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Honda CTX700D, Руководство по обслуживанию, Страница: 424 / 548

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Содержание CTX700D

Страница 1: ...2014 SERVICE MANUAL wm ...

Страница 2: ......

Страница 3: ...Most sections start with an assembly or system illustration service information and troubleshooting for the section The subsequent pages give detailed procedure Refer to the troubleshooting in each section according to the malfunction or symptom In case of an engine trouble refer to PGM FI section troubleshooting first Your safety and the safety of others is very important To help you make informe...

Страница 4: ...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 Moly 60 U S ...

Страница 5: ...VES LLI CLUTCH GEARSHIFT LINKAGE CTX700 A N NA a Q DUAL CLUTCH TRANSMISSION DCT CTX700D ND a UJ z ALTERNATOR STARTER CLUTCH wm o z UJ CRANKCASE TRANSMISSION BALANCER m CRANKSHAFT PISTON CYLINDER m ENGINE REMOVAL INSTALLATION jm FRONT WHEEL SUSPENSION STEERING ma t 0 CO REAR WHEEL SUSPENSION I HYDRAULIC BRAKE a w ANTI LOCK BRAKE SYSTEM ABS CTX700A D NA ND 30 BATTERY CHARGING SYSTEM 3D P c2 o LIGHTS...

Страница 6: ...MEMO J ...

Страница 7: ...1 GENERAL INFORMATION 1 SERVICE RULES 1 2 MODEL IDENTIFICATION 1 3 SPECIFICATIONS 1 5 TORQUE VALUES 1 12 LUBRICATION SEAL POINTS 1 19 CABLE HARNESS ROUTING 1 21 EMISSION CONTROL SYSTEMS 1 47 1 1 ...

Страница 8: ...Harness Routing page 1 21 9 Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind ABBREVIATION Throughout this manual the following abbreviations are used to identify the respective parts or systems Abbrev term Full term ABS Anti lock Brake System CKP sensor Crankshaft Position sensor DOT Dual Clutch Transmission DLC Data Link Connector DTC Diag...

Страница 9: ...TYPE REGION EVAP ABS DCT FRONT SIDE COWL REAR GRIP CTX700 U S A 0 0 U S A 50 state model 0 CTX700A Canada 0 0 0 CTX700D U S A 0 0 0 0 U S A 50 state model 0 CTX700N U S A U S A 50 state model 0 CTX700NA Canada 0 CTX700ND U S A 0 0 U S A 50 state model 0 Be sure to refer to the procedure for the appropriate version of the CTX700 1 3 ...

Страница 10: ...e body identification number 1 is stamped on the lower left side of the throttle body as shown yy The color label 1 is attached on the left side of the rear frame When ordering color coded parts always specify the designated color code v V V 7 The safety certification label 1 is located on the left side of the frame 0 7 Sfr The Emission Control Information Label 1 is located on the left side of th...

Страница 11: ... mm 4 3 in Front tire size 120 70ZR17M C 58W Rear tire size 160 60ZR17M C 69W Front tire brand BRIDGESTONE BT023FG METZELER ROADTEC Z8 INTERACT E Rear tire brand BRIDGESTONE BT023R G METZELER ROADTEC Z8 INTERACT Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 27 40 Trail length 114 mm 4 5 in Fuel tank capacity 12 4 liters 3 28 US gal 2 7 Imp gal ENGINE Cylinder arra...

Страница 12: ...rn system 1 N 2 3 4 5 6 CTX700D ND Automatic and electric shift left hand operated return system N 1 2 3 4 5 6 ELECTRICAL Ignition system Computer controlled digital transistorized with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Regulator rectifier FET shorted triple phase full wave rectification Lighting system Battery PGM FI SPECIFICATI...

Страница 13: ...ICATION SYSTEM SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Engine oil capacity CTX700 A N NA After draining 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 CTX700D ND 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 ...

Страница 14: ... 1 30 1 50 0 051 0 059 1 9 0 07 Valve spring free length 49 07 1 932 48 1 1 89 Cylinder head warpage 0 10 0 004 Cylinder head camshaft journal I D 41 995 42 019 1 6533 1 6543 42 027 1 6546 Cylinder head to camshaft clearance 0 045 0 084 0 0018 0 0033 0 10 0 004 CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS CTX700 A N NA Unit mm in ITEM STANDARD SERVICE LIMIT Clutch lever freeplay 10 20 0 4 0 8 _ Clutch ...

Страница 15: ... 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 clearance M5 0 020 0 070 0...

Страница 16: ...0015 0 05 0 002 Connecting rod small end I D 17 964 17 977 0 7072 0 7078 17 985 0 7081 Crankpin bearing oil clearance 0 026 0 044 0 0010 0 0017 0 05 0 002 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 1 5 0 06 Cold tire pressure Up to 90 kg 200 lbs load 250 kPa 2 50 kgf cm2 36 psi Up to maximum weight capacity 250 kPa 2 50 kgf cm2 36...

Страница 17: ...NS ITEM SPECIFICATIONS Battery Type YTZ12S Capacity 12 V 11 0 Ah 10HR Current leakage 0 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 45 kW 5 000 rpm Charging coil resistance 20 C 68 F 0 1 0 5 n LIGHTS METERS SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight 12 V 60 55 W Brak...

Страница 18: ...d bolt 3 8 See page 2 19 MAINTENANCE ITEM Q TY THREAD DIA mm TORQUE N m kgf m Ibf ft REMARKS Air cleaner housing cover screw 6 5 1 1 0 1 0 8 Spark plug 2 14 22 2 2 16 Valve adjusting screw lock nut 8 7 14 1 4 10 Apply engine oil to the threads and seating surface Camshaft maintenance cap 1 36 4 0 0 4 3 0 See page 3 9 Timing hole cap 1 14 10 1 0 7 Apply grease to the threads Crankshaft hole cap 1 3...

Страница 19: ...0 Cooling fan mounting nut 1 3 1 0 0 1 07 Apply locking agent to the threads LUBRICATION SYSTEM ITEM Q TY THREAD DIA mm TORQUE N m kgf m Ibf ft REMARKS Oil filter boss 1 20 Apply locking agent to the threads Coating width 6 5 1 0 mm 0 26 0 04 in from tip Engine oil filter cartridge 1 20 26 2 7 19 Apply engine oil to the threads CYLINDER HEAD VALVES ITEM Q TY THREAD DIA mm TORQUE N m kgf m Ibf ft R...

Страница 20: ...00D ND ITEM Q TY THREAD DIA mm TORQUE N m kgf m Ibfft REMARKS 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 08 0 04 in from tip Linear solenoi...

Страница 21: ... 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 in except 2 0 1 0 mm 0 08 0 04 in from tip Balancer shaft 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 Crankcase m...

Страница 22: ... mounting bolt 5 8 42 4 3 31 ALOC bolt replace with a new one Front axle 1 18 74 7 5 55 Apply grease to the sliding surface Front axle pinch bolt 1 8 22 2 2 16 Fork socket bolt 2 8 20 2 0 15 Apply locking agent to the threads Bottom bridge pinch bolt 2 10 39 4 0 29 Fork cap 2 37 22 2 2 16 Top bridge pinch bolt 2 8 22 2 2 16 Front brake caliper mounting bolt 2 8 30 3 1 22 ALOC bolt replace with a n...

Страница 23: ...22 ALOC bolt replace with a new one 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 Rear brake caliper pin 1 12 27 2 8 20 Apply 0 4 g 0 01 oz silicone grease to the sliding surf...

Страница 24: ...ly 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 1 22 Gearshift spindle return spring pin 1 8 23 2 3 17 Clutch lever pivot bolt CTX700 A N NA 1 6 1 0 0 1 0 7 Apply grease to the sliding surface Clutch lever pivot nut CTX700 A N NA 1 6 6 0 0 6 4 4 4 1 ...

Страница 25: ...surface Shift 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 CTX700D ND Oil joint pipe O ring CTX700D ND Clutch oil guide collar O rings CTX700D ND ...

Страница 26: ...ep sliding area Pillion step sliding area Cable lubricant Seat lock cable inside Clutch cable inside CTX700 A N NA Parking brake cable inside CTX700D ND Honda bond A or Pro Honda Handgrip Cement U S A only or equivalent Handlebar grip rubber inside Honda bond A or equivalent Brake pad retainer mating surface Silicone grease Front brake lever sliding surface and lever to master piston contacting ar...

Страница 27: ...ITCH WIRE THROTTLE CABLE B THROTTLE CABLE A LEFT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE CTX700D ND i LEFT HANDLEBAR SWITCH WIRE PARKING BRAKE CABLE PARKING BRAKE CABLE THROTTLE CABLE B THROTTLE CABLE A 0 to 0 Z Vs FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLE A THROTTLE CABLE B FRONT BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE 1 21 ...

Страница 28: ...HT 3P Orange CONNECTOR FRONT BRAKE IGNITION HOSE SWITCH WIRE HEADLIGHT 3P Black CONNECTOR MAIN WIRE HARNESS CTX700A THROTTLE CABLE B THROTTLE CABLE A COMBINATION METER CLUTCH CABLE FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE FRONT RIGHT TURN SIGNAL POSITION LIGHT 3P Light blue CONNECTOR 16P Gray CONNECTOR e q 9 9 LJ w I WI I o i JS K LEFT HANDLEBAR SWITCH WIRE FRONT LEFT TURN SIGNAL POSITION LIGH...

Страница 29: ...WITCH WIRE FRONT LEFT TURN SIGNAL POSITION LIGHT 3P Orange CONNECTOR MAIN WIRE HARNESS CTX700N THROTTLE CABLE B THROTTLE CABLE A FRONT RIGHT TURN SIGNAL POSITION LIGHT WIRE COMBINATION METER 16P Gray CONNECTOR CLUTCH CABLE r t f n RIGHT HANDLEBAR SWITCH WIRE l HEADLIGHT STAY IGNITION FRONT BRAKE HEADLIGHT 3P Black SWITCH WIRE HOSE CONNECTOR FRONT LEFT TURN SIGNAL POSITION LIGHT WIRE FRONT TURN SIG...

Страница 30: ...BAR SWITCH WIRE HEADLIGHT STAY CTX700ND THROTTLE CABLE A IGNITION SWITCH WIRE HEADLIGHT 3P Black CONNECTOR THROTTLE FRONTBRAKE COMBINATION METER CABLE B HOSE 16P Gray CONNECTOR MAIN WIRE HARNESS PARKING BRAKE CABLE FRONT RIGHT TURN SIGNAL POSITION LIGHT WIRE n sri j J e RIGHT HANDLEBAR SWITCH WIRE A J u FRONT LEFT TURN SIGNAL POSITION LIGHT WIRE FRONTTURN SIGNAL POSITION LIGHT CONNECTORS Right 3P ...

Страница 31: ...LEFT TURN SIGNAL POSITION 3P Orange CONNECTORS No 1 IGNITION COIL WIRE LEFT HANDLEBAR SWITCH 14P Gray CONNECTOR COMBINATION METER 16P Gray CONNECTOR MAIN WIRE HARNESS 2P Black CONNECTOR Optional 70 Y I 0 O 3 r LEFT HANDLEBAR SWITCH WIRE PARKING BRAKE CABLE FRONT LEFT TURN SIGNAL POSITION 3P Orange CONNECTOR LEFT HANDLEBAR SWITCH 6P Black CONNECTOR No 1 IGNITION COIL WIRE LEFT HANDLEBAR SWITCH 14P ...

Страница 32: ...LEBAR SWITCH 14P Gray CONNECTOR LEFT HANDLEBAR SWITCH WIRE No 1 IGNITION COIL WIRE CTX700ND COMBINATION METER 16P Gray CONNECTOR PARKING BRAKE CABLE MAIN WIRE HARNESS J rr cx l s l1 t l 30 to LEFT HANDLEBAR SWITCH WIRE No 1 IGNITION COIL WIRE LEFT HANDLEBAR SWITCH 6P Black CONNECTOR LEFT HANDLEBAR SWITCH 14P Gray CONNECTOR J oe ...

Страница 33: ...LE B RIGHT HANDLEBAR SWITCH IGNITION SWITCH 2P Brown CLUTCH CABLE 8P Blue CONNECTOR CONNECTOR CTX700A THROTTLE CABLE A THROTTLE CABLE B CLUTCH CABLE MAIN WIRE HARNESS RIGHT HANDLEBAR SWITCH WIRE IGNITION SWITCH 2P Brown CONNECTOR No 2 IGNITION COIL WIRE Y f W y RIGHT HANDLEBAR SWITCH FRONT WHEEL SPEED THROTTLE CABLE A THROTTLE CABLE B 8P Blue CONNECTOR SENSOR WIRE FRONT BRAKE HOSE CLUTCH CABLE 1 2...

Страница 34: ...n THROTTLE CABLE A THROTTLE CABLE B THROTTLE CABLE A THROTTLE CABLE B RIGHT HANDLEBAR SWITCH 6P Black CONNECTOR FRONT BRAKE HOSE FRONT WHEEL SPEED SENSOR WIRE PARKING BRAKE CABLE RIGHT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS CLUTCH CABLE No 2 IGNITION COIL WIRE RIGHT HANDLEBAR SWITCH 8P Blue CONNECTOR m CLUTCH CABLE w IGNITION SWITCH 2P Brown CONNECTOR THROTTLE CABLE A THROTTLE CABLE B FRONT BRAKE...

Страница 35: ...NITION COIL WIRE MAIN WIRE HARNESS PARKING BRAKE CABLE A THROTTLE CABLE A THROTTLE CABLE B PARKING BRAKE CABLE FRONT BRAKE HOSE IGNITION SWITCH 2P Brown CONNECTOR All type CTX700 N RIGHT HANDLEBAR SWITCH FRONT WHEEL SPEED 6P Black CONNECTOR SENSOR WIRE CTX7OOA D NA ND FRONT BRAKE HOSE CP FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE 1 29 ...

Страница 36: ...n CTX700D ND T o d v AIR CLEANER HOSING DRAIN HOSE No 1 IGNITION COIL WIRE HORN WIRE CONNECTORS k EOP SWITCH 1P Gray CONNECTOR O2 SENSOR CAP MAIN WIRE HARNESS LEFT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH 6P Black CONNECTOR LEFT HANDLEBAR SWITCH 14P Gray CONNECTOR No 1 IGNITION COIL WIRE HAZARD DIODE O n m t NDEX MARK Rear 7 5 Left 30 22 5 t Left FUEL FEED HOSE RADIATOR LOWER WATER HOSE ...

Страница 37: ...AR BRAKE LIGHT SWITCH 2P Black CONNECTOR CTX700D ND 50 state model shown RIGHT HANDLEBAR SWITCH 8P Blue CONNECTOR No 2 IGNITION COIL WIRE RADIATOR SIPHON HOSE RADIATOR RESERVE TANK OVERFLOW HOSE IGNITION SWITCH 2P Brown CONNECTOR RIGHT HANDLEBAR SWITCH 6P Black CONNECTOR STARTER MOTOR CABLE ECT SENSOR 2P Black CONNECTOR REAR BRAKE LIGHT SWITCH 2P Black CONNECTOR o INDEX MARK A Top 2 Right o k Righ...

Страница 38: ...WITCH SPRING 0 0 1 3 RADIATOR RESERVE TANK OVERFLOW HOSE CTX700 N IAT SENSOR 2P Black CONNECTOR THROTTLE CABLE A THROTTLE CABLE B IACV 4P Black CONNECTOR MAIN WIRE HARNESS HAZARD DIODE w mi o 9 m 3 CLUTCH CABLE J ECT SENSOR 2P Black CONNECTOR SENSOR UNIT 5P Black CONNECTOR FUEL INJECTOR 2P Gray CONNECTOR i 1J 0 ...

Страница 39: ... Black CONNECTOR THROTTLE CABLE B A IACV 4P Black CONNECTOR No 2 IGNITION COIL WIRE CONNECTORS CLUTCH CABLE EOT SENSOR 2P Black CONNECTOR FRONT WHEEL SPEED SENSOR FUEL INJECTOR 2P Gray 2P Blue CONNECTOR CONNECTOR THROTTLE THROTTLE CABLE A CABLE B A IACV 4P Black CONNECTOR No 2 IGNITION COIL WIRE CONNECTORS PARKING BRAKE CABLE EOT SENSOR 2P Black CONNECTOR FRONT WHEEL SPEED SENSOR FUEL INJECTOR 2P ...

Страница 40: ...EL SPEED SENSOR 2P Blue CONNECTOR CTX700A NA only O INDEX S MARK CLUTCH CABLE 90 22 5 180 22 5 Front Front INDEX MARK CTX700D ND IAT SENSOR 2P Black CONNECTOR MAIN WIRE HARNESS HAZARD DIODE INDEX MARK FAN MOTOR 3P Gray CONNECTOR FRONT WHEEL SPEED SENSOR 2P Blue CONNECTOR a PARKING BRAKE CABLE 90 22 5 K 180 22 5 Front INDEX MARK 1 34 ...

Страница 41: ...1 IGNITION COIL WIRE MAIN WIRE HARNESS To HORN O 0 0 O AIR CLEANER HOSING DRAIN HOSE CTX700 N D ND type 50 state model shown EVAP CANISTER to FUEL TANK HOSE A 3 Z Lb r1 FUEL TRAY DRAIN HOSE VACUUM HOSE EVAP CANISTER to EVAP PURGE CONTROL SOLENOID VALVE HOSE 1 35 ...

Страница 42: ...L SOLENOID VALVE HOSE FUEL FEED HOSE FUEL PUMP 3P Black CONNECTOR I 1 imJ 7 cz A VACUUM HOSE CLUTCH CABLE CTX700D ND 50 state model shown FUEL TRAY DRAIN HOSE EVAP CANISTER to EVAP PURGE CONTROL SOLENOID VALVE HOSE FUEL FEED HOSE EVAP PURGE CONTROL SOLENOID VALVE 2P Black CONNECTOR EVAP CANISTER to FUEL TANK HOSE FUEL PUMP 3P Black CONNECTOR F 1 I o VACUUM HOSE PARKING BRAKE CABLE J 1 3fi ...

Страница 43: ...WIRE FUEL TANK BREATHER HOSE SIDESTAND SWITCH WIRE FUEL TANK BREATHER HOSE FUEL TRAY DRAIN HOSE CTX700 A N NA 50 state model FUEL PUMP 3P Black CONNECTOR BATTERY NEGATIVE CABLE FUEL FEED HOSE FUEL TRAY DRAIN HOSE EVAP CANISTER BREATHER HOSE MAIN WIRE HARNESS To ECM MAIN WIRE HARNESS Cv n ALTERNATOR WIRE L U NEUTRAL SWITCH o V EVAP CANISTER DRAIN HOSE EVAP CANISTER DRAIN HOSE SIDESTAND SWITCH WIRE ...

Страница 44: ...ack SHIFT PEDAL ANGLE SENSOR CONNECTOR 3p B ue CONNECTOR Optional FUEL TANK BREATHER HOSE CTX700D ND 50 state model FUEL PUMP 3P Black CONNECTOR BATTERY NEGATIVE CABLE FUEL FEED HOSE MAIN WIRE HARNESS To PCM MAIN WIRE HARNESS FUEL TRAY DRAIN HOSE EVAP CANISTER BREATHER HOSE EVAP CANISTER DRAIN HOSE 4 z nn u tr ALTERNATOR WIRE NEUTRAL SWITCH I o o SHIFT CONTROL MOTOR 2P Black CONNECTOR SIDESTAND SW...

Страница 45: ...stay CKPSENSOR WIRE STARTER MOTOR CABLE CTX700D ND 50 state model shown REAR WHEEL SPEED BRAKE SENSOR WIRE PIPE GROUND TERMINAL o ALARM 6P CONNECTOR Optional REAR WHEEL SPEED SENSOR 2P Gray CONNECTOR sfcrr Qt _ O PARKING BRAKE CABLE EVAP CANISTER to FUEL TANK HOSE EVAP CANISTER to EVAP PURGE CONTROL SOLENOID VALVE HOSE STARTER MOTOR CABLE No 2 CLUTCH EOP SENSOR 3P Gray CONNECTOR CLUTCH LINE EOP SE...

Страница 46: ...Optional BANK ANGLE SENSOR 2P Black CONNECTOR VS SENSOR 3P Black CONNECTOR CTX700A NA VS SENSOR 3P Black BATTERY NEGATIVE CABLE CONNECTOR MAIN WIRE HARNESS FUEL PUMP 3P Black CONNECTOR CKP SENSOR 2P Red CONNECTOR SIDESTAND SWITCH 2P Gray CONNECTOR GROUND TERMINAL m Q 1 U T CKP SENSOR WIRE STARTER MOTOR CABLE REAR WHEEL SPEED SENSOR 2P Gray CONNECTOR ALARM 6P CONNECTOR Optional BANK ANGLE SENSOR AB...

Страница 47: ...nal BANK ANGLE SENSOR 2P Black CONNECTOR ABS MODULATOR 18P Black CONNECTOR CTX700D ND PCM 33P Black CONNECTOR BANK ANGLE SENSOR SIDESTAND SWITCH 2P Black CONNECTOR 2P Gray CONNECTOR PCM 33P Gray CONNECTOR REAR WHEEL SPEED SENSOR 2P Gray CONNECTOR ALARM 6P CONNECTOR Optional LINEAR SOLENOID VALVE 4P Green CONNECTOR k SHIFT SPINDLE ANGLE SENSOR PARKING OUTER MAINSHAFT SENSOR FUEL PUMP 3P Black CONNE...

Страница 48: ...INAL S P Es S Qi W MAIN WIRE HARNESS Insert into the battery box CTX700A D NA ND BANK ANGLE SENSOR 2P Black CONNECTOR GROUND TERMINAL t V m o Q 8 REAR WHEEL SPEED SENSOR 2P Gray CONNECTOR ALARM 6P CONNECTOR Optional MAIN WIRE HARNESS Insert into the battery box MAIN WIRE HARNESS To REGULATOR RECTIFIER 1 AO ...

Страница 49: ...TX700A NA only To ABS MODULATOR CTX700A NA only BANK ANGLE SENSOR WIRE CTX700D ND BATTERY POSITIVE CABLE TERMINAL BATTERY NEGATIVE CABLE TERMINAL STARTER RELAY SWITCH 4P Red CONNECTOR STARTER MOTOR CABLE To GROUND TERMINAL REAR WHEEL SPEED To ABS SENSOR WIRE MODULATOR PCM 33P Gray CONNECTOR BANK ANGLE SENSOR WIRE DLC r 7 h ECM 33P Black CONNECTOR MAIN WIRE HARNESS DLC 1 7 A PCM 33P Black CONNECTOR...

Страница 50: ... GENERAL BNFORMATION CTX700 N O o 0 G o I CTX700A D NA ND REAR BRAKE HOSE REAR BRAKE HOSE GROUND CABLE REAR WHEEL SPEED SENSOR WIRE 0 o o 1 a a 3 J PARKING BRAKE CABLE CTX700D ND only i AA ...

Страница 51: ...e boss REGULATOR RECTIFiER 3P Black CONNECTOR y PARKING BRAKE CABLE CTX700D ND only GROUND TERMINAL ALTERNATOR 3P Gray CONNECTOR REAR WHEEL SPEED SENSOR WIRE CTX700A D NA ND only REAR BRAKE HOSE All type MAIN WIRE HARNESS BRAKE TAIL LIGHT 6P Black CONNECTOR I O CM Q r r W TT TURN SIGNAL HAZARD RELAY 4P CONNECTOR 1 45 ...

Страница 52: ...LIGHT 2P Light blue CONNECTOR a u REAR LEFT TURN SIGNAL LIGHT 2P Orange CONNECTOR SEAT LOCK CABLE BRAKE TAIL LIGHT 6P Black CONNECTOR All type Insert into the rear fender A BRAKE TAIL LIGHT 6P Black CONNECTOR REAR RIGHT TURN SIGNAL LIGHT WIRE REAR LEFT TURN SIGNAL LIGHT WIRE 1 AR ...

Страница 53: ...tor s Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect SOURCE OF EMISSIONS The combustion process produces carbon monoxide CO oxides of nitrogen NOx and hydrocarbons HC The control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when su...

Страница 54: ...wing acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use 2 the use of the vehicle after such device or element of design has been remov...

Страница 55: ...CTX700 A D 2 7 HEADLIGHT CTX700 A D 2 8 HEADLIGHT CTX700N NA ND 2 8 RADIATOR SIDE COVER CTX700N NA ND 2 10 FRONT FENDER 2 10 SIDE SHELTER 2 11 CENTER SHELTER 2 12 UNDER COWL LID 2 12 UNDER CENTER COWL 2 13 UNDER SIDE COWL 2 13 MAIN STEP 2 14 SEAT 2 14 REAR GRIP CTX700 A D 2 15 REAR SIDE COWL 2 15 REAR CENTER COWL 2 16 LEFT CRANKCASE REAR COVER 2 16 LEFT REAR UNDER COVER 2 17 SWIGARM PIVOT COVER 2 ...

Страница 56: ...he exhaust pipe gasket with new ones after removing the exhaust pipe from the engine When installing the exhaust system loosely install all of the exhaust pipe fasteners Always tighten the exhaust pipe joint nuts first then tighten the mounting bolts Always inspect the exhaust system for leaks after installation TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor pe...

Страница 57: ...ngarm pivot cover page 2 17 14 Under side cowl page 2 13 15 Main step page 2 14 16 Seat page 2 14 17 Rear grip page 2 15 18 Rear side cowl page 2 15 23 Rear fender A page 2 17 24 Rear fender B page 2 18 25 Chain cover page 2 18 BODY PANEL REMOVAL CHART This chart shows removal order of frame covers by means of arrow 1 Front inner cover 2 Front center cowl I 3 Wind screen 4 Meter cover 16 Seat 5 Fr...

Страница 58: ... crankcase rear cover page 2 16 14 Left rear under cover page 2 17 15 Swingarm pivot cover page 2 17 16 Rear fender A page 2 17 17 Rear fender B page 2 18 18 Chain cover page 2 18 BODY PANEL REMOVAL CHART This chart shows removal order of frame covers by means of arrow 1 Headlight 2 Radiator side cover 3 Front fender 7 Under center cowl 10 Seat 1 4 Side shelter v 5 Center shelter 6 Under cowl lid ...

Страница 59: ...e front inner cover page 2 5 Remove the two trim clips 1 Release the four snap fit clips 2 and remove the front center cowl 3 by releasing the lower side tab 4 Installation is in the reverse order of removal WIND SCREEN CTX700 A D 2 1 C m f v 3 HH Q J m m Mi 4 a m mmwm i REMOVAL INSTALLATION Remove the front center cowl page 2 5 Remove the following Socket bolts 1 Plastic washers 2 Rubber washers ...

Страница 60: ...crew 1 0 Nm 0 1 kgf m 0 7 Ibf ft 3 I 1 2 FRONT SIDE COWL CTX700 A D REMOVAL INSTALLATION Remove the front center cowl page 2 5 Remove the following Trim clip A 1 Two trim clips B 2 Socket bolt 3 collar 4 Two socket bolts 5 washers 6 Disconnect the front turn signal position light 3P connector 7 Release the bosses 8 from the grommets Pull the right front side cowl 9 forward and release the tabs 10 ...

Страница 61: ...sassembly RADIATOR SIDE INNER COVER CTX700 A D REMOVAL INSTALLATION 1 3 2 V V 4 5 Remove the two trim clips 1 socket bolts 2 and radiator side inner cover 3 Installation is in the reverse order of removal 2 1 1 0 I 1 3 FRONT SPOILER CTX700 A D REMOVAL INSTALLATION Remove the front side cowls page 2 6 Remove the four socket bolts 1 and front spoiler 2 Installation is in the reverse order of removal...

Страница 62: ... 31 6 A m o 9 7 4 5 REMOVAL INSTALLATION Remove the two socket bolts 1 and collars 2 Remove the headlight assembly 3 by releasing it from the holes 4 of the bottom bridge Disconnect the following Headlight 3P Black connector 5 Right turn signal position light 3P Light blue connector 6 Left turn signal position light 3P Orange connector 7 Release the wire band boss 8 Remove the rubber caps 9J Insta...

Страница 63: ...ket bolts 1 and headlight cover 2 from the headlight 3 Remove the four special bolts 1 and headlight stay 2 from the headlight unit 3 Remove the three socket bolts 1 and meter upper cover 2 Assembly is in the reverse order of disassembly 2 W 2 i m m 2 9 ...

Страница 64: ...remove the radiator side cover 3 by releasing the slot 4 from the frame Installation is in the reverse order of removal m 2 m m a f r 3 m 4 FRONT FENDER REMOVAL INSTALLATION Remove the following Two bolts 1 hose guide 2 Four socket bolts 3 Front fender 4 Stay 5 Front side reflectors 6 Installation is in the reverse order of removal 1 3 4 6 r m V w IS I m 2 5 9_i n ...

Страница 65: ...ps 1 Large head Trim clip 2 Two socket bolts 3 Release the three bosses 4 from the grommets Remove the side shelter 5 by releasing the upper side tabs 6 and two snap fit clips 7 Installation is in the reverse order of removal m M m u V mm s JI1 Mla 3TST 1 Be mm m a EP1 Wm 4 2 DISASSEMBLY ASSEMBLY Remove the three screws 1 and side cover 2 Assembly is in the reverse order of disassembly 1 2 2 11 ...

Страница 66: ...tallation is in the reverse order of removal DISASSEMBLY ASSEMBLY 2 1 4 3 k Remove the four screws 1 and inner center cover 2 Remove the eight screws 3 luggage box 4 and packing 5 Assembly is in the reverse order of disassembly 1 4 3 2 5 UNDER COWL LID REMOVAL INSTALLATION Remove the trim clip 1 Remove the under cowl lid 2 by releasing the tabs 3 from the grooves Installation is in the reverse ord...

Страница 67: ... page 2 12 Socket bolts 1 washers 2 Remove the right under side cowl 3 by releasing the hose 4 from the hose guides as shown Remove the collars 5 from the under side cover Installation is in the reverse order of removal LEFT SIDE CTX700NA shown 4 CTX700 A N NA only wmmsm PMSI Jr 5 CTX700 A N NA only Remove the under center cowl page 2 13 Remove the three socket bolts 1 washers 2 and left under sid...

Страница 68: ...n the reverse order of removal TORQUE Main step mounting bolt 27 N m 2 8 kgf m 20 Ibf ft SEAT i 2 w m Left side 3 Right side Li 3 REMOVAL INSTALLATION Unlock the seat 1 using the ignition key 2 Pull the seat backward and remove it Install the seat by aligning the hooks 3 with grooves of the frame Push the rear end of the seat and lock the seat catch 3 1 2 i i 2 14 ...

Страница 69: ...hown 4 2 j A f M 1 REAR GRIP CTX700 A D REMOVAL INSTALLATION Remove the following Caps 1 Socket bolts 2 Washers 3 Rear grips 4 Collars 5 Installation is in the reverse order of removal REAR SIDE COWL REMOVAL INSTALLATION 1 4 2 S 3 5 Remove the following Seat page 2 14 Rear grip page 2 15 CTX700 A D Three trim clips 1 Socket bolt 2 Rubber washer 3 Release the two bosses 4 and snap fit clip 5 Slight...

Страница 70: ...700 A N NA Remove the gearshift arm pinch bolt 1 and gearshift arm 2 Remove the three bolts 3 and left crankcase rear cover 4 Installation is in the reverse order of removal Align the gearshift arm slit with the punch mark Replace the gearshift arm pinch bolt with a new one TORQUE Gearshift arm pinch bolt 12 N m 1 2 kgf m 9 Ibf ft CTX700D ND Remove the two bolts 1 and left crankcase rear cover 2 I...

Страница 71: ...y pull the side cover 1 and release its boss 2 from the grommet 3 of the swingarm pivot cover 4 Remove the two socket bolts 5 and swingarm pivot cover Installation is in the reverse order of removal 1 2 w 3 4 5 REAR FENDER A REMOVAL INSTALLATION Remove the following Rear center cowl page 2 16 Seat lock key cylinder page 2 15 Four bolts 1 and luggage hooks 2 Two socket bolts 3 large head Two socket...

Страница 72: ...ounting nut 1 7 N m 0 2 kgf m 1 3 Ibf ft 1 2 3 8 9 6 7 4 5 REAR FENDER B REMOVAL INSTALLATION Remove the following Rear fender A page 2 17 Turn signal hazard relay page 22 22 Battery page 21 5 Two socket bolts 1 Screw 2 Rear fender B 3 Installation is in the reverse order of removal CHAIN COVER 2 1 h S 4 PC 3 REMOVAL INSTALLATION Remove the two socket bolts 1 Remove the chain cover 2 by releasing ...

Страница 73: ...TION Remove the muffler page 2 19 Disconnect the Oz sensor 1P Black connector page 4 36 Remove the bolt 1 and release the ground terminal 2 Remove the following Exhaust pipe mounting bolt 3 washer 4 Three joint nuts 5 Exhaust pipe 6 Collar 7 Gasket 8 Installation is in the reverse order of removal Replace the gasket with a new one TORQUE Exhaust pipe joint nut 28 N m 2 9 kgf m 21 Ibf ft m 3 m 7 d8...

Страница 74: ...tor 3 Sidestand switch 2P Gray connector 4 Wire band bosses 5 Release and disconnect the following Rear wheel speed sensor 2P Gray connector 6 CTX700A D NA ND Bank angle sensor 2P Black connector 7 Remove the following Two socket bolts 8 Two bolts 9 Three bolts 10 collars 11 CTX700A D NA ND Four bolts 12 ground terminals 13 Center cross plate Installation is in the reverse order of removal 5 CTX70...

Страница 75: ...CTX700D ND 3 11 ENGINE IDLE SPEED 3 11 RADIATOR COOLANT 3 12 COOLING SYSTEM 3 12 EVAPORATIVE EMISSION CONTROL SYSTEM 50 STATE MODEL ONLY 3 13 DRIVE CHAIN 3 13 BRAKE FLUID 3 16 BRAKE PADS WEAR 3 17 BRAKE SYSTEM 3 18 BRAKE LIGHT SWITCH 3 18 BRAKE LOCK OPERATION CTX700D ND 3 18 HEADLIGHT AIM 3 19 CLUTCH SYSTEM CTX700 A N NA 3 20 SIDESTAND 3 20 SUSPENSION 3 21 NUTS BOLTS FASTENERS 3 21 WHEELS TIRES 3 ...

Страница 76: ...ATHER NOTE 3 C C C C C C 3 6 SPARK PLUG EVERY 16 000 mi 25 600 Km I EVERY 32 000 mi 51 200 Km R 3 6 VALVE CLEARANCE I l I I i M l I I 3 7 ENGINE OIL INITIAL 600 mi 1 000 km or 1 month R REGULAR EVERY 8 000 mi 12 800 km or 12 months R 3 9 ENGINE OIL FILTER R R R R 3 10 ENGINE IDLE SPEED I I I I I I I 3 11 RADIATOR COOLANT NOTE 5 I I R 3 12 COOLING SYSTEM I I I 3 12 EVAPORATIVE EMISSION CONTROL SYST...

Страница 77: ...R 3 11 ENGINE IDLE SPEED I I I I I I I 3 11 RADIATOR COOLANT NOTE 5 I I R 3 12 COOLING SYSTEM I I I 3 12 EVAPORATIVE EMISSION CONTROL SYSTEM NOTE 4 I I 3 13 DRIVE CHAIN EVERY 500 mi 800 Km I L 3 13 BRAKE FLUID NOTE 5 I I R I I R 3 16 BRAKE PADS WEAR I I I I I I 3 17 BRAKE SYSTEM I I I I 3 18 BRAKE LIGHT SWITCH I I I 3 18 BRAKE LOCK OPERATION I I I I I I I 3 18 HEADLIGHT AIM I I I 3 19 SIDESTAND I ...

Страница 78: ...throttle grip for smooth operation Check that the throttle opens and automatically closes in all steering positions If the throttle grip does not return properly lubricate the throttle grip housing If the throttle grip still does 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 not change I...

Страница 79: ...n 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 CTX700 A N NA 3 2 CTX700D ND 2 1 3 21 1 1 AIR CLEANER REMOVAL INSTALLATION Remove the center shelter page 2 12 Disconnec...

Страница 80: ... hose if necessary Service if the deposits level can be seen in the transparent section of the air cleaner housing drain hose Check the air cleaner housing drain hose 1 If necessary remove the drain plug 2 from the air cleaner housing drain hose and drain the deposits into a suitable container Reinstall the drain plug securely SPARK PLUG 1 mSmmlSmM I 1 B i 2 REMOVAL INSTALLATION Disconnect the spa...

Страница 81: ...35 C 95 F r After the valve clearance inspection check the engine idle speed page 3 11 Inspection and adjustment of the valve clearance can be serviced with the engine installed in the frame Remove the cylinder head cover page 10 5 Remove the timing hole cap and crankshaft hole cap Remove the camshaft maintenance cap 1 and O ring 2 11 2 HDHHB A o f Cylinder Rotate the crankshaft counterclockwise a...

Страница 82: ... t n j a No 2 CYLINDER 2 3 Loosen the lock nut 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 TORQUE 14 Nm 1 4 kgf m 10 Ibfft After tightening the lock nut recheck the valve clearance Apply engine oil to a ne...

Страница 83: ...shaft hole cap 15 N m 1 5 kgf m 11 Ibfft 1 m jH Cm h ENGINE OIL OIL LEVEL INSPECTION Hold the motorcycle in an upright position Start the engine and let it idle for 3 5 minutes 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 i...

Страница 84: ... qt at oil filter change 3 7 liters 3 9 US qt 3 3 Imp qt at disassembly CTX700D ND 3 2 liters 3 4 US qt 2 8 Imp qt at draining 3 4 liters 3 6 US qt 3 0 Imp qt at oil filter change 4 1 liters 4 3 US qt 3 6 Imp qt at disassembly Install the oil filler cap dipstick 1 Check the engine oil level page 3 9 Make sure there are no oil leaks ENGINE OIL FILTER Drain the engine oil page 3 10 Remove the oil fi...

Страница 85: ... the engine with the recommended engine oil and check that there are no oil leaks page 3 9 ENGINE IDLE SPEED 4 5 2 6 rv i 3 1 5 NOTE Inspect the idle speed after all other engine maintenance items have been performed and are within specifications Before checking the idle speed inspect the following items No DTC and MIL blinking Spark plug condition page 3 6 Air cleaner element condition page 3 5 T...

Страница 86: ...tifreeze Reinstall the reserve tank cap Check to see if there are any coolant leaks when the coolant level decreases very rapidly If the reserve tank becomes completely empty there is a possibility of air getting into the cooling system Be sure to remove any air from the cooling system page 8 4 COOLING SYSTEM 1 A m t i I 2 i 1 m m i mMI Ia i I Check the radiator air passages for clogging or damage...

Страница 87: ...ckets DRIVE CHAIN SLACK 25 35 mm 1 0 1 4 in NOTICE Excessive chain slack 50 mm 2 0 in or more may damage the frame WARNING Amputation hazard Never inspect or adjust the drive chain while the engine is running 25 35 mm 1 0 1 4 in ADJUSTMENT Loosen the rear axle nut 1 Loosen the lock nuts 2 and turn the adjusting nuts 3 until the correct drive chain slack is obtained Make sure the index lines 4 on b...

Страница 88: ...appears unserviceable Be sure the drive chain has dried completely before lubricating Lubricate the drive chain with drive chain lubricant 2 RECOMMENDED LUBRICANT Pro Honda HP Chain Lube or equivalent NOTICE Do not use a chain lubricant NOT designed specifically for use with O ring chains to lubricate the drive chain Wipe off the excess oil or drive chain lubricant SPROCKET INSPECTION Remove the l...

Страница 89: ... A N NA 114 LINKS CTX700D ND 112 LINKS REPLACEMENT CHAIN DID DID520V0 RK RK520KHO Never reuse the old drive chain master link master link plate and O rings Insert 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 TOOL Drive chain tool set 07HMH MR...

Страница 90: ...the fluid level is low check the brake pads for wear page 3 17 A low fluid level may be due to wear of the brake pads If the brake pads are worn and caliper pistons are pushed out this accounts for a low fluid level If the brake pads are not worn and fluid level is low check the entire system for leaks page 3 18 FRONT BRAKE Turn the handlebar to the left so that the reservoir is level and check th...

Страница 91: ...nd diaphragm 6 Fill the reservoir with DOT 4 brake fluid from a sealed container to the UPPER level line Install the removed parts in the reverse order of removal TORQUE Rear master cylinder reservoir mounting bolt 10 Nm 1 0 kgf m 7 Ibf ft V f V r JBk 1 4 5 2 6 1 3 4 BRAKE PADS WEAR BRAKE PADS Always replace the brake pads as a set to assure even disc pressure Check the brake pads for wear Replace...

Страница 92: ...ight switch does not comes on just prior to the brake actually being require adjustment 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 Install the under cowl lid page 2 12 BRAKE LOCK OPERATION CTX700D ND m 2 INSPECTION Support the motorcycle using a safety stand or hoist ...

Страница 93: ...ade with the parking brake caliper _ 4 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 TORQUE 17 N m 1 7 kgf m 13 Ibf ft Recheck the parking brake operation HEADLIGHT AIM Su...

Страница 94: ... the lock nut 2 and turn the adjusting nut to adjust the freeplay Tighten the lock nut while holding the adjusting nut If proper freeplay cannot be obtained or the clutch slips during test ride disassemble and inspect the clutch page 11 8 1 1 i mm A Hi as 2 S n SSDESTAND INSPECTION Support the motorcycle using a safety stand or hoist Check the sidestand spring 1 for damage or loss of tension Check...

Страница 95: ...steners Replace damaged components which cannot be repaired Loose worn or damaged suspension parts impair motorcycle stability and control Tighten all nuts and bolts For fork service page 17 18 REAR SUSPENSION INSPECTION Check the action of the rear shock absorber by compressing the rear end several times Check the entire shock absorber assembly for leaks damage or loose fasteners Replace damaged ...

Страница 96: ...Front tire page 1 10 Rear tire page 1 10 Check the tires for cuts embedded nails or other damage Check the front and rear wheels for trueness Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches the following limits Front tire page 1 10 Rear tire page 1 10 STEERING HEAD BEARINGS Support the motorcycle using a safety stand or hoist raise the front wheel ...

Страница 97: ...RMATION 4 5 PGM FI SYMPTOM TROUBLESHOOTING 4 7 PGM FI TROUBLESHOOTING INFORMATION 4 7 DTC INDEX 4 10 SENSOR UNIT POWER LINE INSPECTION 4 11 DTC TROUBLESHOOTING 4 12 MIL CIRCUIT TROUBLESHOOTING 4 32 IAT SENSOR 4 32 ECT SENSOR 4 33 BANK ANGLE SENSOR 4 33 ECM PCM 4 34 02 SENSOR 4 36 4 1 ...

Страница 98: ...SOR DLC IACV O2 SENSOR CTX700D ND FUSE BOX FUEL CUT RELAY FAN CONTROL RELAY NEUTRAL DIODE EOP SWITCH SIDESTAND SWITCH VS SENSOR CKP SENSOR FUEL EVAP PURGE CONTROL SENSOR UNIT INJECTOR SOLENOID VALVE FUEL PUMP MAP SENSOR TP SENSOR ECTSENSOR BANK ANGLE SENSOR IGNITION SWITCH COMBINATION METER o PCM IAT SENSOR IACV O2 SENSOR DLC FUSE BOX FUEL CUT RELAY FAN CONTROL RELAY EOP SWITCH SIDESTAND SWITCH VS...

Страница 99: ...Br R Y BI O O 8 i i i ECM G Y G Y BI W R W J LL FAN 8 9 IATS 7 ECT 87 EOP 21 IAT SENSOR Bu Bl Bu 9 TA o o BI FAN CONTROL RELAY G FAN MOTOR P W ECT SENSOR TW P Y 5 Lg 9 EOPSWTCH BI V Y e W G BI 02 j 8 Br 02 SENSOR Bu Y C 0Q CKP SENSOR 1 1 Y Y OH PCP1 Br W Y G 0 Y Bu I C G 0 IGNITION COIL SPARK PLUG G R LB 8 Y G ACV1A 17 NEUTRAL NBSDREAL b SWITCH Bl V W ACV1B 160 IACV Gr R ACV2A 15 Bi P BI IACV2B 3 ...

Страница 100: ...CPB r J G Y G Y Bl W Gr Bu l I FAN B18f 9 7 87 IAT SENSOR Bl Bu RAM TA B9 o o Bl FAN CONTROL RELAY I 3 FAN MOTOR p w ECT SENSOR B20 Bl P Y L q OB31 POIL EOP SWITCH Bl V Y oINJ2 B4 21 W G ei X _L i 02 SENSOR Br Bu Y c Y B11 P B G C W Y Y BL r G 0 B6 C M IGNITION COIL SPARK PLUG m Y G IACV1A B17 v w c IACV1B B16 B30 NEUTRAL H IACV Gr R IACV2A B15 NEUTRAL SWITCH P BI 29 G G W B28 SSTAND V PVJPGT B12 ...

Страница 101: ...hart The PGM FI system is provided with fail safe function to secure a minimum running capability even when there is any trouble in the system When any abnormality is detected by the self diagnosis function running capability is secured by making use of the numerical values of a situation preset in the simulated program map It must be remembered however that when any abnormality is detected in inj...

Страница 102: ... CTX700D ND only TR SENSOR SERIAL COMMUNICATION LINE To COMBINATION METER High coolant temperature indicator signal Engine oil pressure indicator signal Engine speed signal MIL signal Gear position indicator signal CTX700D ND only To PCM VS sensor signal Ignition switch OFF time information COMBINATION METER Co VS SENSOR WHEN THERE IS A PROBLEM IN THE SERIAL COMMUNICATION LINE When an open or shor...

Страница 103: ... or misfiring during acceleration Inspect the ignition system page 5 6 Poor performance driveability and poor fuel economy 1 Inspect the fuel supply system page 7 4 2 Inspect the air cleaner element page 3 5 3 Inspect the ignition system page 5 6 Faulty pressure regulator fuel pump Faulty fuel injector Faulty MAP sensor Idle speed is below specifications or fast idle too low No DTC and MIL blinkin...

Страница 104: ... ECM PCM detects the problem at present when the ignition switch ON and engine stop switch Q or idling with the sidestand down The MIL will stay ON when the engine speed is over 1 850 rpm or with the sidestand up The MIL has two types of blinks a long blink and short blink The long blinking lasts for 1 3 seconds the short blinking lasts for 0 3 seconds One long blink is the equivalent of ten short...

Страница 105: ... page 4 9 2 Turn the ignition switch ON and engine stop switch O 3 Disconnect the SCS connector 1 from the DLC 2 Connect the SCS connector to the DLC again while the MIL stays ON about 5 seconds reset receiving pattern 4 The stored DTC is erased if the MIL goes off and starts blinking successful pattern The DLC must be jumped while the MIL lights If not the MIL will not start blinking In that case...

Страница 106: ...r poor contact of the VS sensor connector Open or short circuit in the VS sensor wire Faulty VS sensor Engine operates normally 4 21 12 1 12 No 1 Fuel injector circuit malfunction Loose or poor contact of the fuel injector connector Fuel injector or its circuit malfunction Engine does not start Fuel injector fuel pump and ignition coil shut down 4 22 13 1 13 No 2 Fuel injector circuit malfunction ...

Страница 107: ...sure the voltage at the sensor unit 5P Black connector 1 of the wire harness side Connection CTX700 A N NA Yellow red Green yellow CTX700D ND Yellow violet Green yellow Standard 4 75 5 25 V 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 12 NO GO TO STEP 2 2 Sensor Unit Input Voltage Line Short C...

Страница 108: ...recheck NO Open circuit in the Yellow red wire Open circuit in the Yellow violet wire Open circuit in the Green yellow wire DTC TROUBLESHOOTING DTC 1 1 MAP SENSOR LOW VOLTAGE NOTE If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 CTX700D ND 1 MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch o Check the MAP sensor with the MCS Is about...

Страница 109: ...Turn the ignition switch OFF Check for continuity between the sensor unit 5P Black connector 1 of the wire harness side and ground Connection Violet red ground Is there continuity YES Short circuit in the Violet red wire NO GO TO STEP 5 5 MAP Sensor Inspection Replace the sensor unit with a known good one page 7 14 Turn the ignition switch OFF Connect the sensor unit 5P Black connector Erase the D...

Страница 110: ...Black connector page 7 14 Connect the sensor unit 5P Black connector 1 terminals at the wire harness side with a jumper wire 2 Connection Violet red Green yellow Turn the ignition switch ON Check the MAP sensor with the MCS Is about 0 V indicated YES Faulty sensor unit MAP sensor NO GO TO STEP 4 4 MAP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Remove the jumper wire Di...

Страница 111: ... V indicated YES GO TO STEP 4 NO GO TO STEP 3 3 ECT Sensor Resistance Inspection Turn the ignition switch OFF Measure the resistance at the ECT sensor 2P Black connector 1 terminals of the sensor side Standard 1 0 1 3 kQ 40 C 104 F Is the resistance within 1 0 1 3 kQ 40 C 104 F YES Replace the ECM PCM with a known good one and recheck NO Faulty ECT sensor 4 ECT Sensor Output Line Short Circuit Ins...

Страница 112: ...t the wire harness side with a jumper wire 2 Connection Pink white Green yellow Turn the ignition switch ON Check the ECT sensor with the MCS Is about 0 V indicated YES Inspect the ECT sensor page 22 13 NO GO TO STEP 3 ECT Sensor Line Open Circuit Inspection Turn the ignition switch OFF Remove the jumper wire Disconnect the following ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33P Gray con...

Страница 113: ... NO Replace or repair the abnormal circuit 3 TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P Black connector page 7 14 Check for continuity between the sensor unit 5P Black connector 1 of the wire harness side and ground Connection Red yellow Ground Is there continuity YES Short circuit in the Red yellow wire NO GO TO STEP 4 4 TP Sensor Out...

Страница 114: ...ed YES GO TO STEP 3 NO GO TO STEP 2 2 TP Sensor Inspection Check that the TP sensor voltage increases continuously when moving the throttle from fully closed to fully opened using the data list menu of the MCS Is the voltage increase continuously YES Intermittent failure NO Replace the TP sensor sensor unit with a known good one and recheck 3 TP Sensor Resistance Inspection Turn the ignition switc...

Страница 115: ...itialize Learning Procedure page 12 81 CTX700D ND 1 IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch o Check the IAT sensor with the MCS Is about 0 V indicated YES GO TO STEP 2 NO Intermittent failure 2 IAT Sensor Inspection Turn the ignition switch OFF Disconnect the IAT sensor 2P Black connector page 4 32 Turn the ignition switch ON Check the IAT sensor with the MC...

Страница 116: ...ctor 1 terminals at the wire harness side with a jumper wire 2 Connection Gray blue Green yellow Turn the ignition switch ON Check the IAT sensor with the MCS Is about 0 V indicated YES Faulty IAT sensor NO GO TO STEP 3 1 Gr Bu G Y 2 3 IAT Sensor Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the following ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33P Gray connector...

Страница 117: ...eck Check the DTC with the MCS Is the DTC 86 1 indicated YES Check the meter communication malfunction page 4 29 NO Replace the combination meter with a known good one and recheck 4 VS Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the VS sensor 3P Black connector page 22 12 Turn the ignition switch ON Measure the voltage at the VS sensor 3P Black connector 1 of the wire h...

Страница 118: ...d recheck NO Faulty original VS sensor DTC 12 1 No 1 FUEL INJECTOR NOTE Before starting the inspection check for loose or poor contact on the fuel injector 2P Gray connector and ECM PCM 33P connector s then recheck the DTC If the PCM is replaced perform the clutch Initialize Learning Procedure page 12 81 CTX700D ND 1 Fuel Injector System Inspection Erase the DTCs page 4 9 Turn the ignition switch ...

Страница 119: ...stance within 11 6 12 4 Q 20 C 68 F YES GO TO STEP 5 NO Faulty fuel injector 5 Fuel Injector Signal Line Open Circuit Inspection Disconnect the following ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33P Gray connector page 4 34 CTX700D ND Check for continuity between the ECM PCM 33P connector 1 and fuel injector 2P Gray connector 2 of the wire harness side Connection No 1 Pink yellow Pink y...

Страница 120: ...lure 2 O2 Sensor Short Circuit Inspection 3 Turn the ignition switch OFF Disconnect the O2 sensor 1P Black connector page 4 36 Check for continuity between the O2 sensor 1P Black connector 1 of the wire harness side and ground Connection White green Ground Is there continuity YES Short circuit in the White green wire NO GO TO STEP 3 1 W G Q O2 Sensor Line Open Circuit Inspection 1 Disconnect the f...

Страница 121: ...29 1 IACV NOTE Before starting the inspection check for loose or poor contact on the IACV 4P Black connector and ECM PCM 33P connector s then recheck the DTC If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 CTX700D ND 1 Recheck DTC Erase the DTCs page 4 9 Turn the ignition switch ON and engine stop switch O Check the IACV with the MCS Is the DTC 29 1 indicated YES...

Страница 122: ...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 Connection A D B C Standard 110 150 Cl 25 C 77 F Is the resistance within 110 150 Cl 25 C 77 F YES Replace the ECM PCM with a known good one and recheck NO Faulty IACV A D B C o 1 DTC 33 2 EEPROM NOTE If the ...

Страница 123: ...ntinuity YES GO TO STEP 3 NO Short circuit in the Black wire 1 B Q Bank Angle Sensor Output Line Short Circuit Inspection Disconnect the following ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33P Gray connector page 4 34 CTX700D ND Check for continuity between the bank angle sensor 2P Black connector 1 of the wire harness side and ground Connection Black blue Ground Is there continuity YES ...

Страница 124: ...round Standard Battery voltage Does the standard voltage exist YES GO TO STEP 3 NO Open circuit in the Black wire 3 Bank Angle Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the following ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33P Gray connector page 4 34 CTX700D ND Check for continuity between the bank angle sensor 2P Black connector 1 of the wire...

Страница 125: ...e MCS Is the DTC 86 1 indicated YES GO TO STEP 2 NO Intermittent failure 2 Combination Meter Serial Line Short Circuit inspection Turn the ignition switch OFF Disconnect the following Combination meter 16P Gray connector CTX700 A D page 2 6 CTX700N NA ND page 22 7 ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33P Gray connector page 4 34 CTX700D ND Check for continuity between the combinatio...

Страница 126: ...DJA110 Does the standard voltage exist YES GO TO STEP 5 NO Inspect the combination meter page 22 7 Cu n L U 1 2 1 R Bu V ECM Serial Line Output Voltage Inspection Turn the ignition switch OFF Disconnect the combination meter 16P Gray connector Connect the ECM PCM 33P connector Remove the DLC 1 from the battery box Remove the dummy connector from the DLC Short the DLC terminals using a special tool...

Страница 127: ...s the DTC 87 1 indicated YES GO TO STEP 2 NO Intermittent failure 2 EOP Switch Output Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the following EOP switch 1P Gray connector page 22 14 ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33P Gray connector page 4 34 CTX700D ND Check for continuity between the EOP switch 1P Gray connector 1 and ECM PCM 33P connector 2 of the ...

Страница 128: ...mperature indicator do not come on inspect the serial communication line page 22 8 If the MIL stays on check as follows Turn the ignition switch OFF Disconnect the following ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33P Gray connector page 4 34 CTX700D ND Check for continuity between the ECM PCM 33P connector 1 of the wire harness side and ground CONNECTION Brown Ground STANDARD No conti...

Страница 129: ...sor 2P Black connector Fill the cooling system with recommended coolant page 8 4 BANK ANGLE SENSOR wg 3 SV Jml 2 REMOVAL INSTALLATION Remove the left side shelter page 2 11 Disconnect the bank angle sensor 2P Black connector 1 and release it from the center cross plate Release the wire band boss 1 Remove the two bolts 2 and bank angle sensor assembly 3 Remove the two socket bolts 1 collars 2 and b...

Страница 130: ...N foK yfo approximately 42 5 HORIZONTAL approximately 42 5 ECM REMOVAL INSTALLATION CTX700 A N NA Remove the seat page 2 14 Turn the ignition switch OFF Release the band 1 and remove the ECM 2 from the battery box Disconnect the ECM 33P Black connector 3 Installation is in the reverse order of removal PCM REMOVAL INSTALLATION CTX700D ND n r i If 4 Remove the seat page 2 14 Turn the ignition switch...

Страница 131: ...PCM 33P connector 1 of the wire harness side and ground Connection Black Ground Standard Battery voltage TOOL Test probe 2 packs 07ZAJ RDJA110 Does the standard voltage exist YES GO TO STEP 2 NO Open or short circuit in the Black wire Faulty ignition switch Blown main fuse 30 A Blown sub fuse 7 5 A ENG STOP Faulty engine stop switch 2 ECM PCM Ground Line Inspection Turn the ignition switch OFF Che...

Страница 132: ...it less than 1 2 of a turn Remove the O2 sensor 1 NOTICE Do not use an impact wrench while removing or installing the O2 sensor or it may be damaged Install and hand tighten the O2 sensor 1 Tighten the O2 sensor to the specified torque TORQUE 24 5 N m 2 5 kgf m 18 Ibf ft Connect the O2 sensor cap 1 to the O2 sensor by pushing it straight Connect the O2 sensor 1P Black connector 2 NOTICE Take care ...

Страница 133: ...5 IGNITION SYSTEM n SYSTEM LOCATION 5 2 IGNITION SYSTEM INSPECTION 5 6 SYSTEM DIAGRAM 5 3 IGNITION TIMING 5 8 SERVICE INFORMATION 5 4 IGNITION COIL 5 8 TROUBLESHOOTING 5 5 CKP SENSOR 5 9 5 1 ...

Страница 134: ...OILS ENGINE STOP SWITCH BANK ANGLE SENSOR IGNITION SWITCH SPARK PLUGS NEUTRAL SWITCH SIDESTAND SWITCH CKP SENSOR MAIN FUSE 30 A PCM FUSE BOX FUEL CUT RELAY IGNITION SWITCH CLUTCH SWITCH SPARK PLUGS MAIN FUSE 30 A ECM FUSE BOX FUEL CUT RELAY NEUTRAL DIODE NEUTRAL SWITCH SIDESTAND SWITCH CKP SENSOR CTX700D ND RJ ...

Страница 135: ...A PLUG G BANKANGLE SENSOR CLUTCH SWITCH Y G O 2P RED Y W Y CKP J SENSOR oTo NEUTRAL INDICATOR NEUTRAL DIODE 14P GRAY Lg B B NEUTRAL SWITCH CTX700D ND R Bl A Bl MAIN FUSE IGNITION 30 A SWITCH A F 15 A PCM BATTERY R BI Bl W Bl Bu 8P BLUE W Y ENGINE STOP SWITCH Bl R W Y ENG STOP 7 5 A Br Bl Br v CQy o o Br BI Bl Bl FUEL CUT RELAY Y Bu Bu Y Br Bu Y n No 1 IGNITION COIL H A n Y Bu 2P Bl G W G i V SPARK...

Страница 136: ...d to poorly connected or corroded connections Check those connections before proceeding Make sure the battery is adequately charged 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 34 Refer to following components informations Ignition switch page 22 17 Engine stop switch page 22 18 Bank angle sen...

Страница 137: ...onnection in Green and 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 CTX700 A N NA 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 CTX700 A N NA Green red and L...

Страница 138: ...er TOOLS IgnitionMate peak voltage tester MTP07 0286 U S A only or Peak voltage adaptor 07HGJ 0020100 Not available In U S A with commercially available digital multimeter impedance 10 MQ DCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE 2 V 1 NOTE Check all system connections before performing this inspection Loose connectors can cause incorrect readings If the system is disconnected incorrect peak ...

Страница 139: ...il primary peak voltage PEAK VOLTAGE 100 V minimum If the peak voltage is abnormal follow the checks described in the troubleshooting table page 5 5 Install the side shelters page 2 11 CKP SENSOR PEAK VOLTAGE NOTE Check the cylinder compression and check that the spark plugs are installed correctly in the cylinder head Disconnect the following ECM 33P Black connector page 4 34 CTX700 A N NA PCM 33...

Страница 140: ...he 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 IDLE SPEED 1 200 100 rpm The ignition timing is correct if the F mark 2 on the flywheel aligns with the index notch 3 on the alternator c...

Страница 141: ...blue connector 3 Remove the bolts 4 spacers 5 and ignition coil 6 from the ignition coil stay Installation is in the reverse order of removal 3 4 5 2 i r 3 X 1 1 6 2 2 L 8 I It Ei 1 raff 1 1 i 3 4 m 4 5 as m 2 m M L i m 6 1 CKPSENSOR REMOVAL INSTALLATION CTX700 A N NA Remove the right crankcase cover page 11 4 Remove the wire grommet 1 from the right crankcase cover Remove the CKP sensor mounting ...

Страница 142: ... CKP sensor mounting bolts 2 and CKP sensor 3 Installation is in the reverse order of removal Apply locking agent to the CKP sensor mounting bolt threads page 1 19 Apply locking agent to the right crankcase cover wire clamp bolt threads page 1 13 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 Ibf ft 2i 3 ...

Страница 143: ...TRIC STARTER D 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 CTX700 A N NA 6 11 STARTER RELAY CTX700D ND 6 12 6 1 ...

Страница 144: ...TARTER SWITCH STARTER RELAY SWITCH MAIN FUSE 30 A 9 5 55 CT NEUTRAL SWITCH FUSE BOX SIDESTAND SWITCH NEUTRAL DIODE ECM BATTERY CTX700D ND IGNITION SWITCH ENGINE STOP SWITCH STARTER SWITCH STARTER MOTOR STARTER RELAY SWITCH MAIN FUSE 30 A 9 0 cffi a jts V NEUTRAL SWITCH FUSE BOX STARTER RELAY PCM BATTERY 1 J fi 9 ...

Страница 145: ...O Bl R O X W Y STARTER ENGINE STOP SWITCH SWITCH From NEUTRAL INDICATOR NEUTRAL SWITCH R BI ENG STOP 7 5 A Bl Black G Green Lg Light green R Red Y Yellow W White CTX700D ND Bl h Bl h BATTERY STARTER MOTORjPI Bl Black G Green R Red V Violet W White Y Yellow To PCM B STARTER RELAY SW TCH MAIN FUSE 30 A Y R R R BI IGNITION SWITCH Bl R O G R W Y ENGINE STOP SWITCH STARTER SWITCH ENG STOP 7 5 A CLy D B...

Страница 146: ...e starter motor The motor could suddenly start causing serious injury A weak battery may be unable to turn 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 17 Starter switch page 22 18 Engine stop switch page ...

Страница 147: ...nect 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 STEP 6 NO Loose or...

Страница 148: ...TEP 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 6 10 I...

Страница 149: ...NO Faulty clutch switch 2 Sidestand Switch Inspection Check the sidestand switch operation page 22 21 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 Poorly connected bat...

Страница 150: ...able 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 TORQUE Starter motor terminal nut 10 N m 1 0 kgf m 7 lbf ft 1 2 3 O 4 5 6 1 1 DISASSEMBLY ASSEMBLY MOTOR CASE SEAL RING SEAL RING FRONT COVER 1 O RING BOLTS O RING O Q o NEGATIVE BRUSHES o 3 0 SCREW 0 NUT WASHER INSULATOR ARMATURE BRUSH HOLDER SPRING REAR COVER POS...

Страница 151: ...t of rear cover 1 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 3 2 1 4 ARMATURE Clean the metallic debris off between commutator bars 13 Check the commutator bar...

Страница 152: ...p switch Q the starter relay input voltage is normal GROUND LINE CTX700 A N NA 1 Disconnect the starter relay switch 4P Red connector 11 Check for continuity between the Green red wire of the wire harness side ground line and ground If there is continuity when the transmission is in neutral or when the clutch is disengaged and the sidestand is retracted the ground circuit of the relay coil is norm...

Страница 153: ...ease the starter relay switch 1 from the battery box tabs 2 Release the rubber cover 3 Disconnect the starter relay switch 4P Red connector 4 Remove the bolts 5 and cables 6 Installation is in the reverse order of removal 4 1 3 it is 5 6 2 NEUTRAL DIODE CTX700 A N NA INSPECTION Remove the seat page 2 14 Open the fuse box cover and remove the neutral diode 11 Check for continuity between the neutra...

Страница 154: ...r relay 1 Connect an ohmmeter to the starter relay 1 connector terminals Connect a 12 V battery to the starter relay connector terminals as shown There should be continuity only when 12 V battery is connected If there is no continuity only when the 12 V battery is connected replace the starter relay 1 1 i f T I 0 Q 1 J 6 12 ...

Страница 155: ...ION 7 3 FUEL LINE REPLACEMENT 7 4 FUEL TANK 7 7 FUEL PUMP UNIT 7 10 AIR CLEANER HOUSING 7 13 THROTTLE BODY 7 14 Qj FUEL INJECTOR 7 18 IACV 7 20 FUEL CUT RELAY 7 21 EVAP PURGE CONTROL SOLENOID VALVE 50 STATE MODEL 7 22 EVAP CANISTER 50 STATE MODEL 7 22 7 1 ...

Страница 156: ...FUEL SYSTEM COMPONENT LOCATION j 9 o 7 O ...

Страница 157: ...e operation Prevent dirt and 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 ...

Страница 158: ...IDE 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 or special tool to release them from the locking pawls 3 U S A TOOL Fuel retainer compressor 07AMF 001A100 Pull the fuel feed hose of...

Страница 159: ... removed 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 Align retainer tabs with joint rubber grooves If it is hard to connect put a small amount of engine oil on the fuel injector joint 3 Make sure the connection is secure and that the pawls are firmly locked into place check visually and by pulling th...

Страница 160: ... 9 mm 07ZAJ S7C0100 5 Attachment joint 8 mm 9 mm 07ZAJ S7C0200 U S A TOOLS Fuel pressure gauge 0 100 psi 07406 004000B or 07406 004000C Pressure manifold hose 07AMJ HW3A100 Adaptor C male 07AAJ S6MA300 Adaptor C female 07AAJ S6MA500 Temporarily connect the battery negative cable and fuel pump 3P Black connector Turn the ignition switch ON and engine stop switch O Start the engine and let it idle R...

Страница 161: ... flowed Amount of fuel flow 230 cm3 7 8 US oz 8 1 Imp oz minimum 10 seconds at 12 V 1 Hi K If fuel flow is less than specified inspect the following Fuel line leaking Pinched or clogged fuel feed hose Fuel pump unit page 7 10 Clogged fuel filter page 7 10 Connect the quick connect fitting and normalize the fuel pressure page 7 5 FUEL TANK REMOVAL INSTALLATION Except 50 state model 50 state model R...

Страница 162: ... Remove the fuel tank mounting bolts then lift up and support the fuel tank page 7 13 4 Check the fuel quick connect fitting 1 for dirt and clean if necessary Place a shop towel over the quick connect fitting 5 Pull and release the joint rubber 1 from the retainer 6 Hold the connector with one hand and squeeze the retainer tabs 2 with the other hand or special tool to release them from the locking...

Страница 163: ...k connect fitting onto the pipe until both retainer pawls 2 lock with a CLICK Align the quick connect fitting with the pipe If it is hard to connect put a small amount of engine oil on the pipe end 3 Make sure the connection is secure and that the pawls are firmly locked into place check visually and by pulling the connector 1 4 Make sure the joint rubber 2 is in place between the retainer tabs 3 ...

Страница 164: ...unit 2 and packing 3 Be careful not to damage the fuel level sensor float arm DISASSEMBLY INSPECTION 2 1 g w m 3 Remove the screws 1 Black wire terminals 2 and stoppers 3 Disconnect the Pink wire connector 4 and Blue wire connector 5 Remove the fuel pump unit assembly 1 and O ring 2 from the fuel pump stay 3 Remove the chamber 1 Release the tabs 2 and remove the fuel level sensor assembly 3 from t...

Страница 165: ...sary Remove the pressure regulator 1 and O ring 2 from the fuel filter 3 ASSEMBLY HI 3 2 J m v 2 1 a m 3 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 C2 PI 3 l N M m 2 Align 7 11 ...

Страница 166: ...e groove with the fuel pump stay tab Install the stoppers 1 Black wire terminals 2 and screws 3 Tighten the screws securely Connect the Pink wire connector 4 and Blue wire connector 5 INSTALLATION m Y 2 3 x Align 1 1 1 2 KM ft i 1 2 3 mmm 4 mm 5 Yuf Install a new packing 1 onto the fuel pump unit 2 Always replace the packing with a new one Be careful not to pinch any dirt or debris between the fue...

Страница 167: ...isconnect the crankcase breather hose 1 from the cylinder head 1 I n ill Disconnect the lAT sensor 2P Black connector 1 Loosen the air cleaner connecting hose band screw 2 Remove the bolts 3 washer 4 and collar 5 Remove the fuel tank mounting bolts 6 and washer 7 then slightly pull the fuel tank 8 backward Disconnect connecting hose and remove the air cleaner housing 9 Installation is in the rever...

Страница 168: ...5 3 NOTICE Do not remove the sensor unit unless it is replaced The throttle body sensor unit is factory pre set Do not disassemble in a way other than shown in this manual Do not snap the throttle valve from full open to full close after the throttle cable has been removed It may cause incorrect idle operation Do not damage the throttle body It may cause incorrect throttle valve operation Do not l...

Страница 169: ... passages and compressed air sensor hole with a Check the air passage for clogs piece of wire will damage the throttle body ASSEMBLY I n 3 mmmmr a NOTE For IACV installation page 7 21 J THROTTLE BODY O RING SENSOR UNIT TORX SCREWS 3 4 N m 0 3 kgf m 2 5 Ibf ft TORX SCREWS 2 1 N m 0 2 kgf m 1 5 Ibf ft SETTING PLATE 0 O a i m IACV J O RING 7 15 ...

Страница 170: ...rews 1 to the specified torque TORQUE 3 4 N m 0 3 kgf m 2 5 Ibf ft INSTALLATION Align 2 A g tUP r 1 m L i 1 Align 1 3 Pi mm Install the throttle body assembly 1 to the cylinder head by aligning the tab with the insulator groove Tighten the insulator band screw 2 to the specified range Connect the throttle cables 3 to the throttle drum and throttle cable stay Tighten the throttle cable B lock nut 4...

Страница 171: ...on switch OFF 3 Short the DLC 1 terminals using a special tool Connection Brown Green TOOL 2 SCS service connector 070PZ ZY30100 4 Disconnect the ECT sensor 2P Black connector 11 Short the ECT sensor 2P Black connector terminals of the wire harness side with a jumper wire 2 5 Turn the ignition switch ON and engine stop switch O then MIL will start blinking Disconnect the jumper wire while the MIL ...

Страница 172: ...tion is not reset repeat the reset procedure from step 1 7 Turn the ignition switch OFF 8 Install the removed parts in the reverse order of removal FUEL INJECTOR REMOVAL Relieve the fuel pressure and disconnect the quick connect fitting from the fuel injector side page 7 4 Remove the fuel tank page 7 7 Disconnect the fuel injector 2P Gray connectors 1 Remove the clip 2 from the fuel rail Remove th...

Страница 173: ...o 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 fuel injector connector Install the seal ring to the fuel injector 4 being careful not to damage them Install the O ring to the fuel injector Install the fuel injectors 1 to the fuel rail 2 being careful not to damage the O ring Align the fuel injector body with th...

Страница 174: ...n the throttle body and is operated by the step motor When the ignition switch is turned ON and engine stop switch O the IACV operates for a few seconds Check the step motor operating beep sound with the ignition switch turned ON and engine stop switch O Disconnect the IACV 4P Black connector 1 Remove the IACV setting plate torx screws 2 and setting plate 3 Remove the IACV 4 and O ring 5 INSPECTIO...

Страница 175: ...RQUE 2 1 Nm 0 2 kgf m 1 5 Ibf ft Connect the IACV 4P Black connector 5 Install the air cleaner housing page 7 13 FUEL CUT RELAY 3 s Align 1 5 Align 4 2 3 INSPECTION Remove the seat page 2 14 Open the fuse box cover and remove the fuel cut relay 11 Connect a ohmmeter to the fuel cut relay 1 terminals Connect a 12 V battery to the fuel cut relay terminals as shown There should be continuity only whe...

Страница 176: ...ttery is connected to the EVAP purge control solenoid valve terminals Check the resistance between the terminals of the EVAP purge control solenoid valve STANDARD 30 34 Q 20 C 68 F If the resistance is out of specification replace the EVAP purge control solenoid valve 1 fr SIPIL B A 5 E EVAP CANISTER 50 STATE MODEL REMOVAL INSTALLATION Remove the fuel tank page 7 7 Disconnect the following from th...

Страница 177: ...EM FLOW PATTERN 8 2 SERVICE INFORMATION 8 3 TROUBLESHOOTING 8 3 SYSTEM TESTING 8 4 COOLANT REPLACEMENT 8 4 THERMOSTAT THERMOSTAT HOUSING 8 5 RADIATOR 8 7 WATER PUMP 8 9 RADIATOR RESERVE TANK 8 11 FAN CONTROL RELAY 8 11 8 1 ...

Страница 178: ...COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR CAP THERMOSTAT RADIATOR RADIATOR RESERVE TANK 0 X dk a a 3 SJ a V IN WATER PUMP R 9 ...

Страница 179: ... coolant on painted surfaces After servicing the system check for leaks with a cooling system tester Refer to the ECT sensor inspection page 22 13 TROUBLESHOOTING Engine temperature too high Faulty high coolant temperature indicator or ECT sensor Thermostat stuck closed Faulty radiator cap Insufficient coolant Passage blocked in radiator hoses or water jacket Air in system Faulty cooling fan motor...

Страница 180: ...ents Do not exceed 137 kPa 1 4 kgf cm2 20 psi Repair or replace components if the system will not hold specified pressure for at least 6 seconds COOLANT REPLACEMENT REPLACEMENT AIR BLEEDING NOTE When filling the system or reserve tank with coolant or checking the coolant level place the motorcycle in an upright position on a flat level surface Remove the following Right front side cowl page 2 6 CT...

Страница 181: ...sufficient level of coolant in the reserve tank will decrease If so fill to the upper level line with coolant After installation check that there are no coolant leaks Install the following Right front side cowl page 2 6 CTX700 A D Right radiator side cover page 2 10 CTX700N NA ND THERMOSTAT THERMOSTAT HOUSING REMOVAL INSTALLATION Drain the coolant page 8 4 Remove the following Air cleaner housing ...

Страница 182: ...tat air bleed hole with the rib side bolt hole Tighten the water hose band screws to the specified range page 8 8 Fill the recommended coolant mixture to the filler neck and bleed the air page 8 4 INSPECTION m Align m Visually inspect the thermostat 1 for damage Check for damage of the seal ring 2 Wear insulated gloves and adequate eye protection Keep flammable materials away from the electric hea...

Страница 183: ...t wheel speed sensor page 20 21 Remove the following Front side cowls page 2 6 CTX700 A D Radiator side covers page 2 10 CTX700N NA ND Remove the bolt 1 and radiator lower stay 2 by releasing it from the radiator boss 3 Remove the bolt 4 and release the radiator mounting rubbers 5 from the boss of the frame 3 5 jj m m 4 Hi Disconnect the fan motor 3P Gray connector 1 Release the wire band boss 2 a...

Страница 184: ... 0 1 mm 0 0 04 in Disassemble and assemble the radiator as following the illustration Align the cooling fan and fan motor shaft flat surfaces Apply locking agent to the cooling fan mounting nut threads i I RADIATOR COLLARS SIDE COVER WASHERS SOCKET BOLTS r rrc COOLING FAN FAN MOTOR s id j COOLING FAN MOUNTING NUT 1 0 N m 0 1 kgf m 0 7 Ibf ft i SHROUD Align the cut outs 8 4 N m 0 9 kgf m 6 2 Ibf ft...

Страница 185: ...ary REMOVAL INSTALLATION 1 Remove the following Left front side cowl page 2 6 CTX700 A D Left radiator side cover page 2 10 CTX700N NA ND Left under side cowl page 2 13 Drain the coolant page 8 4 Loosen the water hose band screws 1 and disconnect the radiator lower water hose 2 and water bypass hose 3 When connecting the water bypass hose align the index mark with the water pump tab Remove the fol...

Страница 186: ...rom the water pump body Replace the packing with new one Remove the water pump body 1 and O rings 2 from the cylinder head Installation is in the reverse order of removal Replace the O rings with new ones Apply engine oil to the large O ring Align the water pump slit with camshaft tab Tighten the water hose band screws to the specified range page 8 8 Fill the recommended coolant mixture to the fil...

Страница 187: ...e and drain the coolant from the reserve tank Installation is in the reverse order of removal Fill the radiator reserve tank with the recommended coolant page 3 12 FAN CONTROL RELAY m V 2 MI 1 3 1 9TV l ji I 3 5 i m 2 Hi INSPECTION Remove the seat page 2 14 Open the fuse box cover and remove the fan control relay 1 Connect an ohmmeter to the fan control relay 1 connector terminals Connect a 12 V b...

Страница 188: ...MEMO ...

Страница 189: ...ATION SYSTEM LUBRICATION SYSTEM DIAGRAM 9 2 SERVICE INFORMATION 9 4 TROUBLESHOOTING 9 5 OIL PRESSURE INSPECTION 9 6 OIL FILTER BOSS OIL PUMP CTX700 A N NA OIL PUMP CTX700D ND OIL STRAINER 9 6 9 7 9 8 9 11 m 9 1 ...

Страница 190: ... CAMSHAFT PISTON EOP SWITCH CRANKSHAFT OIL FILTER CARTRIDGE PRESSURE RELIEF VALVE J r m i i i i 1 5 a I i I I II II II i r U Til I I II II r fffiMHlMTO i f r p N OHr p S Q o Bt f iV iV 3 nm i 5 s 4 r M e 3 n GL f XJ 9 t G Bra T3 OIL PUMP OIL STRAINER MAINSHAFT 9 9 COUNTERSHAFT ...

Страница 191: ...FT f CAMSHAFT PISTON CRANKSHAFT EOP SWITCH OIL FILTER CARTRIDGE PRESSURE RELIEF VALVES Ml 4 i i i r n f f i 4 iV y r i st t I M ENGINE OIL PUMP OIL STRAINER MJF m i m R 5 MAINSHAFT EOPSENSOR CLUTCH OIL PUMP COUNTERSHAFT LINEAR SOLENOID VALVE 9 3 ...

Страница 192: ...service procedures in this section must be performed with the engine oil drained When removing and installing the oil pump use care not to allow dust or dirt to enter the engine If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil leaks and that oil pressure is correct TOOLS ...

Страница 193: ... 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 Blown cylinder...

Страница 194: ...ally available Fill the engine with the recommended engine oil page 3 10 Warm the engine to normal operating temperature approximately 80 C 176 F and increase the engine speed to 5 000 rpm and read the oil pressure STANDARD 470 kPa 4 8 kgf cm2 68 psi at 5 000 rpm 80 C 176 F Stop the engine and remove the tools Install the engine oil filter cartridge page 3 10 OIL FILTER BOSS INSPECTION Remove the ...

Страница 195: ...rings with a new one Align the oil pump shaft tab with the balancer shaft slit DISASSEMBLY ASSEMBLY m e i 1 2 mKrn Align a O r 1 1 2 Remove the bolts 1 oil pump cover 2 and dowel pins 3 Remove the thrust washer 4 oil pump shaft 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...

Страница 196: ...rances according to LUBRICATION SYSTEM SPECIFICATIONS page 1 7 If any of the measurement is out of the service limit replace the oil pump as an assembly OIL PUMP CTX700D ND REMOVAL INSTALLATION Remove the right crankcase cover page 12 57 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 th...

Страница 197: ...BRICATION SYSTEM 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 M 2 1 2 3 2 1 1 2 m c i m 4 3 9 9 ...

Страница 198: ... oil pump clearances according to LUBRICATION SYSTEM SPECIFICATIONS page 1 7 If any of the measurement is out of the service limit replace the oil pump as an assembly ASSEMBLY Assembly is in the reverse order of disassembly Dip all parts in clean engine oil OIL PUMP PLATE CLUTCH OIL PUMP INNER ROTOR DRIVE PIN CLUTCH OIL PUMP OUTER ROTOR DOWEL PIN a a 0 o 0 DRIVE PIN a SK DOWEL PIN OIL PUMP COVER O...

Страница 199: ... strainer screen and check for damage replace it if necessary INSTALLATION M BM 2 1 u a a a 1 1 1 Apply engine oil to a new seal ring 1 and install it onto the oil strainer 2 Install the oil strainer into the crankcase while aligning the oil strainer boss with the crankcase groove TO r r 1 1 F4 I 2 Clean the oil pan mating surface thoroughly Apply liquid sealant TB1207B manufactured by Three Bond ...

Страница 200: ...and bolts 2 Tighten the bolts in a crisscross pattern in 2 or 3 steps Install the exhaust pipe muffler page 2 19 Fill the engine with the recommended engine oil and check that there are no oil leaks page 3 9 Nfafeli ll 1 gL imlyjk it r 5 9 12 ...

Страница 201: ...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 7 CAM CHAIN TENSIONER 10 10 CAMSHAFT 10 12 BEI CYLINDER HEAD 10 14 10 1 ...

Страница 202: ...T LOCATION 10 N m 1 0 kgf m 7 lbf ft 56 N m 5 7 kgf m 41 lbf ft 4 0 N m 0 4 kgf m 3 0 lbf ft 44 N m 4 5 kgf m 32 lbf ft 29 N m 3 0 kgf m 21 lbf ft 0 12 N m 1 2 kgf m 9 lbf ft 0 3 J a a a 0 0 o a V o a O m 0 5 IS r CD J CD J j 10 2 ...

Страница 203: ...the cylinder head Clean the oil passages before assembling cylinder head Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head TOOLS Gear holder 2 5 07724 0010100 or 07724 001A100 U S A only Valve spring compressor 07757 0010000 Valve guide reamer 5 010 mm 07984 MA60001 or 07984 MA6000D U S A only Valve guide driver 07942 8920000 Valve guide driver 07...

Страница 204: ...d Valves Incorrect valve clearance adjustment Burned or bent valve Incorrect valve timing Broken valve spring Uneven valve 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 Excess...

Страница 205: ...stops rising The maximum reading is usually reached within 4 7 seconds STANDARD 1 775 kPa 18 1 kgf cm2 257 psi at 470 rpm Low compression can be caused by 1 o J v 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 CYLINDER HEAD COVER REMOVAL INSTALLATION ...

Страница 206: ...is in the reverse order of removal Check the mounting rubbers 1 are in good condition replace them if necessary Install the mounting rubbers with their UP mark 2 facing up TORQUE Cylinder head cover socket bolts 10 N m 1 0 kgf m 7 Ibfft Rear master cylinder reservoir mounting bolt 10 N m 1 0 kgf m 7 Ibf ft S X 1 2 o DISASSEMBLY ASSEMBLY Remove the breather plate mounting bolts 1 When assembly appl...

Страница 207: ...bolt 12 Nm 1 2 kgf m 9 Ibf ft ROCKER ARM ts 1 mt c S 2 1 REMOVAL Remove the cylinder head cover page 10 5 Remove the camshaft maintenance cap 1 and O ring 2 Remove the crankshaft hole cap Turn the crankshaft counterclockwise and align the A mark 1 on the cam sprocket with the lower cylinder head index line 2 Remove the rocker arm shaft bolts 1 2 if 06 LI 1 v m A w i 1 i _ E 1 W i 1 hs 1 10 7 ...

Страница 208: ... rocker arms from the rocker arm shaft 2 Apply molybdenum oil solution to the rocker arm sliding surface and rocker arm shaft outer surface Install the washers and rocker arms to the rocker arm shaft NOTE 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 3 1 4 1 5 0 0 a 1 3 1 A 6 4...

Страница 209: ...nder head index line 2 If it 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 t...

Страница 210: ...e cap is equivalent with 30 Install the following Cylinder head cover page 10 5 Crankshaft hole cap page 3 9 2 7 1 1 tJSLi m is li 2 CAM CHAIN TENSIONER CAM CHAIN INSPECTION Remove the cylinder head cover page 10 5 Measure the cam chain tensioner wedge B 1 length SERVICE LIMIT 6 0 mm 0 24 in Replace the cam chain with a new one if the projection exceeds the service limit For the cam chain replacem...

Страница 211: ...am chain tension page 10 11 Install the thermostat housing page 8 5 INSPECTION 3 u ii m 2i 8 r a i Align Remove the cam chain tensioner page 10 11 Check the cam chain tensioner 1 for wear or damage Replace the cam chain tensioner if necessary Remove the cam chain guide page 10 14 Check the cam chain guide 2 for wear or damage Replace the cam chain guide if necessary APPLYING CAM CHAIN TENSION Remo...

Страница 212: ... 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 1 m m as 3 PI 4 2 I V 1 3 1 0 TH Inspect the following parts for damage abnormal wear deformation burning or clogs in oil passages Cam sprocket C...

Страница 213: ...ge 3 7 Align the 1 mark 1 on the cam sprocket with the upper index line 2 on the cylinder head and install the cam chain onto the cam sprocket Install the cam sprocket onto the camshaft by aligning the groove with the pin 1 Ww L J mm a a m m m m m 9 m m 2 1 Align Apply engine oil to the cam sprocket bolt threads and seating surface Install the cam sprocket bolt 1 Hold the flywheel mounting bolt an...

Страница 214: ... water bypass hose index mark with the water pump tab Tighten the water hose band screws to the specified range page 8 8 Install the engine CTX700 A N NA page 16 9 CTX700D ND page 16 18 Ha ll I 1 Align 3 sacs 2 iHw JALIGN 1 mmtk si 2 1 CYLINDER HEAD REMOVAL Remove the following Engine CTX700 A N NA page 16 5 CTX700D ND page 16 14 Cylinder head cover page 10 5 Right crankcase cover CTX700 A N NA pa...

Страница 215: ...and realign the A mark with the lower cylinder head index line Remove the cam chain tensioner page 10 11 Insert the gear holder 1 gear and driven gear TOOL Gear holder 2 5 between the primary drive 07724 0010100 or 07724 001A100 U S A only 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...

Страница 216: ... 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 FT 5 a m cipr s A 1 2 L i Ji PI K3E yujc T m L T L aL 1 m IS m 3 2 3 n n x m m y i r 10 16...

Страница 217: ...ring 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 m m 5 3 2 m 4 INSPECTION Inspect the following parts for damage abnormal wear deformation burning or clogs in oil passages Cylinder head Inner outer valve springs Valve guides Measure each part and clearance according to CYLINDER HEAD VALVE...

Страница 218: ...lipers 1 Use cutting oil on the reamer during this operation Drive in the valve guides to the specified depth from the top of the cylinder head SPECIFIED DEPTH IN 17 7 18 0 mm 0 70 0 71 in EX 19 6 19 9 mm 0 77 0 78 in TOOL 1 Valve guide driver 07743 0020000 Not available in U S A Let the cylinder head cool to room temperature Ream new valve guides after installation Insert the reamer 1 from the co...

Страница 219: ...t cutters grinders or equivalent valve seat refacing equipment are recommended to correct worn valve seats If the contact area is too high on the valve the seat must be lowered using a 32 flat cutter If the contact area is too low on the valve the seat must be raised using a 60 interior cutter Refinish the seat to specifications using a 45 finish cutter Use a 45 cutter to remove any roughness or i...

Страница 220: ...he 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 all residual compound off the cylinder head and valve Recheck the seat contact after lapping 0 o o o o 1 INSULATOR ASSEMBLY 2 7 N o STEM SEAL SPRING SEAT VALVE GUIDE INTAKE VALVE COTTERS RETAINER VALVE SPRING J EXHAUST VALVE 10 20 ...

Страница 221: ...oils facing the combustion chamber Install the valve spring retainer 5 Install the valve cotters using the special tool as shown TOOL Valve spring compressor 07757 0010000 To prevent loss of tension do not compress the valve spring more than necessary Grease the cotters to ease installation Tap the valve stems gently with plastic hammer and shaft as shown to seat the cotters firmly Support the cyl...

Страница 222: ... 10 22 INSTALLATION 1 11 13 mm 0 4 0 5 in ffinnTi m 2 Align Install the partition plate 1 to the No 1 cylinder intake side Install the partition plate with its tab 2 side facing inside Install the cam chain guide 1 Align the cam chain guide end with the groove in the crankcase Align the cam chain guide tabs with the grooves in the crankcase Install the dowel pins 1 and new gasket 2 2 1 v 1 1 as 1 ...

Страница 223: ...l and tighten the cylinder head special bolts in a crisscross pattern in 2 or 3 steps to the specified torque TORQUE 44 N m 4 5 kgf m 32 Ibf ft Install and tighten the 6 mm bolts 1 Turn the crankshaft clockwise and align the index lines 1 with the crankcase matting surface while the TOP mark 2 is facing down 1 2 f m a um m m jMitm m M r f H m m CTX700 A N NA 1 r 4 A A A S3 as mm 2 Align x V CTX700...

Страница 224: ... 10 11 Apply engine oil to a new O ring 1 and install it to the camshaft maintenance cap 2 Temporarily install the camshaft maintenance cap to the cylinder head If the engine is removed from the frame tighten the camshaft maintenance cap to the specified torque TORQUE 4 0 N m 0 4 kgf m 3 0 Ibfft If the engine is installed on the frame insert a feeler gauge 0 1 mm 1 between the camshaft maintenance...

Страница 225: ...NKAGE CTX700 A N NA COMPONENT LOCATION 11 2 SERVICE INFORMATION 11 2 TROUBLESHOOTING 11 3 RIGHT CRANKCASE COVER 11 4 CLUTCH 11 6 PRIMARY DRIVE GEAR CKP SENSOR ROTOR 11 11 GEARSHIFT LINKAGE 11 13 GEARSHIFT PEDAL 11 16 HI 11 1 ...

Страница 226: ...f ft SERVICE INFORMATION GENERAL This section covers service of the clutch and gearshift linkage All service can be done with the engine installed in the frame Engine oil viscosity and level have an effect on clutch disengagement Oil additives also effect clutch performance and are not recommended When the clutch does not disengage or the motorcycle creeps with the clutch lever pulled in inspect t...

Страница 227: ...ed 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 Damaged or bent shift fork Bent shift fork shaft Bent shift fork claw Loose shift drum stopper plate bolt Dama...

Страница 228: ...de cover 2 Remove the two collars 3 from the right engine side cover Remove the bolts 4 and clutch cable guide 5 then disconnect the clutch cable 6 from the clutch lifter arm Ul Loosen the right crankcase cover bolts 1 in a crisscross pattern in 2 or 3 steps and remove the bolts and sealing washer 2 Replace the sealing washer with a new one Remove the right crankcase cover 3 Remove the dowel pins ...

Страница 229: ... 3 9 CLUTCH LIFTER ARM REMOVAL INSTALLATION Remove the clutch lifter rod A 1 Remove the snap ring 2 clutch lifter arm 3 and return spring 4 from the right crankcase cover m m 3 m 811 MS 1 aa s l mm m 4 Install the clutch lifter arm 1 return spring 2 and snap ring 3 Align the return spring hook 4 with right crankcase cover Align the return spring end 5 with clutch lifter arm groove Make sure the sn...

Страница 230: ...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 special tool and loosen the clutch center lock nut 1 TOOL Clutch center holder 2 07JMB MN50302 U S A TOOLS Holder plate 07HGB 001010B Holder collar 07HGB 001020B Remove and discard the lock nut Remove the lock washer 1 and thrust washer 2 2 m 4 y m m 12 1 3 s...

Страница 231: ...at 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 Remove the clutch outer guide 1 CLUTCH GEARSHIFT LINKAGE CTX700 A N NA bx i m yj m P 2 31 4 7 5 6 it i 3 m 1 a J m m HI 0 1 I 0 I k 1 11 7 ...

Страница 232: ...asure each part according to CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS page 1 8 Replace any if it is out of service limit Replace the clutch springs as a set Replace the clutch discs and plates as a set INSTALLATION CLUTCH OUTER GUIDE CLUTCH OUTER THRUST WASHER PRESSURE PLATE 1 CLUTCH DISC C CLUTCH PLATE 7 CLUTCH DISC B 12 N m 1 2 kgf m 9 Ibf ft TlCLUTCH LIFTER ROD B CLUTCH DISC A m 0 3 0 0 1 JUDDER...

Страница 233: ...er V rsl K 0 m m A M 1 i C m 8 i Apply engine oil to the clutch discs entire surface Install the spring seat 1 judder spring 2 and clutch disc B 3 to the clutch center 4 Install the clutch discs C 5 and clutch plates 6 alternately starting with the clutch plate Install the clutch disc A 7 and pressure plate 8 7 30 CLUTCH DISC A CLUTCH DISC B 5 3 5 9 mm 0 21 0 23 in 9 CLUTCH DISC C w H 71 1 I 1 2 3...

Страница 234: ...her 1 Install the lock washer 2 with its OUTSIDE mark 3 facing out Apply engine oil to a new clutch center lock nut threads and seating surface Install the clutch center lock nut 1 onto the mainshaft Hold the pressure plate with the special tool and tighten the lock nut to the specified torque TOOL Clutch center holder 2 07JMB MN50302 U S A TOOLS Holder plate 07HGB 001010B Holder collar 07HGB 0010...

Страница 235: ...rface Install the clutch lifter rod B 4 Install the right crankcase cover page 11 4 Nr T sc 3 111 1 A I m 4 2 PRIMARY DRIVE GEAR CKP SENSOR ROTOR REMOVAL Remove the right crankcase cover page 11 4 Hold the primary drive gear 1 using a special tool and remove the primary drive gear mounting bolt 2 and washer 3 TOOL 4 Gear holder 2 5 07724 0010100 or 07724 001A100 U S A only Remove the gear holder R...

Страница 236: ...tor with its MGS mark 2 facing out Apply engine oil to the primary drive gear mounting bolt threads and seating surface 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 TOOL 3 Gear holder 2 5 07724 0010100 or 07724 001A100 U S A only TORQUE 93 Nm 9 5 kgf m 69 Ibf ft ...

Страница 237: ...e 1 Remove the gearshift spindle 1 and washer 2 Remove the following Shift drum stopper arm pivot bolt 1 Washers 2 Stopper arm 3 Return spring 4 Remove the shift drum center socket bolt 5 shift drum stopper plate 6 and dowel pin 7 Remove the bolt 1 and setting plate 2 Remove the gearshift spindle oil seal 3 7 1 r 2 m m 11 u i 1 1 5 3 SB 4 I m Wtm 7 S 1 2 3 m m 2 1 11 13 ...

Страница 238: ...place them if necessary Check the gearshift spindle 3 for wear or bend Check the spindle arm 4 for wear damage or deformation Replace the gearshift spindle as an assembly if necessary 4 2 3 1 INSTALLATION Install a new gearshift spindle oil seal 1 as shown Install the oil seal with its marked side facing out Apply grease to the oil seal lips Install the setting plate 1 and a new bolt 2 Align the s...

Страница 239: ...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 3 i m J U Align 1 Apply locking agent to the shift drum center socket bolt threads page 1 14 Install and tighten the shift drum center socket bolt 1 to the specified torque TORQUE 23 N m 2 3 kgf m 17 Ibf ft a 6P3 iSrnJ IH ul BSMBi ...

Страница 240: ... sliding surface and dust seal lips Installation is in the reverse order of removal Apply grease to the gearshift pedal tie rod ball joint area TORQUE Gearshift pedal pivot bolt 39 N m 4 0 kgf m 29 Ibfft Gearshift arm pinch bolt 12 N m 1 2 kgf m 9 Ibf ft Adjust the tie rod length so that the distance between the ball joint ends is standard length as shown After adjustment tighten the gearshift ped...

Страница 241: ...6 MODE SHIFT INDICATOR CIRCUIT TROUBLESHOOTING 12 56 AT MT MODE SWITCH TROUBLESHOOTING 12 56 RIGHT ENGINE SIDE COVER 12 57 RIGHT CRANKCASE COVER 12 57 DUAL CLUTCH 12 66 PRIMARY DRIVE GEAR CKP SENSOR ROTOR 12 69 SHIFT CONTROL MOTOR REDUCTION GEARS 12 70 GEARSHIFT LINKAGE 12 73 MAINSHAFT SENSOR 12 76 TR SENSOR 12 76 SHIFT SPINDLE ANGLE SENSOR 12 77 CLUTCH EOP SENSOR 12 78 EOT SENSOR 12 79 DCT SHIFT ...

Страница 242: ...DUAL CLUTCH TRANSMISSION DCT CTX700D ND COMPONENT LOCATION 23 N m 2 3 kgf m 17 lbf ft CP 12 N m 1 2 kgf m 9 lbf ft I 12 2 ...

Страница 243: ...are shared in the PGM FI and DCT systems and they may affect the operation 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 9 Shift indicator blinks or DTC for the DCT system page 12 7 Symptom of the DCT system operation page 12 5 Serial communication line page 22 8 Refer to the...

Страница 244: ... Select the Linear Solenoid 1 or Linear Solenoid 2 5 Start the engine and let it idle 6 Make sure that the transmission is in neutral position 7 Select the Drive Linear Solenoid To 0 kPa Drive Linear Solenoid To 400 kPa or Drive Linear Solenoid To 800 kPa mode Measure the linear solenoid current at each mode TOOLS SCS service connector 070PZ ZY30100 Test probe 2 packs 07ZAJ RDJA110 IgnitionMate pe...

Страница 245: ...ON 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 tightened to their correct torque values Replace the damaged components if necessary and tighten the loose fasteners to the specified torque DCT ELECTRICAL SYSTEM LOCATION VS SEN...

Страница 246: ...OES NOT DISENGAGE 58 No 2 CLUTCH DOES NOT DISENGAGE 59 4 Bl W 1 SHIFT PEDAL I ANGLE SENSOR Y R Y R G Q Y V Y V WBy B19 SFTPANGl G Y OPTIONAL 1 0 Ru G MAINSHAFT COUNTERSHAFT SPEED RATIO 71 72 V G A17 PLINE G Y G Y R22 SG 9 49 LINEBDP SENSOR FAIL SAFE RELAY 32 v G Y R B14 VCC Y R v IGNITION HOLD RELAY 37 G Y V Y G No 1 CLUTCH EOPSENSOR Y G Y R 47 Af PC1 v mmmmm A5 PC2 I No 1 CLUTCH SLIPS 68 G Y 3 I ...

Страница 247: ...ESHOOTING page 12 5 1 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 v v V r HI FAIL SAFE FUNCTION The DCT system is provided with a fail safe function to secure a minimum running capab...

Страница 248: ...n 2 5 sec 2 5 sec 0 4 sec DTC 14 DTC 8 DTC 14 One long blink 10 blinks Eight short blinks plus four short blinks Pattern repeated 1 cycle Shift indicator Check When the ignition switch is turned ON with the engine stop switch to O the shift indicator will stay on for a few seconds then go off CURRENT DTC STORED DTC The DTC is indicated in two ways according to the failure status If the PCM detects...

Страница 249: ... read the DTC without the MCS use the following procedure r v v y A m Reading DTC with the shift indicator 1 Turn the ignition switch OFF Remove the seat page 2 14 2 Remove the DLC 1 from the battery box Remove the dummy connector from the DLC Short the DLC terminals using a special tool Connection Brown Green TOOL 2 SCS service connector 070PZ ZY30100 3 Make sure the engine stop switch is turned ...

Страница 250: ...While pushing the shift switch 1 turn the ignition switch ON and engine stop switch Q 2 Push the shift switch 2 3 Push the shift switch 4 The self diagnostic memory is erased if the shift indicatorgoes off and starts blinking as shown U ml 2 2 sec r ON n OFF 2 sec 2 sec k y 3 sec 3 sec 3 sec I Pattern repeated 1 cycle NOTE Note that the self diagnostic memory cannot be erased if the ignition switc...

Страница 251: ...shiftfunctiondoes not work while driving Only shifted into 1st gear 12 21 23 1 23 Shift spindle operation malfunction while operating gearshift mechanism Gearshift mechanism malfunction Shift spindle angle sensor malfunction Gearshiftfunctiondoes not work while driving Only shifted into 1st gear 12 22 24 1 24 Shift control motor drive circuit Shift control motor or its circuit malfunction Shift co...

Страница 252: ...n clutch engage Engine oil level low Faulty oil pump Faulty clutch oil circuit Clutch line EOP sensor malfunction Faulty PCM Engine does not operate 12 34 49 2 49 Clutch line low oil pressure when engine running Engine oil level low Faulty oil pump Faulty clutch oil circuit Clutch line EOP sensor malfunction Faulty PCM Engine does not operate 51 1 51 TR sensor low voltage Loose or poor contact of ...

Страница 253: ...does not work 57 1 57 Gearshift mechanism malfunction Gearshift mechanism malfunction TR sensor or its circuit malfunction Faulty PCM Gearshiftfunction does not work while driving Engine does not operate 12 45 57 2 57 Gear position malfunction jumps out of gear Gearshift mechanism malfunction TR sensor or its circuit malfunction Faulty PCM Gearshiftfunction does not work while driving Engine does ...

Страница 254: ...ntact of the linear solenoid valve and No 2 clutch EOP sensor connectors No 2 linear solenoid valve or its circuit malfunction Faulty PCM Engine does not operate 64 1 64 No 2 clutch oil pressure high No 2 clutch EOP sensor malfunction Faulty clutch oil circuit No 2 linear solenoid valve malfunction Faulty PCM Gearshift function does not work while driving Engine does not operate 64 2 64 No 2 clutc...

Страница 255: ...unction Faulty PCM Gearshift function does not work 72 1 72 Outer mainshaft countershaft speed ratio failure VS sensor or its circuit malfunction Outer mainshaft sensor or its circuit malfunction Faulty PCM Gearshift function does not work 12 53 84 1 84 CPU in the PCM malfunction Faulty PCM Gearshift system stops 12 53 1 1 1 Shift pedal angle sensor Optional malfunction Shift pedal angle sensor or...

Страница 256: ...ne Check the clutch line EOP sensor with the MCS 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 page 12 78 Turn the ignition switch ON and engine stop switch O Check the clutch line EOP sensor with the MCS Is about 0 V indicated YES GO TO STEP 3 NO Replace the clutch line E...

Страница 257: ...nectors and recheck the DTC If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 1 Clutch Line EOP Sensor System Inspection Check the clutch line EOP sensor with the MCS 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 connector page 12 78 Con...

Страница 258: ...place the PCM with a known good one and recheck NO Open circuit in the Violet green wire DTC 19 1 CKP SENSOR NO SIGNAL B22 2 1 G Y Q 2 Q V G 1 A17 NOTE 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 Clutch Initialize Learning Procedure page 12 81 1 CKP sensor Peak Voltage In...

Страница 259: ... the shift spindle angle sensor 3P Gray and PCM 33P connectors and recheck the DTC If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 1 Shift Spindle Angle Sensor System Inspection Check the shift spindle angle sensor with the MCS 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 ...

Страница 260: ...erminal and ground Connection Violet red ground Is there continuity YES Short circuit in the Violet red wire NO GO TO STEP 5 1 cmV R Q 5 Shift Spindle Angle Sensor Inspection Replace the shift spindle angle sensor with a known good one page 12 77 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 wit...

Страница 261: ... connector Turn the ignition switch ON Check the shift spindle angle sensor with the MCS 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 MCS Is Low voltage abou...

Страница 262: ...pindle angle sensor shaft check the shift spindle angle sensor voltage with the MCS When turning the sensor shaft clockwise Voltage increase When turning the sensor shaft counterclockwise Voltage decrease 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 prope...

Страница 263: ...TO STEP 2 NO Open circuit in the Pink blue wire Open circuit in the Yellow blue wire 2 Shift Control Motor Line Short Circuit Inspection 3 Check for continuity between the wire harness side shift control motor 2P Black connector 1 terminals and ground Connection Pink blue Ground Yellow blue Ground Is there continuity YES Short circuit in the Pink blue wire Short circuit in the Yellow blue wire NO ...

Страница 264: ...trol motor and reduction gears properly or replace faulty parts 3 Shift Control Motor Condition Inspection Remove the shift control motor page 12 70 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 turn in both directions YES GO TO STEP 4 ...

Страница 265: ...utch Initialize Learning Procedure page 12 81 1 DTC Recheck Erase the DTCs page 12 10 Check the DTC with the MCS Is DTC 32 1 or 37 1 indicated YES DTC 32 1 indicated page 12 26 DTC 37 1 indicated page 12 26 NO GO TO STEP 2 2 Shift Control Motor Line Open Circuit Inspection Disconnect the following PCM 33P Black connector page 4 34 Shift control motor 2P Black connector page 12 70 Check for continu...

Страница 266: ...ck the DTC with the MCS 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 NOTE Before starting the inspection check for loose or poor contact on the PCM 33P Black connector and recheck the DTC If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 1 PCM DCT Drive Circuit Sub Power...

Страница 267: ...low red wire 2 N D Shift Switch Inspection Turn the ignition switch OFF Check for continuity between the switch side right handlebar switch 6P Black connector 1 terminals in each switch position Connection N switch Light green blue Red D switch Black yellow Red Is there continuity with the switch pushed and no continuity with the switch released YES GO TO STEP 3 NO Faulty N D shift switch 3 N D Sh...

Страница 268: ...ialize Learning Procedure page 12 81 1 Shift Switch Power Input Voltage Inspection Disconnect the left handlebar switch 6P Black connector page 22 18 Turn the ignition switch ON with the engine stop switch o Measure the voltage between the wire harness side left handlebar switch 6P Black connector 1 terminal and ground Connection Yellow red Ground Is the voltage within 4 75 5 25 V YES GO TO STEP 2...

Страница 269: ...side PCM 33P Black connector 1 terminals and ground Connection A7 Ground A30 Ground TOOL Test probe 2 packs 07ZAJ RDJA110 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 A7 Q Q A30 1 DTC 44 1 EOT SENSOR LOW VOLTAGE NOTE If the PCM is replaced perform the Clutch Initialize Learning Procedure...

Страница 270: ...SOR HIGH VOLTAGE HI Bu G O NOTE Before starting the inspection check for loose or poor contact on the EOT sensor 2P Black and PCM 33P connectors and recheck the DTC If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 1 EOT Sensor System Inspection Check the EOT sensor with the MCS Is about 5 V indicated YES GO TO STEP 2 NO Intermittent failure 2 EOT Sensor Inspection...

Страница 271: ...nals Connection Green yellow B22 TOOL Test probe 2 packs 07ZAJ RDJA110 Is there continuity YES Replace the PCM with a known good one and recheck NO Open circuit in the Green yellow wires DTC 47 1 or 48 1 No 1 or No 2 CLUTCH EOP SENSOR LOW VOLTAGE Bu G C 2 i i 1 r PT1 I 1 A19 1 Q G Y j 2 I i i IT _ B22 NOTE If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 1 Clutch ...

Страница 272: ... ground Connection No 1 clutch EOP sensor Yellow green Ground No 2 clutch EOP sensor Black green Ground Is there continuity YES Short circuit in the Yellow green wire Short circuit in the Black green wire NO Replace the PCM with a known good one and recheck 1 V nP in Y G or Bl G Q DTC 47 2 or 48 2 No 1 or No 2 CLUTCH EOP SENSOR HIGH VOLTAGE NOTE Before starting the inspection check for loose or po...

Страница 273: ...ge 4 34 Check for continuity between the wire harness side clutch EOP sensor 3P Gray connector 1 and PCM 33P Gray connector 2 terminals Connection Green yellow B22 TOOL Test probe 2 packs 07ZAJ RDJA110 Is there continuity YES GO TO STEP 4 NO Open circuit in the Green yellow wire 4 Clutch EOP Sensor Output Line Open Circuit Inspection Disconnect the PCM 33P Black connector page 4 34 Check for conti...

Страница 274: ...Filter Condition Inspection Check the clutch oil filter page 3 11 Is the oil filter in good condition YES GO TO STEP 4 NO Replace the clutch oil filter 4 Clutch Line EOP Sensor Inspection Replace the clutch line EOP sensor with a known good one page 12 78 Erase the DTCs page 12 10 Test ride the motorcycle above 2 000 rpm and stop the engine Check the clutch line EOP sensor with the MCS Is DTC 49 1...

Страница 275: ...TR sensor 3P Black connector 1 terminals Connection Yellow red Green yellow Is the voltage within 4 75 5 25 V YES GO TO STEP 3 NO Open circuit in the Yellow red wire 1 G Y Y R e 3 TR Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the PCM 33P Black connector page 4 34 Check for continuity between the wire harness side TR sensor 3P Black connector 1 and PCM 33P Bl...

Страница 276: ...V indicated YES GO TO STEP 2 NO Intermittent failure 2 TR Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the TR sensor 3P Black connector page 12 76 Turn the ignition switch ON and engine stop switch O Measure the voltage between the wire harness side TR sensor 3P Black connector 1 terminals Connection Yellow red Green yellow Is the voltage within 4 75 5 25 V YE...

Страница 277: ...30 Light green TOOL Test probe 2 packs 07ZAJ RDJA110 Is there continuity YES GO TO STEP 3 NO Open circuit in the Light green wire 3 Neutral Switch Inspection Replace the neutral switch with a known good one page 22 20 Connect the PCM 33P Gray connector and neutral switch connector Turn the ignition switch ON and engine stop switch O Recheck the DTC with the MCS Is DTC 52 1 indicated YES Replace th...

Страница 278: ...10 Test ride the motorcycle and stop the engine Check the DTC with the MCS Is DTC 53 1 indicated YES GO TO STEP 2 NO Intermittent failure 2 Inner Mainshaft Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the inner mainshaft sensor 3P Black connector page 12 76 Turn the ignition switch ON and engine stop switch O Measure the voltage between the wire harness side inner mainsh...

Страница 279: ...age 4 34 Check for continuity between the wire harness side inner mainshaft sensor 3P Black connector 1 and PCM 33P Gray connector 2 terminals Connection Green yellow B22 TOOL Test probe 2 packs 07ZAJ RDJA110 Is there continuity YES Replace the PCM with a known good one and recheck NO Open circuit in the Green yellow wire 6 Inner Mainshaft Sensor Output Line Open Circuit Inspection 2 nz G Y 1 B22 ...

Страница 280: ...se the DTCs page 12 10 Test ride the motorcycle and stop the engine Check the DTC with the MCS Is DTC 53 1 indicated YES Replace the PCM with a known good one and recheck NO Faulty original inner mainshaft sensor DTC 54 1 OUTER MAINSHAFT SENSOR SPEED LOW NOTE Before starting the inspection check for loose or poor contact on the outer mainshaft sensor 3P Black and PCM 33P connectors and recheck the...

Страница 281: ...tput Line Inspection Measure the voltage between the wire harness side 3P Black connector 1 terminal and ground Connection Pink yellow Ground Is the voltage within 4 75 5 25 V YES GO TO STEP 8 NO GO TO STEP 6 4 Outer Mainshaft Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the PCM 33P Black connector page 4 34 Check for continuity between the wire harness side ou...

Страница 282: ...nnector 1 and PCM 33P Black connector 2 terminals Connection Pink yellow A21 TOOL Test probe 2 packs 07ZAJ RDJA110 Is there continuity YES GO TO STEP 7 NO Open circuit in the Pink yellow wire 7 Outer Mainshaft Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side outer mainshaft sensor 3P Black connector 1 terminal and ground Connection Pink yellow Ground I...

Страница 283: ... connector page 12 57 Bu Measure the resistance between the linear solenoid valve side 4P Green connector 1 terminals Connection Blue Gray Standard 5 0 5 6 O 20 C 68 F Ip H 1 Is the resistance within standard range CL 4 YES GO TO STEP 3 NO Faulty linear solenoid valve Gr 3 No 1 Linear Solenoid Valve Input ground Line Open Circuit Inspection Disconnect the PCM 33P Black connector page 4 34 Check fo...

Страница 284: ...ion 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 Clutch Initialize Learning Procedure page 12 81 1 DTC Recheck Recheck the DTC with the MCS Is DTC 56 1 or 56 2 indicated YES GO TO STEP 2 NO Intermittent failure 2 No 2 Linear Solenoid Valve Inspection Turn the ignition switch OFF Disconnect ...

Страница 285: ...nuity between the wire harness side linear solenoid valve 4P Green connector 1 terminals and ground Connection Pink white Ground Brown white Ground Is there continuity YES Short circuit in the Pink white wire Short circuit in the Brown white wire NO Replace the PCM with a known good one and recheck DTC 57 1 GEARSHIFT MECHANISM MALFUNCTION See page 12 24 1 A11 2 P W Br W Q A22 1 P W Br W Q Q DTC 57...

Страница 286: ... page 12 31 DTC 47 2 is indicated page 12 32 DTC 55 1 is indicated page 12 43 DTC 55 2 is indicated page 12 43 NO GO TO STEP 2 2 No 1 Clutch EOP Sensor Inspection Replace the No 1 clutch EOP sensor with a known good one page 12 78 Erase the DTCs page 12 10 Test ride the motorcycle and stop the engine Check the No 1 clutch EOP sensor with the MCS Is DTC 61 1 61 2 61 3 61 4 62 1 or 62 2 indicated YE...

Страница 287: ...or Inspection Replace the No 2 clutch EOP sensor with a known good one page 12 78 Erase the DTCs page 12 10 Test ride the motorcycle and stop the engine Check the No 2 clutch EOP sensor with the MCS s Is DTC 63 1 63 2 63 3 63 4 64 1 or 64 2 indicated YES GO TO STEP 3 NO Faulty original No 2 clutch EOP sensor 3 PCM Inspection Replace the PCM with a known good one page 4 34 Test ride the motorcycle ...

Страница 288: ... 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 obstructions Check installation condition of the p...

Страница 289: ...nect the PCM 33P Black connector page 4 34 Turn the ignition switch ON and engine stop switch O Measure the voltage between the PCM 33P Black connector 1 and ground while slowly turning the rear wheel by hand Connection A32 Ground Standard Repeat 0 to 5 V TOOL Test probe 2 packs 07ZAJ RDJA110 Is the indicated voltage at the standard value YES Replace the PCM with a known good one and recheck 1 V A...

Страница 290: ... Is there continuity YES GO TO STEP 6 NO Open circuit in the Pink green wire 6 VS Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side VS sensor 3P Black connector 1 terminal and ground Connection Pink green Ground Is there continuity YES Short circuit in the Pink green wire NO GO TO STEP 7 1 P G V 2 1 n P G A32 1 3 P G O 7 VS Sensor Inspection Turn the ig...

Страница 291: ...any problem code YES Follow the problem code index page 20 8 NO GO TO STEP 3 3 Front Wheel Speed Sensor Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the following ABS modulator 18P connector page 20 7 PCM 33P Black connector page 4 34 Check for continuity between the ABS modulator 18P connector 1 and PCM 33P Black connector 2 terminals Connection Pink A33 TOOL Test probe 2 ...

Страница 292: ...rance within the standard range YES Replace the PCM with a known good one and recheck I NO Faulty No 1 clutch assembly DTC 69 1 No 2 CLUTCH OPERATION MALFUNCTION CLUTCH SLIPS NOTE If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 1 DTC Recheck Erase the DTCs page 12 10 Test ride the motorcycle above 18 km h 11 mph Stop the engine Check the DTC with the MCS Is DTC 6...

Страница 293: ...ed page 12 49 NO GO TO STEP 2 2 DTC Recheck 2 Erase the DTCs page 12 10 Test ride the motorcycle above 18 km h 11 mph Stop the engine Check the DTC with the MCS Is DTC 71 1 or 72 1 indicated YES Replace the PCM with a known good one and recheck NO Intermittent failure DTC 84 1 CPU IN THE PCM MALFUNCTION NOTE If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 1 DTC R...

Страница 294: ...O Intermittent failure 2 Shift Pedal Angle Sensor Input Voltage Inspection Turn the ignition switch OFF Remove the left under side cowl page 2 13 Disconnect the shift pedal angle sensor 3P Blue connector Turn the ignition switch ON Measure the voltage between the wire harness side shift pedal angle sensor 3P Blue connector 1 terminals Connection Yellow red Green yellow Is the voltage within 4 75 5...

Страница 295: ...ue connector 1 and ground Connection Yellow violet Ground Is there continuity YES Short circuit in Yellow violet wire NO GO TO STEP 6 6 Shift Pedal Angle Sensor Resistance Inspection Measure the resistance at the sensor side shift pedal angle sensor 3P Black connector 1 terminals Connection Yellow red Blue green Standard 4 6 kQ 20 C 68 F Operate the DCT shift pedal to check that the resistance cha...

Страница 296: ...nd recheck the AT MT mode switch operation If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 1 AT MT mode switch Power Input Voltage Inspection Disconnect the right handlebar switch 6P Black connector page 22 18 Turn the ignition switch ON with the engine stop switch O Measure the voltage between the wire harness side right handlebar switch 6P Black connector 1 ter...

Страница 297: ...e the PCM with a known good one and recheck NO Open circuit in the White yellow wire RIGHT ENGINE SIDE COVER 1 21 V 77 77 W Y L L A27 REMOVAL INSTALLATION Remove the right under side cowl page 2 13 Remove the three socket bolts 1 and right engine side cover 2 Installation is in the reverse order of removal RIGHT CRANKCASE COVER 2 m REMOVAL Drain the engine oil page 3 10 Remove the following Side s...

Страница 298: ...llowing Bolt 2 and shift spindle angle sensor 3 Bolt 4 and wire clip stay 5 Bolts 6 and wire clamps 7 Remove the wire harness and shift spindle angle sensor wire from the right crankcase cover Remove the bolts 1 and right crankcase cover 2 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 2 1 a in m m m 03 m J 6 7 i S...

Страница 299: ...ht crankcase cover page 12 57 Remove the right crankcase cover wire clamp bolt 1 and wire clamp 2 Remove the wire grommets 3 from the right crankcase cover 3 2 m a m Hi m Remove the bolts 1 and linear solenoid valve body 2 1 7A u a w 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 1 2 m C I t ei 1 3 m III ...

Страница 300: ... Remove the stopper plate from the linear solenoid valves Wash all the parts with a high flash point or non flammable solvent and blow through all oil passages with compressed air to clean completely Check the linear solenoid valves 1 and valve body 2 for scratches scoring or damage 1 3 m its j 5 i I 7 mm 2 1 ft k 2 17 fin ...

Страница 301: ...LVE BODY COVER CKP SENSOR MOUNTING BOLTS J l0ESS n f f 12 N m 1 2 kgf m 9 lbf ft WIRE CLAMP DOWEL PIN Coat linear solenoid valves 1 with engine oil Set the stopper plate 2 into the grooves in the solenoid valves 2 si WlM c r ll 1 Install the linear solenoid valves 1 and stopper plate 2 into the valve body Apply locking agent to the threads of the stopper plate bolt 3 page 1 14 Install the stopper ...

Страница 302: ...he bolts in the sequence as shown Apply liquid sealant TB1207B manufactured by Three Bond or equivalent to the CKP sensor wire grommet and linear solenoid valve wire grommet sealing surface Set the linear solenoid valve wire grommet 1 and CKP sensor wire grommet 2 into the groove in the right crankcase cover Apply locking agent to the threads of the right crankcase cover wire clamp bolts 3 page 1 ...

Страница 303: ...lable in U S A Remove the O rings from the oil guide collar r2 A R PI m I m Coat new O rings 1 with engine oil and install them into the grooves in the oil guide collar 2 Install the oil guide collar into the right crankcase cover until it is seated Align the oil guide collar index mark and tabs with the right crankcase cover index mark and slits 2 B 1 1 I 1 m 4 m Align Align Install the snap ring...

Страница 304: ...ings 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 TB1207B manufactured by Three Bond or equivalent to the right crankcase cover mating surface as shown Install the right crankcase cover 1 Install the bolts 2 and tighten them in a crisscross pattern in 2 or 3 steps i...

Страница 305: ... 2 kgf m 9 Ibf ft Connect the clutch EOP sensor 3P connectors 6 Connector with no mark to the upper sensor connector with P mark to the middle sensor and connector with 1 mark to the lower sensor Connect the linear solenoid valve 4P Green connector 1 and install it to the ABS modulator stay Secure the wire band 2 to the frame pipe with the starter motor cable Connect the CKP sensor 2P Red connecto...

Страница 306: ...ar 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 from the mainshaft Remove the seat rings 1 from the mainshaft grooves DISASSEMBLY 2 t C m a j 3 9 1 li m x N m v 2 r WM m m KM m Remove clutch guide 1 1 clutch guide 2 2 and washers 3 from the clutches 2 1 if 3 i I cc ...

Страница 307: ... service limit replace the clutch assembly ASSEMBLY f I 8 r rr i i 120 120 sill 120 i 1 11 Coat new O rings 1 with engine oil and install them into the grooves in the primary driven gear Install the clutch assemblies 2 onto the primary driven gear Apply engine oil to the needle bearings in the primary driven gear The primary driven gear has the index line 1 on its flange for the installation direc...

Страница 308: ... the gear teeth with the clutch disc tabs INSTALLATION 2 1 3 Apply engine oil to new seal rings 1 and install them into the mainshaft grooves Push in the seal rings to seat them into the grooves Install the dual clutch assembly 1 onto the mainshaft being careful not to damage the seal rings Install the ball bearing 2 onto clutch guide 1 3 with the marked side facing out Remove the 6 mm socket bolt...

Страница 309: ...he 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 drive gear bolt TOOL 2 Gear holder 2 5 07724 0010100 o...

Страница 310: ... Black connector 11 Remove the bolts 2 and shift control motor 3 Remove the bolt 1 wire clip stay 2 and TR sensor 3 Remove the O ring 4 from the TR sensor Remove the bolts 1 and reduction gear cover 2 Remove the dowel pins 1 and gasket 2 Remove the reduction gears 3 3 L A Q m Hi 2 3 4 1 V i SJ a I IS f H 2 mi I i i ii yy Q 1 I Vm 4 2 v 3 2 1 SI e m V t 7 A c 1 1 19 70 ...

Страница 311: ...IFT CONTROL MOTOR Apply 2 4 g 0 07 0 14 oz of specified grease to the reduction gear journals and teeth SPECIFIED GREASE Unirex N3 grease Exxon Mobil Install the reduction gear B 1 and reduction gear C 2 by aligning the gear ends with the ribs of the crankcase Check that 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 g...

Страница 312: ...R 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 TORQUE 12 N m 1 2 kgf m 9 Ibf ft Coat a new O ring 1 with engine oil and install it into the groove in the shift control motor 2 2 m U u l m 1 US I F 1 mm Align 1 3 v 4 m pw 9 2 2 11 V f m B J 3 8 v m csjf _ 7 1 1 ...

Страница 313: ...ver page 2 16 GEARSHIFT LINKAGE n O J M R S5 t 3 I 2 REMOVAL Remove the following Shift control motor reduction gears page 12 70 Dual clutch page 12 66 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 2 i l U A m i J it c I m A I y IIS f w ...

Страница 314: ... Drum shifter Ratchet pawls Plungers Plunger springs Replace if necessary GEARSHIFT SPINDLE Check the return springs 1 for fatigue or damage replace them if necessary Check the gearshift spindle 2 for wear or bend Check the spindle arm 3 for wear damage or deformation Replace the gearshift spindle as an assembly if necessary 1 2 3 INSTALLATION Install the following 8 x 20 mm dowel pins 1 Shift dru...

Страница 315: ...ll the stopper arm side collar 2 and guide plate distance collar 3 r 3 m m mm I B Hjj K r 1 2 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 3 2 1 44 5 4 Install the drum shifter guide plate drum shifter assembly 1 Apply locking agent to the threads of the guide plate bolts 2 page 1 14 Install the guide plate bolt...

Страница 316: ...uter mainshaft sensor Remove the fuel tank page 7 7 Disconnect the inner mainshaft sensor 3P Black connector 1 then remove the bolt 2 and inner mainshaft sensor 3 Remove the ABS modulator page 20 23 Disconnect the outer mainshaft sensor 3P Black connector 4 then remove the bolt 5 and outer mainshaft sensor 6 Remove the O rings 7 from the mainshaft sensors Installation is in the reverse order of re...

Страница 317: ...nd TORQUE TR sensor bolt 12 Nm 1 2 kgf m 9 Ibf ft SHIFT SPINDLE ANGLE SENSOR REMOVAL INSTALLATION 2 6 3 4 w Fa 5 1 3 1 55 li K m A 9 5 Align Remove the following Right side shelter page 2 11 Right engine side cover page 12 57 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 ...

Страница 318: ...ge 12 57 Disconnect the following No 1 clutch EOP sensor 3P Gray connector 1 No 2 clutch EOP sensor 3P Gray connector 2 Clutch line EOP sensor 3P Black connector 3 Remove the clutch EOP sensors 4 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 TORQUE 19 6 N m 2 0 kgf m 14 lbf...

Страница 319: ...tarting the 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 Blue connector is disconnected 1 Install the shift pedal to the vehicle and connect the shift pedal angle sensor 3P Blue connector 2 Turn the...

Страница 320: ...celled DTC 1 1 DTC 1 blink SHIFT PEDAL ANGLE 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 Blue connector is connected 1 Remove the shift pedal from the vehicle and disconnec...

Страница 321: ...ansmission 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 NOTE If the PCM is replaced with a new one when the ignition switch is turned on the D and S indicators 1 will come on to indicate that the clutch initialization learning procedure...

Страница 322: ...CM 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 interval of 2 seconds NOTE When the engine is not warmed up enough the large L 4 extremely low oil temperatu...

Страница 323: ...Stop the engine NOTE 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 x1i OOr min E ZL B jr f PPL BBBt j r km h s x1000r m...

Страница 324: ...MEMO ...

Страница 325: ...13 ALTERNATOR STARTER CLUTCH COMPONENT LOCATION 13 2 SERVICE INFORMATION 13 3 TROUBLESHOOTING 13 3 ALTERNATOR COVER 13 4 FLYWHEEL 13 5 STARTER CLUTCH 13 7 STATOR 13 10 3 13 1 ...

Страница 326: ...ALTERNATOR STARTER CLUTCH COMPONENT LOCATION S 0 0 m 0 1 J Q 05 0 s 157 N m 16 0 kgf m 116 Ibf ft 1 j 13 ...

Страница 327: ...ernator inspection page 21 8 For CKP sensor inspection page 5 6 For starter motor service page 6 8 TOOLS Flywheel holder 07725 0040001 Rotor puller 07933 3290001 TROUBLESHOOTING Starter motor turns but engine does not turn Faulty starter clutch Damaged starter reduction gear shaft Damaged starter idle gear shaft Damaged or faulty starter motor pinion gear Damaged starter driven gear 13 3 ...

Страница 328: ... the frame Release the wire bands 1 CTX700D ND only Release the shift pedal angle sensor 3P Blue connector Optional 1 from the stay Loosen the alternator cover bolts 2 in a crisscross pattern in 2 or 3 steps and remove the bolts and stays 3 Remove the alternator cover 4 NOTE The alternator cover stator is magnetically attracted to the flywheel be careful during removal Remove the dowel pins 1 oil ...

Страница 329: ...alant than necessary Fill the engine with the recommended engine oil and check that there are no oil leaks page 3 9 1 FLYWHEEL REMOVAL Remove the alternator cover page 13 4 Remove the starter idle gear shaft 1 and starter idle gear 2 Remove the starter reduction gear shaft 3 and starter reduction gear 4 f 4 2 BtS i 1 9 HI 83 is 3 1 Hold the flywheel 1 using the special tool and loosen the flywheel...

Страница 330: ...ION its Hi Si V 2 2 3 i 4 f i wk Mi K 9k 0 1 Inspect the following parts for scratch damage abnormal wear and deformation Starter reduction gear shaft Starter reduction gear Woodruff key Needle bearing Replace if necessary INSTALLATION Install the woodruff key 1 Be careful not to damage the key groove and crankshaft Apply engine oil to the needle bearing rotating area Install the needle bearing 2 ...

Страница 331: ...wheel holder 07725 0040001 TORQUE 157 N m 16 0 kgf m 116 Ibf ft NOTE 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 idle gear 3 and shaft 4 Install the starter reduction gear with its OUT mark 5 facing out Install the alternator cover page ...

Страница 332: ...ly 1 Remove the starter one way clutch 1 from the starter clutch outer 2 INSPECTION 1 3 c 2 1 i m i Inspect the following parts for scratch damage abnormal wear and deformation Starter driven gear Starter clutch outer Starter one way clutch Measure each part according to ALTERNATOR STARTER CLUTCH SPECIFICATIONS page 1 8 Replace any part if it is out of service limit 1 I J J J 4 1 Q ...

Страница 333: ...STARTER CLUTCH OUTER 7 ONE WAY CLUTCH FLYWHEEL 30 N m 3 1 kgf m 22 Ibf ft i Apply engine oil to the starter one way clutch 1 sliding surface Install the starter one way clutch to the starter clutch outer 2 Install the starter clutch assembly 1 1 H isa f 2 nl r m 13 9 ...

Страница 334: ...UE 30 N m 3 1 kgf m 22 Ibf ft 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 6 Install the flywheel page 13 6 1 2 m m IEES 3 m REMOVAL Remove the alternator cover page 13 4 Remove the alternator wire clamp bolt 1 wire clamp 2 and grommet 3 from the alternator cover Remove the altern...

Страница 335: ... to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbf ft Apply liquid sealant TB1207B manufactured by Three Bond 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 1 15 Install the wire clamp 4 and alternator wire clamp bolt 5 m 3 1 9 F m m I m H 5 1 2i 4 Tighte...

Страница 336: ...MEMO ...

Страница 337: ...MISSION BALANCER COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 4 TROUBLESHOOTING 14 5 CRANKCASE SEPARATION 14 6 TRANSMISSION CTX700 A N NA 14 7 TRANSMISSION CTX700D ND 14 14 BALANCER 14 21 CRANKCASE ASSEMBLY 14 23 14 1 ...

Страница 338: ... Ibf ft 24 N m 2 4 kgf m 18 Ibf ft 20 N m 2 0 kgf m 15_lbf ft 150 24 N m 2 4 kgf m 18 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 1 I 0 n mm 12 N m 1 2 kgf m 9 Ibf ft o9 n 0 0 o Q m k 12 N m 1 2 kgf m 9 Ibf ft 1 12 N m 1 2 kgf m 9 Ibf ft 24 N m 2 4 kgf m 18 Ibf ft 1A O ...

Страница 339: ...bf ft 20 N m 2 0 kgf m 15 lbf ft 150 39 N m 4 0 kgf m 29 lbf ft 12 N m 1 2 kgf m 9 lbf ft W 12 N m 1 2 kgf m 9 lbf ft I f f f 24 N m 2 4 kgf m 18 lbf ft I r 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 24 N m 2 4 kgf m 18 lbf ft 14 3 ...

Страница 340: ...apply sealant to their mating surfaces Wipe off excess sealant thoroughly GENERAL CTX700D ND 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 14 Engine oil filter page 3 10 EOP switch page 22 14 Starter motor page 6 8 Cylinder head pa...

Страница 341: ...le CTX700 A N NA page 11 13 CTX700D ND page 12 73 Transmission jumps out of gear Worn gear dogs Worn gear shifter groove Bent shift fork shaft Worn or bent shift forks Broken shift drum stopper arm CTX700 A N NA page 11 13 CTX700D ND page 12 73 Broken shift drum stopper arm return spring CTX700 A N NA page 11 13 CTX700D ND page 12 73 Broken gearshift spindle return spring CTX700 A N NA page 11 13 ...

Страница 342: ...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 pry the crankcase halves with a screwdriver r X i fetwls m m r HH 4 Q iSsi...

Страница 343: ...tershaft 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 expand the snap ring and pul...

Страница 344: ...ing 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 1 m e hi SHIFT DRUM SHIFT FORK Remove the shift drum bearing set plate bolts 1 and set plate 2 Remove the fork shaft 1 and shift forks 2 Remove the shift drum 1 and shift drum bearing 2 V m 2 1 W m v m Jit Wm m nsV m...

Страница 345: ...rking side facing toward the inside of the crankcase Remove the following Crankshaft page 15 5 Piston page 15 14 Countershaft mainshaft page 14 7 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 oil to a new left mainshaft bear...

Страница 346: ...um oil solution to the spline bushing outer surface bushing inner and outer surface shift fork grooves Assemble the mainshaft and countershaft MAINSHAFT MAINSHAFT M1 GEAR 16T THRUST WASHER M5 GEAR BUSHING M5 GEAR 30T 0 0 0 SPLINE WASHER SNAP RING THRUST WASHER M3 4 GEAR 22 25T SNAP RING SPLINE WASHER M6 GEAR BUSHING M6 GEAR 37T SPLINE WASHER LOCK WASHER M2 GEAR 19T spin E EE3 j 14 m ...

Страница 347: ... 36T COUNTERSHAFT COUNTERSHAFT BEARING SET RING OIL SEAL Assemble the transmission gears and shafts Coat each gear with clean engine oil and check for smooth movement Align the lock washer tabs with the spline washer grooves Always install the thrust washers and snap rings with the chamfered rolled edge facing away from the thrust load Install the snap rings 1 so that the end gap aligns with the g...

Страница 348: ...nstall 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 TORQUE 12 N m 1 2 kgf m 9 Ibf ft 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 Install the shift drum shift fork pag...

Страница 349: ...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 mm mms 2 m m I in 2 Apply locking agent to the shift drum bearing set plate bolt threads page 1 15 Install the set plate 1 and shift drum bearing set plate bolts 2 Tighten...

Страница 350: ... 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 of the disassembled parts gea...

Страница 351: ...m 1 and shift drum bearing 2 INSPECTION 1 a a 2 m m 2 rnM w 1 2 Inspect the following parts for scratch damage abnormal wear and deformation Transmission gears Transmission bushings Transmission bearings Shift drum bearing Shift forks Shift fork shaft Measure each part according to CRANKCASE TRANSMISSION SPECIFICATIONS page 1 9 Replace any part if it is out of service limit 14 15 ...

Страница 352: ...ves 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 oil to a new left mainshaft bearing 1 Drive the left mainshaft bearing into the upper crankcase until it is fully seated using the special tools TOOLS 2 Driver 15 x 280L 07949 3710001 3 Attachment 42 x 47 mm...

Страница 353: ... outer surfaces and gear shifter grooves Assemble the mainshaft and countershaft MAINSHAFT INNER MAINSHAFT M1 GEAR 15T THRUST WASHER M5 GEAR BUSHING y M5 GEAR 30T SPLINE WASHER SNAP RING I M3 GEAR 22T THRUST WASHER SEAL RINGS m M4 GEAR 25T SNAP RING SPLINE WASHER M6 GEAR 37T M6 GEAR BUSHING THRUST WASHER NEEDLE BEARING OUTER MAINSHAFT M2 GEAR 21T NEEDLE BEARING j Gear teeth rotating surfaces and b...

Страница 354: ... WASHER C3 GEAR BUSHING C3 GEA 2 Ti iV o SPLINE WASHER 0 LOCK WASHER C4 GEAR BUSHING f THRUST WASHER C2 GEAR BUSHING SPLINE WASHER SNAP RING C4 GEAR 30T SPLINE WASHER SNAP RING C6 GEAR 31T C2 GEAR 40T THRUST WASHER NEEDLE BEARING NEEDLE BEARING CAP J Gear teeth rotating surfaces and bearing Bushing surfaces and gear shifter grooves y a z Li I I 1 m J 14 1R ...

Страница 355: ...NSTALLATION CORRECT 3 C f r 1 L C v INCORRECT 1 MAINSHAFT COUNTERSHAFT Install the mainshaft assembly 1 into the upper crankcase m m w 1 m x tm m m 1 alii 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 V wm X 0 1 1 Apply locking agent to the mainshaft bearing set p...

Страница 356: ...into the lower crankcase 3 2 3 Hi 4 u A 2 1 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 1 2 Apply molybdenum oil solution to the shift fork shaft outer surfaces shift fork claws and guide pins Install the countershaft shift ...

Страница 357: ...ble the crankcase page 14 23 BALANCER REMOVAL Separate the crankcase halves page 14 6 Remove the balancer shaft bearing set plate bolts 1 j 5 and set plate 2 l I I 3 I m Slift i 1 m Remove the balancer shaft 1 and right balancer shaft bearing 2 INSPECTION 2 ft wmmsBm H1RE8 1 d 1 m S It r A m r S8 i Us 2 1 Inspect the following parts for scratch damage abnormal wear and deformation Balancer driven ...

Страница 358: ... 47 mm 07746 0010300 4 Pilot 20 mm 07746 0040500 INSTALLATION in mm i m 1 2 I rer 4 m m 1 m 3 4 A mm s i 1 1 Apply engine oil to the right balancer shaft bearing 1 Install the balancer shaft 2 and right balancer shaft bearing into the lower crankcase Install the bearing into the crankcase with the marked side facing out Apply locking agent to the balancer shaft bearing set plate bolts threads page...

Страница 359: ...e 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 Align the balancer driven gear 1 and balancer driven sub gear 2 teeth then install a 6 x 14 mm socket bolt 3 to the balancer driven gear and balancer driven sub gear holes at the lower crankcase inspection hole 4 Apply molybdenum oil solution to the main...

Страница 360: ... additive for axial tension stability Do not remove the oil additive from the new crankcase main journal bolt surfaces Make sure the upper and lower crankcase are seated securely Tighten the crankcase main journal bolts in numerical order as shown in a crisscross pattern in 2 or 3 steps to the specified torque Further tighten the crankcase main journal bolts 150 1 2 m m m ZA m i 2 3 j A as m P A m...

Страница 361: ...g washer 2 The sealing washer location is indicated on the upper crankcase by the A mark 3 Tighten the crankcase 8 mm bolts to the specified torque TORQUE 24 N m 2 4 kgf m 18 Ibf ft Install the cam chain 1 to the crankshaft Install the removed parts in the reverse order of removal page 14 4 3 m ism sf mm J 1 1 2 1 gr k 14 25 ...

Страница 362: ...MEMO i i j ...

Страница 363: ...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 15 1 ...

Страница 364: ...CRANKSHAFT PISTON CYLINDER COMPONENT LOCATION 10 N m 1 0 kgf m 7 lbf ft 90 o o r o o o is 3 5 i 1 _9 ...

Страница 365: ...r reassembly The crankpin and main journal bearing inserts are select fit and are identified by color codes Select replacement bearings from the code tables After selecting new bearings recheck the oil clearance with plastigauge Incorrect oil clearance can cause major engine damage Clean the oil passages in the upper crankcase with compressed air before installing the pistons TOOLS Piston pin tool...

Страница 366: ...r 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 crankpi...

Страница 367: ...ngine 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 NOTICE 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 cr...

Страница 368: ...all the main journal bearings 1 and crankpin bearings 2 into the original locations NOTICE 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...

Страница 369: ...euse connecting rods and bearing caps that have been improperly installed because their mating surfaces will be damaged Align m V6 R 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 1 Apply engine oil to new crankpin bearing cap bolt threads and seating surfaces Install and tighten new cran...

Страница 370: ...EARING 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 7 I m K mPA 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 hole Do not...

Страница 371: ...scross pattern in 2 or 3 steps to the specified torque Further tighten the crankcase main journal bolts 120 TORQUE 20 Nm 2 0 kgf m 15 Ibf ft 120 Remove the crankcase main journal bolt and lower crankcase 2 H v ir i 6n n I m if v Measure the compressed plastigauge at its widest point on each main journal to determine the oil clearance SERVICE LIMIT 0 05 mm 0 002 in If the oil clearance exceeds the ...

Страница 372: ...RNAL BEARING SELECTION TABLE BEARING SUPPORT I D CODE A B C 37 000 37 006 mm 1 4567 1 4569 in 37 006 37 012 mm 1 4569 1 4572 in 37 012 37 018 mm 1 4572 1 4574 in MAIN JOURNAL O D CODE 1 34 010 34 016 mm 1 3390 1 3392 in E Yellow D Green C Brown 2 34 004 34 010 mm 1 3387 1 3390 in D Green C Brown B Black 3 33 998 34 004 mm 1 3385 1 3387 in C Brown B Black A Blue NOTICE After selecting new bearings ...

Страница 373: ...sual 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 m 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 plastigauge 1 len...

Страница 374: ...s and 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 TORQUE 10 N m 1 0 kgf m 7 lbf ft 90 Remove the bearing caps and measure the compressed plastigauge at its widest point on the crankpin to determine the oil clearance SERVICE LIMIT 0 05 mm 0 002 in If the oil clearance exceeds the service limit...

Страница 375: ... 1 6929 1 6931 in 43 006 43 012 mm 1 6931 1 6934 in 43 012 43 018 mm 1 6934 1 6936 in 43 018 43 024 mm 1 6936 1 6939 in CRANKPIN O D CODE A 39 994 40 000 mm 1 5746 1 5748 in H White G Red F Pink E Yellow B 39 988 39 994 mm 1 5743 1 5746 in G Red F Pink E Yellow D Green C 39 982 39 988 mm 1 5741 1 5743 in F Pink E Yellow D Green C Brown D 39 976 39 982 mm 1 5739 1 5741 in E Yellow D Green C Brown B...

Страница 376: ...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 CTX700 A N NA page 14 7 CTX700D ND page 14 14 Remove the piston connecting rod assembly 1 from the top of the cylinder NOTICE Do not try to remove the connecting rod piston assembly from the ...

Страница 377: ...Piston base 07TGF 001000A 07PAF 0010300 07973 6570600 07973 6570500 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 TOOLS Piston pin tool set 07PAF 0010000 1 Pilot collar 18 mm 07PAF 0010640 2 3 Piston base head insert 07PAF 0010500 U S A TOOLS 1 Pilot collar 18 mm 07PAF 0010640 2 3 Piston base head insert ...

Страница 378: ...ert pin 2 insert adjuster 3 pilot collar 4 and a hydraulic press 1 4 2 3 2 3 4 H INSPECTION Inspect the following parts for scratch damage abnormal wear and deformation Cylinder Piston Piston rings Piston pin Connecting rod small end Measure each part and calculate the clearance according to CRANKSHAFT PISTON CYLINDER SPECIFICATIONS page 1 10 Replace any part if it is out of service limit 1 I I PI...

Страница 379: ...nnecting rod 5 TOOL 3 Pilot collar 18 mm 07PAF 0010640 Place the piston connecting rod and pilot collar on the special tools 6 TOOLS Piston pin tool set Piston base head insert Piston base head Piston pin pilot Piston base spring Piston base U S A TOOLS Piston base head insert Piston pin pilot Piston base spring Piston base 07PAF 0010000 07PAF 0010500 07PAF 0010400 07PAF 0010300 07973 6570600 0797...

Страница 380: ...0 o Install the piston connecting rod assembly with the IN mark 3 facing the intake side Apply engine oil 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 NOTICE While installing the piston be ca...

Страница 381: ...MOVAL INSTALLATION COMPONENT LOCATION 16 2 SERVICE INFORMATION 16 4 ENGINE REMOVAL CTX700 A N NA 16 5 ENGINE INSTALLATION CTX700 A N NA 16 9 ENGINE REMOVAL CTX700D ND 16 14 ENGINE INSTALLATION CTX700D ND 16 18 16 1 ...

Страница 382: ...gf m 40 lbf ft 54 N m 5 5 kgf m 40 lbf ft 59 N m 6 0 kgf m 44 lbf ft 54 N m 5 5 kgf m 40 lbf ft 4 0 r X 27 N m 2 8 kgf m 20 lbf ft 10 N m 1 0 kgf m 7 lbf ft 27 N m 2 8 kgf m 20 lbf ft 10 N m 1 0 kgf m 7 lbf ft 27 N m 2 8 kgf m 20 lbf ft t I I 10 N m 1 0 kgf m 7 lbf ft 4 C O ...

Страница 383: ... kgf m 40 lbf ft 54 N m 5 5 kgf m 40 lbf ft 59 N m 6 0 kgf m 44 lbf ft 54 N m 5 5 kgf m 40 lbf ft 27 N m 2 8 kgf m 20 lbf ft 71 m if 1 3 o 3 27 N m 2 8 kgf m 20 lbf ft 10 N m 1 0 kgf m 7 lbf ft 27 N m 2 8 kgf m 20 lbf ft 10 N m 1 0 kgf m 7 lbf ft 16 3 ...

Страница 384: ...the engine installed in the frame Starter motor page 6 8 Throttle body page 7 14 Water pump page 8 9 Oil pump CTX700 A N NA page 9 7 Oil pump CTX700D ND page 9 8 Rocker arm page 10 7 Clutch CTX700 A N NA page 11 6 Gearshift linkage CTX700 A N NA page 11 13 Primary drive gear CKP sensor rotor CTX700 A N NA page 11 11 Dual clutch CTX700D ND page 12 66 Gearshift linkage CTX700D ND page 12 73 Primary ...

Страница 385: ...ator page 8 7 Radiator reserve tank page 8 11 Fuel tank page 7 7 Throttle body page 7 14 CTX700A NA only Remove the two socket bolts 1 and right engine side cover 2 Remove the bolts 3 and clutch cable guide 4 then disconnect the clutch cable 5 from the clutch lifter arm 6 5 V 6 4 2 s p I 3 1 Disconnect the fuel injector 2P Gray connectors 1 and ECT sensor 2P Black connector 2 Release the clip 3 fr...

Страница 386: ...ve the bolt 4 and ground cable 5 Disconnect the neutral switch connector 1 Remove the wire bands 2 bolt 3 and setting plate 4 Release the all wires and hoses from the guide 5 Disconnect the following Battery negative cable page 21 5 Alternator 3P Gray connector page 21 7 Release the wire band boss 1 Release the starter relay switch 2 from the battery box as shown Pull out the alternator wire harne...

Страница 387: ...ts 7 and left main step base plate assembly 8 Remove the bolt 1 reservoir cover 2 and rear master cylinder reservoir 3 Remove the bolts 4 and rear brake bracket assembly 5 from the frame Remove the bolts 1 and right main step base plate assembly 2 Disconnect the spark plug cap 1 Release the spark plug wire clamp 2 from the frame Disconnect the EOP switch 1P Gray connector 3 5 2 m m m t mm i m Rfr ...

Страница 388: ... hanger bolts 1 and collar 2 Remove the front lower hanger bolts 1 and collars 2 Remove the rear engine hanger nuts 1 collars 2 and bolts 3 Carefully maneuver the engine and remove it out of the frame to the right During engine removal hold the engine securely and be careful not to damage the frame and engine 3 r 9 im a riyX h SSIIHJ I a mm m Left side iti H u Sf up i 3KJ I m mm u 1 I F 1 2 B Left...

Страница 389: ...r the engine The jack height must be continually adjusted to relieve stress for ease bolt installation Carefully align the mounting points with the jack to prevent damage to engine frame water hose wires and cables 5 3 2 4 6 1 During engine installation hold the engine securely and be careful not to damage the frame and engine Place the engine in the frame then loosely install all the bolts nuts a...

Страница 390: ... specified torque TORQUE 54 N m 5 5 kgf m 40 Ibf ft Install the drive sprocket 1 washer 2 and drive sprocket bolt 3 Tighten the drive sprocket bolt to the specified torque TORQUE 54 N m 5 5 kgf m 40 Ibf ft Secure the spark plug wire clamp 1 to the tab of the frame Connect the spark plug cap 2 Connect the EOP switch 1P Gray connector 3 Right Left side side H m I fet H LELI s 1 m a a c i i I r s m k...

Страница 391: ...t 5 4 3 1 ft 9 2 Set the left main step base plate assembly 1 and install and tighten the bolts 2 to the specified torque TORQUE 27 Nm 2 8 kgf m 20 Ibf ft Connect the horn wire connectors 3 and spark plug cap 4 Install the wire band 5 and secure the spark plug wire clamp 6 to the tab of the frame Connect the water hose 7 to the water pump Tighten the water hose band screw 8 to the specified range ...

Страница 392: ...minal nut 4 Tighten the starter motor terminal nut to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Reposition the rubber cap 5 properly on the starter motor terminal Connect the VS sensor 3P Black connector 1 Connect the CKP sensor 2P Red connector 2 and secure it to the stay Secure the wire band 3 to the frame pipe Connect the water hose 1 to the thermostat cover by aligning the paint ma...

Страница 393: ...all the following Throttle body page 7 16 Fuel tank page 7 7 Radiator reserve tank page 8 11 Radiator page 8 7 Swingarm pivot covers page 2 17 Exhaust pipe muffler page 2 19 Left crankcase rear cover page 2 16 Main steps page 2 14 Inspect the following Throttle grip freeplay page 3 4 Clutch lever freeplay page 3 20 Adjust the drive chain slack page 3 13 Fill the engine with the recommended engine ...

Страница 394: ...e 8 7 Radiator reserve tank page 8 11 Fuel tank page 7 7 Throttle body page 7 14 Disconnect the fuel injector 2P Gray connectors 1 and ECT sensor 2P Black connector 2 Release the clip 3 from the fuel rail Release the wire band boss 4 and main wire harness 5 from the wire clamp 6 Loosen the band screw 1 and disconnect the water hose 2 from the thermostat cover Release the following connectors from ...

Страница 395: ...and ground cable 5 1 2 3 1 V p S 4 5 Disconnect the VS sensor 3P Black connector 1 and EOT sensor 2P Black connector 2 Release the TR sensor 3P Black connector 3 from the stay and disconnect it Remove the wire bands 4 1 3 2 j 9 4 Release the shift pedal angle sensor 3P Blue connector Optional 1 from the stay Remove the sidestand switch wire clamp 2 from the stay Disconnect the shift control motor ...

Страница 396: ...nnect the water hose 2 from the water pump Disconnect the horn wire connectors 3 and spark plug cap 4 Remove the wire band 5 and release the spark plug wire clamp 6 from the frame Remove the bolts 7 and left main step base plate assembly 8 Remove the bolt 1 reservoir cover 2 and rear master cylinder reservoir 3 Remove the bolts 4 and rear brake bracket assembly 5 from the frame Remove the bolts 1 ...

Страница 397: ...ess for ease of bolt removal Remove the drive sprocket bolt 1 washer 2 and drive sprocket 3 Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal Remove the upper engine hanger bolts 1 and collar 2 Remove the front lower hanger bolts 1 and collars 2 2 1 r i m 3 3 o Sjgpj J v I Hi o mm 2 1 iRight side Left side P s 1 2 Loft side Right side mm i m t 1 r w...

Страница 398: ...llar right side 4 and 47 mm collar left side 5 Rear lower side 10 mm collar right side 6 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 jack to prevent damage to engine frame water hose wires and cables 5 3 2 4 a 6 1 During engine installation hold the...

Страница 399: ... Right side ri Mi m Tighten the rear upper engine hanger nut 1 to the specified torque TORQUE 54 N m 5 5 kgf m 40 Ibf ft m as am I Isi I u H N Install the drive sprocket 1 washer 2 and drive sprocket bolt 3 Tighten the drive sprocket bolt to the specified torque TORQUE 54 Nm 5 5 kgf m 40 Ibf ft Secure the spark plug wire clamp 1 to the frame Connect the spark plug cap 2 Connect the EOP switch 1P G...

Страница 400: ... main step base plate assembly 1 and install and tighten the bolts 2 to the specified torque TORQUE 27 N m 2 8 kgf m 20 Ibf ft Connect the horn wire connectors 3 and spark plug cap 4 Install the wire band 5 and secure the spark plug wire clamp 6 to the tab of the frame Connect the water hose 7 to the water pump Tighten the water hose band screw 8 to the specified range page 8 8 Route the alternato...

Страница 401: ...3 and EOT sensor 2P Black connector 4 Install the ground cable 1 and starter motor mounting 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 TORQUE 10 N m 1 0 kgf m 7 Ibf ft Reposition the rubber cap 5 properly on the starter motor terminal Connect the clutch EOP sensor 3P con...

Страница 402: ...he wire band boss 4 and main wire harness 5 to the wire clamp 6 Install the following Throttle body page 7 16 Fuel tank page 7 7 Radiator reserve tank page 8 11 Radiator page 8 7 Swingarm pivot covers page 2 17 Exhaust pipe muffler page 2 19 Right engine side cover page 12 57 Left crankcase rear cover page 2 16 Main steps page 2 14 Inspect the throttle grip freeplay page 3 4 Adjust the drive chain...

Страница 403: ...17 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 17 2 SERVICE INFORMATION 17 3 TROUBLESHOOTING 17 4 HANDLEBAR 17 5 FRONT WHEEL 17 14 FORK 17 18 STEERING STEM 17 24 D 17 1 ...

Страница 404: ...s o5 pen 0H gsvg OC oH C TQOV c O M X03 XO 5 22 tttf W 76 C r rV t r 6 toVW 26 vrf A O 39 vrf w AWT P 2 0 VoV l 56 22 ...

Страница 405: ...pplying the brake lever Use only tires marked TUBELESS and tubeless valves on rim marked TUBELESS TIRE APPLICABLE For brake system information page 19 5 TOOLS Bearing remover head 20 mm 07746 0050600 JB Bearing remover shaft 07GGD 0010100 Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Attachment 52 x 55 mm 07746 0010400 Pilot 20 mm 07746 0040500 Fork seal driver 07947 KA50100 Fork seal d...

Страница 406: ...bearing Weak front 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 Incorre...

Страница 407: ...rake light switch connectors 1 Remove the bolts 2 holder 3 and master cylinder 4 Keep the brake master cylinder upright to prevent air from entering the hydraulic system Remove the screws 1 Separate the right handlebar switch housing 2 Remove the screws 1 Separate the throttle housing 2 Disconnect the throttle cables 3 from the throttle pipe 4 then remove the throttle pipe 5 2 1 m 3 4 3 U 1 2 1 2 ...

Страница 408: ...r 3 Remove the following Caps 1 Bolts 2 Holders 3 Handlebar 4 INSTALLATION CTX700 A N NA 3 4 1 2 1 3 2 1 2 3 4 Clean the inside surface of the handlebar grip and outside surface of the handlebar and throttle pipe Apply Honda bond A or Pro Honda Handgrip Cement U S A only or equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe Wait 3 5 minut...

Страница 409: ... 5 4 5 3 1 I I 0 o _ Align 2 Install the left handlebar switch housing 1 by aligning the locating pin with the handlebar hole gn 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 Ibf ft 1 Install the clutch lever bracket 1 holder 2 UP mark 3 facing up and bolts 4 Align the end of the clutch lever bracket with th...

Страница 410: ... by aligning the locating pin with the handlebar hole 1 3 mm m X 2 SEasu Align 4 1 r Align 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 ibf ft 1 Install the master cylinder 1 holder 2 UP mark 3 facing up and bolts 4 Align the end of the master cylinder with the punch mark on the handlebar and tighten the up...

Страница 411: ...tle grip freeplay page 3 4 REMOVAL CTX700D ND 1 2 3 Remove the handlebar weights page 17 13 Remove the rearview mirrors 1 Release the wire band 2 and two wire clamps 3 from the handlebar 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 ...

Страница 412: ...he 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 Remove the following Caps 1 Bolts 2 Holders 3 Handlebar 4 4 3 1 N m 2 2 S 1 2 1 1 2 I m 3 4 1 i 17 10 ...

Страница 413: ...ch marks with the top bridge top surface Hold the handlebar and install the holders 2 with its punch marks 3 facing forward Install the handlebar holder bolts 4 Tighten the upper bolts first then the lower bolts to the specified torque Install the caps 5 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 ...

Страница 414: ...2 kgf m 9 Ibfft 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 Ibf ft Install the parking brake lever bracket 1 Align the parking brake lever bracket locating p...

Страница 415: ...andlebar weight mounting screw 2 then remove both handlebar weights Install the handlebar weight to both handlebars aligning each cutout Hold the handlebar weight Install and tighten a new handlebar weight mounting screw to the specified torque TORQUE 10 Nm 1 0 kgf m 7 lbf ft 1 INNER WEIGHT REPLACEMENT Remove the throttle pipe or grip rubber from the handlebar CTX700 A N NA page 17 5 CTX700D ND pa...

Страница 416: ...r to the handlebar CTX700 A N NA page 17 6 CTX700D ND page 17 11 5 2 1 4 48S 3 2 3 1 FRONT WHEEL REMOVAL CTX700A D NA ND only Remove the brake pads page 19 9 Remove the bolts 1 and front wheel speed sensor 2 from the caliper bracket Check that there is no iron or other magnetic deposits between the pulser ring and front wheel speed sensor Remove any deposits Check the sensor tip for deformation or...

Страница 417: ...ire balance mark 1 light mass point a paint dot on the side wall must be located next to the valve stem 2 Remount the tire if necessary Note the rotating 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 par...

Страница 418: ... lbf ft BRAKE DISC BEARING 6204UU DISTANCECOLLAR 0 0 O o 0 o 0 7 0 0 V Oo o o o EH DUST SEAL DUST SEAL PULSER RING CTX700A D NA ND BEARING 6204UU WHEEL BEARING REPLACEMENT Install the bearing remover head 1 into the bearing 2 From the opposite side install the bearing remover shaft 3 and drive out the bearing from the wheel hub Remove the distance collar and drive out the other bearing TOOLS 1 Bea...

Страница 419: ...010000 3 Attachment 42 x 47 mm 07746 0010300 4 Pilot 20 mm 07746 0040500 INSTALLATION 2 1 3 4 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 axle to the specified torque TORQUE 74 N m 7 5 kgf m 55 Ibf ft CTX700A D NA ND Install the front wheel speed sens...

Страница 420: ... bolt 1 to the specified torque TORQUE 22 Nm 2 2 kgf m 16 Ibf ft 1 REMOVAL Remove the following Front wheel page 17 14 Front fender page 2 10 Remove the brake caliper mounting bolts 1 and brake caliper bracket assembly 2 Loosen the top bridge pinch bolts 1 When the fork is ready to be disassembled loosen the fork cap 2 Hold the fork legs 3 and loosen the bottom bridge pinch bolts 4 and lower the f...

Страница 421: ...4 unless it is necessary to replace with a new one 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 Set the fork slider 1 in a vise with a piece of wood or soft jaws to avoid damage Remove the fork socket bolt 2 and sealing washer 3 Remove the fork piston 1 and rebound spring 2 from the fork ...

Страница 422: ...y remove the slider bushing 4 by prying the bushing gap with a screwdriver until the bushing can be pulled off by hand m 1 1 2 3 4 m w i INSPECTION Inspect the following parts for damage abnormal wear bend deformation scoring and teflon coating wear Fork tube Fork slider Fork spring Rebound spring Piston ring Fork piston Oil lock piece Guide bushing Back up ring Measure each part according to FRON...

Страница 423: ...o not open the bushing slit more than necessary Install the oil seal with its marked side facing up Install the slider bushing 1 being careful not to damage the coating of the bushing if it has been removed Remove the burrs from the bushing mating surface being careful not to peel off the coating Apply fork fluid to a new oil seal lips Install the guide bushing 2 back up ring 3 and oil seal 4 onto...

Страница 424: ...r 4 Set the fork slider in a vise with a piece of wood or soft jaws to avoid damage Install a new sealing washer 1 to the fork socket bolt 2 Apply locking agent to the fork socket bolt threads and install it Tighten the fork socket bolt 1 to the specified torque TORQUE 20 Nm 2 0 kgf rn 15 Ibf ft Drive the oil seal 1 until the stopper ring groove 2 is visible using the special tools TOOLS 3 Fork se...

Страница 425: ...rk pipe several times to remove any trapped air from the lower portion of the fork pipe Compress the fork pipe fully and measure the fluid level from the top of the fork pipe FLUID LEVEL 103 mm 4 1 in 103 mm 4 1 in Pull the fork pipe up and install the fork spring 1 with the tightly wound coil side facing down Install the spring seat 2 and spring collar 3 3 2 m 1 DOWN Apply fork fluid to a new O r...

Страница 426: ...per bracket assembly 1 and tighten new brake caliper mounting bolts 2 to the specified torque TORQUE 30 Nm 3 1 kgf m 22 Ibf ft Install the following Front fender page 2 10 Front wheel page 17 17 CTX700NA shown 2 1 STEERING STEM REMOVAL CTX700A D Remove the following Handlebar CTX700 AN NA page 17 5 CTX700D ND page 17 9 Center shelter page 2 12 Headlight assembly page 2 8 CTX700N NA ND Disconnect t...

Страница 427: ...bination meter 16P Gray connector 1 Remove the four wire band bosses 2 Remove the two bolts 3 and combination meter stay assembly 4 Remove the cap 1 and steering stem nut 2 Remove the bolt 1 and brake hose guide 2 3 1 4 m m 2 1 2 CTX700 N i CTX700A D NA ND 2 1 17 25 ...

Страница 428: ... Remove the following Dust seal 1 Upper bearing inner race 2 Upper steering head bearing 3 Steering stem 4 Lower steering head bearing 5 BEARING REPLACEMENT A lx 2 F few 1 a 4 1 5 2 3 4 Replace the bearing outer and inner races as a set Remove the upper outer race 1 using a special tool TOOLS Ball race remover set 07953 MJ10000 2 Remover attachment 07953 MJ10100 3 Remover handle 07953 MJ10200 U S ...

Страница 429: ... with a chisel or equivalent tools being careful not to damage the steering stem Remove the steering head bearing dust seal 4 Apply specified grease to a new steering head bearing dust seal lips page 1 19 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 TOOL 3 Attachment 30 mm I D 07746 0030300 Drive in a n...

Страница 430: ...t LOCK NUT LOCK WASHER ADJUSTING NUT UPPER DUST SEAL UPPER INNER RACE UPPER BEARING UPPER OUTER RACE BEARINGS BEARING RACES DUST SEALS 1 Apply 3 5 g 0 1 0 2 oz of specified grease to each steering head bearing inner races and outer races sliding surface page 1 19 Apply specified grease to a new steering head bearing dust seal lips page 1 19 Install the bearings 1 in the lower inner race and upper ...

Страница 431: ... seat the bearings Retighten the adjusting nut 1 to the specified torque using a special tool TOOL 2 Steering stem socket 07916 3710101 TORQUE 23 N m 2 3 kgf m 17 Ibf ft Install a new lock washer 1 aligning its short bent tabs with the grooves in the steering stem adjusting nut Install the lock nut 2 until it contacts with the lock washer Further tighten the lock nut within 90 to align its grooves...

Страница 432: ...e TORQUE 103 N m 10 5 kgf m 76 Ibf ft 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 3 to the steering stem nut CTX700 A D Route the following to the wire guides 1 Throttle cables 2 Front brake hose 3 Clutch cable CTX700 A parking brake cable CTX700D 4 Secure the two wire band bosses 5 CTX700 N ...

Страница 433: ...he wire band bosses 3 Connect the combination meter 16P Gray connector 4 Install the wire harness 1 to the clamp 2 Connect the ignition switch 2P Brown connector 3 and install the wire band 4 Install the following Handlebar CTX700 A N NA page 17 5 CTX700D ND page 17 9 Center shelter page 2 12 Headlight assembly page 2 8 CTX700N NA ND CTX700NA shown 2 1 m m P CTX700NA shown 2 Hi PI 3 4 17 31 ...

Страница 434: ... MEMO i V 1 t i b i ...

Страница 435: ...18 REAR WHEEL SUSPENSION COMPONENT LOCATION 18 2 SERVICE INFORMATION 18 3 TROUBLESHOOTING 18 4 REAR WHEEL 18 5 SHOCK LINKAGE 18 9 SHOCK ABSORBER 18 11 SWINGARM 18 13 i 18 1 ...

Страница 436: ...N CTX700NA shown 1 44 N m 4 5 kgf m 32 Ibf ft 98 N m 10 0 kgf m 72 Ibf ft 44 N m 4 5 kgf m 32 Ibf ft CTX700D ND J f r l CTX700A D NA ND r CTX700D ND r z r 44 N m 4 5 kgf m 32 Ibf ft 98 N m 10 0 kgf m 72 Ibf ft 44 N m 4 5 kgf m 32 Ibf ft 1 18 2 ...

Страница 437: ...tires marked TUBELESS and tubeless valves on rim marked TUBELESS TIRE APPLICABLE Use Honda Genuine replacement bolts and nuts for all suspension pivot and mounting point For brake system information page 19 5 TOOLS Driver 07749 0010000 Attachment 22 x 24 mm 07746 0010800 Attachment 28 x 30 mm 07946 1870100 Attachment 42 x 47 mm 07746 0010300 Attachment 37 mm 07ZMD MBW0200 Pilot 17 mm 07746 0040400...

Страница 438: ...eel bearing Worn driven flange bearing Faulty tire Bent frame or 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 13 Soft suspension Insufficient tire pressure Stiff suspension Bent shock absorber damper rod Damaged suspension or swingarm p...

Страница 439: ...ensor 2 fcrxTOOA D NA ND o only I Loosen the lock nut 1 drive chain adjusting nut 2 and gp 7gg 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 Do not operate the Remove the axle 7 adjusting plate and rear wheel brake pedal after removing the rear wheel 2 I 6 i i 7 m i 9 2 m 1 1 i 1 2 5 3 1 Sir J Sf I 1 M m ...

Страница 440: ...emble and assemble the rear wheel as following illustration For wheel balance service page 17 15 Install the rear wheel dust seal until it is flush with the wheel hub surface Install the rear brake disc with the i marked side facing out DRIVEN FLANGE BRAKE DISC IS p y j K v 11 DUST SEAL PULSER RING CTX700A D NA ND only BEARING 22 x 50 x 15 DUST SEAL Oil BEARING 6204UU DISTANCE COLLAR r 5 msm O RIN...

Страница 441: ...ring must be 2 Driver 07749 0010000 replaced with new 3 Attachment 42 x 47 mm 07746 0010300 ones 4 Pilot 20 mm 07746 0040500 Install the distance collar 5 Drive in a new left side bearing 6 squarely until it is seated on the distance collar 6 2 M w s 5 sr N m CSS 1 IS 3 4 Drive the rear wheel distance collar B 1 to a new driven flange bearing 2 TOOLS 3 Driver 07749 0010000 4 Attachment 28 x 30 mm ...

Страница 442: ...e brake pads Install the drive chain 1 over the driven sprocket Apply a thin coat of grease to the rear axle outer surface Install 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 TORQUE 98 N m 10 0 kgf m 72 Ibf ft A 7 1 iff m r ir m m 1 2 ...

Страница 443: ...parking brake lock operation page 3 18 SHOCK LINKAGE P CTX700A D NA ND only m m p nr m W m 0 I 2 2 i am H V 1 m REMOVAL INSTALLATION Support the motorcycle using a safety stand or hoist raise the rear wheel off the ground Remove the following Shock link bolt 1 and nut 2 Shock absorber lower mounting bolt 3 and nut 4 Shock arm bolt 5 and nut 6 Shock linkage assembly 7 Installation is in the reverse...

Страница 444: ...N m 4 5 kgf m 32 Ibfft 4 Sr m w s 3 1 2 2 i 1 INSPECTION Inspect the following parts for damage abnormal wear deformation and crack Shock arm plates Shock link Pivot collars Needle bearings Replace if necessary BEARING REPLACEMENT Remove the needle bearings 1 using the special tools TOOLS 2 Bearing remover set 17 mm 07936 3710300 3 Remover handle 07936 3710100 4 Remover weight 07741 0010201 or 079...

Страница 445: ...ist raise the rear wheel off the ground Remove the right swingarm pivot cover page 2 17 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 order of removal TORQUE Shock absorber mounting nut 44 Nm 4 5 kg...

Страница 446: ... install the old bearing once the bearing has been removed the bearing must be replaced with a new one Drive the needle bearing 1 out of the lower pivot using a hydraulic press and special tool TOOLS 2 Driver 15 X 280L 3 Attachment 22 x 24 mm 4 Pilot 17 mm 07949 3710001 07746 0010800 07746 0040400 Apply molybdenum disulfide grease to new needle bearings rotating area Install the needle bearing 1 i...

Страница 447: ...rill 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 inflate the bag with air from the motor and help keep the ...

Страница 448: ...unting bolt 3 and nut 4 Remove the swingarm pivot nut 1 washer 2 pivot bolt 3 and swingarm 4 DISASSEMBLY INSPECTION CTX700D ND only 2 j 1 UM2 3 4 4 1 2 3 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 5 1 2 3 4 4 j I 1R _1A ...

Страница 449: ...ve the collar 1 form the shock absorber bracket Check the collar for wear damage or fatigue Check the needle bearings 2 for damage or loose fit replace it if necessary page 18 15 INSPECTION A 1 f 2 3 tfC 4 1 2 r 2 1 Inspect the following parts for damage abnormal wear and deformation Swingarm Pivot collars Bearings Drive chain slider page 18 13 Replace if necessary PIVOT BEARING REPLACEMENT Remove...

Страница 450: ... the shock absorber bracket using the special tools TOOLS 2 Bearing remover set 17 mm 07936 3710300 3 Remover handle 07936 3710100 4 Remover weight 07741 0010201 or 07936 371020A U S A only Apply molybdenum disulfide grease to a new needle bearing rotating area Install the needle bearing 1 into the left pivot with the marked side facing up to the specified range using a hydraulic press and special...

Страница 451: ...ydraulic press and special tools as shown TOOLS 2 Driver 07749 0010000 3 Attachment 37 mm 07ZMD MBW0200 4 Pilot 30 mm 07746 0040700 Apply molybdenum disulfide grease to a new needle bearing rotating area Install the 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 TOOLS 2 ...

Страница 452: ...ING 3 SB NEEDLE BEARING COLLAR DRIVE CHAIN ADJUSTERS Install the collar 1 to the shock absorber bracket Apply molybdenum disulfide grease to new dust seal lips Install the distance collar 1 and dust seals 2 to the swingarm 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...

Страница 453: ... 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 TORQUE 98 N m 10 0 kgf m 72 Ibf ft 3 4 pl m 2 m m V 3 2 1 m 2 Set the shock arm 1 and install the shock absorber lower mounting bolt 2 Install and tighten the shock absorber lower mount...

Страница 454: ...ensor wire 1 CTX700A D NA ND only and brake hose 2 to the brake hose guides 3 Install the brake hose guide and socket bolts 4 Tignten the socket bolts securely Install the following Rear wheel page 18 8 Chain cover page 2 18 Swingarm pivot covers page 2 17 CTX700D ND only 1 i m m l 2 r CTX700NA shown i 3 I S m 1 i w L 7 2 fjf m m rjm m r j 1 j 18 20 ...

Страница 455: ...OOTING 19 6 BRAKE FLUID REPLACEMENT AIR BLEEDING 19 7 BRAKE PAD DISC 19 9 FRONT MASTER CYLINDER 19 12 REAR MASTER CYLINDER 19 14 FRONT BRAKE CALIPER 19 16 REAR BRAKE CALIPER 19 18 BRAKE PEDAL 19 19 PARKING BRAKE CALIPER CTX700D ND 19 19 PARKING BRAKE LEVER CTX700D ND 19 24 19 1 ...

Страница 456: ...COMPONENT LOCATION CTX700NA shown 12 N m 1 2 kgf m 9 Ibf ft 34 N m 3 5 kgf m 25 Ibf ft a 0 a o CTX700 N 34 N m 3 5 kgf m 25 Ibf ft 30 N m 3 1 kgf m 22 Ibf ft i 34 N m 3 5 kgf m 25 Ibf ft 17 N m 1 7 kgf m 13 Ibf ft 1Q 9 ...

Страница 457: ...HYDRAULIC BRAKE CTX700 A N NA 34 N m 3 5 kgf m 25 lbf ft 1 12 N m 1 2 kgf m 9 lbf ft 27 N m 2 8 kgf m 20 lbf ft 10 N m 1 0 kgf m 7 lbf ft 0 34 N m 3 5 kgf m 25 lbf ft 22 N m 2 2 kgf m 16 lbf ft 19 3 ...

Страница 458: ...700D ND 1 34 N m 3 5 kgf m 25 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 27 N m 2 8 kgf m 20 Ibf ft ks o o 0 0 0 a o 10 N m 1 0 kgf m 7 Ibf ft 34 N m 3 5 kgf m 25 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft J 31 N m 3 2 kgf m 23 Ibf ft 1 Q _A ...

Страница 459: ...uces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Check the brake system by applying the brake lever or pedal after the air bleeding Never allow contaminates dirt water etc to get into an open reservoir Once the hydraulic system has been opened or if the brake feels spongy the system must be bled Always use fresh DOT 4 brake flui...

Страница 460: ...er 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 Warped deformed brake disc Sticking worn caliper piston Brake drags Contaminated brake pad disc Misaligned wheel Badly worn brake pad disc Warped deformed brake disc...

Страница 461: ...caliper bleed valve 2 Loosen the bleed valve and pump the brake lever pedal until no more fluid flows out of the bleed valve BRAKE FLUID FILLING AIR BLEEDING Do not mix different Fill the reservoir with DOT 4 brake fluid from a sealed types of fluid they container are not compatible Connect a automatic refill system to the reservoir If an automatic refill system is not used add fluid when the flui...

Страница 462: ...sistance 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 turn Wait several seconds and then close the bleed valve NOTE Do not release the brake lever pedal until the bleed valve has been closed 2 Release the brake lever pedal slowly and wait several seconds after it reaches the end of its travel 2 Front side shown 1 Fro...

Страница 463: ...t operate the Remove the brake pad pin 1 and brake pads 2 brake lever after removing the brake pads Install the brake pads 1 to the brake 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 is in good condition replace if necessary Apply silicone grease to the brake pad pin stopper ring 2 and inst...

Страница 464: ...hat the retainer and pad spring are installed to the brake caliper Lower the caliper Loosely install a new rear brake caliper mounting bolt m Check that the brake pad pin stopper ring 2 is in good condition replace it if necessary Apply silicone grease to the brake pad pin stopper ring Install the brake pad pin 3 by pushing the pads against the pad spring to align the brake pad pin holes in the pa...

Страница 465: ...ns 1 Remove 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 TORQUE 31 Nm 3 2 kgf m 23 Ibf ft Tighten the parking brake pad pins to the speci...

Страница 466: ...reverse order of removal Install the master cylinder holder with the UP mark 4 facing up Align the end of the master cylinder with the handlebar punch mark 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 TORQUE Front master...

Страница 467: ...ups as a set Do not allow the piston cup lips to turn inside out Align the switch boss with the master cylinder hole properly SECONDARY PRIMARY PISTON CUP PISTON CUP 1 0 N m 0 1 kgf m 0 7 lbf ft BOOT BRAKE LEVER SNAP RING MASTER PISTON SPRING 0 10 g 0 004 oz MASTER CYLINDER BRAKE LIGHT SWITCH 0 10 g 0 004 oz 5 9 N m 0 6 kgf m 4 4 lbf ft 1 2 N m 0 1 kgf m 0 9 lbf ft INSPECTION Inspect the following...

Страница 468: ...bly 5 j Remove and discard the cotter pin 1 Remove the joint pin 2 and disconnect the push rod joint from the brake pedal Remove the master cylinder mounting bolts 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 TORQUE R...

Страница 469: ...ston and cups Do not allow the piston cup lips to turn inside out O RING MASTER CYLINDER HOSE JOINT SPRING PRIMARY PISTON CUP 1 5 N m 0 2 kgf m 1 1 Ibf ft MASTER PISTON SECONDARY PISTON CUP PUSH ROD When the push rod has been disassembled adjust the push rod length so that the distance from the center of the master cylinder lower mounting bolt hole to the center of the joint pin hole is standard l...

Страница 470: ...t 1 and wire clamp 2 Two bolts 3 and front wheel speed sensor 4 Brake pads page 19 9 Oil bolt 1 Sealing washers 2 Brake hose 3 Mounting bolts 4 Brake caliper 5 Installation is in the reverse order of removal Replace the brake caliper mounting bolts and sealing washers with new ones Be sure to rest the eyelet stopper pin against the caliper body when tightening the oil bolt Before installing the wh...

Страница 471: ...stons with the opening toward the pads 4 0 4 g 0 01 oz CALIPER PIN 8 22 N m 2 2 kgf m CALIPER PIN BOOT CALIPER BRACKET PAD RETAINER BLEED VALVE 5 4 N m 0 6 kgf m 5fj STOPPER RING W 4 g 0 01 OZ BRAKE PAD PIN 17 N m 1 7 kgf m DUST SEAL n P STON SEAL CALIPER PISTON PAD SPRING 0 PAD SPRING BRAKE PADS BRACKET PIN BOOT Apply Honda Bond A or equivalent to the retainer seating surface INSPECTION Check the...

Страница 472: ...he eyelet stopper pin against the caliper body when tightening the oil bolt TORQUE Brake hose oil bolt 34 N m 3 5 kgf m Fill and bleed the rear brake hydraulic system page 19 7 1 4 a 8 c 6 5 3 2 50 DISASSEMBLY ASSEMBLY Disassemble and assemble the rear brake caliper as following illustration When removing the caliper piston with compressed air place a shop towel over the piston to prevent damaging...

Страница 473: ...and disconnect the push rod lower joint from the brake pedal 3 Remove the snap ring 4 washer 5 Remove the brake pedal by releasing the return spring 6 Installation is in the reverse order of removal Apply grease to the brake pedal pivot sliding area Replace the cotter pins with new ones 1 2 w 3 SW 6 455 4 5 PARKING BRAKE CALIPER CTX700D ND REMOVAL INSTALLATION Remove the parking brake pads page 19...

Страница 474: ...t 1 1 Remove the following Caliper bracket 1 Pad spring 2 Bracket pin boot 3 Caliper pin boot 4 Sleeve 5 5 4 Remove the parking brake adjuster bolt lock nut 1 while holding the brake arm 2 Remove the brake arm 2 1 Remove the brake shaft boot 1 1 1 I iQ _9n ...

Страница 475: ...emove 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 2 1 1 Inspect the following parts for scoring scratches or damage Caliper cylinder Caliper piston Replace if necessary i 19 21 ...

Страница 476: ... 01 oz BRAKE ARM BRAKE SHAFT BOOT 0 4 g 0 01 oz Install a new dust seal 1 into the seal groove in the caliper Install the dust seal with its flat surface facing inside Apply 0 4 g 0 01 oz minimum of silicone grease to the outer surface of the brake shaft 1 Position the brake shaft so that the punch mark 2 is between the index lines 3 installation range and screw the shaft into the caliper Make sur...

Страница 477: ...e 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 TORQUE 17 Nm 1 7 kgf m 13 Ibf ft 2 m f1 SgMi Align 19 23 ...

Страница 478: ...1 and tighten it to the specified torque TORQUE 22 N m 2 2 kgf m 16 Ibf ft t4 l 5 3 Hi 2 s m PARKING BRAKE LEVER CTX700D ND REMOVAL INSTALLATION Remove the following Left rearview mirror page 17 9 Parking brake switch page 22 17 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 ...

Страница 479: ...emoval Align the parking brake lever bracket locating pin with the handlebar hole TORQUE Parking brake adjuster bolt lock nut 17 N m 1 7 kgf m 13 Ibfft Parking brake cable mounting nut 10 N m 1 0 kgf m 7 Ibf ft Check the parking brake lock operation page 3 18 2 mr si i w 1 3 k 3 u Align I DISASSEMBLY Remove the lower holder cap 1 Remove the spring pin 1 and release shaft 2 Si L a 1 L 2 1 19 25 ...

Страница 480: ...1 washer 2 and parking brake lever 3 Remove the ratchet B 1 Remove the ratchet A 1 and springs 2 ASSEMBLY 3 1 i I m 1 i I k 2 Apply grease to the ratchet A teeth and sliding surface Install the springs 1 and ratchet A 2 mm 1 2 j A t OP ...

Страница 481: ...liding surface Install the parking brake lever 1 Align the parking brake lever hole with the ratchet B tab 2 1 B r Align 1 Apply grease to the washer sliding surface Install the washer 1 and E clip 2 4 i 2 1 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 1 i l m n Align 19 27 ...

Страница 482: ... I HYDRAULIC BRAKE Install the lower holder cap 1 1 l I 3 J i 1Q 9R ...

Страница 483: ... ABS SYSTEM LOCATION 20 2 ABS SYSTEM DIAGRAM 20 3 SERVICE INFORMATION 20 4 ABS TROUBLESHOOTING INFORMATION 20 5 DTC INDEX 20 8 ABS INDICATOR CIRCUIT TROUBLESHOOTING 20 10 ABS TROUBLESHOOTING 20 12 WHEEL SPEED SENSOR 20 20 ABS MODULATOR 20 23 20 1 ...

Страница 484: ...ANTI LOCK BRAKE SYSTEM ABS CTX700A D NA ND ABS SYSTEM LOCATION ABS MODULATOR DLC BATTERY FRONT WHEEL SPEED SENSOR REAR WHEEL SPEED SENSOR 20 2 ...

Страница 485: ...LSER RING REAR WHEEL ABS 2 1 SPEED SENSOR 4 3 Bu W I IG BLS 4 ABS 6 1 6 IND 13 PUMP MOTOR 5 1 GND 9 POWER SUPPLY RELAY ABS 5 4 5 SCS 14 SOLENOID VALVE 3 1 3 2 3 3 3 4 3 7 3 8 8 FVW B 1 1 1 2 1 5 TIRE SIZE 7 1 Bu 15 RVWS W Bl 6 RVW B 1 3 1 4 1 5 O BI P Bu G R ABS INDICATOR COMBINATION METER _T G Y W Br G DLC o ABS MODULATOR 8 1 REAR PULSER RING ABS 2 3 ABS Problem code number Short terminals for re...

Страница 486: ...n or blinks the ABS indicator Take care during the test ride Read ABS TROUBLESHOOTING INFORMATION carefully inspect and troubleshoot the ABS according to the diagnostic troubleshooting flow chart Observe each step of the procedures one by one Write down the DTC and probable faulty part before starting diagnosis and troubleshooting Use a fully charged battery Do not diagnose with a charger connecte...

Страница 487: ...ays on to notify the rider of the problem The ordinary self diagnosis is also made while the motorcycle is running after the pre start diagnosis is completed When the ABS indicator brinks or stays on the cause of the problem can be identified by retrieving the DTC page 20 6 If the ABS indicator does not come on when the ignition switch is turned ON or the ABS indicator stays on after the pre start...

Страница 488: ...UT NOTE The DTC is not erased by turning the ignition switch to OFF while the DTC is being output Note that turning the ignition switch ON again does not indicate the DTC To show the DTC again repeat the DTC readout procedures from the beginning Be sure to record the indicated DTC After diagnostic troubleshooting erase the DTC and perform the pre start self diagnosis procedure to be sure that ther...

Страница 489: ...n The ABS indicator should go off 5 Release the brake lever immediately after the ABS indicator goes off When the DTC is erased the ABS indicator blinks 2 times and stays on If the ABS indicator does not blink 2 times the self diagnostic memory has not been erased so try again CIRCUIT INSPECTION T7 1 s m m e f m INSPECTION AT ABS MODULATOR CONNECTOR Remove the fuel tank page 7 7 Turn the ignition ...

Страница 490: ...ound for a long time when riding wheelie Only either the front or rear wheel rotates The ABS operates continuously The ABS control unit has been disrupted by an extremely powerful radio wave electromagnetic interference probe 1 Insert the test probe into the connector terminal then the digital multimeter probe to the test probe TERMINAL LAYOUT 9 18 8 7 6 5 4 3 2 1 7 1 6 1 5 1 4 1 3 12 11 1 10 Term...

Страница 491: ...Riding condition o ZU I 4 3 Rear wheel lock Riding condition o Stops ABS operation 20 14 5 1 Pump motor lock Pump motor ABS modulator or related wires ABS M fuse 30 A o o Stops ABS operation 20 18 5 4 Power supply relay malfunction Power supply relay ABS modulator or related wires ABS M fuse 30 A o o Stops ABS operation 20 18 6 1 Power circuit under voltage Input voltage too low ABS MAIN fuse 7 5 ...

Страница 492: ... Turn the ignition switch OFF Check for continuity between the wire harness side ABS modulator 18P Black connector 1 terminal and ground TOOL Test probe 07ZAJ RDJA110 CONNECTION 13 Ground Is there continuity YES Short circuit in the Orange black wire NO Faulty combination meter ABS INDICATOR STAYS ON Indicator does not go off when the motorcycle is running but DTC is not stored 1 Service Check Lin...

Страница 493: ... Orange black wire Faulty combination meter if the Orange black wire is OK 3 Modulator Ground Line Open Circuit Inspection Turn the ignition switch OFF Check for continuity between the wire harness side ABS modulator 18P Black connector 1 terminal and ground CONNECTION 9 Ground Is there continuity YES GO TO STEP 4 NO Open circuit in the Green yellow wire 1 i i I I I 9 Q 4 Fuse Inspection Remove th...

Страница 494: ...3 7 ABS TROUBLESHOOTING NOTE Perform inspection with the ignition switch OFF unless otherwise specified All connector diagrams in the troubleshooting are viewed from the terminal side Use a fully charged battery Do not diagnose with a charger connected to the battery When the ABS modulator assembly is detected to be faulty recheck the wire harness and connector connections closely before replacing...

Страница 495: ...tion YES GO TO STEP 3 NO Remove any deposits Install properly or replace faulty part 3 Front Wheel Speed Sensor Line Short Circuit Inspection at sensor side Turn the ignition switch OFF Disconnect the front wheel speed sensor 2P Blue connector page 20 21 Check for continuity between each terminal of the sensor side front wheel speed sensor 2P Blue connector 1 and ground CONNECTION White Ground Blu...

Страница 496: ... modulator 18P Black and front wheel speed sensor 2P Blue connectors Erase the DTC page 20 7 Test ride the motorcycle above 30 km h 19 mph Recheck the DTC page 20 6 Is the DTC 1 1 1 2 2 1 4 1 or 4 2 indicated YES Faulty ABS modulator NO Faulty original wheel speed sensor DTC 1 3 1 4 2 3 or 4 3 Rear Wheel Speed Sensor Circuit Rear Wheel Speed Sensor Rear Pulser Ring Rear Wheel Lock NOTE The ABS ind...

Страница 497: ...ar Wheel Speed Sensor Line Short Circuit Inspection at sensor side Turn the ignition switch OFF Disconnect the rear wheel speed sensor 2P Gray connector page 20 22 Check for continuity between each terminal of the sensor side rear wheel speed sensor 2P Gray connector 1 and ground CONNECTION Blue Ground White Ground Is there continuity YES Faulty rear wheel speed sensor NO GO TO STEP 4 4 Rear Wheel...

Страница 498: ...New Speed Sensor Replace the rear wheel speed sensor with a new one page 20 22 Connect the ABS modulator 18P Black and rear wheel speed sensor 2P Gray connectors Erase the DTC page 20 7 Test ride the motorcycle above 30 km h 19 mph Recheck the DTC page 20 6 Is the DTC 1 3 1 4 2 3 or 4 3 indicated YES Faulty ABS modulator NO Faulty original wheel speed sensor DTC 1 5 Front or Rear Wheel Speed Senso...

Страница 499: ...erminal of the sensor side rear wheel speed sensor 2P Gray connector 1 and ground CONNECTION Blue Ground White Ground Is there continuity YES Faulty rear wheel speed sensor NO GO TO STEP 4 4 Rear Wheel Speed Sensor Line Short Circuit Inspection Check for continuity between each terminal of the wire harness side rear wheel speed sensor 2P Gray connector 1 and ground CONNECTION White black Ground Bl...

Страница 500: ... fuse box and ABS modulator 18P Black connector NO Intermittent failure Replace the ABS M fuse 30 A with a new one and recheck 1 18 Q Motor Power Input Line Open Circuit Inspection 4 Install the ABS M fuse 30 A Disconnect the ABS modulator 18P Black connector page 20 7 Measure the voltage between the wire harness side ABS modulator 18P Black connector 1 terminal and ground CONNECTION 18 Ground Is ...

Страница 501: ...n Red black wire 1 SET 7 NO Intermittent failure Replace the ABS MAIN fuse 7 5 A with a new one and recheck 3 Power Input Line Open Circuit Inspection Install the ABS MAIN fuse 7 5 A Disconnect the ABS modulator 18P Black connector page 20 7 Turn the ignition switch ON and engine stop switch O Measure the voltage between the wire harness side ABS modulator 18P Black connector 1 terminal and ground...

Страница 502: ... 30 km h 19 mph Recheck the DTC page 20 6 Is the DTC 8 1 indicated 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 air gap between the sensor and pulser ring at several points by turning the wheel slowly It must be wi...

Страница 503: ... 2 Remove the bolt 3 and wire clamp 4 then release the speed sensor wire Remove the bolt 5 and brake hose clamp 6 then release the speed sensor wire Release the sensor wire 1 from the clamp 2 Remove the bolt 3 and 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 mater...

Страница 504: ...ocket bolts 1 and brake hose guide 2 Release the brake hose 3 and rear wheel speed sensor wire 4 from the brake hose guide Release the rear wheel speed sensor wire 1 from the clamp 2 Remove the wire band boss 3 Remove the bolts 4 and stay 5 rear 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 mountin...

Страница 505: ...sor 3P Gray connector 2 TR sensor 3P Black connector 3 Junction D 4 Loosen the brake pipe joint nuts 5 and disconnect the brake pipes from the ABS modulator Be careful not to bend or damage the brake pipes Remove the ABS modulator assembly 6 Remove the ABS modulator mounting bolts 1 and ABS modulator 2 from the ABS modulator stay 3 Installation is in the reverse order of removal Apply brake fluid ...

Страница 506: ... MEMO i ...

Страница 507: ... CHARGING SYSTEM SYSTEM LOCATION 21 2 SYSTEM DIAGRAM 21 2 SERVICE INFORMATION 21 3 TROUBLESHOOTING 21 4 BATTERY 21 5 CHARGING SYSTEM INSPECTION 21 6 REGULATOR RECTIFIER 21 7 ALTERNATOR CHARGING COIL 21 8 El 21 1 ...

Страница 508: ...M SYSTEM LOCATION CTX700NA shown MAIN FUSE 30 A BATTERY 3 ALTERNATOR SYSTEM DIAGRAM REGULATOR RECTIFIER I J MAIN FUSE 30 A Q O Bl Bl G R Y Y Y n 0 REGULATOR RECTIFIER BATTERY ALTERNATOR Bl Black G Green R Red Y Yellow J 21 2 ...

Страница 509: ...ltage will drop quickly and eventually die out For this reason the charging system is often suspected as the problem Battery overcharge often results from problems in the battery itself which may appear to be an overcharging symptom If one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions the ...

Страница 510: ...BV Measured CV 15 5 V BV Battery Voltage CV Charging Voltage Is the measured charging voltage within the standard voltage YES Faulty battery NO GO TO STEP 4 4 REGULATOR RECTIFIER SYSTEM INSPECTION Check the voltage and resistance at the regulator rectifier connector page 21 7 Are the results of checked voltage and resistance correct YES GO TO STEP 5 NO Open circuit in related wire Loose or poor co...

Страница 511: ...ON 3 4 z m 4 S 4 c 2 1 Remove the seat page 2 14 Measure the battery voltage using a commercially available digital multimeter VOLTAGE 20 C 68 F Fully charged 13 0 13 2 V Needs charging Below 12 4 V BATTERY TESTING V71 fr ffflll llfrtr ii 5f 1 0 1 Remove the battery page 21 5 Refer to the instructions that are appropriate to the battery testing equipment available to you TOOL Battery tester Micro ...

Страница 512: ...t by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION NOTE 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 seat page 2 14 Connect the multimeter between the positive terminal 1 and negative terminal 2 of the battery NOTE To prevent a short ma...

Страница 513: ...here are no loose connections at the regulator rectifier connectors replace the regulator rectifier S I BATTERY CHARGING LINE INSPECTION Turn the ignition switch OFF Disconnect the regulator rectifier 3P Black connector 1 page 21 7 Measure the voltage between the regulator rectifier 3P Black connector terminal at the wire side and ground CONNECTION Red Ground STANDARD Battery voltage There should ...

Страница 514: ...ernator 3P Black connector terminals at the wire side CONNECTION Yellow Yellow STANDARD 0 1 0 5 Q 20 C 68 F Check for continuity between the alternator 3P Gray connector 1 terminals at the wire side and ground CONNECTION Yellow Ground STANDARD No continuity Replace the stator if the resistance is out of specification or if any wire has continuity to ground For alternator starter replacement page 1...

Страница 515: ...TACHOMETER 22 12 HIGH COOLANT TEMPERATURE INDICATOR ECT SENSOR 22 13 ENGINE OIL PRESSURE INDICATOR EOP SWITCH 22 14 FUEL LEVEL SENSOR 22 15 PARKING BRAKE INDICATOR SWITCH CTX700D ND 22 16 IGNITION SWITCH 22 17 HANDLEBAR SWITCHES 22 18 BRAKE LIGHT SWITCH 22 19 CLUTCH SWITCH CTX700 A N NA 22 19 NEUTRAL SWITCH 22 20 SIDESTAND SWITCH 22 21 HORN 22 22 TURN SIGNAL HAZARD RELAY 22 22 HAZARD DIODE 22 24 2...

Страница 516: ...IGNAL HAZARD RELAY IGNITION SWITCH EOP SWITCH HORN REAR BRAKE LIGHT SWITCH NEUTRAL SWITCH SIDESTAND SWITCH CTX700D ND FRONT BRAKE LIGHT SWITCH FUEL LEVEL SENSOR VS SENSOR ECT SENSOR PARKING BRAKE SWITCH EOP SWITCH HORN 0 TURN SIGNAL HAZARD RELAY IGNITION SWITCH VS SENSOR REAR BRAKE LIGHT SWITCH NEUTRAL SWITCH SIDESTAND SWITCH 22 2 ...

Страница 517: ...ght is ON and remains hot for a while after it is turned OFF Be sure to let it cool down before servicing Check the battery condition before performing any inspection that requires proper battery voltage Use an electric heating element to heat the water coolant mixture for the ECT sensor inspection Keep flammable materials away from the electric heating element Wear protective clothing insulated g...

Страница 518: ...1 Unhook the bulb retainer 2 and remove the headlight bulb 3 NOTICE Avoid touching halogen headlight bulb Finger prints can create hot spots that cause a bulb to break Installation is in the reverse order of removal Install the dust cover with its TOP mark 4 and arrow mark 5 facing up 3 4 W 1 2 TURN SIGNAL LIGHT BULB REMOVAL INSTALLATION Remove the screw 1 collar 2 and turn signal light lens 3 by ...

Страница 519: ...1 mounting plate 2 Remove the turn signal light unit 3 from the headlight side cover 4 by pulling out the wire from the hole of the mounting rubber 5 Installation is in the reverse order of removal TORQUE Turn signal light special screw 1 5 N m 0 2 kgf m 1 1 Ibfft REAR TURN SIGNAL LIGHT UNIT REMOVAL INSTALLATION 5 2 1 3 4 REAR Remove the rear fender A page 2 17 Remove the turn signal light special...

Страница 520: ...uts 1 washers 2 and brake tail light unit 3 Installation is in the reverse order of removal LICENSE LIGHT BULB REMOVAL INSTALLATION Remove the two screws 1 lens 2 and bulb 3 Check the packing 4 is in good condition replace it with a new one if necessary Installation is in the reverse order of removal REMOVAL INSTALLATION Remove the rear fender A page 2 17 Remove the two nuts 1 collars 2 and licens...

Страница 521: ...22 8 Cs w N e mminniuMiimiiii X I REMOVAL INSTALLATION CTX700N NA ND For CTX700 A D page 2 6 Remove the headlight assembly page 2 8 Pull off the dust cover and disconnect the combination meter 16P Gray connector 1 Remove the screws 2 washer 3 and combination meter 4 Installation is in the reverse order of removal TORQUE Combination meter mounting screw 1 0 N m 0 1 kgfrn 0 7 Ibf ft POWER GROUND LIN...

Страница 522: ...PECTION NOTE Check the following items before starting the inspection Check for loose or poor contact on the combination meter 16P Gray connector and ECM PCM 33P connector then recheck the DTC Inspect the sub fuse 7 5 A ENG STOP If the PCM is replaced perform the Clutch Initialize Learning Procedure page 12 81 CTX700D ND Turn the ignition switch ON with the engine stop switch O and check the combi...

Страница 523: ...1 l i m HMI R Bu NO GO TO STEP 2 2 Combination Meter Serial Line Open Circuit Inspection 3 Check for continuity between the combination meter 16P Gray connector 1 and ECM PCM 33P connector 2 of the wire harness side Connection Red blue Red blue TOOL Test probe 2 packs 07ZAJ RDJA110 Is there continuity YES GO TO STEP 3 NO Open circuit in Red blue wire 1 2 n I T N T R Bu DL R Bu Combination Meter Se...

Страница 524: ... Short the DLC terminals using a special tool Connection Brown Green TOOL 2 SCS service connector 070PZ ZY30100 Rotate and hold the throttle grip 1 to the fully open position Turn the ignition switch ON while holding the throttle grip at the fully open position over 10 seconds NOTE The ECM PCM enters the communication diagnostic mode Measure the voltage at the combination meter 16P Gray connector ...

Страница 525: ...igits 3 indicate 1 2 or 3 NOTE The combination meter enter the back light setting mode Push the A button then hour digits 1 start blinking NOTE The combination meter enter the clock setting mode Push the B button until the desired hour 1 and AM PM are displayed NOTE Push and hold to advance the hour fast Push the A button then the minute digits 1 start blinking Ca w N ID CL 3 E3H m IV ten 1 34 17 ...

Страница 526: ...inking If the MIL blinks 11 check the VS sensor system page 4 10 If the above items are OK replace the combination meter page 22 7 VS SENSOR REMOVAL INSTALLATION Disconnect the VS sensor 3P Black connector 1 Remove the bolt 2 and VS sensor 3 Remove the O ring 4 Installation is in the reverse order of removal Replace the O ring with a new one Apply engine oil to a new O ring TACHOMETER i 2 1 w I 1 ...

Страница 527: ...with the MCS page 4 9 Serial communication line page 22 8 1 A x 000 rtr t f A U J i i ECT SENSOR UNIT INSPECTION Remove the ECT sensor page 4 33 Suspend the ECT sensor 1 in a pan of coolant 50 50 mixture on an electric heating element and measure the resistance through the sensor as the coolant heats up Soak the ECT sensor in coolant up to its threads with at least 40 mm 1 6 in from the bottom of ...

Страница 528: ...gine oil pressure indicator stay on and tachometer high coolant temperature indicator do not come on inspect the following DTC with the MCS page 4 9 Serial communication line page 22 8 EOP SWITCH LINE INSPECTION Turn the ignition switch OFF Disconnect the EOP switch 1P Gray connector 1 Check for continuity between the EOP switch connector terminal and ground CONNECTION Light green Ground If there ...

Страница 529: ...ection as follow Disconnect the combination meter 16P Gray connector CTX700 A D page 2 6 CTX700N NA ND page 22 7 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 CONNECTION Black green Black green If there is no continuity check for open circuit in Blac...

Страница 530: ...the ignition switch ON and engine stop switch Q 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 16 PARKING BRAKE SWITCH INSPECTION 1 4 Cs N iIO 1035 0 n ToaA U m i 1 Disconnect the parking brake switch connectors Check for continuity between the pa...

Страница 531: ...se order of removal Apply grease to the parking brake switch spring sliding surface TORQUE Parking brake switch screw 1 2 N m 0 1 kgf m 0 9 Ibf ft IGNITION SWITCH 3 1 2 2 3 5 4 1 INSPECTION Remove the right side shelter page 2 11 Disconnect the ignition switch 2P Brown connector 1 Check for continuity between the wire terminals of the ignition switch connector in each switch position Refer to the ...

Страница 532: ...6 CTX700 A Radiator side covers page 2 10 CTX700N NA Disconnect the following Left handlebar switch 14P Gray connector 1 Right handlebar switch 8P Blue connector 2 Check for continuity between the wire terminals of the handlebar switch connector in each switch position Refer to the wiring diagram for the terminals and switch status page 23 2 ft t m V Right side 2 I CTX700D ND Remove the side shelt...

Страница 533: ... page 2 12 Disconnect the rear brake light switch 2P 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 1 w m mm 1 t CLUTCH SWITCH CTX700 A N NA Disconnect the clutch switch connectors and check for continuity between the terminals There should be continuity with th...

Страница 534: ...sion is in gear If the neutral indicator does not operate properly check the shift indicator blinking with the ignition switch ON and the engine stop switch Q If DTC 52 is indicated with the shift indicator check the neutral switch system page 12 11 If the shift indicator does not indicate any DTC and the neutral indicator does not light with the transmission in neutral check for open circuit in t...

Страница 535: ...nkcase rear cover page 2 16 Release the sidestand switch 2P Gray connector 1 from the stay and disconnect it Remove the wire bands 1 and sidestand switch wire band boss 2 Release the sidestand switch wire 3 from the stays 4 Remove the sidestand switch mounting bolt 1 and sidestand switch 2 Installation is in the reverse order of removal Replace the sidestand switch mounting bolt with a new one Ali...

Страница 536: ...emove the under center cowl page 2 13 Disconnect the wire connectors 1 Remove the bolt 2 and horn 3 Installation is in the reverse order of removal TURN SIGNAL HAZARD RELAY HBIS is 1 3 ms 2 m I SYSTEM INSPECTION Remove the left rear side cowl page 2 15 Turn the ignition switch OFF Release the turn signal hazard relay 1 from the rear fender B Disconnect the turn signal hazard relay 4P connector 21 ...

Страница 537: ...uity between the 4P connector 1 terminal and ground Connection Green Ground Is there continuity YES GO TO STEP 3 NO Open circuit in the Green wire 1 3 Q 3 Turn Signal hazard Switch Line Open Circuit Inspection Connect the 4P connector 1 terminals with a jumper wire Connection Red white Gray Operate the turn signal switch or push the hazard switch Do the turn signal light illuminate YES GO TO STEP ...

Страница 538: ...age YES System is normal replace the turn signal hazard relay NO Open circuit in the Pink blue wire Blown sub fuse 7 5 A ILLUMI STOP HORN 1 P Bu W HAZARD DIODE INSPECTION Remove the left side shelter page 2 11 Remove the hazard diode 1 Check for continuity between the diode 1 terminals When there is continuity a small resistance value will register If there is continuity in one direction the diode...

Страница 539: ...23 WIRING DIAGRAM CTX700 A N NA 23 2 CTX700D ND 23 3 l 23 1 ...

Страница 540: ...MEMO ...

Страница 541: ...MEMO I ...

Страница 542: ...000000 OO HORN t i 3D 3P Bl 3 5 2P 2P I Bu Gr Bl Bl 0 II I I II IBI R a A r CNfO 0OO M S m IS 2F 5P BO OHO Bl S ranc o CN CN 0 1 ALTERNATOR Sills gl n a H si II g ii i aiseei 1i m 5 n cc as m Q 0 03 s m OS o yn II H y H 3 HI l a g s 11 1 1 9 1 O mi i 5 Sif i 2P I Gr REGULATOR RECTIFIER 1 V i u 14P Gr m 118 15 arTTTuI I ssi o 535 m i i r ui L 56 IAT ACV SENSOR o 515 o a FRONT WHEEL I SPEED j SENSOR...

Страница 543: ...Y G Y O GO BRAKE d SHIELD WIRE TA L LIGHT 2P FRONT RIGHT TURN SIGNAL POSITION LIGHT 12V 21 5W O IBIB B HIBia B a Hi IB B BIBIB C O m L LbAwJrXjf U r S 3p Bu B 1 y i Lb 1 G J IT A M WlW n Mwr MW j T r PP Lb REAR LEFT TURN SIGNAL LIGHT 12V 21W V HEADLIGHT T _ i f 12V 60 55W 5 STARTER Sa 5 JL RELAY MAIN FUSE S SWITCH A A 30A s m m M rr Wi 1 A 4 Bl iriinr L l J ftss STARTER IMOTOR FRONT LEFT TURN SIGN...

Страница 544: ... MEMO i j ...

Страница 545: ...OMPRESSION TEST 10 5 CYLINDER HEAD 10 14 CYLINDER HEAD COVER 10 5 DCT ELECTRICAL SYSTEM LOCATION 12 5 DCT SHIFT PEDAL OPTIONAL 12 79 DCT SYMPTOM TROUBLESHOOTING 12 5 DCT SYSTEM DIAGRAM 12 6 DCT TROUBLESHOOTING INFORMATION 12 7 DRIVE CHAIN 3 13 DTC INDEX ANTI LOCK BRAKE SYSTEM ABS 20 8 DUAL CLUTCH TRANSMISSION DCT CTX700D ND 12 11 PGM FI SYSTEM 4 10 DTC TROUBLESHOOTING DUAL CLUTCH TRANSMISSION DCT ...

Страница 546: ...ATOR STARTER CLUTCH 13 3 ANTI LOCK BRAKE SYSTEM ABS 20 4 BATTERY CHARGING SYSTEM 21 3 CLUTCH GEARSHIFT LINKAGE CTX700 A N NA 11 2 COOLING SYSTEM 8 3 CRANKCASE TRANSMISSION BALANCER 14 4 CRANKSHAFT PISTON CYLINDER 15 3 CYLINDER HEADA ALVES 10 3 DUAL CLUTCH TRANSMISSION DOT CTX700D ND 12 3 ELECTRIC STARTER 6 4 ENGINE REMOVAL INSTALLATION 16 4 FRAME BODY PANELS EXHAUST SYSTEM 2 2 FRONT WHEEL SUSPENSI...

Страница 547: ...SPENSION 18 4 TURN SIGNAL LIGHT 22 4 TURN SIGNAL HAZARD RELAY 22 22 UNDER CENTER COWL 2 13 UNDER COWL LID 2 12 UNDERSIDE COWL 2 13 VALVE CLEARANCE 3 7 WATER PUMP 8 9 WHEEL SPEED SENSOR 20 20 WHEELS TIRES 3 22 WIND SCREEN CTX700 A D 2 5 WIRING DIAGRAM CTX700 A N NA 23 2 CTX700D ND 23 3 ...

Страница 548: ...MEMO i i ...

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