Tighten the...

Page 508: ...re Do not expand the snap ring more than necessary for removal To remove a snap ring expand the snap ring and pull it off using the gear behind it Remove the mainshaft bearing set plate bolts 1 and set plate 2 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...

Page 509: ...et 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 Measure the shift fork I D Measure the shift fork claw thickness 1 2 2 1 2 1 2 SERVICE LIMIT 12 03 mm 0 474 in SERVICE LIMIT 5 9 mm 0 23 in ...

Page 510: ...urn 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 TRANSMISSION Check the gear shifter groove and gear dogs for abnormal wear or damage Check the dog holes and gear teeth for abnormal wear or damage SERVICE LIMIT 11 95 mm 0 470 in ...

Page 511: ...S M5 33 04 mm 1 301 in M6 43 04 mm 1 694 in C1 31 06 mm 1 223 in C2 25 03 mm 0 985 in C3 C4 31 04 mm 1 222 in SERVICE LIMITS M5 32 93 mm 1 296 in M6 42 93 mm 1 690 in C1 30 94 mm 1 218 in C2 24 94 mm 0 982 in C3 C4 30 93 mm 1 218 in SERVICE LIMITS M5 0 10 mm 0 004 in M6 0 11 mm 0 004 in C1 0 10 mm 0 004 in C2 0 09 mm 0 004 in C3 C4 0 11 mm 0 004 in SERVICE LIMITS M5 30 03 mm 1 182 in M6 40 038 mm ...

Page 512: ...y quietly or if the inner race fits loosely on the countershaft LEFT MAINSHAFT BEARING REPLACEMENT Remove the following Crankshaft page 15 5 Pistons connecting rods page 15 14 To avoid burns wear heavy gloves when handling the heated upper crankcase Heat the upper crankcase to 80 C 176 F evenly using a heat gun Tap the upper crankcase lightly and remove the left mainshaft bearing 1 Apply engine oi...

Page 513: ...es bushing inner and outer surfaces and gear shifter grooves Assemble the mainshaft and countershaft MAINSHAFT Bushing surfaces and gear shifter grooves Gear teethe rotating surfaces and bearing M3 GEAR 22T OUTER MAINSHAFT M2 GEAR 21T M4 GEAR 25T M6 GEAR 37T M5 GEAR 30T INNER MAINSHAFT M1 GEAR 15T THRUST WASHER M5 GEAR BUSHING SPLINE WASHER SNAP RING SNAP RING M6 GEAR BUSHING THRUST WASHER SPLINE ...

Page 514: ...LINE WASHER SNAP RING C5 GEAR 31T THRUST WASHER C2 GEAR 40T C2 GEAR BUSHING THRUST WASHER NEEDLE BEARING NEEDLE BEARING CAP SPLINE WASHER C4 GEAR BUSHING SPLINE WASHER SNAP RING SNAP RING OIL SEAL COUNTERSHAFT BEARING SET RING C1 GEAR BUSHING SPLINE WASHER LOCK WASHER Bushing surfaces and gear shifter grooves Gear teethe rotating surfaces and bearing ...

Page 515: ...ed in the shaft groove after installing them 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 Apply locking agent to the mainshaft bearing set plate bolts threads page 14 6 ...

Page 516: ...2 and shift drum bearing into the lower crankcase The shift forks have the following identification marks D2M L mark 1 Mainshaft left shift fork D2M R mark 2 Mainshaft right shift fork D2C L mark 3 Countershaft left shift fork D2C R mark 4 Countershaft right shift fork Apply molybdenum oil solution to the shift fork shaft outer surfaces shift fork claws and guide pins Install the countershaft shif...

Page 517: ... the mainshaft countershaft page 14 24 Assemble the crankcase page 14 28 BALANCER REMOVAL Separate the crankcase halves page 14 7 Remove the balancer shaft bearing set plate bolts 1 and set plate 2 Remove the balancer shaft 1 and right balancer shaft bearing 2 INSPECTION Check the balancer shaft 1 and balancer driven gear 2 for excessive wear or damage Replace the balancer shaft if necessary TORQU...

Page 518: ...ger The bearing should turn smoothly and quietly Also check that the inner race of the bearing fits tightly on the balancer shaft Replace the bearing if the inner race does not turn smoothly quietly or if the inner race fits loosely on the balancer shaft LEFT BALANCER SHAFT BEARING REPLACEMENT Drive out the left balancer shaft bearing 1 from the lower crankcase Apply engine oil to a new left balan...

Page 519: ...aft bearing set plate bolts threads page 14 6 Install the balancer shaft bearing set plate 1 with its OUT SIDE mark 2 facing out Install and tighten the balancer shaft bearing set plate bolts 3 to the specified torque CRANKCASE ASSEMBLY Apply liquid sealant Three Bond 1207B or equivalent to the crankcase mating surface as shown Do not apply more liquid sealant than necessary Do not apply liquid se...

Page 520: ...CER Install the oil orifices 1 onto the upper crankcase 2 Install the oil orifices with its narrow hole side facing upper crankcase Install the dowel pins 1 onto the upper crankcase 2 1 2 1 2 NC700X XA S SA NC700XD SD NC700X XA S SA 1 1 NC700XD SD 1 1 2 2 ...

Page 521: ... the index lines 2 on the balancer driven gear as shown Remove the 6 x 14 mm socket bolt 3 Install new crankcase main journal bolts 1 Tighten the crankcase main journal bolts using the Plastic Region Tightening Method Do not reuse the crankcase main journal bolts because the correct axial tension will not be obtained The crankcase main journal bolts are pre coated with an oil additive for axial te...

Page 522: ...w sealing washer 2 The sealing washer location is indicated on the upper crankcase by the mark Tighten the crankcase 8 mm bolts to the specified torque Install the cam chain 1 to the crankshaft Install the removed parts in the reverse order of removal page 14 4 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 Crankcase 8 x 45 mm bolt 3 24 N ...

Page 523: ...MEMO dummyhead dummyhead ...

Page 524: ...5 1 15 dummytext 15 CRANKSHAFT PISTON CYLINDER COMPONENT LOCATION 15 2 SERVICE INFORMATION 15 3 TROUBLESHOOTING 15 4 CRANKSHAFT 15 5 MAIN JOURNAL BEARING 15 8 CRANKPIN BEARING 15 11 PISTON CYLINDER 15 14 ...

Page 525: ...15 2 dummyhead dummyhead CRANKSHAFT PISTON CYLINDER CRANKSHAFT PISTON CYLINDER COMPONENT LOCATION 10 N m 1 0 kgf m 7 lbf ft 90 ...

Page 526: ... 0 001 Left side 0 03 0 001 Main journal bearing oil clearance 0 019 0 037 0 0007 0 0015 0 05 0 002 Cylinder I D 73 000 73 015 2 8740 2 8746 73 07 2 877 Out of round 0 10 0 004 Taper 0 10 0 004 Warpage 0 10 0 004 Piston piston rings Piston O D at 13 mm 0 5 in from bottom 72 976 72 990 2 8731 2 8736 72 970 2 8728 Piston pin bore I D 18 010 18 013 0 7091 0 7092 18 023 0 7096 Piston pin O D 17 996 18...

Page 527: ...er compression too high overheating or knocking Excessive carbon built up on piston head or combustion chamber Excessive smoke Worn cylinder piston or piston ring Improper installation of piston rings Scored or scratched piston or cylinder wall Abnormal noise Worn piston pin or piston pin hole Worn connecting rod small end Worn cylinder piston or piston rings Worn main journal bearings Worn crankp...

Page 528: ...engine damage Mark the bearing caps and bearings as you remove them to indicate the correct cylinder for reassembly Remove the crankpin bearing cap bolts 1 and bearing caps 2 Remove the crankshaft 3 Before removal position all the pistons at TDC Top Dead Center to prevent damaging the crankpin with the connecting rod Remove the main journal bearings 1 from both crankcase halves Remove the crankpin...

Page 529: ... the original locations 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 Apply molybdenum oil solution to the main journal bearing sliding surfaces on the upper crankcase and crankpin bearing sliding surfaces on the connecting rods Apply molybdenum oil solution to the thrust...

Page 530: ...during removal Do not reuse the improperly installed connecting rod and bearing cap because their mating surfaces are damaged Align the I D code number on the connecting rods The crankpin bearing cap bolts cannot be reused Once the bolts have been loosened replace them with new ones Apply engine oil to new crankpin bearing cap bolt threads and seating surfaces Install and tighten new crankpin bear...

Page 531: ...e 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 Check the bearing tabs for damage OIL CLEARANCE INSPECTION Clean off any oil from the bearing inserts and main journals Install the crankshaft 1 onto the upper crankcase Put a strip of plastigauge 1 lengthwise on each main journal avoiding the oil...

Page 532: ...cal order as shown in a crisscross pattern in 2 or 3 steps to the specified torque Further tighten the crankcase main journal bolts 120 Remove the crankcase main journal bolt and lower crankcase Measure the compressed plastigauge at its widest point on each main journal to determine the oil clearance If the oil clearance exceeds the service limit select a replacement bearing BEARING SELECTION Lett...

Page 533: ... clearance with a plastigauge Incorrect clearance can cause severe engine damage BEARING INSTALLATION Clean the bearing outer surfaces and crankcase bearing supports Install the main journal bearing inserts 1 onto the crankcase bearing supports aligning each tab with each groove 1 MAIN JOURNAL BEARING THICKNESS A Blue Thickest B Black C Brown D Green E Yellow Thinnest 1 BEARING SUPPORT I D CODE A ...

Page 534: ...ng inserts for unusual wear or peeling Check the bearing tabs for damage OIL CLEARANCE INSPECTION Clean the mating surface of the connecting rod and crankpin bearing cap with cleaning solvent and blow them with compressed air Clean off any oil from the bearing inserts and crankpins Carefully install the crankshaft onto the upper crankcase Set the connecting rods onto the crankpins Put a strip of p...

Page 535: ...nd seating surfaces Install and tighten the crankpin bearing cap bolts 1 to the specified torque in 2 or 3 steps alternately Further tighten the bolts 90 Remove the bearing caps and measure the compressed plastigauge at its widest point on the crankpin to determine the oil clearance If the oil clearance exceeds the service limit select the correct replacement bearings BEARING SELECTION Numbers 1 2...

Page 536: ...ARING INSTALLATION Clean the bearing outer surfaces crankpin bearing cap and connecting rod Install the crankpin bearings 1 onto the bearing cap and connecting rod aligning each tab with each groove 1 CRANKPIN BEARING THICKNESS B Black Thickest C Brown D Green E Yellow F Pink G Red H White Thinnest 1 CONNECTING ROD I D CODE 1 2 3 4 43 000 43 006 mm 1 6929 1 6931 in 43 006 43 012 mm 1 6931 1 6934 i...

Page 537: ...ting in engine damage Mark the bearing caps and bearings as you remove them to indicate the correct cylinder for reassembly Remove the crankpin bearing cap bolts 1 and bearing caps 2 Remove the crankshaft 3 Remove the countershaft NC700X XA S SA page 14 8 NC700XD SD page 14 17 Remove the piston connecting rod assembly 1 from the top of the cylinder Do not try to remove the connecting rod piston as...

Page 538: ...en the screws 3 Remove the pilot collar Assemble and 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 Piston base head 1 07PAF 0010400 Piston pin pilot 2 07PAF 0010300 Piston base spring 3 07973 6570600 Piston base 4 07973 6570500 1 4 2 3 TOOLS Piston pin tool set 07PAF 0010000 Piston base head insert 07PAF 0010500 Pilot collar ...

Page 539: ... rings for free movement by rotating them in their grooves The rings should be able to move freely grooves without catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring to ring groove clearance Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder Insert the piston ring squarely into...

Page 540: ...clearance Measure the diameter of the piston at 13 mm 0 5 in from the bottom and 90 to the piston pin hole CONNECTING ROD INSPECTION Measure the connecting rod small end I D SERVICE LIMIT 18 023 mm 0 7096 in SERVICE LIMIT 17 988 mm 0 7082 in SERVICE LIMIT 0 035 mm 0 0014 in SERVICE LIMIT 72 970 mm 2 8728 in 13 mm 0 5 in SERVICE LIMIT 17 985 mm 0 7081 in ...

Page 541: ...he maximum reading to determine them Inspect the top of the cylinder for warpage PISTON INSTALLATION Face the connecting rod oil jet 1 to the piston IN mark 2 side Temporarily install the pilot collar 1 to the piston pin pilot and adjust the piston base head inserts 2 as shown then tighten the screws 3 Remove the pilot collar SERVICE LIMIT 73 07 mm 2 877 in SERVICE LIMIT 0 05 mm 0 002 in SERVICE L...

Page 542: ...the piston pin 7 insert pin insert adjuster on the pilot collar Place the piston 1 connecting rod 2 piston pin 3 and special tools on the hydraulic press Press the piston pin until special tools fully seated TOOLS Piston pin tool set 07PAF 0010000 Insert pin 07PAF 0010700 Insert adjuster 07PAF 0010800 TOOL Piston pin tool set 07PAF 0010000 Pilot collar 18 mm 07PAF 0010640 TOOLS Piston pin tool set...

Page 543: ... to the piston and cylinder sliding surface Install the piston connecting rod assemblies 1 into the cylinders using a commercially available piston ring compressor tool 2 When reusing the connecting rods they must be installed in their original locations While installing the piston be careful not to damage the top surface of the cylinder especially around the cylinder bore Be careful not to damage...

Page 544: ... ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 16 2 SERVICE INFORMATION 16 4 ENGINE REMOVAL NC700X XA S SA 16 5 ENGINE REMOVAL NC700XD SD 16 9 ENGINE INSTALLATION NC700X XA S SA 16 15 ENGINE INSTALLATION NC700XD SD 16 21 ...

Page 545: ...ION COMPONENT LOCATION NC700X XA S SA 32 N m 3 3 kgf m 24 lbf ft 10 N m 1 0 kgf m 7 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 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 32 N m 3 3 kgf m 24 lbf ft ...

Page 546: ... NC700XD SD 32 N m 3 3 kgf m 24 lbf ft 10 N m 1 0 kgf m 7 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 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 32 N m 3 3 kgf m 24 lbf ft ...

Page 547: ...mponents require engine removal for service Camshaft page 10 13 Cylinder head valves page 10 16 Transmission NC700X XA S SA page 14 8 Transmission NC700XD SD page 14 17 Balancer page 14 26 Crankshaft page 15 5 Piston cylinder page 15 14 SPECIFICATIONS TORQUE VALUES ITEM SPECIFICATIONS Enginedry weight NC700X XA S SA 60 5 kg 133 4 lbs NC700XD SD 67 3 kg 148 4 lbs Engine oil capacity NC700X XA S SA ...

Page 548: ...e the following Left rear cover page 2 29 Exhaust pipe muffler page 2 32 Radiator page 8 9 Radiator reserve tank page 8 14 Throttle body page 7 15 Disconnect the CKP sensor 2P Red connector 1 and release the CKP sensor harness 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 si...

Page 549: ...witch wire 5 Sidestand switch wire 6 Fuel tank drain hose B 7 Disconnect the VS sensor 3P Black connector 1 Disconnect the injector 2P Gray connectors 1 Release the clip 2 from the fuel rail Loosen the band screw 1 and disconnect the water hose 2 from the water pump Disconnect the spark plug cap 3 Release the spark plug wire clamp 4 from the frame 6 2 1 7 3 4 5 1 2 1 3 4 1 2 ...

Page 550: ...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 Release the main wire harness 3 from the stay 4 and frame 5 Remove the bolts 1 and clutch cable guide 2 then disconnect the clutch cable 3 from the clutch lifter arm 4 2 1 2 1 3 4 1 3 2 5 3 1 2 4 ...

Page 551: ... starter motor mounting bolt 4 and disconnect the ground cable 5 Release the fuel feed hose 6 from the clamp 7 Remove the drive sprocket bolt 1 washer 2 and drive sprocket 3 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 4 5 2 3 1 7 6 3 1 2 2 1 1 2 ...

Page 552: ...ine removal hold the engine securely and be careful not to damage the frame and engine ENGINE REMOVAL NC700XD SD 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 Left rear cover page 2 30 Guard pipe page 2 30 Center cross plat...

Page 553: ...sconnect the alternator 3P Black connector 2 Release the sidestand switch wire harness clamp 1 Release the alternator wire harness 2 Remove the wire band 1 and release the wires and hose from the stay 2 Remove the sidestand switch wire clamp 3 from the stay Disconnect the shift control motor 2P Black connector 4 and neutral switch connector 5 2 1 3 3 2 1 2 1 1 3 5 2 4 ...

Page 554: ...nnect 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 Loosen the band screw 1 and disconnect the water hose 2 from the water pump Disconnect the spark plug cap 3 Release the spark plug wire clamp 4 from the frame 2 1 2 1 1 3 4 1 2 ...

Page 555: ...nd 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 Disconnect the ECT sensor 2P connector 1 Loosen the band screw and disconnect the water hose 2 from the thermostat cover Release the main wire harness 3 from the stay 4 and frame 5 2 1 2 1 3 2 3 1 4 1 3 2 5 ...

Page 556: ...e clamp 4 Disconnect the following Inner mainshaft sensor 3P Black connector 1 Outer mainshaft sensor 3P Black connector 2 Release the rubber cap 1 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 Remove the drive sprocket bolt 1 washer 2 and driv...

Page 557: ...lder 2 Do not twist the brake hose The jack height must be continually adjusted to relieve stress for ease of bolt removal Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal Remove the upper engine hunger bolts 1 and collar 2 Remove the front lower hunger bolts 1 and collars 2 1 2 1 2 Left side 2 Right side 1 1 2 1 1 2 Left side Right side ...

Page 558: ...olt and 10 mm collar Upper left side 4 12 x 35 mm bolt Rear upper side 12 x 276 mm bolt 37 mm collar right side 5 and 47 mm collar left side 6 Rear lower side 12 x 168 mm bolt and 10 mm collar right side 7 Place the jack or other adjustable support under the engine The jack height must be continually adjusted to relieve stress for ease bolt installation Carefully align the mounting points with the...

Page 559: ...unger bolt 2 to the specified torque Tighten the rear upper engine hunger nut 1 to the specified torque Install the right step holder 1 and step holder mounting socket bolts 2 Tighten the step holder mounting socket bolts to the specified torque TORQUE 54 N m 5 5 kgf m 40 lbf ft TORQUE 54 N m 5 5 kgf m 40 lbf ft 1 2 Left side Right side TORQUE 54 N m 5 5 kgf m 40 lbf ft TORQUE 54 N m 5 5 kgf m 40 ...

Page 560: ...Tighten the mounting bolt securely Install the starter motor cable 3 and starter motor terminal nut 4 Tighten the starter motor terminal nut to the specified torque Reposition the rubber cap 5 properly on the starter motor terminal Install the fuel feed hose 6 to the clamp 7 Align the fuel feed hose White paint with clamp Connect the clutch cable 1 to the clutch lifter arm 2 Install clutch cable g...

Page 561: ...th the thermostat cover tab Install the main wire harness 3 to the stay 4 and frame 5 Tighten the water hose band screw to the specified range 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 4 1 3 2 5 Align 0 1 mm 0 0 04 in 2 3 1 1 2 ...

Page 562: ...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 Install the clip 1 to the fuel rail Connect the injector 2P Gray connectors 2 Connect the VS sensor 3P Black connector 1 2 1 3 0 1 mm 0 0 04 in 1 2 1 ...

Page 563: ...ll the wire band 6 Connect the neutral switch connector 7 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 Align the rear brake reservoir stay with the frame tab Tighten the bol...

Page 564: ...he direction of the engine hanger bolts Front lower right side 1 12 x 55 mm bolt and 20 mm collar Front lower left side 2 12 x 80 mm bolt and 41 mm collar Upper right side 3 12 x 45 mm bolt and 10 mm collar Upper left side 4 12 x 35 mm bolt Rear upper side 12 x 276 mm bolt 37 mm collar right side 5 and 47 mm collar left side 6 Rear lower side 12 x 168 mm bolt and 10 mm collar right side 7 Place th...

Page 565: ...unger bolt 2 to the specified torque Tighten the rear upper engine hunger nut 1 to the specified torque Install the right step holder 1 and step holder mounting socket bolts 2 Tighten the step holder mounting socket bolts to the specified torque TORQUE 54 N m 5 5 kgf m 40 lbf ft TORQUE 54 N m 5 5 kgf m 40 lbf ft 1 2 Left side Right side TORQUE 54 N m 5 5 kgf m 40 lbf ft TORQUE 54 N m 5 5 kgf m 40 ...

Page 566: ... bolt 2 Tighten the mounting bolt securely Install the starter motor cable 3 and starter motor terminal nut 4 Tighten the starter motor terminal nut to the specified torque Reposition the rubber cap 5 properly on the starter motor terminal Install the fuel feed hose 6 to the clamp 7 Align the fuel feed hose White paint with clamp Connect the following Inner mainshaft sensor 3P Black connector 1 Ou...

Page 567: ... modulator stay Connect the ECT sensor 2P connector 1 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 Tighten the water hose band screw to the specified range Connect the clutch EOP sensor 3P connectors 1 Install the clamps 2 and bolts 3 Tighten the bolts securely 2 3 4 1 4 1 3 ...

Page 568: ... 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 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 2 3 1 1 2 2 1 3 0 1 mm 0 0 04 in ...

Page 569: ...ct the injector 2P Gray connectors 2 Connect the VS sensor 3P Black connector 1 and EOT sensor 2P Black connector 2 Route the wires and hose properly Connect the neutral switch wire connector 1 and shift control motor 2P Black connector 2 Install the sidestand switch wire clamp 3 onto the stay Set the hose and wires into the stay 4 and install the wire band 5 1 1 2 2 1 5 3 1 4 2 ...

Page 570: ...nect 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 Center cross plate page 2 32 Guard pipe page 2 30 Left rear cover page 2 30 Inspect the throttle grip freeplay page 3 5 Adjust the drive chain slack page 3 16 Fill the engine with the recommended engine oil page 3 12 Connect the quick...

Page 571: ...MEMO dummyhead dummyhead ...

Page 572: ...mmytext 17 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 17 2 SERVICE INFORMATION 17 8 TROUBLESHOOTING 17 9 HANDLEBAR 17 10 FRONT WHEEL 17 20 FORK 17 25 STEERING STEM 17 33 CLUTCH LEVER NC700X XA S SA 17 42 ...

Page 573: ...RING FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION NC700X 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft 74 N m 7 5 kgf m 55 lbf ft 30 N m 3 1 kgf m 22 lbf ft 103 N m 10 5 kgf m 76 lbf ft 22 N m 2 2 kgf m 16 lbf ft 22 N m 2 2 kgf m 16 lbf ft ...

Page 574: ...ONT WHEEL SUSPENSION STEERING NC700XA 22 N m 2 2 kgf m 16 lbf ft 74 N m 7 5 kgf m 55 lbf ft 30 N m 3 1 kgf m 22 lbf ft 103 N m 10 5 kgf m 76 lbf ft 22 N m 2 2 kgf m 16 lbf ft 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft ...

Page 575: ...ONT WHEEL SUSPENSION STEERING NC700XD 22 N m 2 2 kgf m 16 lbf ft 74 N m 7 5 kgf m 55 lbf ft 30 N m 3 1 kgf m 22 lbf ft 103 N m 10 5 kgf m 76 lbf ft 22 N m 2 2 kgf m 16 lbf ft 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft ...

Page 576: ...RONT WHEEL SUSPENSION STEERING NC700S 22 N m 2 2 kgf m 16 lbf ft 74 N m 7 5 kgf m 55 lbf ft 30 N m 3 1 kgf m 22 lbf ft 103 N m 10 5 kgf m 76 lbf ft 22 N m 2 2 kgf m 16 lbf ft 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft ...

Page 577: ...ONT WHEEL SUSPENSION STEERING NC700SA 22 N m 2 2 kgf m 16 lbf ft 74 N m 7 5 kgf m 55 lbf ft 30 N m 3 1 kgf m 22 lbf ft 103 N m 10 5 kgf m 76 lbf ft 22 N m 2 2 kgf m 16 lbf ft 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft ...

Page 578: ...ONT WHEEL SUSPENSION STEERING NC700SD 22 N m 2 2 kgf m 16 lbf ft 74 N m 7 5 kgf m 55 lbf ft 30 N m 3 1 kgf m 22 lbf ft 103 N m 10 5 kgf m 76 lbf ft 22 N m 2 2 kgf m 16 lbf ft 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft ...

Page 579: ...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 NC700X XA XD 514 2 5 cm3 17 4 0 08 US oz 18 1 0 09 Imp oz NC700S SA SD 518 2 5 cm3 17 5 0 08 US oz 18 2 0 09 Imp oz ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Handlebar holder bolt 4 8 22 2 2 16 Handlebar switch housing screw 4 5 2 5 0 3 1 8 Front...

Page 580: ...t fork Loose steering stem adjusting nut Front wheel wobbling Bent rim Worm wheel bearing Faulty tire Insufficient tire pressure Axle not tightened properly Unbalanced tire and wheel Wheel hard to turn Faulty wheel bearing Bent axle Brake drag Soft suspension Weak fork spring Insufficient fork fluid Insufficient tire pressure Incorrect fork fluid viscosity Stiff suspension Incorrect fork fluid vis...

Page 581: ...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 Remove the screws 1 and separate the left handlebar switch housing 2 Remove the left handlebar grip rubber 3 2 1 2 1 2 3 1 4 1 2 3 ...

Page 582: ...ke 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 Separate the throttle housing 2 Disconnect the throttle cables 3 from the throttle pipe 4 then remove the throttle pipe 5 Hold the handlebar 1 and remove the bolts 2 and holder 3 1 4 2 3 1 2 3 4 1 5 2 1 3 2 ...

Page 583: ...r 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 Remove the screws 1 and separate the left handlebar switch housing 2 Remove the left handlebar grip rubber 3 2 1 1 2 1 3 2 4 1 2 3 ...

Page 584: ...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 Hold the handlebar 1 and remove the bolts 2 and holder 3 1 4 2 3 1 2 1 2 1 3 2 ...

Page 585: ...andlebar punch mark with the top bridge top surface Hold the handlebar and install the holder 2 and handlebar holder bolts 3 as shown Tighten the upper bolts first then the lower bolts to the specified torque Apply grease to the throttle cable end and throttle pipe flange groove Install the throttle pipe 1 to the handlebar Connect the throttle cable 2 end to the throttle pipe Install the throttle ...

Page 586: ... mark on the handlebar and tighten the upper bolt first then the lower bolt to the specified torque Connect the brake light switch connectors 5 Install the left handlebar switch housing 1 Align the switch housing locating pin with the handlebar hole 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 1 TORQ...

Page 587: ...rst then the lower bolt Connect the clutch switch connectors 5 Install the handlebar weight 1 to both handlebars aligning each cutout Hold the handlebar weight 1 Install and tighten a new handlebar weight mounting screw 2 to the specified torque Install the rearview mirrors 1 and wire bands 2 Adjust the following Clutch lever freeplay page 3 26 Throttle grip freeplay page 3 5 4 2 5 1 Align 3 Align...

Page 588: ...ebar punch mark with the top bridge top surface Hold the handlebar and install the holder 2 and handlebar holder bolts 3 as shown Tighten the upper bolts first then the lower bolts to the specified torque Apply grease to the throttle cable end and throttle pipe flange groove Install the throttle pipe 1 to the handlebar Connect the throttle cable 2 end to the throttle pipe Install the right handleb...

Page 589: ...e Connect the brake light switch connectors 5 Install the left handlebar switch housing 1 Align the switch housing locating pin with the handlebar hole Install the screws 1 and tighten the upper screw first then tighten the lower screw to the specified torque Install the parking brake lever bracket 1 Align the parking brake lever bracket locating pin with the handlebar hole TORQUE 12 N m 1 2 kgf m...

Page 590: ... Install the handlebar weight 1 to both handlebars aligning each cutout Hold the handlebar weight 1 Install and tighten a new handlebar weight mounting screw 2 to the specified torque Install the rearview mirrors 1 and wire bands 2 Adjust the throttle grip freeplay page 3 5 Check the parking brake lock operation page 3 24 3 1 2 Align 1 TORQUE 10 N m 1 0 kgf m 7 lbf ft 1 2 2 1 ...

Page 591: ...e inner weight align with each cut outs of the inner weight and handlebar weight Install and tighten the handlebar weight screw Install the inner weight assembly 1 into the handlebar Turn the inner weight and hook the weight retainer tab 2 with the tab locking hole 3 in the handlebar Remove the screw and handlebar weight Install the throttle pipe and grip rubber to the handlebar NC700X XA S SA pag...

Page 592: ...t axle pinch bolt 1 and front axle 2 Support the motorcycle using a safety stand or hoist raise the front wheel off the ground Remove the front axle and front wheel Do not operate the brake lever after removing the front wheel Remove the side collars 1 INSPECTION WHEEL RIM Check the wheel rim runout by placing the wheel in a truing stand Spin the wheel by hand and measure the runout using a dial i...

Page 593: ...ing direction marks 1 on the tire and upon tire installation always fit the tire so the marks face the same direction Mount the wheel tire and brake disc assembly on an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this 2 or 3 times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same position...

Page 594: ...isc mounting bolts with new ones Apply grease to the front wheel dust seal lips Install the front wheel dust seal until it is flush with the wheel hub surface Install the front brake disc with the marked side facing out 1 TORQUE Front brake disc mounting bolt 42 N m 4 3 kgf m 31 lbf ft BEARING 6204UU BEARING 6204UU DUST SEAL DISTANCE COLLAR DUST SEAL BRAKE DISC 42 N m 4 3 kgf m 31 lbf ft PULSER RI...

Page 595: ... its marked side facing up until it is fully seated Install the distance collar Drive in a new left side bearing squarely with its marked side facing up until it is seated on the distance collar INSTALLATION Install the side collars 1 Install the front wheel between the fork legs Apply a thin coat of grease to the front axle sliding surface Install the front axle 1 from left side Tighten the front...

Page 596: ...the specified torque With the front brake applied pump the forks up and down several times to seat the axle and check brake operation Tighten the front axle pinch bolt 1 to the specified torque FORK REMOVAL Remove the following Front wheel page 17 20 Front fender page 2 28 Remove the brake caliper mounting bolts 1 and brake caliper bracket assembly 2 NC700XA XD SA SD 1 2 TORQUE 30 N m 3 1 kgf m 22...

Page 597: ...e fork legs 3 and loosen the bottom bridge pinch bolts 4 and lower the fork legs then remove it DISASSEMBLY Be careful not to scratch the fork pipe Remove the dust seal 1 and stopper ring 2 Remove the following Fork cap 1 O ring 2 Spring collar 3 Spring seat 4 Remove the fork spring 1 Drain the fork fluid by pumping the fork pipe several times 1 2 4 3 2 1 1 4 3 2 1 ...

Page 598: ...ing washer 3 Do not remove the fork piston ring 4 unless it is necessary to replace with a new one Remove the fork piston 1 and rebound spring 2 from the fork pipe 3 Using quick successive motions pull the fork pipe out of the fork slider Remove the oil lock piece 1 from the fork slider 2 If the fork piston turns with the socket bolt temporarily install the fork spring spring seat spring collar an...

Page 599: ...e fork spring free length FORK PIPE SLIDER Check the fork pipe 1 and slider 2 for score marks scratches or excessive or abnormal wear Place the fork pipe on V blocks Turn the fork pipe and measure the runout using a dial indicator Actual runout is 1 2 of the total indicator reading 1 3 2 SERVICE LIMITS NC700X XA XD 387 0 mm 15 24 in NC700S SA SD 349 9 mm 13 78 in 2 1 SERVICE LIMIT 0 20 mm 0 008 in...

Page 600: ...coring or scratching or if the teflon is worn so the copper surface appears 2 on more than 3 4 of the entire surface Check the back up ring 3 replace it if there is any distortion at the points shown Do not damage the slider bushing especially the sliding surface To prevent loss of tension do not open the bushing more than necessary If the slider bushing 1 will be removed carefully remove the slid...

Page 601: ...luid to a new oil seal lips Install the guide bushing 2 back up ring 3 and oil seal 4 onto the fork pipe Install the rebound spring 1 to the fork piston 2 and install them into the fork pipe 3 20 N m 2 0 kgf m 15 lbf ft REBOUND SPRING FORK PISTON OIL LOCK PIECE DUST SEAL SEALING WASHER OIL SEAL FORK SLIDER 22 N m 2 2 kgf m 16 lbf ft FORK PISTON RING STOPPER RING FORK PIPE SPRING COLLAR FORK SPRING...

Page 602: ...ing washer 1 to the fork socket bolt 2 Apply locking agent to the fork socket bolt threads and install it If the fork piston turns with the socket bolt temporarily install the fork spring spring seat spring collar and fork cap Tighten the fork socket bolt 1 to the specified torque Drive the oil seal 1 until the stopper ring groove 2 is visible using the special tools 4 3 2 1 2 1 TORQUE 20 N m 2 0 ...

Page 603: ...ipe up and install the fork spring 1 with the tightly wound coil side facing down Install the spring seat 2 and spring collar 3 Apply fork fluid to a new O ring 1 and install it onto the fork cap 2 Loosely install the fork cap by pushing it to the fork pipe 3 1 2 RECOMMENDED FORK FLUID Honda ULTRA CUSHION OIL 10W or equivalent FORK FLUID CAPACITY NC700X XA XD 514 2 5 cm3 17 4 0 08 US oz 18 1 0 09 ...

Page 604: ...Install the front brake caliper bracket assembly 1 and tighten new brake caliper mounting bolts 2 to the specified torque Install the following Front fender page 2 28 Front wheel page 17 24 STEERING STEM REMOVAL NC700X XA XD Remove the following Shroud side cover page 2 14 Handlebar NC700X XA page 17 10 NC700XD page 17 12 Disconnect the ignition switch 2P Brown connector 1 and immobilizer receiver...

Page 605: ... Remove the following Headlight headlight stay page 2 27 Handlebar NC700S SA page 17 10 NC700SD page 17 12 Disconnect the ignition switch 2P Brown connector 1 and immobilizer receiver 4P Black connector 2 NC700S SA SD Remove the headlight cover page 2 27 Disconnect the combination meter 16P Gray connector 1 Remove the socket bolts 2 brake hose guide 3 and combination meter stay 4 2 1 NC700X XA XD ...

Page 606: ...e NC700XD 1 Left handlebar switch wire harness clamp 2 Throttle cables 3 Right handlebar switch wire harness clamp 4 Brake hose 5 Remove the top bridge 6 NC700XA XD SA SD Remove the bolt 1 front wheel speed sensor wire guide 2 and brake hose joints 3 Straighten the lock washer tabs 1 Remove the steering stem adjusting lock nut 2 and lock washer 1 NC700X XA XD 1 5 3 2 4 6 1 3 2 NC700XA XD SA SD 2 1...

Page 607: ...ead bearing 3 Steering stem 4 Lower steering head bearing 5 BEARING REPLACEMENT Replace the bearing outer and inner races as a set Remove the upper outer race using a special tool Remove the lower bearing outer race using the special tool and suitable shaft TOOL Steering stem socket 2 07916 3710101 1 2 2 4 5 1 3 TOOLS Ball race remover set 07953 MJ10000 Remover attachment 1 07953 MJ10100 Remover h...

Page 608: ...ad bearing dust seal 4 Apply specified grease to a new steering head bearing dust seal lips page 1 23 Install the steering head bearing dust seal 1 to the steering stem Install a new lower inner race 2 using a hydraulic press and special tool Drive in a new upper outer race 1 using the special tools Drive in a new lower outer race 1 using the special tools 2 1 3 4 TOOL Attachment 30 mm I D 3 07746...

Page 609: ...e steering stem 2 upper inner race 3 and dust seal 4 Apply engine oil to the steering stem adjusting nut 1 threads Install and tighten the steering stem adjusting nut to the specified torque using a special tool STEERING STEM 39 N m 4 0 kgf m 29 lbf ft NC700XA XD SA SD LOCK NUT LOCK WASHER ADJUSTING NUT UPPER OUTER RACE UPPER INNER RACE UPPER DUST SEAL UPPER BEARING LOWER OUTER RACE LOWER BEARING ...

Page 610: ...er Further tighten the lock nut within 90 to align its grooves with the tabs of the lock washer Bend up the long lock washer tabs 3 into the grooves of the lock nut NC700XA XD SA SD Install the brake hose joints 1 front wheel speed sensor wire guide 2 and bolt 3 Route the wires hose and cable properly page 1 25 Note the installation position of the brake hose joints Right side Brake sub hose C whi...

Page 611: ...t Install the fork legs page 17 33 Tighten the steering stem nut to the specified torque Turn the steering stem left and right lock to lock several times to make sure the steering stem moves smoothly without play or binding Install the cap to the steering stem nut NC700X Install the brake hose clamp 1 and bolt 2 to the bottom bridge Be sure to rest the brake hose clamp against the bottom bridge ta...

Page 612: ... guide 2 and socket bolts 3 Route the wires hose and cable properly page 1 25 Install the brake hose guide against the combination meter stay Connect the combination meter 16P Gray connector 4 NC700S SA SD Install the headlight cover page 2 27 Connect the ignition switch 2P Brown connector 1 and immobilizer receiver 4P Black connector 2 Install the following Headlight headlight stay page 2 27 Hand...

Page 613: ... 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 Install and tighten the clutch lever pivot bolt to the specified torque Install and tighten the clutch lever pivot nut to the specified torque while holding the clutch lever pivot bolt 1 3 2 4 TORQUE 1 0 N m 0 1 kgf m 0 7 lbf ft TORQUE 6 0 N m 0...

Page 614: ...18 1 18 dummytext 18 REAR WHEEL SUSPENSION COMPONENT LOCATION 18 2 SERVICE INFORMATION 18 4 TROUBLESHOOTING 18 5 REAR WHEEL 18 6 SHOCK LINKAGE 18 13 SHOCK ABSORBER 18 14 SWINGARM 18 16 ...

Page 615: ...N COMPONENT LOCATION NC700X XA S SA 12 N m 1 2 kgf m 9 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 44 N m 4 5 kgf m 32 lbf ft 32 N m 3 3 kgf m 24 lbf ft NC700XA SA shown 44 N m 4 5 kgf m 32 lbf ft ...

Page 616: ...d REAR WHEEL SUSPENSION NC700XD SD 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 44 N m 4 5 kgf m 32 lbf ft 32 N m 3 3 kgf m 24 lbf ft 44 N m 4 5 kgf m 32 lbf ft ...

Page 617: ...re pressure Driver only 290 kPa 2 90 kgf cm2 42 psi Driver and passenger 290 kPa 2 90 kgf cm2 42 psi Axle runout 0 2 0 01 Wheel rim runout Radial 2 0 0 08 Axial 2 0 0 08 Wheel balance weight 60 g 2 1 oz max Drive chain Size link NC700X XA S SA DID DID520V0 114LE RK RK520MKO 114LE NC700XD SD DID DID520V0 112LE RK RK520MKO 112LE Slack NC700X XA XD 30 40 1 2 1 6 NC700S SA SD 25 35 1 0 1 4 ITEM Q TY T...

Page 618: ...r swingarm Axle not tightened properly Unbalanced tire and wheel Insufficient tire pressure Wheel hard to turn Brake drag Faulty wheel bearing Faulty driven flange bearing Bent axle Drive chain too tight page 3 16 Soft suspension Weak shock absorber spring Oil leakage from damper unit Insufficient tire pressure Stiff suspension Bent shock absorber damper rod Damaged suspension or swingarm pivot be...

Page 619: ...d sensor 2 Loosen the lock nut 1 drive chain adjusting nut 2 and axle nut 3 Push the rear wheel forward Derail the drive chain 4 from the driven sprocket Remove the axle nut washer 5 and adjusting plate 6 Remove the axle 7 adjusting plate and rear wheel Remove the side collars 1 NC700XA XD SA SD 1 2 NC700XA XD SA SD Do not operate the brake pedal after removing the rear wheel 2 4 7 1 3 6 5 1 ...

Page 620: ...t the outer race fits tightly in the wheel hub and driven flange Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in the wheel hub and driven flange WHEEL BALANCE For wheel balance servicing page 17 22 DRIVEN SPROCKET For driven sprocket inspection page 3 18 DISASSEMBLY Loosen the rear brake disc mounting bolts 1 in a crisscross pattern in 2 or 3 ste...

Page 621: ... driven sprocket nuts 1 and driven sprocket 2 Drive out the rear wheel distance collar B 1 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 1 2 3 1 2 2 1 TOOLS Driver 2 07749 0010000 Attachment 22 x 24 mm 3 07746 0010800 Pilot 20 mm 4 07746 0040500 2 3 4 1 ...

Page 622: ...e wheel hub Remove the distance collar and drive out the other bearing ASSEMBLY 1 TOOLS Bearing remover head 20 mm 07746 0050600 Bearing remover shaft 07GGD 0010100 2 1 BEARING 6204UU BEARING 22 x 50 x 15 DAMPER RUBBER O RING DISTANCE COLLAR DRIVEN FLANGE REAR WHEEL DISTANCE COLLAR B BEARING 6204UU DUST SEAL BRAKE DISC DUST SEAL 42 N m 4 3 kgf m 31 lbf ft PULSER RING NC700XA XD SA SD DRIVEN SPROCK...

Page 623: ...ange bearing 2 Drive in the driven flange bearing collar 1 squarely with its collar side facing down until it is fully seated Install the driven sprocket 1 to the driven flange Install the driven sprocket with its marked side facing out Temporarily install the driven sprocket nuts 2 TOOLS Driver 2 07749 0010000 Attachment 42 x 47 mm 3 07746 0010300 Pilot 20 mm 4 07746 0040500 1 3 4 2 5 6 TOOLS Dri...

Page 624: ...al 3 to the driven flange Install the pulser ring NC700XA XD SA SD 1 onto right wheel hub Install the rear brake disc 2 with its arrow mark 3 facing out Install and tighten new brake disc bolts 4 to the specified torque in a crisscross pattern in 2 or 3 steps Apply grease to a new dust seal lips Install the dust seal 5 to the right wheel hub Do not get grease on the brake disc INSTALLATION Install...

Page 625: ...l the rear axle 2 from the left side through the axle adjusting plate 3 swingarm rear wheel and collars Install the adjusting plate washer 4 and rear axle nut 5 Tighten the rear axle nut to the specified torque Adjust the drive chain slack page 3 16 NC700XA XD SA SD Install the rear wheel speed sensor 1 and bolts 2 Tighten the bolts securely Check the air gap between the rear wheel speed sensor an...

Page 626: ...ove the shock link bolt 1 nut 2 and shock links 3 from the shock arm 4 Remove the collars 1 from the shock arm 2 Check the collars for wear damage or fatigue Check the shock arm for cracks or damage Replace them if necessary Check the needle bearings 3 for damage or loose fit If the needle bearings are damaged replace them page 18 14 Assembly is in the reverse order of disassembly TORQUE Shock abs...

Page 627: ... or hoist raise the rear wheel off the ground Remove the shroud side cover NC700X XA XD page 2 14 Remove the shelter side cover NC700S SA SD page 2 15 Remove the shock arm bolt 1 and nut 2 Remove the shock absorber lower mounting bolt 3 and nut 4 Remove the shock absorber upper mounting nut 1 Remove the shock absorber upper mounting socket bolt 2 and shock absorber Installation is in the reverse o...

Page 628: ...g area and new dust seal lips Install the dust seals until it is flush with the shock absorber surface Install the collar BEARING REPLACEMENT Drive the needle bearing 1 out of the lower pivot using a hydraulic press and special tool Never install the old bearing once the bearing has been removed the bearing must be replaced with new ones Apply molybdenum disulfide grease to new needle bearings rot...

Page 629: ...mper case than the measurement given above or you may drill into the oil chamber Then high pressure oil may cause serious injury Always wear eye protection to avoid getting metal shavings in your eyes when the gas pressure is released The plastic bag is only intended to shield you from the escaping gas Hold the bag around the drill motor and briefly run the drill motor inside the bag this will inf...

Page 630: ... sensor wire NC700XA SA 4 from the brake hose guide NC700XD SD 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 Remove the screws 5 and parking brake cable guides 6 Remove the shock link bolt 1 and nut 2 Remove the shock absorber lower mounting bolt 3 and nut 4 2 1 NC700XA SA shown 1 2 3 4 NC700XD SD 1 2 3 4 5 6 ...

Page 631: ... Remove the drive chain slider mounting screws 1 and washers 2 Remove the drive chain slider 3 by releasing the slider slit 4 from the swingarm tab and slider tabs 5 from the swingarm holes Remove the pivot collars 1 dust seals 2 and distance collar 3 from the swingarm pivot Check the collar for wear damage or fatigue Check the needle bearings 4 for damage or loose fit replace it if necessary page...

Page 632: ...e bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the swingarm pivot Remove and discard the bearing if the race does not turn smoothly and quietly or if it fits loosely in the swingarm pivot page 18 19 PIVOT BEARING REPLACEMENT Remove the snap ring 1 from the right pivot Drive the needle bearing 1 and ball bearing 2 out of the right pivot using a hyd...

Page 633: ...ial tools as shown Apply grease to a new ball bearing rotating area Install the ball 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 15 x 280L 2 07949 3710001 Pilot 32 mm 3 07MAD PR90200 2 1 3 TOOLS Bearing remover set 17 mm 2 07936 3710300 Remover handle 3 07936 3710100 Remover weight 4 07741 0...

Page 634: ...needle bearings 1 into the shock absorber bracket with the marked side facing out until it is flush with the bracket surface using a hydraulic press and special tools as shown Install the snap ring 1 into the right pivot groove securely Do not reuse the snap ring which could easily spin in the groove Make sure that the snap ring is firmly seated in the groove TOOLS Driver 2 07749 0010000 Attachmen...

Page 635: ...arm pivot Install the dust seal flush with the pivot surface Install the wide pivot collar 3 to the swingarm right pivot Install the narrow pivot collar 4 to the swingarm left pivot PIVOT COLLAR DRIVE CHAIN SLIDER SWINGARM DRIVE CHAIN ADJUSTERS DUST SEAL DISTANCE COLLAR NEEDLE BEARING PIVOT COLLAR DUST SEAL SNAP RING BEARING NEEDLE BEARING COLLAR 5 9 N m 0 6 kgf m 4 4 lbf ft WASHER NEEDLE BEARING ...

Page 636: ...oat of grease to the swingarm pivot bolt sliding surface Set the drive chain 1 onto the swingarm 2 and install the swingarm to the frame Install the swingarm pivot bolt 3 from the left side Install the washer 1 and swingarm pivot nut 2 Tighten the swingarm pivot nut to the specified torque Install the right step holder 1 and step holder mounting socket bolts 2 Tighten the step holder mounting sock...

Page 637: ...0XA SA 1 and brake hose 2 to the brake hose guide 3 Install the brake hose guide and socket bolts 4 Tighten the socket bolts securely NC700XD SD Install the rear wheel speed sensor wire 1 and brake hose 2 to the brake hose guide 3 Install the brake hose guide and socket bolts 4 Tighten the socket bolts securely Install the parking brake cable guides 5 and screws 6 Tighten the screws securely Insta...

Page 638: ...NC700X XA S SA Install the gearshift arm 1 to the gearshift spindle Align the gearshift arm slit with the gearshift spindle punch mark Install and tighten a new gearshift arm pinch bolt 2 to the specified torque Install the following Muffler page 2 32 Rear wheel page 18 11 TORQUE 32 N m 3 3 kgf m 24 lbf ft 1 NC700X XA S SA shown 2 TORQUE 12 N m 1 2 kgf m 9 lbf ft NC700X XA S SA 2 1 Align ...

Page 639: ...MEMO dummyhead dummyhead ...

Page 640: ...NC700X S 19 8 BRAKE FLUID REPLACEMENT AIR BLEEDING NC700XA XD SA SD 19 11 BRAKE PAD DISC 19 16 FRONT MASTER CYLINDER 19 20 REAR MASTER CYLINDER 19 23 FRONT BRAKE CALIPER NC700X S 19 26 FRONT BRAKE CALIPER NC700XA XD SA SD 19 28 REAR BRAKE CALIPER 19 30 PARKING BRAKE CALIPER NC700XD SD 19 32 BRAKE PEDAL 19 37 PARKING BRAKE LEVER NC700XD SD 19 38 ...

Page 641: ...ULIC BRAKE HYDRAULIC BRAKE COMPONENT LOCATION 34 N m 3 5 kgf m 25 lbf ft 30 N m 3 1 kgf m 22 lbf ft 12 N m 1 2 kgf m 9 lbf ft 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft NC700X S 17 N m 1 7 kgf m 13 lbf ft NC700XA SA shown ...

Page 642: ...dummyhead HYDRAULIC BRAKE NC700X XA S SA 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft 12 N m 1 2 kgf m 9 lbf ft 22 N m 2 2 kgf m 16 lbf ft 32 N m 3 3 kgf m 24 lbf ft 10 N m 1 0 kgf m 7 lbf ft NC700XA SA shown ...

Page 643: ...myhead HYDRAULIC BRAKE NC700XD SD 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft 12 N m 1 2 kgf m 9 lbf ft 22 N m 2 2 kgf m 16 lbf ft 32 N m 3 3 kgf m 24 lbf ft 10 N m 1 0 kgf m 7 lbf ft 31 N m 3 2 kgf m 23 lbf ft ...

Page 644: ... 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 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 11 043 0 4331 0 4348 ...

Page 645: ...Step holder mounting socket bolt 4 8 32 3 3 24 Rear master cylinder hose joint screw 1 4 1 5 0 2 1 1 Apply locking agent to the threads Rear master cylinder push rod lock nut 1 8 17 1 7 13 Front brake caliper pin 1 8 22 2 2 16 Apply locking agent to the threads Apply 0 4 g 0 01 oz silicone grease to the sliding surface Front brake caliper bracket pin 1 8 12 1 2 9 Apply locking agent to the threads...

Page 646: ... deformed brake disc Sticking worn caliper piston Sticking worn master cylinder piston Bent brake lever pedal Brake lever pedal hard Clogged restricted hydraulic system Sticking worn caliper piston Caliper not sliding properly Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever pedal Brake drags Contaminated brake pad disc Misaligned wheel Badly worn brake pad disc Warpe...

Page 647: ...over 2 set plate 3 and diaphragm 4 Rear brake Support the motorcycle in an upright position Remove the rear brake reservoir mounting bolt 1 and reservoir 2 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 Conne...

Page 648: ...he system again After bleeding the system completely tighten the brake caliper bleed valve to the specified torque If the brake bleeder is not available perform the following procedure Pump up the system pressure with the brake lever pedal until the lever pedal resistance is felt Connect a bleed hose 1 to the bleed valve 2 1 Squeeze the brake lever pedal all the way and loosen the bleed valve 1 4 ...

Page 649: ...ue Rear 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 Install the reservoir and rear brake reservoir mounting bolt Align the reservoir tab 8 with the reservoir stay upper hole 9 Tighten the bolt to the specified torque 1 Front shown TORQUE 1 5 ...

Page 650: ...r cover 2 set plate 3 and diaphragm 4 Connect a bleed hose 1 to the front brake caliper upper bleed valve 2 Loosen the upper bleed valve and pump the brake lever until no more fluid flows out of the bleed valve PEDAL COMBI BRAKE LINE Support the motorcycle in an upright position Remove the rear brake reservoir mounting bolt 1 and reservoir 2 Remove the cover screws 3 reservoir cover 4 set plate 5 ...

Page 651: ...t of the bleed valve Tighten the bleed valve Connect a bleed hose 1 to the rear brake caliper bleed valve 2 Loosen the bleed valve and pump the brake pedal until no more fluid flows out of the bleed valve Tighten the bleed valve BRAKE FLUID FILLING AIR BLEEDING BRAKE FLUID LINE 1 2 2 1 REAR BRAKE CALIPER ABS MODULATOR FRONT MASTER CYLINDER FRONT BRAKE CALIPER PCV REAR MASTER CYLINDER DELAY VALVE ...

Page 652: ...bleeding the air completely tighten the brake caliper bleed valve to the specified torque If a brake bleeder is not available use the following procedure Fill the reservoir with DOT 4 brake fluid from a sealed container Connect a bleed hose 1 to the front brake caliper upper bleed valve 2 Pressurize the system with the brake lever until lever resistance is felt 1 Squeeze the brake lever all the wa...

Page 653: ...eed valve It is not problem if the fluid flowing out from the center bleed valve contains air bubbles because the lines will be bled later page 19 15 Connect a commercially available brake bleeder 1 to the rear brake caliper bleed valve Repeat above step 1 and 2 for rear brake caliper bleed valve Bleed the hydraulic system page 19 15 If a brake bleeder is not available use the following procedure ...

Page 654: ...r bubbles do not appear in the transparent hose 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 Note that you may feel strong resistance on the rear combi brake pedal during pumping when bleeding air from the caliper This symptom is caused by the PCV function Be sure to apply the brake pedal fully After there are no m...

Page 655: ...move the brake pad pin 1 and brake pads 2 Do not operate the brake lever after removing the brake pads Install new brake pads to the brake caliper so their ends seat against the retainer Make sure that the retainer and pad spring are installed to the brake caliper Check that the brake pad pin stopper ring 3 is in good condition replace if necessary Apply silicone grease to the brake pad pin stoppe...

Page 656: ...ke caliper so their ends seat against the retainer Make sure that the retainer is installed to the caliper bracket Check that the brake pad pin stopper ring 2 is in good condition replace if necessary Apply silicone grease to the brake pad pin stopper ring and install it to the brake pad pin 3 groove Install the brake pad pin by pushing the pads against the pad spring to align the brake pad pin ho...

Page 657: ...the caliper 1 and remove the brake pads 2 Install new brake pads to the brake caliper so their ends seat against the retainer Make sure that the retainer and pad spring 3 are installed to the brake caliper Lower the caliper Loosely install a new rear brake caliper mounting bolt 1 Check that the brake pad pin stopper ring 2 is in good condition replace it if necessary Apply silicone grease to the b...

Page 658: ...e the brake caliper mounting bolt 1 and caliper 2 from the bracket Remove the parking brake pad pins 1 and pads 2 Make sure the pad spring is installed in position Install new parking brake pads and pad pins Install the parking brake caliper and new mounting bolts and tighten the bolt to the specified torque Tighten the parking brake pad pins to the specified torque TORQUE 22 N m 2 2 kgf m 16 lbf ...

Page 659: ...lace the brake disc if the wheel bearings are normal FRONT MASTER CYLINDER REMOVAL INSTALLATION Drain the brake fluid from the hydraulic system NC700X S page 19 8 NC700XA XD SA SD page 19 11 Release the dust cover 1 Loosen the lock nut 2 and remove the rearview mirror Disconnect the brake light switch connectors 3 Remove the brake hose oil bolt 1 sealing washers 2 and brake hose 3 When removing th...

Page 660: ... Tightening the front master cylinder holder bolts upper bolt first then the lower bolt to the specified torque Replace the sealing washers with new ones Install the brake hose eyelet joint against the master cylinder stopper Fill the reservoir to the upper level and bleed the front brake system NC700X S page 19 9 NC700XA XD SA SD page 19 12 TORQUE Front master cylinder holder bolt 12 N m 1 2 kgf ...

Page 661: ...lips to turn inside out Make sure the snap ring is firmly seated in the groove Align the brake light switch boss and master cylinder hole Apply 0 10 g 0 004 oz of silicone grease to the brake lever sliding surface and lever to master piston contacting area Apply 0 10 g 0 004 oz of silicone grease to the brake lever pivot bolt sliding surface TOOL Snap ring pliers 07914 SA50001 SNAP RING RESERVOIR ...

Page 662: ...iston O D REAR MASTER CYLINDER REMOVAL INSTALLATION Drain the brake fluid from the hydraulic system NC700X S page 19 8 NC700XA XD SA SD page 19 11 Remove the muffler page 2 32 Remove the brake hose oil bolt 1 sealing washers 2 and brake hose 3 When removing the oil bolt cover the end of the brake hose to prevent contamination Remove the step holder mounting socket bolts 1 and right step holder 2 1...

Page 663: ...3 and master cylinder 4 from the right step holder Installation is in the reverse order of removal Replace the cotter pin and sealing washers with new ones Install the brake hose eyelet joint against the master cylinder stopper Fill the reservoir to the upper level and bleed the rear brake system NC700X S page 19 9 NC700XA XD SA SD page 19 12 1 3 2 TORQUE Rear master cylinder mounting bolt 12 N m ...

Page 664: ... with a new one Apply brake fluid to a new hose joint O ring Apply locking agent to the rear master cylinder hose joint screw threads If the push rod joint is disassembled adjust the push rod length so that the distance from the center of the master cylinder lower mounting hole to the center of the joint pin hole is standard length as shown After adjustment tighten the push rod lock nut 1 to the s...

Page 665: ...19 16 Remove the brake hose oil bolt 1 sealing washers 2 and brake hose Remove the brake caliper mounting bolts 3 and brake caliper bracket assembly 4 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 joint between the brake caliper body Route the hoses properly page 1 25 Fill the reservoir...

Page 666: ...acket pin threads Replace the piston seals and dust seals with new ones Apply brake fluid to the caliper pistons and new piston seals 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 surf...

Page 667: ... NC700XA XD SA SD REMOVAL INSTALLATION Drain the brake fluid from the hydraulic system page 19 11 Remove the brake pads page 19 17 Remove the bolt 1 and front wheel speed sensor wire guide 2 Remove the bolts 3 and front wheel speed sensor 4 Remove the brake hose oil bolts 1 sealing washers 2 and brake hoses When removing the oil bolt cover the end of brake hose to prevent contamination SERVICE LIM...

Page 668: ...g page 20 24 DISASSEMBLY ASSEMBLY Disassemble the front brake caliper as following the illustration Be careful not to damage the piston sliding surface If the caliper pin boot and bracket pin boot are hard or deteriorated replace it with a new one TORQUE Front brake caliper mounting bolt 30 N m 3 1 kgf m 22 lbf ft Brake hose oil bolt 34 N m 3 5 kgf m 25 lbf ft 1 2 BLEED VALVE 5 4 N m 0 6 kgf m 4 0...

Page 669: ...g surface Apply 0 4 g 0 01 oz of silicone grease to the caliper pin and bracket pin sliding surface INSPECTION Check the caliper cylinders for scoring or other damage Measure the each caliper cylinder I D Check the caliper pistons for scratches scoring or other damage Measure the each caliper piston O D REAR BRAKE CALIPER REMOVAL INSTALLATION Drain the brake fluid from the hydraulic system NC700X ...

Page 670: ...ed the rear brake system NC700X S page 19 9 NC700XA XD SA SD page 19 12 Check the air gap between the rear wheel speed sensor and pulser ring page 20 24 DISASSEMBLY ASSEMBLY Disassemble the rear brake caliper as following the illustration Be careful not to damage the piston sliding surface If the caliper pin boot and sleeve boot are hard or deteriorated replace it with a new one NC700XA XD SA SD s...

Page 671: ...equivalent to the brake pad retainer mating surface Apply 0 4 g 0 01 oz of silicone grease to the boot inside INSPECTION Check the caliper cylinder for scoring scratches or damage Measure the caliper cylinder I D Check the caliper piston for scoring scratches or damage Measure the caliper piston O D PARKING BRAKE CALIPER NC700XD SD REMOVAL INSTALLATION Remove the parking brake pads page 19 19 Disc...

Page 672: ...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 Remove the brake arm Remove the brake shaft boot 1 1 2 5 1 3 4 1 2 1 ...

Page 673: ... 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 1 2 1 1 2 ...

Page 674: ...ines 3 installation range and screw the shaft into the caliper Make sure that the punch mark is positioned between the index lines with the shaft fully installed PAD SPRING BRACKET PIN BOOT BRAKE SHAFT BRAKE ARM LOCK NUT 17 N m 1 7 kgf m 13 lbf ft CALIPER PIN BOLT 22 N m 2 2 kgf m 16 lbf ft CALIPER PIN BOOT SLEEVE CALIPER PIN BOOT BRACKET BRAKE SHAFT BOOT ADJUSTER BOLT PISTON DUST SEAL PAD PIN 17 ...

Page 675: ... 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 Install the brake shaft boot 1 to the caliper groove Install the brake arm 1 by aligning with the punch marks Install the lock nut 1 and tighten it to the specified torque while holding the brake arm 2 1 2 1 1 Align TORQUE 17 N m 1 7 kgf m 13 lbf ft 1 2 ...

Page 676: ...stall the parking brake caliper pin bolt 1 and tighten it to the specified torque BRAKE PEDAL REMOVAL INSTALLATION Remove the muffler page 2 32 Remove the step holder mounting socket bolts 1 and right step holder 2 Unhook the brake light switch spring 1 from the brake pedal Remove and discard the cotter pin 2 Remove the joint pin 3 and disconnect the push rod lower joint from the brake pedal 4 Rem...

Page 677: ...e 22 23 Loosen the parking brake cable mounting nut 1 Remove the socket bolts 2 holder 3 and parking brake lever bracket 4 Remove the parking brake adjuster bolt lock nut 1 while holding the brake arm 2 Remove the brake arm and release the parking brake cable 3 from the cable guide 4 Turn the parking brake lever bracket 1 and remove the parking brake cable joint 2 from the bracket Disconnect the p...

Page 678: ...bles and wire harness properly page 1 25 Check the parking brake lock operation page 3 24 DISASSEMBLY Remove the lower holder cap 1 Remove the spring pin 1 and release shaft 2 Remove the E clip 1 washer 2 and parking brake lever 3 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 Align 1 1 2 2 1 3 ...

Page 679: ...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 1 1 2 1 2 2 1 ...

Page 680: ...r 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 Install the lower holder cap 1 1 Align 1 2 2 1 Align 1 ...

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Page 682: ...DIAGRAM 20 3 SERVICE INFORMATION 20 4 ABS CONNECTOR LOCATIONS 20 5 ABS TROUBLESHOOTING INFORMATION 20 7 ABS INDICATOR PROBLEM CODE INDEX 20 10 ABS INDICATOR CIRCUIT TROUBLESHOOTING 20 12 ABS TROUBLESHOOTING 20 15 WHEEL SPEED SENSOR 20 24 PCV 20 28 DELAY VALVE 20 28 ABS MODULATOR 20 29 ...

Page 683: ...20 2 dummyhead dummyhead ANTI LOCK BRAKE SYSTEM ABS ANTI LOCK BRAKE SYSTEM ABS ABS SYSTEM LOCATION BATTERY FUSE BOX ABS MODULATOR FRONT WHEEL SPEED SENSOR REAR WHEEL SPEED SENSOR PCV DELAY VALVE DLC ...

Page 684: ...B IG 61 62 54 11 12 DIAG MOTOR GND GND 21 4 10 SCS 13 25 24 FSR B MR B 18 2 3 12 16 8 9 51 52 53 81 21 23 BATTERY FUSE BOX IGNITION SWITCH CLOCK TURN 7 5A ABS M 30 A ABS SOL 30 A ILLUMI STOP HORN 7 5A ABS MAIN 7 5A MAIN 30 A FRONT BRAKE LIGHT SWITCH REAR BRAKE LIGHT SWITCH FRONT WHEEL SPEED SENSOR REAR WHEEL SPEED SENSOR 2P BLUE 8P BLUE 2P GRAY FRONT PULSER RING REAR PULSER RING ABS MODULATOR 25P ...

Page 685: ...ORMATION carefully inspect and troubleshoot the ABS system according to the Diagnostic Troubleshooting flow chart Observe each step of the procedures one by one Write down the problem code and probable faulty part before starting diagnosis and troubleshooting Use a fully charged battery Do not diagnose with a charger connected to the battery After troubleshooting erase the problem code and perform...

Page 686: ...OR 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 NOTE 2 Remove the luggage box page 2 19 REAR WHEEL SPEED SENSOR 2P GRAY CONNECTOR NOTE 1 ABS MODULATOR ABS MODULATOR 25P CONNECTOR NOTE 2 ...

Page 687: ... 14 NOTE 5 Remove the side cowl NC700SA SD page 2 13 NOTE 6 Remove the windscreen page 2 23 DLC NOTE 3 FUSE BOX NOTE 3 ABS fuse 30 A ABS M ABS fuse 30 A ABS SOL ABS fuse 7 5 A ABS MAIN FRONT WHEEL SPEED SENSOR 2P BLUE CONNECTOR NOTE 4 NC700XA XD NC700SA SD FRONT WHEEL SPEED SENSOR 2P BLUE CONNECTOR NOTE 5 COMBINATION METER 16P GRAY CONNECTOR NOTE 6 ...

Page 688: ...tays on to notify the rider of the problem The self diagnosis is also made while the motorcycle is running and the ABS indicator blinks when a problem is detected When the ABS indicator blinks the cause of the problem can be identified by retrieving the problem code following the specified retrieval procedure page 20 8 If the ABS indicator does not come on when the ignition switch is turned ON or ...

Page 689: ... switch to ON again does not indicate the problem code To show the problem code again repeat the problem code retrieval procedures from the beginning Be sure to make a note of the retrieval problem code s After diagnostic troubleshooting erase the problem code s and perform the pre start self diagnosis to be sure that there is no problem in the ABS indicator indicator is operating normally Do not ...

Page 690: ...tool 2 Turn the ignition switch ON and engine stop switch to while squeezing the brake lever The ABS indicator should come on 2 seconds and go off 3 Release the brake lever immediately after the ABS indicator is off The ABS indicator should come on 4 Squeeze the brake lever immediately after the ABS indicator is on The ABS indicator should go off 5 Release the brake lever immediately after the ABS...

Page 691: ...5 A ABS MAIN ABS indicator never come ON at all 20 12 ABS indicator stays ON at all 20 13 11 Front wheel speed sensor circuit malfunction Wheel speed sensor or related wires O O Stops ABS operation 20 15 13 Rear wheel speed sensor malfunction Wheel speed sensor or related wires O O 20 17 12 Front wheel speed sensor circuit malfunction Wheel speed sensor or related wires Electromagnetic interferenc...

Page 692: ...cuit Under voltage Input voltage too low ABS fuse 7 5 A ABS MAIN O O Stops ABS operation 20 22 62 Power circuit Over voltage Input voltage too high O O Stops ABS operation 71 Tire malfunction Tire size O Stops ABS operation 20 24 81 ABS control unit ABS control unit malfunction ABS modulator O O Stops ABS operation 20 24 Problem Code Function failure Detection Symptom Fail safe function Refer to A...

Page 693: ...ection Pull up the lock lever 1 and disconnect the ABS modulator 25P connector 2 Turn the ignition switch ON and engine stop switch to Check the ABS indicator Does the ABS indicator come on YES Faulty ABS modulator NO GO TO STEP 3 3 Indicator Signal Line Short Circuit Inspection Turn the ignition switch OFF Check for continuity between the ABS modulator 25P connector 1 of the wire harness side and...

Page 694: ... 1 of the wire harness side and ground with a jumper wire 2 Turn the ignition switch ON and engine stop switch to Check the ABS indicator Does it go off YES GO TO STEP 3 NO Faulty combination meter 3 Indicator Signal Line Open Circuit Inspection Turn the ignition switch OFF Remove the jumper wire from the combination meter 16P Gray connector Short the ABS modulator 25P connector 1 of the wire harn...

Page 695: ...n the fuse box for blown Is the fuse blown YES GO TO STEP 6 NO GO TO STEP 7 6 Power Input Line Short Circuit Inspection With the ABS fuse 7 5 A ABS MAIN removed check for continuity between the ABS modulator 25P connector 1 of the wire harness side and ground Is there continuity YES Short circuit in Red black wire Replace the ABS fuse 7 5 A ABS MAIN with a new one and recheck NO Intermittent failu...

Page 696: ...er diagnostic troubleshooting erase the problem code page 20 9 then test ride the motorcycle above 30 km h 18 mph and check the other problem code by retrieving the self diagnosis system page 20 8 Before starting the diagnosis and troubleshooting check the ABS indicator circuit page 20 12 PROBLEM CODE 11 12 21 41 or 42 Front Wheel Speed Sensor Front Pulser Ring Front Wheel Lock The ABS indicator m...

Page 697: ...el Speed Sensor Line Short Circuit Inspection at sensor side Turn the ignition switch OFF Disconnect the front wheel speed sensor 2P Blue connector 1 Check for continuity between each terminal of the sensor side front wheel speed sensor 2P Blue connector and ground Is there continuity YES Faulty front wheel speed sensor NO GO TO STEP 4 4 Front Wheel Speed Sensor Line Short Circuit Inspection at wi...

Page 698: ...BS indicator 1 Dose the ABS indicator indicate the code 11 12 21 41 or 42 YES Faulty ABS modulator NO Faulty removed wheel speed sensor PROBLEM CODE 13 14 23 or 43 Rear Wheel Speed Sensor Rear Pulser Ring Rear Wheel Lock The ABS indicator might blink under unusual riding or conditions page 20 10 This is temporary failure Erase the problem code page 20 9 then test ride the motorcycle above 30 km h ...

Page 699: ... part 3 Rear Wheel Speed Sensor Line Short Circuit Inspection at sensor side Turn the ignition switch OFF Disconnect the rear wheel speed sensor 2P Gray connector 1 Check for continuity between each terminal of the sensor side rear wheel speed sensor 2P Gray connector and ground Is there continuity YES Faulty rear wheel speed sensor NO GO TO STEP 4 4 Rear Wheel Speed Sensor Line Short Circuit Insp...

Page 700: ... sensor 2P Gray connectors 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 Dose the ABS indicator indicate the code 13 14 23 or 43 YES Faulty ABS modulator NO Faulty removed wheel speed sensor PROBLEM CODE 31 32 33 34 37 or 38 Solenoid Valve 1 Failure Reproduction Erase the problem code page 20 9 Tes...

Page 701: ... Short circuit in Violet white wire NO Intermittent failure Replace the ABS fuse 30 A ABS M with a new one and recheck 3 Motor 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 Does the standard voltage exist YES GO TO STEP 4 NO Open circu...

Page 702: ... 54 Fail safe Relay 1 Fuse Inspection Check the ABS fuse 30 A ABS SOL 1 in the fuse box for blown Is the fuse blown YES GO TO STEP 2 NO GO TO STEP 3 2 Relay Power Input Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ABS modulator 25P connector 1 Check for continuity between the ABS modulator 25P connector of the wire harness side and ground Is there continuity YES Short ...

Page 703: ...ector 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 54 YES Faulty ABS modulator NO Fail safe relay is normal intermittent failure PROBLEM CODE 61 or 62 Power Circuit 1 Fuse Inspection Check the A...

Page 704: ...witch ON and engine stop switch Measure the voltage between the ABS modulator 25P connector of the wire harness side and ground Does the standard voltage exist YES GO TO STEP 4 NO Open circuit in Red black wire between the ABS modulator 25P connector and ignition switch 4 Failure Reproduction Turn the ignition switch OFF Connect the ABS modulator 25P connector Erase the problem code page 20 9 Test...

Page 705: ...age 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 81 YES Faulty ABS modulator NO ABS control unit is normal intermittent failure WHEEL SPEED SENSOR AIR GAP INSPECTION Support the motorcycle securely using a hoist or equivalent and raise the wheel off the ground Measure the clearance ai...

Page 706: ...L INSTALLATION Remove the bolts 1 and radiator lower stay 2 Release the radiator boss from the radiator mounting rubber 3 Release the fan motor 3P Gray connector 1 air cleaner housing drain hose 2 and spark plug wire 3 from the radiator NC700XA XD Remove the shroud side cover page 2 14 Remove the front wheel speed sensor 2P Blue connector 1 from the frame and disconnect the connector 2 1 Align 1 3...

Page 707: ...front wheel speed sensor wire guide 4 Remove the bolts 5 and front wheel speed sensor 6 Clean around the mounting area of the caliper bracket thoroughly and be sure that no foreign material is allowed to enter the mounting hole Installation is in the reverse order of removal Route the wire and hoses properly page 1 25 Make sure the radiator mounting rubber slits facing down Align radiator lower st...

Page 708: ... wheel speed sensor wire 4 from the brake hose guide Remove the clamp 1 and release the rear wheel speed sensor wire 2 Remove the bolts 3 and rear wheel speed sensor 4 Clean around the mounting area of the caliper bracket thoroughly and be sure that no foreign material is allowed to enter the mounting hole Installation is in the reverse order of removal Route the wire and hoses properly page 1 25 ...

Page 709: ... sliding surface DELAY VALVE 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 nut 1 and disconnect the brake pipe from the delay valve 2 Remove the delay valve mounting bolts 3 and delay valve Be careful not to bent or damage the brake pipes Installation is in the reverse order of re...

Page 710: ...CV page 20 28 Pull up the lock lever 1 and disconnect the ABS modulator 25P connector 2 Release the main wire harness clamp s 3 from the ABS modulator stay Loosen the brake pipe joint nuts 1 and disconnect the brake pipes from the ABS modulator Remove the ABS modulator stay mounting bolts 1 collars 2 and ABS modulator assembly 3 Be careful not to bent or damage the brake pipes 3 1 2 3 NC700XA only...

Page 711: ...properly page 1 25 2 1 3 TORQUE PCV mounting bolt 12 N m 1 2 kgf m 9 lbf ft Delay valve mounting bolt 12 N m 1 2 kgf m 9 lbf ft Brake pipe joint nut 14 N m 1 4 kgf m 10 lbf ft BRAKE PIPE JOINT NUT 14 N m 1 4 kgf m 10 lbf ft ABS MODULATOR 25P CONNECTOR ABS MODULATOR STAY ABS MODULATOR STAY MOUNTING BOLTS COLLARS DELAY VALVE DELAY VALVE MOUNTING BOLTS 12 N m 1 2 kgf m 9 lbf ft PCV MOUNTING BOLT LONG...

Page 712: ...om the ABS modulator stay Pull up the lock lever 1 and disconnect the ABS modulator 25P connector 2 Release the main wire harness clamps 3 from the ABS modulator stay Loosen the brake pipe joint nuts 1 and disconnect the brake pipes from the ABS modulator Remove the center cross plate page 2 32 Remove the TR sensor 3P Black connector 1 and Junction D 24P connector 2 from the ABS modulator stay Rem...

Page 713: ...bf ft Delay valve mounting bolt 12 N m 1 2 kgf m 9 lbf ft Brake pipe joint nut 14 N m 1 4 kgf m 10 lbf ft BRAKE PIPE JOINT NUT 14 N m 1 4 kgf m 10 lbf ft ABS MODULATOR 25P CONNECTOR ABS MODULATOR STAY ABS MODULATOR STAY MOUNTING BOLTS COLLARS DELAY VALVE DELAY VALVE MOUNTING BOLTS 12 N m 1 2 kgf m 9 lbf ft PCV MOUNTING BOLT LONG 12 N m 1 2 kgf m 9 lbf ft PCV PCV MOUNTING BOLT SHORT 12 N m 1 2 kgf ...

Page 714: ...xt 21 BATTERY CHARGING SYSTEM SYSTEM LOCATION 21 2 SYSTEM DIAGRAM 21 2 SERVICE INFORMATION 21 3 TROUBLESHOOTING 21 5 BATTERY 21 6 CHARGING SYSTEM INSPECTION 21 7 REGULATOR RECTIFIER 21 8 ALTERNATOR CHARGING COIL 21 9 ...

Page 715: ...ead BATTERY CHARGING SYSTEM BATTERY CHARGING SYSTEM SYSTEM LOCATION SYSTEM DIAGRAM ALTERNATOR REGULATOR RECTIFIER MAIN FUSE 30 A BATTERY BATTERY REGULATOR RECTIFIER MAIN FUSE 30 A ALTERNATOR G R Y Y Y G Green R Red Y Yellow ...

Page 716: ...ntenance of the battery Check if the battery is frequently under heavy load such as having the headlight and taillight ON for long periods of time without riding the motorcycle The battery will self discharge when the motorcycle is not in use For this reason charge the battery every two weeks to prevent sulfation from occurring When checking the charging system always follow the steps in the troub...

Page 717: ... Battery Type YTZ12S Capacity 12 V 11 Ah Current leakage 1 2 mA maximum Voltage 20 C 68 F Fully charged 13 0 13 2 V Needs charging Below 12 4 V Charging current Normal 1 1 A 5 10 h Quick 5 5 A 1 h Alternator Capacity 0 42 kW 5 000 min 1 rpm Charging coil resistance 20 C 68 F 0 1 0 5 Ω ...

Page 718: ... battery NO GO TO STEP 4 4 REGULATOR RECTIFIER SYSTEM INSPECTION Check the voltage and resistance at the regulator rectifier connector page 21 8 Are the results of checked voltage and resistance correct YES GO TO STEP 5 NO Open circuit in related wire Loose or poor contacts of related terminal Shorted wire harness 5 ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil page 21 9 I...

Page 719: ...itive cable first then connect the negative cable For digital clock setting procedure page 22 14 VOLTAGE INSPECTION Remove the maintenance lid page 21 6 Measure the battery voltage using a commercially available digital multimeter BATTERY TESTING Remove the battery page 21 6 Refer to the instructions that are appropriate to the battery testing equipment available to you Always turn the ignition sw...

Page 720: ...e by one and measuring the current CHARGING VOLTAGE INSPECTION Make sure the battery is in good condition before performing this test Start the engine and warm it up to the operating temperature then stop the engine Remove the maintenance lid page 21 6 Connect the multimeter between the positive terminal 1 and negative terminal 2 of the battery To prevent a short make absolutely certain which are ...

Page 721: ...lign the rear brake reservoir stay with the frame tab SYSTEM INSPECTION Check connectors for loose contact or corroded terminals Inspect the following items Battery charging line page 21 8 Ground line page 21 9 Charging coil page 21 9 If all components of the charging system are normal and there are no loose connections at the regulator rectifier connectors replace the regulator rectifier BATTERY ...

Page 722: ...the stator coil to make this test Disconnect the alternator 3P Black connector 1 page 21 8 Measure the resistance between the alternator 3P Black connector each terminals at the wire side Check for continuity between the alternator 3P Black connector 1 each terminals at the wire side and ground Replace the stator if the resistance is out of specification or if any wire has continuity to ground For...

Page 723: ...MEMO dummyhead dummyhead ...

Page 724: ...ER 22 8 SPEEDOMETER VS SENSOR 22 16 TACHOMETER 22 18 HIGH COOLANT TEMPERATURE INDICATOR ECT SENSOR 22 18 ENGINE OIL PRESSURE INDICATOR EOP SWITCH 22 19 FUEL LEVEL SENSOR 22 21 PARKING BRAKE INDICATOR SWITCH NC700XD SD 22 22 IGNITION SWITCH 22 24 HANDLEBAR SWITCHES 22 25 BRAKE LIGHT SWITCH 22 26 CLUTCH SWITCH NC700X XA S SA 22 26 NEUTRAL SWITCH 22 27 SIDESTAND SWITCH 22 28 HORN 22 29 TURN SIGNAL HA...

Page 725: ...ND SWITCH IGNITION SWITCH FRONT BRAKE LIGHT SWITCH EOP SWITCH ECT SENSOR REAR BRAKE LIGHT SWITCH FUEL LEVEL SENSOR CLUTCH SWITCH NEUTRAL SWITCH VS SENSOR TURN SIGNAL HAZARD RELAY HORN SIDESTAND SWITCH IGNITION SWITCH FRONT BRAKE LIGHT SWITCH EOP SWITCH ECT SENSOR REAR BRAKE LIGHT SWITCH FUEL LEVEL SENSOR PARKING BRAKE SWITCH NEUTRAL SWITCH VS SENSOR ...

Page 726: ...odes are used throughout this section SPECIFICATIONS TORQUE VALUES Bu Blue G Green P Pink V Violet Y Yellow Bl Black Gr Gray R Red W White 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 LED Turn signal indicator LED High beam indicator LED Neutral indicator LED Engine oil pressure indica...

Page 727: ...or contact of related terminals Open circuit in Pink blue wire Open circuit in Green red wire 4 VS Sensor Signal Line Inspection With the ignition switch OFF check for continuity between the VS sensor 3P Black connector and combination meter 16P Gray connector Is there continuity YES GO TO STEP 5 NO Open circuit in Pink green wire 5 VS Sensor Signal Inspection Connect the VS sensor 3P Black connec...

Page 728: ...e dust cover tightly against the headlight unit Install the dust cover with its TOP mark 5 and arrow mark 6 facing up Connect the headlight 3P Black connector BULB REPLACEMENT NC700S SA SD Remove the headlight headlight stay page 2 27 Remove the dust cover 1 Unhook the bulb retainer 2 and remove the headlight bulb 3 Avoid touching halogen headlight bulb Finger prints can create hot spots that caus...

Page 729: ... 2 24 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 FRONT NC700S SA SD Remove the headlight headlight stay page 2 27 Disconnect the front turn signal light 3P connector 1 Remove the turn signal light mounting screw 2 setting plate 3 and turn signal...

Page 730: ...CEMENT NC700X XA XD Pull out the position light bulb socket 1 Remove the bulb 2 from the socket replace it with a new one Installation is in the reverse order of removal Route the wires properly page 1 25 BULB REPLACEMENT NC700S SA SD Remove the headlight headlight stay page 2 27 Pull out the position light bulb socket 1 Remove the bulb 2 from the socket replace it with a new one Installation is i...

Page 731: ... poor contact terminals at the combination meter 16P Gray connector Turn the ignition switch ON and engine stop switch check that the tachometer segment 1 move to full scale and then tachometer segment go off If the tachometer segment does not show initial function check the combination meter power input line page 22 10 If the power and ground lines are OK replace the combination meter assembly NC...

Page 732: ...XD page 22 9 NC700SD page 22 9 If the MIL and engine oil pressure indicator are stay on and tachometer high coolant temperature indicator and HISS indicator does not come on inspect the following DTC with the HDS page 4 12 TXD RXD line page 22 11 REMOVAL INSTALLATION NC700X XA XD Remove the windscreen page 2 23 Remove the dust cover 1 Disconnect the combination meter 16P Gray connector 2 Remove th...

Page 733: ...ness side and ground There should be battery voltage with the ignition switch turned ON If there is no voltage check the following Open circuit in the Pink blue wire Blown sub fuse 7 5 A ILLUMI STOP HORN BACK UP VOLTAGE LINE Measure the voltage at the combination meter 16P Gray connector 1 of the wire harness side and ground There should be battery voltage at all times If there is no voltage check...

Page 734: ... and engine stop switch check the combination meter TXD RXD line page 22 12 If the engine stop switch turned the combination meter indicate same operation NC700XD SD Turn the ignition switch ON with the engine stop switch and check the combination meter The TXD RXD line is abnormal if the combination meter shows following MIL 1 and engine oil pressure indicator 2 stay on Shift indicator 3 is blink...

Page 735: ...se 7 5 A ENG STOP 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 Combination Meter Serial Line Short Circuit Inspection Turn the ignition switch OFF Remove the windscreen page 2 23 Remove the dust cover 1 and disconnect the combination meter 16P Gray connector 2 Remove the following Shroud side cov...

Page 736: ... Output Voltage Inspection Connect the combination meter 16P Gray connector Turn the ignition switch ON and engine stop switch while pushing and holding combination meter A button 1 and B button 2 over 10 seconds The combination meter enters the communication diagnostic mode Measure the voltage at the ECM PCM 33P connector 1 of the wire harness side and ground Does the standard voltage exist YES G...

Page 737: ...r 10 seconds The ECM PCM enters the communication diagnostic mode Measure the voltage at the combination meter 16P Gray connector 1 of the wire harness side and ground Does the standard voltage exist YES Inspect the combination meter page 22 10 NO Replace the ECM PCM with a known good one and recheck COMBINATION METER DIGITAL CLOCK SET PROCEDURE Turn the ignition switch ON Push and hold both the c...

Page 738: ...til 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 Push the B button until the desired minute 1 is displayed Push and hold to advance the minute fast Push the A button then digital clock is set Push the A button and B button The combination meter return to the normal mode 1 1 1 1 ...

Page 739: ...ssembly NC700X XA page 22 9 NC700S SA page 22 9 If pulse voltage does not appear check for open or short circuit in Pink green wire If the Pink green wire is OK check for the VS sensor signal line page 22 17 SYSTEM INSPECTION NC700XD SD If the speedometer does not operate check the following Combination meter system inspection page 22 9 MIL blinking If the MIL blinks 11 check the VS sensor system ...

Page 740: ... not appear the Pink green wire has an open circuit VS SENSOR SIGNAL LINE INSPECTION NC700X XA S SA Remove the windscreen page 2 23 Disconnect the combination meter 16P Gray connector 1 Disconnect the VS sensor 3P Black connector 1 Check for continuity between the combination meter 16P Gray connector 1 and VS sensor 3P Black connector 2 of the wire harness side If there is no continuity check for ...

Page 741: ...n meter assembly NC700X XA XD page 22 9 NC700S SA SD page 22 9 HIGH COOLANT TEMPERATURE INDICATOR ECT SENSOR SYSTEM INSPECTION If the high coolant temperature indicator does not operate properly check the following Combination meter system inspection NC700X XA S SA page 22 8 NC700XD SD page 22 9 TXD RXD line page 22 11 MIL blinking If the MIL blinks 7 check the ECT sensor system page 4 45 ECT sens...

Page 742: ... comes on when the ignition switch is turned ON then goes off when the engine starts If the engine oil pressure indicator does not come on with the ignition switch turned ON check the combination meter system inspection NC700X XA S SA page 22 8 NC700XD SD page 22 9 The engine oil pressure indicator does not go out when the engine running check the following Engine oil level page 3 12 TXD RXD line ...

Page 743: ... recheck If the ECM PCM is replaced perform the following Key Registration Procedure page 23 6 Clutch Initialize Learning Procedure NC700XD SD page 12 120 EOP SWITCH REMOVAL INSTALLATION Remove the radiator reserve tank page 8 14 Disconnect the EOP switch 1P Gray connector 1 Remove the EOP switch 2 from the crankcase Installation is in the reverse order of removal Apply sealant to the EOP switch t...

Page 744: ...ch is ON perform the inspection as follow Disconnect the combination meter 16P Gray connector page 22 8 Disconnect the fuel pump unit 3P Black connector page 7 10 Check for continuity between the combination meter 16P Gray connector 2 and fuel pump unit 3P Black connector 3 of the wire harness side If there is no continuity check for open circuit in Black green wire and loose contact of the wire h...

Page 745: ... connector terminals with a jumper wire Turn the ignition switch ON The parking brake indicator should come on If the indicator does not come on check for open circuit in the Black Brown and Green wires If the indicator comes on check the parking brake switch page 22 22 PARKING BRAKE SWITCH INSPECTION Disconnect the parking brake switch connectors Check for continuity between the parking brake swi...

Page 746: ...ke 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 Apply grease to the parking brake switch spring sliding surface Align the parking brake lever holder cover hole with the holder boss 1 4 3 1 2 TORQUE Parking brake switch screw 1 2 N m 0 1 kgf m 0 9 lbf ft Align ...

Page 747: ...n each switch position Refer to the wiring diagram for the terminals and switch status NC700X page 24 2 NC700XA page 24 3 NC700XD page 24 4 NC700S page 24 5 NC700SA page 24 6 NC700SD page 24 7 REMOVAL INSTALLATION Remove the top bridge page 17 33 Remove the ignition switch mounting bolts 1 and ignition switch 2 Installation is in the reverse order of removal Replace the ignition switch mounting bo...

Page 748: ...C700XA page 24 3 NC700XD page 24 4 NC700S page 24 5 NC700SA page 24 6 NC700SD page 24 7 LEFT HANDLEBAR SWITCHES Remove the shroud side cover NC700X XA XD page 2 14 Remove the headlight headlight stay NC700S SA SD page 2 27 Disconnect the following Left handlebar switch 10P Gray connector 1 Left handlebar switch 3P Black connector NC700XD 2 Left handlebar switch 7P Green connector NC700SD 3 Check f...

Page 749: ...XA XD page 2 14 Remove the shelter side cover NC700S SA SD page 2 15 Disconnect the rear brake light switch 3P Black connector 1 and check for continuity between the terminals There should be continuity with the brake pedal applied and there should be no continuity with the brake pedal released CLUTCH SWITCH NC700X XA S SA Disconnect the clutch switch connectors and check for continuity between th...

Page 750: ...re between the neutral diode and neutral indicator If the continuity inspection is abnormal replace the neutral switch page 22 28 INSPECTION NC700XD SD Make sure that the neutral indicator 1 comes on when the ignition switch is turned ON and transmission is in neutral and goes off when the transmission is in gear If the neutral indicator does not operate properly check the shift indicator blinking...

Page 751: ...he neutral switch connector 1 Remove the neutral switch 2 and sealing washer 3 from the crankcase Install the neutral switch with a new sealing washer and tighten it Connect the neutral switch connector Install the reduction gears shift control motor page 12 110 SIDESTAND SWITCH INSPECTION Remove the following Shroud side cover NC700X XA XD page 2 14 Shelter side cover NC700S SA SD page 2 15 Left ...

Page 752: ... switch 2 Installation is in the reverse order of removal Replace the sidestand switch mounting bolt with a new one Align the sidestand switch tab with the sidestand hole Align the sidestand switch groove with the return spring holding pin Route the wire properly page 1 25 HORN INSPECTION Remove the lower cowl page 2 28 Disconnect the wire connectors 1 from the horn 2 Connect the 12 V battery to t...

Page 753: ...00X XA XD page 2 16 Remove the side cowl NC700S SA SD page 2 13 Turn the ignition switch OFF Release the turn signal hazard relay 1 from the luggage box Disconnect the turn signal hazard relay 4P connector 2 from the turn signal hazard relay Check the following at the wire harness side 4P connector 1 Battery Power Source Line Open Circuit Inspection Measure the voltage between the 4P connector 1 t...

Page 754: ... Do the turn signal light illuminate YES GO TO STEP 4 NO Open circuit in the Gray wire Faulty turn signal switch or hazard switch left handlebar switch Faulty turn signal light circuits 4 Ignition Switch Power Source Line Open Circuit Inspection Turn the ignition switch ON Measure the voltage between the 4P connector 1 terminal and ground Is there battery voltage YES System is normal replace the t...

Page 755: ... 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 Route the wire properly page 1 25 1 2 ...

Page 756: ...ISS SYSTEM LOCATION 23 2 SYSTEM DIAGRAM 23 2 SERVICE INFORMATION 23 3 KEY REGISTRATION PROCEDURES 23 3 DIAGNOSTIC CODE INDICATION 23 6 TROUBLESHOOTING 23 8 HISS INDICATOR 23 10 ECM NC700X XA S SA PCM NC700XD SD 23 11 IMMOBILIZER RECEIVER 23 12 ...

Page 757: ... ANGLE SENSOR ENGINE STOP SWITCH BATTERY FUSE BOX ECM PCM IMMOBILIZER RECEIVER HISS INDICATOR CKP SENSOR MAIN 30 A 2P RED BATTERY ENG STOP 7 5 A CLOCK TURN 7 5 A Bl R Bl Bl R Bl R W G G O R Bu G O Y G Y Bu P Y R Bu Y R Y R 4P BLACK O Bu P G O P G Y Y W Y Bl Black Bu Blue G Green O Orange P Pink R Red W White Y Yellow G R ENGINE STOP SWITCH IGNITION SWITCH R W Y Bl R W Y 8P BLUE ...

Page 758: ...th the shape of the original key 3 Apply 12 V battery voltage to the CKP sensor lines of the ECM PCM using the special tool page 23 6 4 Turn the ignition switch ON with the original key and engine stop switch The HISS indicator comes on and it remains on The code of the original key recognized by the ECM PCM If there is any problem in the immobilizer system HISS the system will enter the diagnosti...

Page 759: ...tive terminal for two seconds or more then connect it again The indicator remains on for approx two seconds then it blinks four times repeatedly The immobilizer system HISS enters the registration mode Registrations of all key except the original key set near the receiver are cancelled 7 Turn the ignition switch OFF and remove the key 8 Install the ignition switch page 22 24 9 Turn the ignition sw...

Page 760: ...e normal mode 20 Check that the engine can be started using all registered key When all keys have been lost 1 Obtain a new ECM PCM and new key set 2 Replace the ignition switch with a new one page 22 24 3 Replace the ECM PCM with a new one page 4 67 4 Turn the ignition switch ON with a first new key and engine stop switch The HISS indicator comes on for two seconds then it blinks four times repeat...

Page 761: ...ator will remain for approx ten seconds then it will indicate the diagnostic code page 23 7 7 Turn the ignition switch OFF and remove the second key The system ECM PCM will not enter the normal mode unless the two keys are registered in ECM PCM The third new key cannot be continuously registered When it is necessary to register the third key follow the procedures When the key has been lost or addi...

Page 762: ...ire harness Follow the troubleshooting page 23 8 Identification code is disagree Jamming by the other transponder Keep the other vehicle s transponder key away from the immobilizer receiver more than 50 mm 2 0 in Secret code is disagree ON OFF 10 sec BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Registration is overlapped The key is already registered properly Use a new key or cancelled key Code sign...

Page 763: ...uit in Red white wire 4 TXD RXD Line Inspection between The ECM PCM and Combination Meter Check the TXD RXD line Red blue wire between the ECM PCM 33P connector and combination meter 16P Gray connector page 23 10 Is there continuity NO Open circuit in Red blue wire YES GO TO STEP 5 5 Power Input Line Inspection at The ECM PCM Connector Check the power input line Black red and Black wire at the ECM...

Page 764: ...P sensor 2P Red connector page 23 11 Is there continuity YES Open circuit in Yellow wire Open circuit in White yellow and or Green orange wire NO Faulty ECM PCM Diagnostic code is indicated Code signals cannot send or receive 1 Immobilizer Receiver Power Input Line Inspection Check the power input line Yellow red wire at the immobilizer receiver 4P Black connector page 23 12 Is there approx 5 V YE...

Page 765: ...INE INSPECTION Measure the voltage between the combination meter 16P Gray connector terminals There should be battery voltage at all times TXD RXD LINE INSPECTION Disconnect the following ECM 33P Black connector NC700X XA S SA 1 PCM 33P Gray connector NC700XD SD 1 Combination meter 16P Gray connector 2 Check for continuity between the ECM PCM 33P connector and combination meter 16P Gray connector ...

Page 766: ...onnector of the ECM NC700XD SD Remove the luggage box lid hinge assembly page 2 19 Turn the ignition switch OFF Disconnect the PCM 33P Gray connector 1 Perform the following inspections at the wire harness side connector of the PCM POWER INPUT LINE INSPECTION Turn the ignition switch ON and engine stop switch Measure the voltage between the ECM PCM 33P connector 1 terminal and ground There should ...

Page 767: ...or 2 and CKP sensor 2P Red connector terminals There should be continuity between the same color wire terminals IMMOBILIZER RECEIVER INSPECTION Remove the shroud side cover NC700X XA XD page 2 14 Remove the headlight headlight stay NC700S SA SD page 2 27 Disconnect the immobilizer receiver 4P Black connector 1 CONNECTION Green orange Ground Green Ground TOOL Test probe 07ZAJ RDJA110 1 G O G CONNEC...

Page 768: ...should be continuity at all times SIGNAL 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 There should be approx 5 V Disconnect the ECM PCM 33P connector 1 page 23 11 Check for continuity between the ECM PCM 33P connector and immobilizer receiver 4P Black connector 2 ter...

Page 769: ...all the top bridge page 17 38 REPLACEMENT PARTS FOR PROBLEM Accessory lock means the luggage box lid lock and seat lock CONNECTION Blue Ground TOOL Test probe 07ZAJ RDJA110 Bu 1 Route the receiver wire properly page 1 25 2 1 Problem Replacement parts Transponder Key Immobilizer receiver ECM PCM Ignition switch assembly Key set Accessory lock and key One Key has been lost or additional spare key is...

Page 770: ...24 1 24 dummytext 24 WIRING DIAGRAM NC700X 24 2 NC700XA 24 3 NC700XD 24 4 NC700S 24 5 NC700SA 24 6 NC700SD 24 7 ...

Page 771: ...00XD SD 12 2 ENGINE REMOVAL INSTALLATION 16 2 FRONT WHEEL SUSPENSION STEERING 17 2 FUEL SYSTEM 7 2 HYDRAULIC BRAKE 19 2 REAR WHEEL SUSPENSION 18 2 COOLANT REPLACEMENT 8 6 COOLING SYSTEM 3 16 CRANKCASE ASSEMBLY 14 28 CRANKCASE BREATHER 3 8 CRANKCASE SEPARATION 14 7 CRANKPIN BEARING 15 11 CRANKSHAFT 15 5 CYLINDER COMPRESSION TEST 10 5 CYLINDER HEAD 10 16 CYLINDER HEAD COVER 10 5 D DCT CONNECTOR LOCA...

Page 772: ... 15 RADIATOR RESERVE TANK 8 14 REAR BRAKE CALIPER 19 30 REAR FENDER A 2 12 REAR FENDER B 2 12 REAR FENDER MUD GUARD U type 2 10 REAR MASTER CYLINDER 19 23 REAR WHEEL 18 6 REGULATOR RECTIFIER 21 8 RIGHT CRANKCASE COVER CLUTCH GEARSHIFT LINKAGE NC700X XA S SA 11 5 DUAL CLUTCH TRANSMISSION DCT NC700XD SD 12 97 RIGHT ENGINE SIDE COVER NC700XD SD 2 30 ROCKER ARM 10 8 S SEAT COWL 2 9 SENSOR UNIT POWER L...

Page 773: ... GEARSHIFT LINKAGE NC700X XA S SA 11 4 COOLING SYSTEM 8 4 CRANKCASE TRANSMISSION BALANCER 14 6 CRANKSHAFT PISTON CYLINDER 15 4 CYLINDER HEAD VALVES 10 4 ELECTRIC STARTER 6 5 FRAME BODY PANELS EXHAUST SYSTEM 2 6 FRONT WHEEL SUSPENSION STEERING 17 9 HYDRAULIC BRAKE 19 7 IGNITION SYSTEM 5 5 IMMOBILIZER SYSTEM HISS 23 8 LIGHTS METERS SWITCHES 22 4 LUBRICATION SYSTEM 9 5 REAR WHEEL SUSPENSION 18 5 TURN...

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