Хонда трансальп руководство

15:08

Honda XL700V Transalp обзор.

20:58

Обзор Honda Transalp 700. Не то, чем кажется.

22:28

Обзор Honda XL700V Transalp 2011 г.в

04:00

Максимальная скорость Honda Transalp 700 (Top speed of Honda Transalp 700)

13:42

Обзор Honda Transalp XL700

06:51

Honda XL700V Transalp 2008

08:53

Honda Transalp 700, 1335 км за 13 часов

16:27

Honda Transalp XL700 off road

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Chapters

Troubleshooting

• Page 1
  Honda Transalp XL700V/VA Manual de Servicio Técnico…
• Page 2
  TYPE CODE • Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TYPE EUROPEAN DIRECT SALES (Poland, Slovenia, Croatia, Latvia, Norway, Switzerland, Spain, Netherlands, Austria, Portugal, Belgium, Denmark, Greece, Italy, Macedonia, Romania, Bulgaria, Ukraine, Israel, Finland, Sweden, Iceland, Russia, Germany, Luxemburg, Hungary, Czech, Slovakia) U.K.

• Page 3: Service Information

  Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.

• Page 4: How To Use This Manual

  TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE TROUBLESHOOTING LATEST PRODUCT INFORMATION AVAIL- ABLE AT THE TIME OF APPROVAL FOR INDEX PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE WITHOUT INCURRING OBLIGATION WHATSO- EVER.

• Page 5
  ® Example: Molykote G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

• Page 6: Table Of Contents

  1. GENERAL INFORMATION SERVICE RULES ········································· 1-2 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ····································· 1-10 MODEL IDENTIFICATION··························· 1-3 REAR WHEEL/SUSPENSION SPECIFICATIONS ····································· 1-10 GENERAL SPECIFICATIONS······················ 1-5 HYDRAULIC BRAKE SPECIFICATIONS··· 1-11 LUBRICATION SYSTEM SPECIFICATIONS········································ 1-7 BATTERY/CHARGING SYSTEM SPECIFICATIONS ····································· 1-11 FUEL SYSTEM (PGM-FI) SPECIFICATIONS········································ 1-7 IGNITION SYSTEM SPECIFICATIONS ····…

• Page 7: Service Rules

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

• Page 8: Model Identification

  GENERAL INFORMATION MODEL IDENTIFICATION XL700VA shown: SERIAL NUMBERS The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. The registered number plate is located on the right side of the frame. REGISTERED NUMBER PLATE…

• Page 9
  GENERAL INFORMATION The engine serial number is stamped on the right side of the ENGINE SERIAL NUMBER crankcase. The throttle body identification number is stamped on the throttle drum side of the throttle body. THROTTLE BODY IDENTIFICATION NUMBER LABEL The color label is attached as shown. When ordering color-coded parts, COLOR LABEL always specify the designated color code.

• Page 10: General Specifications

  GENERAL INFORMATION GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSION Overall length 2,255 mm (88.8 in) Overall width 905 mm (35.6 in) Overall height 1,305 mm (51.4 in) Wheelbase 1,515 mm (59.6 in) Seat height 837 mm (33.0 in) Footpeg height 346 mm (13.6 in) Ground clearance 182 mm (7.2 in) Curb weight…

• Page 11: Specifications

  GENERAL INFORMATION ITEM SPECIFICATIONS ELECTRICAL Ignition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier FET shorted/triple phase full-wave rectifi- cation Lighting system Battery…

• Page 12: Cooling System Specifications

  – change After disassembly 2.9 liters (3.1 US qt, 2.6 Imp qt) – Recommended engine oil Honda «4-stroke motorcycle oil» or an equivalent Oil recommendation: API classification SG or higher – (except oils labeled as energy conserv- ing on the circular API service label)

• Page 13: Cylinder Head/Valves Specifications

  GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT 1,373 ± 98 kPa Cylinder compression at 400 min (rpm) – (14.0 ± 1.0 kgf/cm , 199 ± 14 psi) 0.15 ± 0.02 (0.006 ± 0.001) Valve clearance –…

• Page 14: Clutch/Gearshift Linkage Specifications

  GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch lever freeplay 10 – 20 (3/8 – 13/16) – Clutch Spring free length 43.2 (1.70) 41.7 (1.64) Disc thickness Disc A 2.62 – 2.78 (0.103 – 0.109) 2.3 (0.09) Disc B 2.92 –…

• Page 15: Rear Wheel/Suspension Specifications

  – max. Fork Spring free length 621.4 (24.47) 609.0 (23.98) Tube runout – 0.20 (0.008) Honda ULTRA CUSHION OIL 10W or Recommended fork fluid – equivalent Fluid level 104 (4.1) – 598 ± 2.5 cm (20.2 ± 0.08 US oz, Fluid capacity –…

• Page 16: Specifications

  GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Specified brake fluid DOT 4 – Front Brake disc thickness 3.8 – 4.2 (0.15 – 0.17) 3.5 (0.14) Brake disc warpage – 0.30 (0.012) Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022) Master piston O.D.

• Page 17: Electric Starter Specification

  GENERAL INFORMATION ELECTRIC STARTER SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.0 (0.47) 6.5 (0.26) LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight (High) 12 V – 55 W Headlight (Low) 12 V – 55 W Position light 12 V –…

• Page 18: Torque Values

  GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES FASTENER TYPE N·m (kgf·m, lbf·ft) FASTENER TYPE N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6) (Include SH flange bolt) 6 mm flange bolt (8 mm head, small flange)

• Page 19
  GENERAL INFORMATION FUEL SYSTEM (PGM-FI) THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) ECT sensor 24.5 (2.5, 18) Bank angle sensor mounting screw 1.5 (0.2, 1.1) MAP sensor mounting screw 5.0 (0.5, 3.7) IAT sensor mounting screw 4.0 (0.4, 3.0) Air cleaner housing cover screw 1.2 (0.1, 0.9) sensor…
• Page 20
  GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Clutch lifter plate bolt 12 (1.2, 9) Clutch center lock nut 128 (13.1, 94) Apply engine oil to the threads and seating sur- face. Stake Shift drum stopper arm pivot bolt 12 (1.2, 9) Apply locking agent.
• Page 21
  GENERAL INFORMATION REAR WHEEL/SUSPENSION THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Drive chain slider mounting screw 6 (0.6, 4.4) Rear axle nut 88 (9.0, 65) U-nut Shock absorber upper mounting nut 44 (4.5, 32) U-nut Shock absorber lower mounting bolt 44 (4.5, 32) Swingarm pivot nut 88 (9.0, 65)
• Page 22
  GENERAL INFORMATION LIGHTS/METERS/SWITCHES THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Front brake light switch screw 1.2 (0.1, 0.9) Turn signal lens screw 0.9 (0.1, 0.7) Neutral switch 12 (1.2, 9) EOP switch PT 1/8 12 (1.2, 9) Apply sealant to the threads.

• Page 23: Lubrication & Seal Points

  GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Molybdenum disulfide Camshaft lobes/journals oil (a mixture of 1/2 Valve stem (valve guide sliding surface) engine oil and 1/2 molyb- Rocker arm slipper surface denum disulfide grease) Rocker arm shaft outer surface Crankpin bearing thrust surface Crankshaft main journal Clutch outer guide outer surface…

• Page 24
  GENERAL INFORMATION MATERIAL LOCATION REMARKS Locking agent Cam sprocket bolt threads Coating width: 6.5 ± 1 mm (0.26 ± 0.04 in) Starter clutch torx bolt threads Coating width: 6.5 ± 1 mm (0.26 ± 0.04 in) Oil pump driven sprocket bolt threads Coating width: 6.5 ±…
• Page 25
  Steering head bearing dust seal lips extreme pressure (Kyodo Yushi EXCELITE EP2, Shell stamina EP2 or equivalent) Honda bond A or equiva- Handlebar grip rubber inside lent Air cleaner housing contacting surface with air funnel Engine oil…

• Page 26: Cable & Harness Routing

  GENERAL INFORMATION CABLE & HARNESS ROUTING XL700V THROTTLE CABLES CLUTCH CABLE LEFT FRONT TURN SIGNAL WIRE FRONT BRAKE LIGHT SWITCH WIRE RIGHT FRONT TURN SIGNAL WIRE LEFT HANDLEBAR SWITCH WIRE BANK ANGLE SENSOR WIRE MAIN WIRE HARNESS HEADLIGHT 2P (BLACK) CONNECTORS 1-21…

• Page 27
  GENERAL INFORMATION BANK ANGLE SENSOR THROTTLE CABLES 3P (BLACK) CONNECTOR LEFT HANDLEBAR 10P (GRAY) CONNECTOR MAIN WIRE HARNESS CLUTCH CABLE FRONT BRAKE HOSES 1-22…
• Page 28
  GENERAL INFORMATION IMMOBILIZER RECEIVER WIRE IGNITION SWITCH WIRE RIGHT HANDLEBAR 8P (GRAY) CONNECTOR FRONT BRAKE PIPES FRONT BRAKE HOSES 1-23…
• Page 29
  GENERAL INFORMATION THROTTLE CABLES FRONT BRAKE MAIN HOSE CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH 8P (GRAY) CONNECTOR CLUTCH SWITCH WIRE FAN MOTOR WIRE LEFT HANDLEBAR SWITCH IMMOBILIZER RECEIVER 10P (GRAY) CONNECTOR 4P (NATURAL) CONNECTOR IGNITION SWITCH 2P (BROWN) CONNECTOR 1-24…
• Page 30
  GENERAL INFORMATION FRONT BRAKE HOSE FRONT BRAKE HOSE 1-25…
• Page 31
  GENERAL INFORMATION THROTTLE BODY SUB HARNESS 14P (GRAY) CONNECTOR IAT SENSOR LEFT HANDLEBAR SWITCH 2P (GRAY) CONNECTOR 10P (GRAY) CONNECTOR MAIN WIRE HARNESS ECT SENSOR 3P (GRAY) CONNECTOR SIPHON HOSE THROTTLE CABLES THROTTLE BODY SUB HARNESS REAR (#1) INJECTOR 2P (GRAY) CONNECTOR 1-26…
• Page 32
  GENERAL INFORMATION RIGHT HANDLEBAR SWITCH 8P (GRAY) CONNECTOR IGNITION SWITCH 2P (BROWN) CONNECTOR FRONT IGNITION COIL WIRE FAN MOTOR 2P (BLACK) CONNECTOR MAP SENSOR 3P (BLACK) CONNECTOR IACV 4P (BLACK) CONNECTOR FRONT (#2) INJECTOR 2P (GRAY) CONNECTOR CMP SENSOR 2P (NATURAL) CONNECTOR TP SENSOR 3P (BLUE) CONNECTOR 1-27…
• Page 33
  GENERAL INFORMATION HORN WIRE CKP SENSOR 2P (RED) CONNECTOR SIDESTAND SWITCH SIDESTAND SWITCH WIRE 2P (GREEN) CONNECTOR CLUTCH CABLE CKP SENSOR 2P (RED) CONNECTOR SIDESTAND SWITCH 2P (GREEN) CONNECTOR CKP SENSOR WIRE 1-28…
• Page 34
  GENERAL INFORMATION SIPHON HOSE FRONT IGNITION COIL IAT SENSOR 2P (GRAY) CONNECTOR THROTTLE BODY SUB HARNESS 14P (GRAY) CONNECTOR VACUUM HOSES FUEL FEED HOSE MAIN WIRE HARNESS CRANKCASE BREATHER DRAIN HOSE FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE AIR SUPPLY HOSES FUEL HOSE PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR…
• Page 35
  GENERAL INFORMATION FUEL FEED HOSE MAP SENSOR 3P (BLACK) CONNECTOR REAR (#1) INJECTOR 2P (GRAY) CONNECTOR FRONT (#2) INJECTOR 2P (GRAY) CONNECTOR VACUUM HOSES FUEL PUMP WIRE FUEL HOSE FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE 1-30…
• Page 36
  GENERAL INFORMATION FUSE/RELAY BOX TURN SIGNAL RELAY STARTER RELAY SWITCH REGULATOR/RECTIFIER 2P (NATURAL) CONNECTOR ALTERNATOR 3P (NATURAL) CONNECTOR ECM 33P CONNECTORS INSIDE BOOT CONNECTORS: – DLC 4P (RED) CONNECTOR – OPTION (SECURITY) 6P (NATURAL) CONNECTOR – OPTION 4P (NATURAL) CONNECTOR 1-31…
• Page 37
  GENERAL INFORMATION FUEL PUMP 3P (NATURAL) CONNECTOR REAR BRAKE LIGHT SWITCH STARTER MOTOR CABLE 2P (BLACK) CONNECTOR VS SENSOR 2P (ORANGE) CONNECTOR SENSOR 4P (BLACK) CONNECTOR BATTERY NEGATIVE (–) CABLE 1-32…
• Page 38
  GENERAL INFORMATION STARTER MOTOR CABLE CRANKCASE BREATHER DRAIN HOSE ALTERNATOR WIRE SIDESTAND SWITCH WIRE NEUTRAL SWITCH/ EOP SWITCH WIRE 1-33…
• Page 39
  GENERAL INFORMATION SIPHON HOSE REAR IGNITION COIL WIRES NEUTRAL SWITCH/ EOP SWITCH WIRE ALTERNATOR WIRE VS SENSOR WIRE RESERVE TANK FUEL TANK OVERFLOW HOSE BREATHER HOSE REAR BRAKE HOSE STARTER MOTOR CABLE FUEL TANK DRAIN HOSE 1-34…
• Page 40
  GENERAL INFORMATION REAR MASTER CYLINDER RESERVE TANK HOSE REAR BRAKE HOSE VS SENSOR WIRE 1-35…
• Page 41
  GENERAL INFORMATION INSIDE BOOT CONNECTORS: – TAIL/BRAKE LIGHT 3P (NATURAL) CONNECTOR – RIGHT TURN SIGNAL 2P (LIGHT BLUE) CONNECTOR RIGHT REAR – LEFT TURN SIGNAL 2P (ORANGE) CONNECTOR TURN SIGNAL WIRE – LICENSE LIGHT 3P (BLACK) CONNECTOR LEFT REAR TURN SIGNAL WIRE MAIN WIRE HARNESS SEAT LOCK CABLE 1-36…

• Page 42: General Information

  GENERAL INFORMATION XL700VA THROTTLE CABLES CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE FRONT BRAKE LEFT FRONT LIGHT SWITCH WIRE TURN SIGNAL WIRE RIGHT FRONT TURN SIGNAL WIRE BANK ANGLE SENSOR WIRE MAIN WIRE HARNESS HEADLIGHT 2P (BLACK) CONNECTORS 1-37…

• Page 43
  GENERAL INFORMATION BANK ANGLE SENSOR THROTTLE CABLES 3P (BLACK) CONNECTOR LEFT HANDLEBAR 10P (GRAY) CONNECTOR MAIN WIRE HARNESS CLUTCH CABLE FRONT BRAKE MAIN HOSE FRONT BRAKE SUB HOSE FRONT WHEEL SPEED SENSOR WIRE 1-38…
• Page 44
  GENERAL INFORMATION IGNITION SWITCH WIRE IMMOBILIZER RECEIVER WIRE FRONT BRAKE MAIN HOSES RIGHT HANDLEBAR 8P (GRAY) CONNECTOR 1-39…
• Page 45
  GENERAL INFORMATION THROTTLE CABLES FRONT BRAKE MAIN HOSE CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH 8P (GRAY) CONNECTOR CLUTCH SWITCH WIRE FAN MOTOR WIRE LEFT HANDLEBAR SWITCH IMMOBILIZER RECEIVER 10P (GRAY) CONNECTOR 4P (NATURAL) CONNECTOR IGNITION SWITCH FRONT WHEEL SENSOR 2P (BROWN) CONNECTOR…
• Page 46
  GENERAL INFORMATION FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE MAIN PIPE FRONT BRAKE SUB HOSE FRONT BRAKE MAIN PIPE FRONT BRAKE MAIN HOSE 1-41…
• Page 47
  GENERAL INFORMATION THROTTLE BODY SUB HARNESS 14P (GRAY) CONNECTOR IAT SENSOR 2P (GRAY) CONNECTOR LEFT HANDLEBAR SWITCH 10P (GRAY) CONNECTOR MAIN WIRE HARNESS FRONT BRAKE SUB PIPE ECT SENSOR 3P (GRAY) CONNECTOR SIPHON HOSE THROTTLE CABLES THROTTLE BODY SUB HARNESS REAR (#1) INJECTOR 2P (GRAY) CONNECTOR 1-42…
• Page 48
  GENERAL INFORMATION RIGHT HANDLEBAR SWITCH 8P (GRAY) CONNECTOR IGNITION SWITCH 2P (BROWN) CONNECTOR FRONT IGNITION COIL WIRE FAN MOTOR 2P (BLACK) CONNECTOR MAP SENSOR 3P (BLACK) CONNECTOR FRONT BRAKE MAIN PIPES IACV FRONT (#2) INJECTOR TP SENSOR 4P (BLACK) CONNECTOR 2P (GRAY) CONNECTOR 3P (BLUE) CONNECTOR CMP SENSOR…
• Page 49
  GENERAL INFORMATION HORN WIRE CKP SENSOR 2P (RED) CONNECTOR SIDESTAND SWITCH SIDESTAND SWITCH WIRE 2P (GREEN) CONNECTOR CLUTCH CABLE CKP SENSOR 2P (RED) CONNECTOR SIDESTAND SWITCH 2P (GREEN) CONNECTOR CKP SENSOR WIRE 1-44…
• Page 50
  GENERAL INFORMATION SIPHON HOSE IAT SENSOR 2P (GRAY) CONNECTOR FRONT IGNITION COIL THROTTLE BODY SUB HARNESS 14P (GRAY) CONNECTOR FUEL FEED HOSE VACUUM HOSES MAIN WIRE HARNESS FRONT BRAKE MAIN PIPES CRANKCASE BREATHER DRAIN HOSE FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE AIR SUPPLY HOSES FRONT BRAKE…
• Page 51
  GENERAL INFORMATION FUEL FEED HOSE MAP SENSOR 3P (BLACK) CONNECTOR REAR (#1) INJECTOR 2P (GRAY) CONNECTOR FRONT (#2) INJECTOR 2P (GRAY) CONNECTOR VACUUM HOSES FUEL PUMP WIRE FUEL HOSE FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE 1-46…
• Page 52
  GENERAL INFORMATION PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR FRONT BRAKE SUB PIPE FUEL TANK BREATHER HOSES FUEL TANK DRAIN HOSE FUEL PUMP 3P (NATURAL) CONNECTOR FRONT BRAKE MAIN PIPES BATTERY POSITIVE (+) CABLE 1-47…
• Page 53
  GENERAL INFORMATION FUSE/RELAY BOX TURN SIGNAL RELAY STARTER RELAY SWITCH REGULATOR/RECTIFIER 2P (NATURAL) CONNECTOR ALTERNATOR 3P (NATURAL) CONNECTOR ECM 33P CONNECTORS INSIDE BOOT CONNECTORS: – DLC 4P (RED) CONNECTOR ABS MODULATOR 26P CONNECTOR – ABS SERVICE CHECK 3P (NATURAL) CONNECTOR –…
• Page 54
  GENERAL INFORMATION FUEL PUMP 3P (NATURAL) CONNECTOR STARTER MOTOR CABLE VS SENSOR 2P (ORANGE) CONNECTOR SENSOR BATTERY NEGATIVE (–) CABLE 4P (BLACK) CONNECTOR 1-49…
• Page 55
  GENERAL INFORMATION STARTER MOTOR CABLE CRANKCASE BREATHER DRAIN HOSE ALTERNATOR WIRE SIDESTAND SWITCH WIRE NEUTRAL SWITCH/ EOP SWITCH WIRE 1-50…
• Page 56
  GENERAL INFORMATION FRONT BRAKE SUB PIPE FRONT BRAKE MAIN PIPES REAR BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR VS SENSOR 2P (ORANGE) CONNECTOR REAR BRAKE HOSES REAR MASTER CYLINDER RESERVE TANK HOSE 1-51…
• Page 57
  GENERAL INFORMATION SIPHON HOSE REAR IGNITION COIL WIRES NEUTRAL SWITCH/ EOP SWITCH WIRE VS SENSOR WIRE ALTERNATOR WIRE RESERVE TANK FUEL TANK OVERFLOW HOSE BREATHER HOSE REAR BRAKE HOSE STARTER MOTOR CABLE FUEL TANK DRAIN HOSE 1-52…
• Page 58
  GENERAL INFORMATION REAR MASTER CYLINDER RESERVE TANK HOSE REAR BRAKE HOSE VS SENSOR WIRE 1-53…
• Page 59
  GENERAL INFORMATION INSIDE BOOT CONNECTORS: – TAIL/BRAKE LIGHT 3P (NATURAL) CONNECTOR – RIGHT TURN SIGNAL 2P (LIGHT BLUE) CONNECTOR RIGHT REAR – LEFT TURN SIGNAL 2P (ORANGE) CONNECTOR TURN SIGNAL WIRE – LICENSE LIGHT 3P (BLACK) CONNECTOR LEFT REAR TURN SIGNAL WIRE MAIN WIRE HARNESS SEAT LOCK CABLE 1-54…

• Page 60: Emission Control Systems

  Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.

• Page 61
  GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a pulse secondary air supply system, a three-way catalytic converter and PGM-FI system. No adjustment should be made about the exhaust emission control systems. The exhaust emission control system is separate from the crankcase emission control system.

• Page 62: Noise Emission Control System

  GENERAL INFORMATION THREE-WAY CATALYTIC CONVERTER This motorcycle is equipped with a three-way catalytic converter. The three-way catalytic converter is in the exhaust system. Through chemical reactions, it converts HC, CO and NOx in the engine’s exhaust to carbon dioxide (CO ), dinitrogen (N ) and water vapor.

• Page 63
  MEMO…

• Page 64: Frame/Body Panels/Exhaust System

  2. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATION··························· 2-2 FRONT SIDE COWL···································· 2-9 SERVICE INFORMATION ··························· 2-3 WIRE HARNESS COVER ·························· 2-10 TROUBLESHOOTING ································· 2-3 AIR GUIDE ················································ 2-10 SEAT···························································· 2-4 WINDSCREEN ·········································· 2-11 SIDE COVER················································ 2-4 HEADLIGHT PLATE ·································· 2-11 REAR CARRIER ···········································…

• Page 65: Body Panel Location

  FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATION FRAME/BODY PANELS/EXHAUST SYSTEM INNER CENTER COWL REAR CARRIER WINDSCREEN SEAT FRONT SIDE COWL FENDER COVER HEADLIGHT PLATE FRONT CENTER COWL REAR FENDER A FRONT FENDER REAR FENDER C SIDE COVER REAR FENDER B UNDER COWL…

• Page 66: Service Information

  FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels and exhaust system. • Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. •…

• Page 67: Seat

  FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION Unhook the seat lock using the ignition key. Remove the seat backward. SEAT SLITS Install the seat by inserting prongs to the frame and slits properly. PRONGS PRONGS IGNITION KEY SIDE COVER REMOVAL/INSTALLATION Remove the seat (page 2-4). Be careful not to damage the side Remove the trim clip and bolts.

• Page 68: Rear Carrier

  FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws and front side cover from the SCREWS side cover. Assembly is in the reverse order of disassembly. SIDE COVER FRONT SIDE COVER REAR CARRIER REMOVAL/INSTALLATION Remove the seat (page 2-4). CARRIER RUBBERS Remove the following: –…

• Page 69: Fender Cover

  FRAME/BODY PANELS/EXHAUST SYSTEM FENDER COVER REMOVAL/INSTALLATION Remove the rear carrier (page 2-5). FENDER COVERS Disconnect the turn signal 2P connectors. BOLT 2P CONNECTORS Remove the bolts, screws and fender covers. Installation is in the reverse order of removal. SCREWS BOLTS REAR FENDER A REMOVAL/INSTALLATION Remove the rear carrier (page 2-5).

• Page 70: Rear Fender C

  FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER C REMOVAL/INSTALLATION Remove the following: SEAT LOCK CABLE – Fender cover (page 2-6) SEAT OPENER – Rear fender A (page 2-6) MOUNTING BOLTS Disconnect the seat lock cable from the seat opener. Remove the stay bolts, collars and rear fender A mounting stay.

• Page 71: Rear Fender B

  FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER B REMOVAL/INSTALLATION (XL700VA) Remove the rear fender C (page 2-7). Remove the screws and mud guard. Remove the trim clip, bolt and rear fender B. Installation is in the reverse order of removal. SCREWS TRIM CLIP BOLT REAR FENDER B MUD GUARD…

• Page 72: Inner Center Cowl

  FRAME/BODY PANELS/EXHAUST SYSTEM INNER CENTER COWL REMOVAL/INSTALLATION Remove the trim clips and inner center cowl. TRIM CLIPS Installation is in the reverse order of removal. INNER CENTER COWL FRONT SIDE COWL REMOVAL/INSTALLATION Remove the inner center cowl (page 2-9). PRONG Remove the bolt and screw.

• Page 73: Wire Harness Cover

  FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws, inner cowl and lid. INNER COWL Assembly is in the reverse order of disassembly. SCREWS WIRE HARNESS COVER REMOVAL/INSTALLATION Remove the front side cowl (page 2-9). WIRE HARNESS COVER Remove the trim clips. GROMMET Release the boss on the wire harness cover from the grommet and remove the wire harness cover.

• Page 74: Windscreen

  FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN REMOVAL/INSTALLATION Remove the screws, plastic washers, windscreen WINDSCREEN NUTS and nuts. Installation is in the reverse order of removal. SCREWS/WASHERS HEADLIGHT PLATE REMOVAL/INSTALLATION Remove the windscreen (page 2-11). Remove the bolts and screw. Release the tabs on the headlight plate from slit. SCREW Disconnect the turn signal 2P connector and remove 2P CONNECTOR…

• Page 75: Front Center Cowl

  FRAME/BODY PANELS/EXHAUST SYSTEM FRONT CENTER COWL REMOVAL/INSTALLATION Remove the headlight plate (page 2-11). Remove the screws, bolts and front center cowl. Installation is in the reverse order of removal. BOLTS FRONT CENTER COWL SCREWS DISASSEMBLY/ASSEMBLY Remove the screws, headlight rim and meter panel. METER PANEL Assembly is in the reverse order of disassemble.

• Page 76: Front Fender

  FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER Remove the brake hose clamp bolts. XL700VA only: Remove the socket bolts and bolts. SOCKET BOLTS Remove the front fender and mounting plate for- ward. Installation is in the reverse order of removal. FRONT FENDER BOLTS MOUNTING PLATE CLAMP BOLTS…

• Page 77: Exhaust System

  FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL MUFFLER Remove the following: EXHAUST PIPE PROTECTOR – Right front side cowl (page 2-9) – Right side cover (page 2-4) – Under cowl (page 2-13) Remove the bolts. Slide the lower exhaust pipe protector forward and remove it.

• Page 78
  FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE Disconnect the O sensor 4P (Black) connector and 4P (BLACK) CONNECTOR release the O sensor wire from the clamp. CLAMP Remove the bolts and exhaust joint protector. JOINT PROTECTOR BOLTS Remove the bolts and rear exhaust pipe protector B. PROTECTOR B BOLTS Remove the bolts and rear exhaust pipe protector A.
• Page 79
  FRAME/BODY PANELS/EXHAUST SYSTEM Remove the exhaust pipe joint nuts. REAR: FRONT: JOINT NUTS Loosen the exhaust pipe band bolts. BAND BOLTS Remove the exhaust chamber mounting bolts. RIGHT: LEFT: MOUNTING BOLTS 2-16…
• Page 80
  FRAME/BODY PANELS/EXHAUST SYSTEM Remove the exhaust chamber, front exhaust pipe and rear exhaust pipe assembly. Remove the front exhaust pipe, rear exhaust pipe and joint gaskets. EXHAUST CHAMBER FRONT EXHAUST PIPE JOINT GASKETS REAR EXHAUST PIPE Remove the exhaust pipe gaskets. GASKETS 2-17…
• Page 81
  FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION 4P (BLACK) CONNECTOR 39.2 N·m (4.0 kgf·m, 29 lbf·ft) GASKET GASKETS 30.8 N·m (3.1 kgf·m, 23 lbf·ft) 26.5 N·m (2.7 kgf·m, 20 lbf·ft) 39.2 N·m (4.0 kgf·m, 29 lbf·ft) 22.1 N·m (2.3 kgf·m, 16 lbf·ft) 30.8 N·m (3.1 kgf·m, 23 lbf·ft) GASKETS EXHAUST PIPE If the exhaust pipe stud bolts are loose, tighten…
• Page 82
  FRAME/BODY PANELS/EXHAUST SYSTEM Install new exhaust pipe gaskets. REAR: FRONT: GASKETS Install new joint gaskets on the front and rear exhaust pipes, and install the exhaust pipes to the exhaust chamber. Install the exhaust pipes and exhaust chamber assembly. EXHAUST CHAMBER FRONT EXHAUST PIPE JOINT GASKETS REAR EXHAUST PIPE…
• Page 83
  FRAME/BODY PANELS/EXHAUST SYSTEM Install and tighten the exhaust pipe joint nuts to the REAR: FRONT: specified torque. TORQUE: 22.1 N·m (2.3 kgf·m, 16 lbf·ft) JOINT NUTS Tighten the exhaust chamber mounting bolt to the RIGHT: LEFT: specified torque. TORQUE: 30.8 N·m (3.1 kgf·m, 23 lbf·ft) BOLTS Tighten the exhaust pipe band bolts securely.
• Page 84
  FRAME/BODY PANELS/EXHAUST SYSTEM Install the rear exhaust pipe protector B and bolts. PROTECTOR B Tighten the bolts securely. BOLTS Install the exhaust joint protector and tighten the JOINT PROTECTOR bolts securely. BOLTS Connect the O sensor 4P (Black) connector and 4P (BLACK) CONNECTOR clamp the O sensor wire.
• Page 85
  FRAME/BODY PANELS/EXHAUST SYSTEM Install the muffler mounting bolts and collar. BOLT/COLLAR Tighten the muffler mounting bolts to the specified torque. TORQUE: 39.2 N·m (4.0 kgf·m, 29 lbf·ft) BOLT Tighten the muffler band bolt to the specified torque. TORQUE: 21 N·m (2.1 kgf·m, 15 lbf·ft) BAND BOLT Install the pillion step holder.

• Page 86: Heat Guard Plate

  FRAME/BODY PANELS/EXHAUST SYSTEM HEAT GUARD PLATE REMOVAL/INSTALLATION Remove the exhaust system (page 2-14). Remove the bolts, terminal collar, heat guard plate HEAT GUARD PLATE BOLTS and collars. Installation is in the reverse order of removal. TERMINAL COLLAR COLLARS SIDESTAND REMOVAL/INSTALLATION Remove the sidestand switch (page 20-25).

• Page 87
  MEMO…
• Page 88
  3. MAINTENANCE SERVICE INFORMATION ··························· 3-2 DRIVE CHAIN············································ 3-17 MAINTENANCE SCHEDULE ······················ 3-4 DRIVE CHAIN SLIDER ······························ 3-21 FUEL LINE ··················································· 3-5 BRAKE FLUID ··········································· 3-22 THROTTLE OPERATION····························· 3-6 BRAKE PADS WEAR ································ 3-23 AIR CLEANER·············································· 3-7 BRAKE SYSTEM······································· 3-24 CRANKCASE BREATHER ···························…

• Page 89: Service Information

  0.15 ± 0.02 mm (0.006 ± 0.001 in) Valve clearance 0.20 ± 0.02 mm (0.008 ± 0.001 in) Recommended engine oil Honda «4-stroke motorcycle oil» or an equivalent Oil recommendation: API classification SG or higher (except oils labeled as energy conserving on circular API…

• Page 90
  MAINTENANCE TORQUE VALUES Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft) Timing hole cap 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply engine oil to the threads. Crankshaft hole cap 15 N·m (1.5 kgf·m, 11 lbf·ft) Apply engine oil to the threads. Valve adjusting screw lock nut 23 N·m (2.3 kgf·m, 17 lbf·ft) Apply engine oil to the threads and…

• Page 91: Maintenance Schedule

  ** STEERING HEAD BEARINGS 3-30 * Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.

• Page 92: Fuel Line

  MAINTENANCE FUEL LINE FUEL TANK LIFTING Remove the following: BOLT/WASHER – Seat (page 2-4) – Front side cowl (page 2-9) Remove the fuel tank mounting bolt/washer and move the fuel tank to the backward. Lift and open the fuel tank. SHOP TOWEL Turn the handlebar to left and lock with ignition key.

• Page 93: Throttle Operation

  MAINTENANCE Move the fuel tank forward, then install and tighten BOLT/WASHER the fuel tank mounting bolt/washer to the specified torque. TORQUE: 26.4 N·m (2.7 kgf·m, 19 lbf·ft) Install the removed parts in the reverse order removal. THROTTLE OPERATION Check for any deterioration or damage to the throt- tle cables.

• Page 94: Air Cleaner

  MAINTENANCE Major adjustment is made with the lower adjuster. ADJUSTER LOCK NUT Loosen the lock nut, turn the adjuster as required. Tighten the lock nut while holding the adjuster. Recheck the throttle operation. AIR CLEANER • The viscous paper element type air cleaner can not be cleaned because the element contains a dust adhesive.

• Page 95: Crankcase Breather

  MAINTENANCE CRANKCASE BREATHER Service more frequently when riding in rain, at full throttle, or after the motorcycle is washed or over- turned. Service if the deposit level can be seen in the drain plug. Pull out the crankcase breather drain hose from the frame rearward.

• Page 96
  MAINTENANCE INSPECTION Check the insulator for cracks or damage, and the CENTER ELECTRODE electrodes for wear, fouling or discoloration. Replace the plug if necessary. RECOMMENDED SPARK PLUG: NGK: CPR8EA-9 DENSO: U24EPR9 Clean the spark plug electrodes with a wire brush or special plug cleaner.

• Page 97: Index

  MAINTENANCE VALVE CLEARANCE INSPECTION • After the valve clearance inspection, check the engine idle speed (page 5-78). • Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F). FRONT: Remove the cylinder head cover (page 8-6). TIMING HOLE CAP Remove the timing and crankshaft hole caps.

• Page 98
  MAINTENANCE Loosen the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge. TOOL: Tappet adjust wrench, 4 mm 07908-KE90100 Hold the adjusting screw and tighten the lock nut to Apply engine oil to the specified torque.

• Page 99: Engine Oil

  MAINTENANCE Check the valve clearances by inserting a feeler When checking the FEELER GAUGE ADJUSTING SCREW gauge between the adjusting screw and valve stem. clearance, slide the feeler gauge from VALVE CLEARANCES: the center toward IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in) the outside.

• Page 100: Engine Oil Filter

  UPPER LEVEL LOWER LEVEL RECOMMENDED ENGINE OIL: Honda «4-stroke motorcycle oil » or an equivalent Oil recommendation: API service classification SG or higher (except oils labeled as energy conserving on the circular API service label)

• Page 101
  MAINTENANCE Remove the oil filter cartridge using the special tool OIL FILTER WRENCH and let the remaining oil drain out. TOOL: Oil filter wrench 07HAA-PJ70101 OIL FILTER Coat a new O-ring with engine oil and install it to OIL FILTER O-RING the oil filter cartridge.

• Page 102: Radiator Coolant

  MAINTENANCE RADIATOR COOLANT Check the coolant level of the reserve tank with the «UPPER» LEVEL engine running at normal operating temperature. The level should be between the «UPPER» and «LOWER» level lines with the motorcycle is in an upright position. If the level is low, remove the reserve tank cap, and fill the tank to the «UPPER»…

• Page 103: Secondary Air Supply System

  MAINTENANCE Remove the under cowl (page 2-13). Check for any coolant leakage from the water pump, radiator hoses and hose joints. Check the radiator hoses for cracks or deterioration and replace them if necessary. Check that all hose clamps are tight. Install the under cowl (page 2-13).

• Page 104: Drive Chain

  MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF, place the motorcycle Never inspect and on its sidestand and shift the transmission into neu- adjust the drive tral. chain while the engine is running. Check the slack in the drive chain lower run midway between the sprockets.

• Page 105: Cleaning And Lubrication

  MAINTENANCE CLEANING AND LUBRICATION Clean the chain with non-flammable or high flash SOLVENT SOFT BRUSH point solvent and wipe it dry. Be sure the chain has dried completely before lubri- cating. Inspect the drive chain for possible damage or wear. CLEANING Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable.

• Page 106
  MAINTENANCE Check the attaching bolts and nuts on the drive and Drive sprocket: DRIVE SPROCKET driven sprockets. If any are loose, torque them. Apply engine oil to the driven sprocket TORQUE: nut threads. Drive sprocket bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft) Driven sprocket nut: 45 N·m (4.6 kgf·m, 33 lbf·ft) BOLT Driven sprocket:…
• Page 107
  MAINTENANCE Locate the crimped pin ends of the master link from MASTER LINK the outside of the chain, and remove the link with the drive chain tool set. TOOL: Drive chain tool set 07HMH-MR10103 Remove the drive chain. DRIVE CHAIN TOOL SET Remove the excess drive chain links from the new Include the master drive chain with the drive chain tool set.

• Page 108: Drive Chain Slider

  MAINTENANCE Make sure that the master link pins are installed MASTER LINK PINS properly. Measure the master link pin length projected from the plate. STANDARD LENGTH: DID: 1.30 – 1.50 mm (0.051 – 0.059 in) RK: 1.20 – 1.40 mm (0.047 – 0.055 in) Stake the master link pins.

• Page 109: Brake Fluid

  MAINTENANCE BRAKE FLUID Spilled fluid can damage painted, plastic or rubber parts. Place a shop towel over these parts whenever the system is serviced. • Do not mix different types of fluid, as they are not compatible with each other. •…

• Page 110: Front Brake Pads

  MAINTENANCE Fill the reservoir with DOT 4 brake fluid from a CASTING LEDGE sealed container to the casting ledge. Install the diaphragm, set plate and reservoir cap, and tighten the cap screws. TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) REAR Remove the seat (page 2-4).

• Page 111: Rear Brake Pads

  MAINTENANCE REAR BRAKE PADS Check the brake pad for wear. BRAKE PADS Replace the brake pads if either pad is worn to the XL700VA only: wear limit groove. WEAR LIMIT GROOVES Replace the brake pads if either pad is worn any- XL700V only: XL700VA: where to a thickness of 1 mm (0.04 in).

• Page 112: Brake Lever Adjustment

  MAINTENANCE Firmly apply the brake lever or pedal, and check that no air has entered the system. If the lever or pedal feels soft or spongy when oper- ated, bleed the air from the system. For air bleeding procedures – XL700V (page 15-7) –…

• Page 113: Brake Light Switch

  MAINTENANCE BRAKE LIGHT SWITCH • The brake light switch on the front brake master cylinder cannot be adjusted. If the front brake light switch actuation and brake engagement are not synchronized, either replace the switch unit or the malfunctioning parts of the system. •…

• Page 114: Clutch System

  MAINTENANCE CLUTCH SYSTEM Inspect the clutch cable for kinks or damage, and lubricate the cable if necessary. Measure the clutch lever freeplay at the end of the lever. FREEPLAY: 10 – 20 mm (3/8 – 13/16 in) 10 – 20 mm (3/8 –…

• Page 115: Suspension

  MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by applying the front brakes and compressing the front suspension sev- eral times. Check the entire assembly for leaks, damage or loose fasteners. Replace damaged components which cannot be Loose, worn or repaired.

• Page 116: Nuts, Bolts, Fasteners

  MAINTENANCE REAR SUSPENSION ADJUSTMENT COMPRESSION DAMPING ADJUSTER Do not turn the adjuster more than the given posi- ADJUSTER tions or the adjuster may be damaged. • Damping adjustment is referenced from the full hard position. The compression damping can be adjusted by turn- ing the adjuster.

• Page 117: Steering Head Bearings

  MAINTENANCE Inspect the spokes for looseness by tapping them with a screwdriver. If a spoke does not sound clearly, or if it sounds dif- Tap on the spokes ferent from the other spokes, tighten it to the speci- and be sure that the fied torque.

• Page 118
  MAINTENANCE Check for steering stem bearings by grabbing the fork legs and attempting to move the front fork side to side. Replace the bearings if any looseness is noted (page 13-31). 3-31…
• Page 119
  MEMO…
• Page 120
  4. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ·········· 4-2 OIL PRESSURE CHECK ······························ 4-5 SERVICE INFORMATION ··························· 4-3 OIL PUMP ··················································· 4-5 TROUBLESHOOTING ································· 4-4…
• Page 121
  LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM ROCKER ARM CAMSHAFT PISTON OIL JET MAINSHAFT CRANKSHAFT EOP SWITCH COUNTERSHAFT OIL PUMP OIL STRAINER OIL FILTER PRESSURE RELIEF VALVE…
• Page 122
  – change After disassembly 2.9 liters (3.1 US qt, 2.6 Imp qt) – Recommended engine oil Honda «4-stroke motorcycle oil» or an equivalent Oil recommendation: API classification SG or higher – (except oils labeled as energy conserv- ing on the circular API service label)
• Page 123
  LUBRICATION SYSTEM TOOLS Oil pressure gauge set Oil pressure gauge attachment 07506-3000001 07510-4220100 or equivalent commercially avail- or equivalent commercially avail- able able TROUBLESHOOTING Oil level too low • Oil consumption • External oil leak • Worn piston rings • Improperly installed piston rings •…

• Page 124: Oil Pressure Check

  LUBRICATION SYSTEM OIL PRESSURE CHECK Remove the EOP switch (page 20-19). OIL PRESSURE GAUGE Connect an oil pressure gauge attachment and gauge to the EOP switch hole. TOOLS: Oil pressure gauge set 07506-3000001 or equivalent commer- cially available Oil pressure gauge attachment 07510-4220100 or equivalent commer- cially available Check the oil level and add the recommended oil if…

• Page 125
  LUBRICATION SYSTEM DISASSEMBLY OIL PUMP BODY Remove the oil pipe, oil pipe seal and O-ring. O-RING PIPE SEAL OIL PIPE Remove the pressure relief valve and O-ring. RELIEF VALVE O-RING Remove the oil strainer and packing. STRAINER PACKING Remove the bolts and pump body from the pump PUMP BODY cover.
• Page 126
  LUBRICATION SYSTEM Remove the dowel pins. DRIVE PIN DOWEL PINS Remove the washer, drive shaft, drive pin, inner and outer rotors. WASHER DRIVE SHAFT INNER ROTOR OUTER ROTOR PRESSURE RELIEF VALVE Check the operation of the pressure relief valve by SNAP RING pushing on the piston.
• Page 127
  LUBRICATION SYSTEM INSPECTION Measure each clearance at several points and use the largest reading to compare the service limit. BODY CLEARANCE Temporarily assemble the inner rotor, outer rotor, BODY CLERARANCE drive pin and pump shaft into the pump body. Measure the body clearance. SERVICE LIMIT: 0.35 mm (0.014 in) TIP CLEARANCE Measure the tip clearance.
• Page 128
  LUBRICATION SYSTEM OIL PUMP ASSEMBLY Dip all parts in clean engine oil. 13 N·m (1.3 kgf·m, 10 lbf·ft) DRIVE PIN OUTER ROTOR OIL PUMP BODY SNAP RING DOWEL PINS SPRING O-RING INNER ROTOR THRUST WASHER DRIVE SHAFT OIL PIPE WASHER O-RING PISTON PACKING…
• Page 129
  LUBRICATION SYSTEM Install the pump cover on the pump body. PUMP BODY Install and tighten the bolts to the specified torque. TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft) BOLTS Clean the oil strainer. STRAINER Align Coat a new oil strainer packing with engine oil and install it to the oil pump body.
• Page 130
  LUBRICATION SYSTEM INSTALLATION Install the dowel pin and collars. COLLARS DOWEL PIN Coat new O-rings with engine oil and install them. O-RINGS Install the oil pump assembly into the crankcase OIL PUMP ASSEMBLY securely. Install the pressure relief valve cover and tighten the OIL PUMP ASSEMBLY bolts securely.
• Page 131
  MEMO…
• Page 132
  5. FUEL SYSTEM (PGM-FI) COMPONENT LOCATION ·························· 5-2 FUEL TANK ··············································· 5-61 SERVICE INFORMATION ··························· 5-3 AIR CLEANER HOUSING ························· 5-62 SYMPTOM TROUBLESHOOTING ············· 5-6 THROTTLE BODY ····································· 5-65 PGM-FI SYSTEM LOCATION ····················· 5-7 INJECTOR ················································· 5-69 PGM-FI SYSTEM DIAGRAM ······················ 5-8 MAP SENSOR···········································…

• Page 133: Component Location

  FUEL SYSTEM (PGM-FI) COMPONENT LOCATION FUEL SYSTEM (PGM-FI) 26.4 N·m (2.7 kgf·m, 19 lbf·ft) 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)

• Page 134: Service Information

  FUEL SYSTEM (PGM-FI) SERVICE INFORMATION GENERAL • Be sure to relieve the fuel pressure while the engine is OFF. • For PGM-FI system location (page 5-7). • The PGM-FI system is equipped with the Self-Diagnostic System described (page 5-13). If the malfunction indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures to remedy the problem.

• Page 135
  FUEL SYSTEM (PGM-FI) TORQUE VALUES ECT sensor 24.5 N·m (2.5 kgf·m, 18 lbf·ft) Bank angle sensor mounting screw 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) MAP sensor mounting screw 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft) IAT sensor mounting screw 4.0 N·m (0.4 kgf·m, 3.0 lbf·ft) Air cleaner housing cover screw 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) sensor…
• Page 136
  FUEL SYSTEM (PGM-FI) Imrie diagnostic tester (model 625) sensor wrench or Peak voltage adaptor 07LAA-PT50101 07HGJ-0020100 with commercially available digital multimeter (impedance 10MΩ/DCV minimum)

• Page 137: Symptom Troubleshooting

  FUEL SYSTEM (PGM-FI) SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 5-17) and begin the appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the ECM memory, do the diag- nostic procedure for the symptom, in sequence listed below, until you find the cause.

• Page 138: Pgm-Fi System Location

  FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM LOCATION XL700VA shown: IACV IAT SENSOR TP SENSOR BANK ANGLE SENSOR MAP SENSOR FUEL PUMP ECT SENSOR FUEL PUMP RELAY INJECTORS CMP SENSOR CKP SENSOR SENSOR PAIR CONTROL SOLENOID VALVE VS SENSOR…

• Page 139: Pgm-Fi System Diagram

  FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM DIAGRAM FUSE IGNITION FUSE SWITCH R/Bl Bl/Br MAIN ENGINE STOP FUSE FUSE SWITCH ENGINE STOP W/Bl Bl/W R/Bu FUSE FUEL PUMP FUEL PUMP RELAY BATTERY W/Bl Bl/W BANK ANGLE SENSOR Bl/W Br/Bl O2-1 Bl/W IGP 1 HTCNT1 Bl/G (21, 23)

• Page 140: Pgm-Fi Connector Locations

  FUEL SYSTEM (PGM-FI) PGM-FI CONNECTOR LOCATIONS Note 1: Remove the front center cowl (page 2-12). COMBINATION METER 20P CONNECTOR (Note 1) Note 2: Remove the under cowl (page 2-13). CKP SENSOR 2P (RED) CONNECTOR (Note 2)

• Page 141
  FUEL SYSTEM (PGM-FI) Note 3: Remove the left front side cowl (page 2-9). Note 4: Remove the air cleaner housing (page 5-62). IAT SENSOR 2P (GRAY) CONNECTOR (Note 4) ECT SENSOR 3P (GRAY) CONNECTOR (Note 3) REAR (#1) INJECTOR 2P (GRAY) CONNECTOR 5-10…
• Page 142
  FUEL SYSTEM (PGM-FI) Note 5: Remove the wire harness cover (page 2-10). MAP SENSOR 3P (BLACK) CONNECTOR (Note 5) IACV 4P (BLACK) CMP SENSOR 2P (NATURAL) CONNECTOR (Note 5) CONNECTOR (Note 5) FRONT (#2) INJECTOR 2P (GRAY) CONNECTOR (Note 5) TP SENSOR 3P (BLUE) CONNECTOR (Note 5) 5-11…
• Page 143
  FUEL SYSTEM (PGM-FI) Note 6: Remove the left side cover (page 2-4). XL700VA: ABS MODULATOR 26P CONNECTOR (Note 6) ECM 33P (GRAY) CONNECTOR (Note 6) ECM 33P (BLACK) CONNECTOR (Note 6) Note 7: Remove the battery tray (page 17-6). VS SENSOR 2P (ORANGE) CONNECTOR (Note 7) SENSOR 4P (BLACK) CONNECTOR…

• Page 144: General Troubleshooting

  FUEL SYSTEM (PGM-FI) PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term «intermittent failure» means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out, the original problem may be intermittent.

• Page 145
  FUEL SYSTEM (PGM-FI) MIL Blink Pattern • If the HDS pocket tester is not available, DTC can be read from the ECM memory by the MIL blink pattern. • The number of MIL blinks is the equivalent the main code of the DTC (the sub code cannot be displayed by the MIL).
• Page 146
  FUEL SYSTEM (PGM-FI) Reading DTC with the MIL Turn the ignition switch OFF. SCS CONNECTOR Remove the left side cover (page 2-4). Remove the dummy connector and short the DLC terminals using the special tool. Connection: Brown – Green TOOL: SCS connector 070PZ-ZY30100 Make sure the engine stop switch is turned to «…
• Page 147
  FUEL SYSTEM (PGM-FI) TEST HARNESS CONNECTION Remove the left side cover (page 2-4). 33P (GRAY) CONNECTOR Turn the ignition switch OFF. Disconnect the ECM 33P (Black and Gray) connectors. 33P (BLACK) CONNECTOR Connect the ECM test harness between the main wire harness and ECM TEST HARNESS ECM.

• Page 148: Dtc Index

  FUEL SYSTEM (PGM-FI) DTC INDEX Refer to Refer to Function Failure Symptom/Fail-safe function (MIL blinks) (DTC) (MIL) MAP sensor circuit low voltage (less than 0.2 V) • Engine operates normally 1-1 (1) 5-18 5-38 • MAP sensor or its circuit malfunction MAP sensor circuit high voltage (more than 3.9 V) •…

• Page 149: Dtc Troubleshooting

  FUEL SYSTEM (PGM-FI) DTC TROUBLESHOOTING DTC 1-1 (MAP SENSOR LOW VOLTAGE) • Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) con- nector and ECM 33P connectors, then recheck the DTC. 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch «…

• Page 150
  FUEL SYSTEM (PGM-FI) 4. MAP Sensor Output Line Short Circuit Inspec- tion Check for continuity between the MAP sensor 3P MAP SENSOR 3P (BLACK) CONNECTOR (Black) connector of the wire harness side and (Wire side/female terminal) ground. Connection: Light green/yellow – ground Is there continuity? –…
• Page 151
  FUEL SYSTEM (PGM-FI) 3. MAP Sensor Input Voltage Inspection Turn the ignition switch OFF. MAP SENSOR 3P (BLACK) CONNECTOR Remove the jumper wire. (Wire side/female terminal) Turn the ignition switch ON and engine stop switch » «. Measure the voltage at the wire harness side. Connection: Yellow/red (+) –…
• Page 152
  FUEL SYSTEM (PGM-FI) 2. Manifold Absolute Pressure Test Turn the ignition switch OFF. Check for connection and installation of the MAP sensor vacuum hose. Is the MAP sensor vacuum hose connection cor- rect? – GO TO STEP 3. – Correct the hose installation VACUUM HOSE 3.
• Page 153
  FUEL SYSTEM (PGM-FI) 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the ECT sensor termi- nals. Connection: Pink/white – Green/orange STANDARD: 2.3 – 2.6 kΩ (20°C/68°F) Is the resistance within 2.3 – 2.6 k Ω ? –…
• Page 154
  FUEL SYSTEM (PGM-FI) 3. ECT Sensor Open Circuit Inspection Turn the ignition switch OFF. ECT SENSOR 3P ECM 33P (GRAY) Disconnect the jumper wire. (GRAY) CONNECTOR (Wire side/ Disconnect the ECM 33P connectors. CONNECTOR (Wire female terminal) Check for continuity between the ECM 33P con- side/female terminal) nectors and ECT sensor 3P (Gray) connector.
• Page 155
  FUEL SYSTEM (PGM-FI) 3. TP Sensor Input Voltage Inspection Turn the ignition switch OFF. TP SENSOR 3P (BLUE) CONNECTOR Disconnect the TP sensor 3P (Blue) connector. (Wire side/female terminal) Turn the ignition switch ON and engine stop switch » «. Measure the voltage at the wire harness side.
• Page 156
  FUEL SYSTEM (PGM-FI) 7. TP Sensor Inspection Replace the throttle body with a known good one. Clear the DTC’s (page 5-15). Turn the ignition switch ON and engine stop switch » «. Check the TP sensor with the HDS. Is DTC 8-1 indicated? –…
• Page 157
  FUEL SYSTEM (PGM-FI) 4. TP Sensor Input Voltage Inspection Turn the ignition switch ON and engine stop TP SENSOR 3P (BLUE) CONNECTOR switch » «. (Wire side/female terminal) Measure the voltage at the wire harness side. Connection: Yellow/red (+) – Green/orange (–) Is the voltage within 4.75 –…
• Page 158
  FUEL SYSTEM (PGM-FI) DTC 9-2 (IAT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the IAT 2P (Gray) sensor connec- tor and ECM 33P connectors, then recheck the DTC. 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch «…
• Page 159
  FUEL SYSTEM (PGM-FI) DTC 11-1 (VS SENSOR) • Before starting the troubleshooting, check the following. – Speedometer/VS sensor (XL700V: 20-11) – ABS indicator problem code (XL700VA: 16-10) • Before starting the inspection, check for loose or poor contact on the VS sensor 2P (Orange) con- nector, combination meter 20P connector, ABS modulator 26Pconnector (XL700VA) and ECM 33P connectors, then recheck the DTC.
• Page 160
  FUEL SYSTEM (PGM-FI) 3. ECM Signal Line Open Circuit Inspection Disconnect the ECM 33P (Gray) connector. XL700V: 33P (GRAY) CONNECTOR Disconnect the ABS modulator 26P connector. (Wire side/female terminal) Check the continuity between the ECM 33P (Gray) connector and combination meter 20P connector (XL700V) or ABS modulator 26P con- nector (XL700VA).
• Page 161
  FUEL SYSTEM (PGM-FI) DTC 12-1 (No.1 REAR INJECTOR) • Before starting the inspection, check for loose or poor contact on the injector 2P (Gray) connector ECM 33P connectors, then and recheck the DTC. DTC INJEC- POWER SIGNAL SIGNAL INPUT LINE LINE AT ECM No.1…
• Page 162
  FUEL SYSTEM (PGM-FI) 4. Injector Signal Line Open Circuit Inspection Disconnect the ECM 33P (Black) connector. FRONT INJECTOR 2P (GRAY) Check for continuity between the ECM 33P CONNECTOR (Wire side/female terminal) (Black) connector and injector 2P (Gray) connec- tor. Connection: SIGNAL LINE – SIGNAL LINE TOOL: Test probe 07ZAJ-RDJA110…
• Page 163
  FUEL SYSTEM (PGM-FI) DTC 18-1 (CMP SENSOR) • Before starting the inspection, check for loose or poor contact on the CMP sensor 2P (Natural) con- nector and ECM 33P connectors, then recheck the DTC. 1. CMP Sensor Peak Voltage Inspection Turn the ignition switch OFF.
• Page 164
  FUEL SYSTEM (PGM-FI) DTC 19-1 (CKP SENSOR) • Before starting the inspection, check for loose or poor contact on the CKP sensor 2P (Red) connec- tor and ECM 33P connectors, then recheck the DTC. 1. CKP Sensor Peak Voltage Inspection Turn the ignition switch OFF.
• Page 165
  FUEL SYSTEM (PGM-FI) DTC 21-1 (O SENSOR) • Before starting the inspection, check for loose or poor contact on the O sensor 4P (Black) connec- tor and ECM 33P connectors, then recheck the DTC. 1. O Sensor System Inspection Clear the DTC’s (page 5-15). Start the engine and warm it up to coolant tem- perature is 80°C (176°F).
• Page 166
  FUEL SYSTEM (PGM-FI) 4. O Sensor Inspection Replace the O sensor with a known good one (page 5-84). Clear the DTC’s (page 5-15). Start the engine and warm it up to coolant tem- perature is 80°C (176°F). Check the O sensor with the HDS.
• Page 167
  FUEL SYSTEM (PGM-FI) 4. O Sensor Heater Open circuit Inspection Turn the ignition switch OFF. ECM 33P (GRAY) CONNECTOR Disconnect the ECM 33P (Gray) connector. (Wire side/female terminal) Check for continuity between the ECM 33P (Gray) connector and O sensor 4P (Black) con- nector of the wire harness side.
• Page 168
  FUEL SYSTEM (PGM-FI) 3. IACV Circuit Continuity Inspection Disconnect the ECM 33P (Black) connector. ECM 33P (BLACK) CONNECTOR Check for continuity between the ECM 33P (Wire side/female terminal) (Black) connector and IACV 4P (White) connec- tor. Connection: A19 – Blue/green Bu/Bl A27 –…

• Page 169: Mil Troubleshooting

  FUEL SYSTEM (PGM-FI) MIL TROUBLESHOOTING MIL 1 BLINK (MAP SENSOR) • Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) con- nector and ECM 33P connectors, then recheck the MIL blinking. 1. MAP Sensor Output Voltage Inspection Connect the ECM test harness to ECM connec- tors (page 5-16).

• Page 170
  FUEL SYSTEM (PGM-FI) 4. MAP Sensor Output Line Short Circuit Inspec- tion Turn the ignition switch OFF. MAP SENSOR 3P (BLACK) CONNECTOR Check for continuity between the MAP sensor 3P (Wire side/female terminal) (Black) connector and ground. Connection: Light green/yellow – Ground Is there continuity? –…
• Page 171
  FUEL SYSTEM (PGM-FI) 2. MAP Sensor Output Voltage Inspection Connect the ECM test harness to ECM connec- tors (page 5-16). Turn the ignition switch ON and engine stop switch » «. Measure the voltage at the test harness termi- nals. Connection: B9 (+) –A18 (–) Is the voltage within 2.7 –…
• Page 172
  FUEL SYSTEM (PGM-FI) 2. ECT Sensor Input Voltage Inspection Turn the ignition switch OFF. 3P CONNECTOR Disconnect the ECT sensor 3P (Gray) connector. (Wire side/female terminals) Turn the ignition switch ON and engine stop switch » «. Measure the voltage at the wire side. Connection: Pink/white (+) –…
• Page 173
  FUEL SYSTEM (PGM-FI) MIL 8 BLINKS (TP SENSOR) • Before starting the inspection, check for loose or poor contact on the TP sensor 3P (Blue) connec- tor and ECM 33P connectors, then recheck the MIL blinking. 1. TP Sensor Output Voltage Connect the ECM test harness to ECM connec- tors (page 5-16).
• Page 174
  FUEL SYSTEM (PGM-FI) 4. TP Sensor Output Line Inspection Turn the ignition switch OFF. Check for continuity between the TP sensor 3P (Blue) connector and test harness terminal. Connection: Red/yellow – B31 Is there continuity? – GO TO STEP 5. –…
• Page 175
  FUEL SYSTEM (PGM-FI) 2. IAT Sensor Input Voltage Inspection Turn the ignition switch OFF. IAT SENSOR 2P (GRAY) CONNECTOR Disconnect the IAT sensor 2P (Gray) connector. (Wire side/female terminal) Turn the ignition switch ON and engine stop switch » «. Measure the voltage at the wire harness side of Gr/Bu IAT sensor connector.
• Page 176
  FUEL SYSTEM (PGM-FI) MIL 11 BLINKS (VS SENSOR) • Before starting the troubleshooting, check the following. – Speedometer/VS sensor (XL700V: 20-11) – ABS indicator problem code (XL700VA: 16-10) • Before starting the inspection, check for loose or poor contact on the VS sensor 2P (Orange) con- nector, combination meter 20P connector, ABS modulator 26P connector (XL700VA) and ECM 33P connectors, then recheck the MIL blinking.
• Page 177
  FUEL SYSTEM (PGM-FI) 2. ECM Signal Line Open Circuit Inspection Disconnect the ABS modulator 26P connector XL700V: (XL700VA). Check for continuity between the combination meter 20P connector (XL700V) or ABS modula- tor 26P connector (XL700VA) and test harness terminal. Connection: Pink/green – B28 Is there continuity? –…
• Page 178
  FUEL SYSTEM (PGM-FI) 2. Injector Resistance Inspection Turn the ignition switch OFF. Measure the resistance of the injector connector terminals. STANDARD: 10 – 14 Ω (20°C/68°F) Is the resistance within 10 – 14 Ω (20 ° C/68 ° F)? – Faulty injector –…
• Page 179
  FUEL SYSTEM (PGM-FI) MIL 13 BLINKS (No.2 FRONT INJECTOR) See page 5-46 MIL 18 BLINKS (CMP SENSOR) • Before starting the inspection, check for loose or poor contact on the CMP sensor 2P (Natural) con- nector and ECM 33P connectors, then recheck the MIL blinking.
• Page 180
  FUEL SYSTEM (PGM-FI) MIL 19 BLINKS (CKP SENSOR) • Before starting the inspection, check for loose or poor contact on the CKP sensor 2P (Red) connec- tor and ECM 33P connectors, then recheck the MIL blinking. 1. CKP Sensor Peak Voltage Inspection at ECM Connect the ECM test harness to the ECM con- nectors (page 5-16).
• Page 181
  FUEL SYSTEM (PGM-FI) MIL 21 BLINKS (O SENSOR) • Before starting the inspection, check for loose or poor contact on the O sensor 4P (Black) connec- tor and ECM 33P connectors, then recheck the MIL blinking. 1. O Sensor System Inspection Start the engine and warm it up to coolant tem- perature is 80°C (176°F).
• Page 182
  FUEL SYSTEM (PGM-FI) MIL 23 BLINKS (O SENSOR HEATER) • Before starting the inspection, check for loose or poor contact on the O sensor 4P (Black) connec- tor and ECM 33P connectors, then recheck the MIL blinking. 1. O Sensor Heater Resistance Inspection Disconnect the O sensor 4P (Black) connector.
• Page 183
  FUEL SYSTEM (PGM-FI) 4. O Sensor Heater Short circuit Inspection Check for continuity between the O sensor 4P SENSOR 4P (BLACK) CONNECTOR (Black) connector and ground. (Wire side/male terminal) Connection: Black/green – Ground Is there continuity? – Short circuit in Black/green wire –…

• Page 184: Mil Circuit Inspection

  FUEL SYSTEM (PGM-FI) 3. IACV Resistance Inspection Connect the IACV 4P (White) connector. Measure the resistance at the test harness termi- nals. Connection: A19 – A29 A16 – A27 STANDARD: 99 – 121 Ω (25°C/77°F) Is the resistance within 99 – 121 Ω (25 ° C/77 ° F)? –…

• Page 185: Fuel Line Inspection

  FUEL SYSTEM (PGM-FI) FUEL LINE INSPECTION FUEL PRESSURE RELIEVING/QUICK CONNECT FITTING REMOVAL • Before disconnecting fuel feed hose, relieve pres- sure from the system as follows. 1. Turn the ignition switch OFF. Lift and support the fuel tank (page 3-5). 2.

• Page 186
  FUEL SYSTEM (PGM-FI) QUICK CONNECT FITTING INSTALLATION • Always replace the retainer of the quick connect fitting when the fuel feed hose is disconnected. • If the rubber cap is damaged or cut, replace it with a new ones. • Do not bent or twist fuel feed hose. •…

• Page 187: Fuel Pressure Test

  FUEL SYSTEM (PGM-FI) 5. Connect the fuel pump 3P (Natural) connector. 3P (NATURAL) CONNECTOR 6. Set the fuel hose to the clamp. FUEL HOSE 7. Connect the battery negative (–) cable to the bat- tery. 8. Turn the ignition switch ON and engine stop switch «…

• Page 188
  FUEL SYSTEM (PGM-FI) After inspection, relieve the fuel pressure and dis- Wrap a shop towel QUICK CONNECT FITTING connect the quick connect fitting (page 5-54). around the attachment to soak Remove the fuel pressure gauge, attachment and up any spilled fuel. manifold from the fuel pump.

• Page 189: Fuel Pump

  FUEL SYSTEM (PGM-FI) Relive the fuel pressure and remove the quick con- nect fitting (page 5-54). HOSE ATTACHMENT Connect the hose attachment to the fuel pump joint. TOOL: Hose attachment, 8 mm/9 mm 07ZAJ-S7C0100 Place the end of the hose into an approved gasoline Wipe spilled container.

• Page 190
  FUEL SYSTEM (PGM-FI) REMOVAL • Be careful not to damage the float arm and fuel level sensor when removing the fuel pump assembly. • Do not disassemble the fuel pump assembly. Remove the fuel tank (page 5-61). NUTS Remove the following: –…
• Page 191
  FUEL SYSTEM (PGM-FI) Place a new packing onto the fuel pump. Always replace the packing with a new Push the front end of the packing to fit it on the fuel one. tank. PUSH PACKING Install the fuel pump assembly as shown. Be careful not to damage the float arm and fuel level…

• Page 192: Fuel Pump Relay

  FUEL SYSTEM (PGM-FI) Install the fuel pump mounting nuts. NUTS Tighten the fuel pump mounting nuts in the speci- fied sequence as shown. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the fuel tank (page 5-61). • If the fuel pump is replaced, check the fuel meter indication at the empty (page 20-17).

• Page 193: Air Cleaner Housing

  FUEL SYSTEM (PGM-FI) Lift and support the fuel tank (page 3-5). BREATHER HOSE Disconnect the fuel tank drain hose and breather hose. Relieve the fuel pressure and remove the quick con- nect fitting (page 5-54). DRAIN HOSE Remove the clip, washer, shaft and fuel tank assem- FUEL TANK bly.

• Page 194
  FUEL SYSTEM (PGM-FI) Loosen the air cleaner housing connecting tube SCREWS band screws. Disconnect the crankcase breather drain hose and AIR SUCTION HOSE PAIR air suction hose from the air cleaner housing. Remove the PAIR control solenoid valve and valve cover from the air cleaner housing.
• Page 195
  FUEL SYSTEM (PGM-FI) INSTALLATION Connect the IAT sensor 2P (Gray) connector. 2P (GRAY) CONNECTOR Connect the crankcase breather hose to the air cleaner housing. BREATHER HOSE Connect the crankcase breather drain hose and AIR SUCTION HOSE PAIR air suction hose to the air cleaner housing. Install the PAIR solenoid valve and valve cover to the air cleaner housing.

• Page 196: Throttle Body

  FUEL SYSTEM (PGM-FI) Install and tighten the bolt/washer securely. BOLT/WASHER Lower the fuel tank (page 3-5). Install the wire harness cover (page 2-10). THROTTLE BODY REMOVAL • Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control.

• Page 197
  FUEL SYSTEM (PGM-FI) Loosen the insulator band screws. BAND SCREWS Remove the throttle body from the insulators. • Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed.
• Page 198
  FUEL SYSTEM (PGM-FI) DISASSEMBLY/ASSEMBLY Disconnect the TP sensor 3P (Blue) connector. 3P (BLUE) Release the throttle body sub harness from the CONNECTOR clamp and remove it. CLAMP SUB HARNESS Disconnect the vacuum hoses. VACUUM HOSES Remove the bolts, MAP sensor stay, funnel set FUNNEL SET PLATES BOLTS plates and O-rings.
• Page 199
  FUEL SYSTEM (PGM-FI) INSTALLATION Check the insulator band angle. Align • Align the insulator band hole with the insulator boss. Install the throttle body to the insulators. INSULATORS Tighten the insulator band screw so that the insula- 12 ± 1 mm tor band distance is 12 ±…

• Page 200: Injector

  FUEL SYSTEM (PGM-FI) Connect the throttle cables to the throttle drum and THROTTLE CABLES THROTTLE DRUM cable bracket. Adjust the throttle grip freeplay (page 3-6). Install the air cleaner housing (page 5-64). BRACKET INJECTOR INSPECTON Start the engine and let it idle. Confirm the injector operating sounds with a sound- ing rod or stethoscope.

• Page 201
  FUEL SYSTEM (PGM-FI) Disconnect the fuel hose quick connector (page 5- FUEL FEED HOSE BOLTS 54). Remove the bolts and fuel feed hose and injector from the throttle body. QUICK CONNECTOR Remove the injector from the fuel feed hose. FUEL FEED HOSE Remove the O-ring and seal ring.

• Page 202: Map Sensor

  FUEL SYSTEM (PGM-FI) Install the injector and fuel feed hose to the throttle SEAL RING body, being careful not to damage the seal ring. INJECTOR Install and tighten the bolts to the specified torque. FUEL FEED HOSE BOLTS TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) Connect the fuel hose quick connector (page 5-55).

• Page 203: Cooling System

  FUEL SYSTEM (PGM-FI) IAT SENSOR REMOVAL/INSTALLATION Remove the air cleaner housing (page 5-62). IAT SENSOR SCREWS Remove the screws and IAT sensor from the air cleaner housing. Installation is in the reverse order of removal. TORQUE: IAT sensor mounting screw: 4.0 N·m (0.4 kgf·m, 3.0 lbf·ft) ECT SENSOR REMOVAL…

• Page 204: Cmp Sensor

  FUEL SYSTEM (PGM-FI) CMP SENSOR REMOVAL Remove the right front side cowl (page 2-9). CMP SENSOR Disconnect the CMP sensor 2P (Natural) connector. Remove the bolt and CMP sensor. BOLT 2P (NATURAL) CONNECTOR INSTALLATION Apply engine oil to a new O-ring and install it onto CMP SENSOR the CMP sensor.

• Page 205
  FUEL SYSTEM (PGM-FI) Turn the ignition switch OFF. BANK ANGLE SENSOR Remove the headlight (page 20-6). Remove the screws and bank angle sensor. Do not disconnect the bank angle Connect the bank angle sensor 3P (Black) connector. sensor connector during inspection. SCREWS 3P (BLACK) CONNECTOR Place the bank angle sensor is normal position as…

• Page 206: Engine Stop Relay

  FUEL SYSTEM (PGM-FI) ENGINE STOP RELAY INSPECTION Remove the seat (page 2-4). ENGINE STOP RELAY Open the fuse box and remove the engine stop relay. Connect the ohmmeter to the relay connector termi- ENGINE STOP RELAY nals. Connection: A – B Connect the 12 V battery to the following relay con- nector terminals.

• Page 207
  FUEL SYSTEM (PGM-FI) 2. ECM Ground Line Inspection Turn the ignition switch OFF. ECM 33P CONNECTORS Check for continuity between the ECM 33P con- (Wire side/female terminal) nectors and ground. Connection: A23 – Ground A24 – Ground B4 – Ground TOOL: Test probe 07ZAJ-RDJA110…
• Page 208
  FUEL SYSTEM (PGM-FI) 4. Engine Stop Relay Inspection 2 Turn the ignition switch OFF. RELAY TERMINAL Jump the engine stop relay connector terminals. Connection: Black/white – Red/blue Turn the ignition switch ON and engine stop switch » «. Measure the voltage at the ECM 33P connector and ground.

• Page 209: Engine Idle Speed

  FUEL SYSTEM (PGM-FI) E, F TYPE Remove the left side cover (page 2-4). BOLT/WASHER Remove the following: BRACKET BOLTS – Rubber band – Trim clip (XL700VA) 33P (GRAY) CONNECTOR – Bolt TRIM CLIP – Nut (XL700VA) – Bolt/washer Remove the ECM bracket bolts and ECM bracket. Disconnect the ECM 33P connectors and remove the ECM.

• Page 210: Iacv

  FUEL SYSTEM (PGM-FI) IACV INSPECTION The IACV is installed on the throttle body and is operated by the step motor. When the ignition switch is turned ON, the IACV operates for a few seconds. Check the step motor operating (beep) sound with the ignition switch turned ON.

• Page 211
  FUEL SYSTEM (PGM-FI) Remove the torx screws, setting plate and IACV. TORX SCREWS Check the IACV for wear or damage. If necessary, replace the IACV with a new one. SETTING PLATE INSTALLATION Turn the slide valve clockwise until lightly seated on IACV.

• Page 212: Secondary Air Supply System

  FUEL SYSTEM (PGM-FI) Install a new O-ring to the IACV cover groove. COVER O-RING Install the IACV cover and tighten the screws to the IACV COVER/O-RING specified torque. TORQUE: 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft) SCREWS Connect the IACV 4P (Black) connector. IACV 4P (BLACK) CONNECTOR Install the air cleaner housing (page 5-64).

• Page 213: Pair Control Solenoid Valve

  FUEL SYSTEM (PGM-FI) Start the engine and open the throttle slightly to be PAIR CONTROL SOLENOID VALVE certain that air is sucked in through the air intake port. If the air is not drawn in, check the air supply hoses for clogs and the PAIR control solenoid valve (page 5-82).

• Page 214
  FUEL SYSTEM (PGM-FI) REMOVAL/INSTALLATION Lift and support the fuel tank (page 3-5). SOLENOID COVER 2P (BLACK) Disconnect the air suction hose and air supply VALVE CONNECTOR hoses from the solenoid valve. Disconnect the solenoid valve 2P (Black) connector. Remove the solenoid valve cover and solenoid valve from the air cleaner housing.

• Page 215: O 2 Sensor

  FUEL SYSTEM (PGM-FI) Install the PAIR check valve to the cylinder head Front: PAIR CHECK VALVES Rear: cover. Install the PAIR check valve cover. Front: BOLTS Rear: Install and tighten the bolts to the specified torque. TORQUE: 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft) Install the cooling fan (page 6-13).

• Page 216
  FUEL SYSTEM (PGM-FI) INSTALLATION Install the O sensor and tighten it to the specified torque. TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft) TOOL: sensor wrench 07LAA-PT50101 Install the exhaust system (page 2-18). SENSOR 5-85…
• Page 217
  MEMO…
• Page 218
  6. COOLING SYSTEM SYSTEM FLOW PATTERN ························· 6-2 THERMOSTAT HOUSING························ 6-10 SERVICE INFORMATION ··························· 6-3 RADIATOR ················································ 6-10 TROUBLESHOOTING ································· 6-4 COOLING FAN ·········································· 6-11 SYSTEM TESTING······································ 6-5 FAN MOTOR RELAY ································ 6-13 COOLANT REPLACEMENT ························ 6-6 WATER PUMP ·········································· 6-14 THERMOSTAT ············································…

• Page 219: System Flow Pattern

  COOLING SYSTEM SYSTEM FLOW PATTERN COOLING SYSTEM RADIATOR CAP RADIATORS RADIATOR RESERVE TANK THERMOSTAT WATER PUMP…

• Page 220: Service Information

  COOLING SYSTEM SERVICE INFORMATION GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. • If any coolant gets in your eyes, rinse them with water and consult a physician immediately. •…

• Page 221: Troubleshooting

  COOLING SYSTEM TROUBLESHOOTING Engine temperature too high • Faulty temperature indicator • Thermostat stuck closed • Faulty radiator cap • Insufficient coolant • Passages blocked in radiator, hoses or water jacket • Air in system • Faulty cooling fan motor •…

• Page 222: System Testing

  COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the right front side cowl (page 2-9). RADIATOR CAP Remove the radiator cap. Test the coolant specific gravity using a hydrome- HYDROMETER ter. STANDARD COOLANT CONCENTRATION: 1:1 (distilled water and the recommended antifreeze) Look for contamination and replace the coolant if necessary.

• Page 223: Coolant Replacement

  COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 6-5). RADIATOR CAP Wet the sealing surfaces of the cap, then install the cap onto the tester. Pressurize the radiator cap using the tester. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low.

• Page 224
  COOLING SYSTEM REPLACEMENT/AIR BLEEDING When filling the system or reserve tank with cool- RADIATOR CAP ant, or checking the coolant level, hold the motorcy- cle in an upright position. Remove the following: – Right front side cowl (page 2-9) – Under cowl (page 2-13) Remove the radiator cap.

• Page 225: Thermostat

  COOLING SYSTEM Remove the radiator reserve tank cap and fill the RESERVE TANK CAP reserve tank to the upper level line. Bleed air from the system as follows: 1. Shift the transmission into neutral. Start the engine and let it idle for 2 – 3 minutes. 2.

• Page 226: Thermostat Inspection

  COOLING SYSTEM THERMOSTAT INSPECTION Visually inspect the thermostat for damage. THERMOSTAT Replace the thermostat if the valve stays open at room temperature. Heat a container of water with an electric heating Wear insulated THERMOMETER element for 5 minutes. gloves and Suspend the thermostat in the heated water to adequate eye THERMOSTAT…

• Page 227: Thermostat Housing

  COOLING SYSTEM THERMOSTAT HOUSING REMOVAL/INSTALLATION Remove the left air guard (page 2-10). BOLT Drain the coolant from by removing the water pump drain bolt (page 6-7). Loosen the band screws and disconnect the water hoses. Remove the thermostat housing mounting bolt. WATER Disconnect the ECT sensor 3P (Gray) connector.

• Page 228: Cooling Fan

  COOLING SYSTEM INSTALLATION Install the radiators and bolts. RADIATORS Tighten the bolts securely. BOLTS Connect the fan motor 2P (Black) connector. 2P (BLACK) CONNECTOR Connect the siphon hose and joint hose. SIPHON HOSE Connect the water hoses and tighten the band screws specified range (page 6-10).

• Page 229
  COOLING SYSTEM Remove the fan motor 2P (Black) connector from NUTS SHROUD the shroud. Remove the nuts and fan motor from the shroud. FAN MOTOR 2P (BLACK) CONNECTOR ASSEMBLY RADIATOR 2.7 N·m (0.3 kgf·m, 2.0 lbf·ft) COOLING FAN FAN MOTOR 5.1 N·m (0.5 kgf·m, 3.8 lbf·ft) 8.4 N·m (0.9 kgf·m, 6.2 lbf·ft) SHROUD…

• Page 230: Fan Motor Relay

  COOLING SYSTEM Install the cooling fan onto the motor shaft, aligning COOLING FAN the flat surfaces. Align Apply locking agent to the cooling fan nut threads. Install and tighten the nut to the specified torque. TORQUE: 2.7 N·m (0.3 kgf·m, 2.0 lbf·ft) INSTALLATION Install the fan motor assembly on the radiator and 2P (BLACK) CONNECTOR…

• Page 231: Water Pump

  COOLING SYSTEM Connect the ohmmeter to the fan control relay con- FAN CONTROL RELAY nector terminals. Connection: A – B Connect the 12 V battery to the following fuel pump relay connector terminals. Connection: C – D There should be continuity only when the 12 V bat- tery is connected.

• Page 232
  COOLING SYSTEM Remove the O-ring from the water pump groove. WATER PUMP O-RING Remove the water pump and O-ring O-RING WATER PUMP INSTALLATION Coat a new O-ring with engine oil and install it onto O-RING the stepped section of the water pump. Install the water pump while aligning its groove with the projection of the oil pump shaft.

• Page 233: Radiator Reserve Tank

  COOLING SYSTEM Align the bolt holes in the pump and crankcase, and WATER PUMP COVER BOLTS install the water pump cover with the bolts and a new sealing washer. Tighten the bolts in a crisscross pattern in several steps. TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft) BOLT/SEALING WASHER Connect the water hoses.

• Page 234: Engine Removal/Installation

  7. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ·························· 7-2 ENGINE REMOVAL ···································· 7-4 SERVICE INFORMATION ··························· 7-3 ENGINE INSTALLATION···························· 7-8…

• Page 235
  ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION 17.6 N·m (1.8 kgf·m, 13 lbf·ft) 88 N·m (9.0 kgf·m, 65 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 53.9 N·m (5.5 kgf·m, 40 lbf·ft) 13 N·m (1.3 kgf·m, 10 lbf·ft) 53.9 N·m (5.5 kgf·m, 40 lbf·ft) 26.4 N·m (2.7 kgf·m, 19 lbf·ft)
• Page 236
  ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • A hoist or equivalent is required to support the motorcycle when removing and installing the engine. • A floor jack or other adjustable support is required to support and maneuver the engine. • Do not support the engine using the engine oil filter or it will be damaged. •…

• Page 237: Engine Removal

  ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-13). PINCH BOLT Drain the coolant by removing the water pump drain bolt (page 6-7). Remove the following: – Both side covers (page 2-4) – ECM (page 5-77) – Fuel tank (page 5-61) –…

• Page 238
  ENGINE REMOVAL/INSTALLATION Disconnect the neutral switch/EOP switch 2P (Natu- BOLT ral) connector. Remove the reserve tank mounting bolt and move the reserve tank slightly. Alternator wire and neutral switch/EOP switch wire pass through the between reserve tank and frame. 2P (NATURAL) CONNECTOR WIRES Release the alternator wire and neutral switch/EOP switch wire from the wire guide.
• Page 239
  ENGINE REMOVAL/INSTALLATION Disconnect the air supply hoses from the PAIR Front: Rear: check valve covers. AIR SUPPLY HOSES Remove the clutch cable holder bolt and disconnect CLUTCH CABLE HOLDER the clutch cable end from the clutch lifter arm. BOLT CLUTCH CABLE Remove the rubber cap and starter motor terminal STARTER MOTOR CABLE nut.
• Page 240
  ENGINE REMOVAL/INSTALLATION Loosen the rear axle nut. BOLT SPROCKET Turn the drive chain adjusting nuts and make drive chain slack fully (page 3-17). Remove the bolts, fixing plate and drive sprocket. FIXING PLATE Remove the swingarm pivot covers. PIVOT COVERS Remove the bolts and under cowl stay from the UNDER COWL STAY engine mounting plate.

• Page 241: Engine Installation

  ENGINE REMOVAL/INSTALLATION Remove the engine hanger nut, bolt and collar. COLLAR BOLT/NUT Remove the swingarm pivot nut and bolt. PIVOT NUT/BOLT Move the swingarm backward and the engine to During engine right. removal, hold the Slide out the drive chain from the gearshift spindle engine securely and and countershaft.

• Page 242
  ENGINE REMOVAL/INSTALLATION Tighten the swingarm pivot nut to the specified SWINGARM PIVOT NUT torque. TORQUE: 88 N·m (9.0 kgf·m, 65 lbf·ft) Tighten the engine hanger nut to the specified torque. TORQUE: 53.9 N·m (5.5 kgf·m, 40 lbf·ft) Tighten the engine hanger nut, then tighten the ENGINE HANGER NUT engine hanger plate nut to the specified torque.
• Page 243
  ENGINE REMOVAL/INSTALLATION Install the pivot covers. PIVOT COVERS Install the drive sprocket with the drive chain onto SPROCKET Align the countershaft. Install the fixing plate onto the countershaft, align- ing each tooth with the countershaft grooves. Rotate the fixing plate and align the each bolt hole. FIXING PLATE Install the drive sprocket bolts and tighten them to BOLTS…
• Page 244
  ENGINE REMOVAL/INSTALLATION Connect the starter motor cable and tighten the ter- STARTER MOTOR CABLE minal nut to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) BOLT Connect the ground cable and tighten the bolt securely. RUBBER CAP GROUND CABLE Connect the clutch cable end to the clutch lifter arm.
• Page 245
  ENGINE REMOVAL/INSTALLATION Connect the horn connectors. HORN CONNECTORS Install the neutral switch/EOP switch wire and alter- nator wire to the wire guide. WIRE GUIDE WIRES Route the neutral switch/EOP switch and alternator BOLT wires, and connect the neutral switch/EOP switch 2P (Natural) connector.
• Page 246
  ENGINE REMOVAL/INSTALLATION Install the ECM stay. STAY Install and tighten the nut, bolt/washer and bolt. Install the trim clip (XL700VA only). CLIP (XL700VA) BOLT BOLT/WASHER Install the guide plate, drive sprocket cover and COVER bolts. Tighten the bolts to the specified torque. TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft) GUIDE PLATE BOLTS…
• Page 247
  MEMO…
• Page 248
  8. CYLINDER HEAD/VALVES COMPONENT LOCATION ·························· 8-2 CYLINDER HEAD DISASSEMBLY ··········· 8-15 SERVICE INFORMATION ··························· 8-3 VALVE GUIDE REPLACEMENT ··············· 8-19 TROUBLESHOOTING ································· 8-5 VALVE SEAT INSPECTION/ REFACING················································· 8-20 CYLINDER COMPRESSION························ 8-6 CYLINDER HEAD ASSEMBLY ················· 8-23 CYLINDER HEAD COVER REMOVAL ········ 8-6 CYLINDER HEAD INSTALLATION···········…

• Page 249: Component Location

  CYLINDER HEAD/VALVES COMPONENT LOCATION CYLINDER HEAD/VALVES 10 N·m (1.0 kgf·m, 7 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 40 N·m (4.1 kgf·m, 30 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)

• Page 250: Service Information

  CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL • This section covers service of the rocker arm, camshaft, cylinder head and valve. • The cylinder head services can be done with the engine installed in the frame. • Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike the cylinder head cover and cylinder head too hard during removal.

• Page 251
  CYLINDER HEAD/VALVES TOOLS Valve spring compressor Valve guide reamer, 5.510 mm Valve guide driver, 5.5 mm 07757-0010000 07984-2000001 07742-0010100 Valve seat cutter, 27.5 mm (45° EX) Valve seat cutter, 33 mm (45° IN) Flat cutter, 33 mm (32° IN) 07780-0010200 07780-0010800 07780-0012900 or equivalent commercially…

• Page 252: Troubleshooting

  CYLINDER HEAD/VALVES TROUBLESHOOTING Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. Compression too low, hard starting or poor performance at low speed •…

• Page 253: Cylinder Compression

  CYLINDER HEAD/VALVES CYLINDER COMPRESSION If the engine must be running to do some work, make sure the area is well-ventilated, Never run the engine in an enclosed area. Warm up the engine to normal operating tempera- To measure the ture. cylinder Stop the engine, disconnect the spark plug caps and compression of…

• Page 254
  CYLINDER HEAD/VALVES Remove the cylinder head cover and gasket. Be careful not to CYLINDER HEAD COVER damage the wire harness and mating surfaces when removing the cylinder head cover. GASKET Remove the dowel pin. DOWEL PIN REAR Remove the following: BOLT –…

• Page 255: Camshaft Removal

  CYLINDER HEAD/VALVES Remove the cylinder head cover and gasket. Be careful not to CYLINDER HEAD COVER damage the wire harness and mating surfaces when removing the cylinder head cover. GASKET Remove the dowel pin. DOWEL PIN CAMSHAFT REMOVAL • The camshaft can be serviced with the engine in the frame.

• Page 256
  CYLINDER HEAD/VALVES Measure the cam chain tensioner wedge B length as 6 mm (0.2 in) WEDGE B shown. SERVICE LIMIT: 6 mm (0.2 in) Replace the cam chain with a new one if the projec- tion exceeds the service limit. For the cam chain replacement, remove the follow- ing: Front:…
• Page 257
  CYLINDER HEAD/VALVES Remove the camshaft. CAMSHAFT INSPECTION CAMSHAFT RUNOUT Support both end journals of the camshaft with V- MEASUREMENT POINT blocks and check the camshaft runout with a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.05 mm (0.002 in) CAM LOBE HEIGHT Check the cam lobe surfaces for scoring or evidence of insufficient lubrication.
• Page 258
  CYLINDER HEAD/VALVES CAM SPROCKET Check the cam sprocket for wear or damage. CYLINDER HEAD Check the camshaft journal surfaces of cylinder head for scoring, scratches or evidence of insuffi- cient lubrication. JOURNALS CAMSHAFT OIL CLEARANCE Clean off any oil from the journals of the camshaft PLASTIGAUGE holders, cylinder head and camshaft.
• Page 259
  CYLINDER HEAD/VALVES Remove the camshaft holder and measure the com- PLASTIGAUGE pressed plastigauge at its widest point on each cam- shaft journal to determine the oil clearance. SERVICE LIMIT: 0.10 mm (0.004 in) When the service limit is exceeded, replace the cam- shaft and recheck the oil clearance.

• Page 260: Cylinder Head Removal

  CYLINDER HEAD/VALVES CAMSHAFT HOLDER INSPECTION Check the camshaft journal surfaces of each cam- JOURNALS shaft holder for scoring, scratches or evidence of insufficient lubrication. CYLINDER HEAD REMOVAL • The cylinder head service can be done with the engine in the frame. •…

• Page 261
  CYLINDER HEAD/VALVES Remove the bolt water hose joint and O-ring. Front cylinder head BOLT only: O-RING Remove the cam chain tensioner mounting bolts BOLTS/SEALING WASHERS and sealing washers. Remove the cam chain tensioner. CAM CHAIN TENSIONER Remove the 8 mm bolts. 10 mm NUTS/WASHERS Loosen the 10 mm nuts in a crisscross pattern in several steps.

• Page 262: Cylinder Head Disassembly

  CYLINDER HEAD/VALVES Remove the gasket and dowel pins. GASKET DOWEL PINS Remove the cam chain guide. CAM CHAIN GUIDE CYLINDER HEAD DISASSEMBLY Remove the following: O-RING BOLTS – Spark plug (page 3-8) – Cylinder head (page 8-13) Remove the bolts, insulator and O-ring. INSULATOR Remove the bolt, water hose joint and O-ring.

• Page 263
  CYLINDER HEAD/VALVES Remove the cotters using a special tool. Mark all parts SPRING COMPRESSOR during disassembly TOOL: so they can be Valve spring compressor 07757-0010000 placed back in their original position. Compressing the valve spring more than necessary will cause loss of valve spring tension. COTTERS Remove the valve spring compressor, then remove Do not reuse the…
• Page 264
  CYLINDER HEAD/VALVES VALVE SPRING Check the valve spring for fatigue or damage. Measure the free length of each valve spring. SERVICE LIMIT: 43.9 mm (1.73 in) VALVE STEM, VALVE GUIDE Check each valve for bending, burning, scratches or abnormal wear. Insert the valves in their original positions in the cyl- inder head.
• Page 265
  CYLINDER HEAD/VALVES Measure each valve guide I.D. and record it. SERVICE LIMIT: IN/EX: 5.54 mm (0.218 in) Subtract each valve stem O.D. from the correspond- ing guide I.D. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.07 mm (0.003 in) EX: 0.09 mm (0.004 in) If the stem-to-guide clearance exceeds the service limit, determine if a new guide with standard…

• Page 266: Valve Guide Replacement

  CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Refinish the valve seats whenever the valve guides are replaced to prevent uneven seating. Chill new valve guides in a freezer section of refrig- erator for about an hour. Heat the cylinder head to 130 – 140°C (275 – 290°F) Using a torch to with a hot plate or oven.

• Page 267: Valve Seat Inspection/Refacing

  CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING INSPECTION Clean all intake and exhaust valves thoroughly to LAPPING TOOL remove carbon deposits. Apply a thin coat of Prussian Blue to each valve face. Tap the valve against the valve seat several times using a hand-lapping tool, without rotating valve, to make a clear pattern.

• Page 268
  CYLINDER HEAD/VALVES VALVE SEAT REFACING • Follow the refacer manufacturer’s operating instructions. • Reface the valve seat whenever the valve guide has been replaced. • Be careful not to grind the seat more than neces- 45° sary. 60° 32° If the contact area is too high on the valve, the seat CONTACT TOO HIGH OLD SEAT must be lowered using a 32°…
• Page 269
  CYLINDER HEAD/VALVES Using a 60° cutter, remove the bottom 1/4 of the old seat. OLD SEAT WIDTH TOOLS: Interior cutter, 34 mm (IN) 07780-0014700 Interior cutter, 26 mm (EX) 07780-0014500 Cutter holder, 5.5 mm 07781-0010101 or equivalent com- mercially available 60°…

• Page 270: Cylinder Head Assembly

  CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY COTTERS SPRING RETAINER VALVE SPRING SPRING SEAT STEM SEAL VALVE GUIDE EXHAUST VALVE INTAKE VALVES Blow out all of the oil passages in the cylinder head STEM SEAL with compressed air. Coat new stem seal with engine oil. Install the spring seat and new stem seal.

• Page 271
  CYLINDER HEAD/VALVES Install the cotters using a special tool. Grease the cotters SPRING COMPRESSOR to ease installation. TOOL: Valve spring compressor 07757-0010000 Compressing the valve springs more than neces- sary will cause loss of valve spring tension. COTTERS Support the cylinder head so the valve heads will not contact anything and possibly get damaged.

• Page 272: Cylinder Head Installation

  CYLINDER HEAD/VALVES Coat a new O-ring with engine oil and install it to O-RING the insulator groove. INSULATOR Install the insulator with «UP» mark facing up. BOLTS Install and tighten the bolts securely. Install the following: – Cylinder head (page 8-25) –…

• Page 273
  CYLINDER HEAD/VALVES Install the dowel pins and a new gasket. GASKET DOWEL PINS The cylinder heads are identified by marks on their MARKS oil pockets. • «F» for front cylinder head • «R» for rear cylinder head Install the cylinder head to the cylinder. 10 mm NUTS/WASHERS Apply engine oil to the each bolts and nuts threads and seating surfaces.
• Page 274
  CYLINDER HEAD/VALVES Install the cam chain tensioner bolts with new seal- BOLTS/SEALING WASHERS ing washers and tighten them alternately. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install a new O-ring to the water hose joint. Front cylinder head O-RING only: Install the water hose joint by aligning the bolt hole Front cylinder head BOLT…

• Page 275: Camshaft Installation

  CYLINDER HEAD/VALVES Align the bolt holes in the radiator and stay. Front cylinder head only: Install and tighten the radiator lower mounting bolts securely. Install the following: – CMP sensor (page 5-73) – Camshaft (page 8-28) – Cylinder head cover (page 8-33) Fill and bleed the cooling system (page 6-7).

• Page 276
  CYLINDER HEAD/VALVES • The rocker arms are identified by the stamped ROCKER ARMS marks: «IN» for intake rocker arm «EX» for exhaust rocker arm • The intake rocker arm shaft has two holes on each end. • The exhaust rocker arm shaft has two grooves on each end.
• Page 277
  CYLINDER HEAD/VALVES Then check the identification mark «R» on the rear «R» MARK camshaft. – If the «R» mark faces up, turn the crankshaft counterclockwise 1-16/45 (488°) turn (align the «FT» mark on the flywheel with the index notch) and begin installation of the front camshaft. –…
• Page 278
  CYLINDER HEAD/VALVES CAMSHAFT INSTALLATION Lubricate the camshaft lobe and journal surfaces The front camshaft CAMSHAFT MARK with molybdenum disulfide oil solution. uses the same service procedure Install the camshaft with the camshaft identification as the rear mark (R: rear camshaft, F: front camshaft) facing up. camshaft.
• Page 279
  CYLINDER HEAD/VALVES Clean and apply locking agent to the cam sprocket Be careful not to let BOLTS bolt threads (page 1-18). the cam sprocket bolts fall into the Align the cam sprocket bolt holes in the cam crankcase. sprocket, CMP sensor rotor (rear cylinder head only) and camshaft.

• Page 280: Cylinder Head Cover

  CYLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION Clean the gasket groove and cylinder head mating surface of the cylinder head cover. Check the gasket is in good condition, replace it if necessary. Install the gasket into the groove. Clean the cylinder head cover mating surface of the cylinder head.

• Page 281
  CYLINDER HEAD/VALVES Check the condition of the rubber seals, replace them if necessary. Install the rubber seals onto the cylinder head cover in the direction as shown. RUBBER SEAL Install the washers. BOLTS/WASHERS/RUBBER SEALS Install and tighten the cylinder head cover bolts to the specified torque.
• Page 282
  9. CYLINDER/PISTON COMPONENT LOCATION ·························· 9-2 CYLINDER/PISTON REMOVAL ················· 9-4 SERVICE INFORMATION ··························· 9-3 CYLINDER/PISTON INSTALLATION······· 9-10 TROUBLESHOOTING ································· 9-3…
• Page 283
  CYLINDER/PISTON COMPONENT LOCATION CYLINDER/PISTON…
• Page 284
  CYLINDER/PISTON SERVICE INFORMATION GENERAL • This section covers service of the piston and cylinder. • The piston and cylinder can be serviced with the engine in the frame. • Take care not to damage the cylinder walls and pistons. • Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during removal.

• Page 285: Cylinder Removal

  CYLINDER/PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL The front cylinder uses the same service procedure as the rear cylinder. Remove the cylinder head (page 8-13). UNDER COWL STAY Remove the bolts and under cowl stay. Front cylinder only: Release the clutch cable and water hoses from under cowl stay.

• Page 286: Piston Removal

  CYLINDER/PISTON Remove the gasket and dowel pins. GASKET Clean off any gasket material from the crankcase Be careful not to upper surface. damage the mating surface. DOWEL PINS Remove the joint collar from the cylinder. JOINT COLLAR Remove the O-rings. O-RINGS PISTON REMOVAL Remove the piston pin clip with pliers.

• Page 287
  CYLINDER/PISTON Spread each piston ring and remove it by lifting up Do not damage the a point opposite the gap. piston ring by spreading the ends too far. PISTON RING Clean carbon deposits from the ring grooves with a Never use a wire used piston ring that will be discarded.
• Page 288
  CYLINDER/PISTON Measure the piston O.D. at a point 15 mm (0.59 in) from the bottom and 90° to the piston pin hole. SERVICE LIMIT: 80.91 mm (3.185 in) Compare this measurement against the maximum 90° 15 mm cylinder I.D. measurement and calculate the cylin- (0.59 in) der-to-piston clearance (page 9-8).
• Page 289
  CYLINDER/PISTON CYLINDER Check the top of the cylinder for warpage with a straight edge and feeler gauge across the stud holes. SERVICE LIMIT: 0.10 mm (0.004 in) Check the cylinder wall for scratches or wear. Measure the cylinder I.D. at three levels on the X and Y axes.
• Page 290
  CYLINDER/PISTON CYLINDER STUD BOLT REPLACEMENT Thread two nuts onto the stud and tighten them 12 mm STUD BOLT together, and use a wrench on them to turn the stud bolt out. 10 mm STUD BOLTS Apply engine oil to the lower threads of a new stud 10 mm STUD BOLT: bolt and install it.

• Page 291: Cylinder/Piston Installation

  CYLINDER/PISTON CYLINDER/PISTON INSTALLATION PISTON RING INSTALLATION Apply engine oil to the piston and piston ring outer surface. «N» MARK TOP RING Carefully install the piston rings into the piston ring Be careful not to grooves with the markings facing up. damage the piston and rings.

• Page 292: Cylinder Installation

  CYLINDER/PISTON Place a clean shop towel over the crankcase to pre- «IN» MARK vent the clip from falling into the crankcase. PISTON Apply engine oil to the piston pin outer surface. Install the piston with the «IN» mark facing intake side.

• Page 293
  CYLINDER/PISTON Slide the joint collar into the hole in the cylinder and CLIPS connect it. Install the retaining clips into the joint collar grooves. JOINT COLLAR Install a new O-ring to the hose joint groove. Front cylinder only: HOSE JOINT Install the hose joint to the front cylinder and tighten the bolts securely.
• Page 294
  10. CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION ························ 10-2 PRIMARY DRIVE GEAR·························· 10-12 SERVICE INFORMATION ························· 10-3 GEARSHIFT LINKAGE ···························· 10-14 TROUBLESHOOTING ······························· 10-4 CLUTCH INSTALLATION ······················· 10-16 RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER REMOVAL ················································· 10-5 INSTALLATION ······································ 10-20 CLUTCH REMOVAL·································· 10-6 10-1…

• Page 295: Component Location

  CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION CLUTCH/GEARSHIFT LINKAGE 23 N·m (2.3 kgf·m, 17 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 15 N·m (1.5 kgf·m, 11 lbf·ft) 88 N·m (9.0 kgf·m, 65 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 128 N·m (13.1 kgf·m, 94 lbf·ft) 10-2…

• Page 296: Service Information

  CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL • The clutch and gearshift linkage can be serviced with the engine in the frame. • Engine oil viscosity, oil level and the use of oil additives have an effect on clutch disengagement. Oil additives of any kind are specifically not recommended.

• Page 297: Troubleshooting

  CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Clutch lever engagement hard • Damaged, kinked or dirty clutch cable • Improperly routed clutch cable • Damaged clutch lifter mechanism • Faulty clutch lifter bearing Clutch will not disengage or motorcycle creeps with clutch disengaged • Too much clutch lever freeplay •…

• Page 298: Right Crankcase Cover

  CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL REMOVAL Drain the engine oil (page 3-13). CLUTCH CABLE HOLDER Remove the exhaust system (page 2-14). Remove the bolts in a crisscross pattern in several steps. Remove the clutch cable holder and disconnect the clutch cable end from the clutch lifter arm.

• Page 299: Clutch Removal

  CLUTCH/GEARSHIFT LINKAGE INSPECTION Check the oil seal for fatigue or damage. Check the needle bearings for wear, damage or loose fit. Replace these parts if necessary. If the oil seal replacement is required, install the oil seal to the case surface. NEEDLE BEARING OIL SEAL Check the clutch lifter arm for wear, damage or…

• Page 300
  CLUTCH/GEARSHIFT LINKAGE Loosen the clutch lifter plate bolts in a crisscross BOLT/SPRING pattern in several steps. Remove the lifter plate/bearing and clutch springs. LIFTER PLATE/BEARING Unstake the clutch center lock nut. Be careful not to Unstake damage the mainshaft threads. Hold the clutch center using the special tool and CLUTCH CENTER HOLDER BOLTS…
• Page 301
  CLUTCH/GEARSHIFT LINKAGE Remove the following: JUDDER SPRING/SPRING SEAT/ – Clutch center CLUTCH DISCS/CLUTCH PLATES – Pressure plate – Clutch disc C – Clutch plates – Clutch disc A – Clutch disc B – Judder spring – Spring seat CLUTCH CENTER PRESSURE PLATE Remove the thrust washer and clutch outer.
• Page 302
  CLUTCH/GEARSHIFT LINKAGE Remove the clutch outer guide. CLUTCH OUTER GUIDE INSPECTION LIFTER PLATE BEARING Turn the inner race of the bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the lifter plate.
• Page 303
  CLUTCH/GEARSHIFT LINKAGE CLUTCH PLATE Check the clutch plate for discoloration. Replace the clutch discs and plates as Check the clutch plate warpage on a surface plate a set. using a feeler gauge. SERVICE LIMIT: 0.30 mm (0.012 in) CLUTCH CENTER Check the clutch center for nicks, indentations or abnormal wear caused by the clutch plates.
• Page 304
  CLUTCH/GEARSHIFT LINKAGE OIL PUMP DRIVE SPROCKET Check the oil pump drive sprocket for wear or dam- age. Measure the I.D. of the drive sprocket. SERVICE LIMIT: 32.16 mm (1.266 in) Calculate the oil pump drive sprocket-to-clutch outer guide clearance. SERVICE LIMIT: 0.24 mm (0.009 in) MAINSHAFT Measure the mainshaft O.D.

• Page 305: Primary Drive Gear

  CLUTCH/GEARSHIFT LINKAGE PRIMARY DRIVE GEAR REMOVAL Remove the clutch (page 10-6). CKP SENSOR BOLTS Remove the CKP sensor bolts. Remove the CKP sensor and grommets. GROMMETS Temporarily install the clutch outer guide, oil pump GEAR HOLDER BOLT/WASHER drive sprocket and clutch outer onto the mainshaft (page 10-16).

• Page 306
  CLUTCH/GEARSHIFT LINKAGE Check the primary drive gear for wear or damage. INSTALLATION Install the primary drive gear on the crankshaft. PRIMARY DRIVE GEAR • Install the primary drive gear, aligning its wide groove with the wide tooth of the crankshaft. •…

• Page 307: Gearshift Linkage

  CLUTCH/GEARSHIFT LINKAGE Install the CKP sensor, wire grommets and tighten CKP SENSOR BOLTS the bolts. Install the clutch (page 10-16). GROMMETS GEARSHIFT LINKAGE REMOVAL Remove the clutch (page 10-6). GEARSHIFT PEDAL PINCH BOLT Remove the pinch bolt and gearshift pedal from the spindle.

• Page 308
  CLUTCH/GEARSHIFT LINKAGE Remove the gearshift spindle from the crankcase GEARSHIFT SPINDLE while unhooking the shifter arm from the gearshift cam plate. SHIFTER ARM INSPECTION Check the gearshift spindle for bend, wear or dam- age. Check the return spring for fatigue or damage. INSTALLATION Install the gearshift spindle, aligning the return GEARSHIFT SPINDLE…

• Page 309: Clutch Installation

  CLUTCH/GEARSHIFT LINKAGE Hold the stopper arm with a screwdriver, and STOPPER ARM tighten the bolt to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) BOLT Apply engine oil to a new O-ring and install it to the OIL FEED PIPE BOLT oil feed pipe.

• Page 310
  CLUTCH/GEARSHIFT LINKAGE Install the oil pump drive chain, drive sprocket and DRIVE SPROCKET DRIVE CHAIN driven sprocket as a set. • Install the driven sprocket with its » » mark fac- ing outside. • Align the flat surfaces of the driven sprocket hole and oil pump shaft end.
• Page 311
  CLUTCH/GEARSHIFT LINKAGE • Clutch disc is available in three types. – Clutch disc B: Clutch disc B has a larger I.D. than disc A and C. SPRING SEAT – Clutch disc A: Black paint on the tab. PRESSURE PLATE Coat the clutch discs with engine oil. JUDDER SPRING Install the spring seat and judder spring to the clutch center as shown.
• Page 312
  CLUTCH/GEARSHIFT LINKAGE Install the thrust washer. «OUTSIDE» MARK Install the spring washer with its «OUTSIDE» mark facing out. SPRING WASHER THRUST WASHER Apply engine oil to the threads and seating surface CLUTCH CENTER HOLDER BOLTS of a new clutch center lock nut and install it onto the mainshaft.

• Page 313: Right Crankcase Cover

  CLUTCH/GEARSHIFT LINKAGE Apply engine oil to the clutch lifter piece sliding sur- CLUTCH LIFTER PIECE BEARING face and install it to the clutch lifter bearing. Tighten the oil pump driven sprocket bolt if it is removed. TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft) Install the right crankcase cover (page 10-20).

• Page 314
  CLUTCH/GEARSHIFT LINKAGE Hook the spring end to the cover tab and lifter arm. Hook RETURN SPRING Apply engine oil to the clutch lifter rod sliding sur- LIFTER ROD face. Install the clutch lifter rod, aligning the rod end with the groove in the clutch lifter arm by turning the LIFTER ARM clutch lifter arm clockwise.
• Page 315
  CLUTCH/GEARSHIFT LINKAGE Connect the clutch cable. CLUTCH CABLE HOLDER Install the right crankcase cover, clutch cable holder, and tighten the bolts in a crisscross pattern in sev- eral steps. Install the exhaust system (page 2-18). Fill the crankcase with the recommended engine oil (page 3-12).
• Page 316
  11. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ························ 11-2 STATOR REMOVAL ································· 11-4 SERVICE INFORMATION ························· 11-3 FLYWHEEL/STARTER CLUTCH ·············· 11-6 TROUBLESHOOTING ······························· 11-3 STATOR INSTALLATION ······················· 11-12 11-1…
• Page 317
  ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH 157 N·m (16.0 kgf·m, 116 lbf·ft) 11-2…
• Page 318
  ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL • This section covers service of the alternator stator and flywheel. All service can be done with the engine installed in the frame. • For alternator charging coil inspection (page 17-9). • For starter motor service (page 19-6). SPECIFICATIONS Unit: mm (in) ITEM…

• Page 319: Stator Removal

  ALTERNATOR/STARTER CLUTCH STATOR REMOVAL Remove the following: STAY – Left front side cowl (page 2-9) – Under cowl (page 2-13) – ECM (page 5-77) – Heat guard plate mounting bolt (page 2-23) – Drive sprocket cover (page 7-4) CLIP Remove the bolt, bolt/washer, nut and trim clip (XL700VA) (XL700VA only).

• Page 320
  ALTERNATOR/STARTER CLUTCH Remove the bolts and left crankcase cover. Loosen the bolts in BOLTS a crisscross pattern in several steps. • The left crankcase cover (stator) is magnetically attracted to the flywheel, be careful during removal. • Be careful not to damage the alternator cover mating surface.

• Page 321: Flywheel Removal

  ALTERNATOR/STARTER CLUTCH FLYWHEEL/STARTER CLUTCH FLYWHEEL REMOVAL Remove the left crankcase cover (page 11-4). For alternator IDLE GEAR REDUCTION GEAR charging coil Remove the starter reduction gear and shaft. inspection (page Remove the starter idle gear and shaft. 17-9). SHAFTS Remove the flywheel bolt and washer while holding The flywheel bolt FLYWHEEL HOLDER the flywheel using the special tool.

• Page 322
  ALTERNATOR/STARTER CLUTCH STARTER IDLE/REDUCTION GEAR INSPECTION STARTER IDLE GEAR/SHAFT Check the starter idle gear and shaft for wear or IDLE GEAR damage. SHAFT STARTER REDUCTION GEAR/SHAFT Check the starter reduction gear and shaft for wear REDUCTION GEAR or damage. SHAFT STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL Check the operation of the one-way clutch by turn-…

• Page 323: Starter Clutch Inspection

  ALTERNATOR/STARTER CLUTCH Remove the torx bolts while holding the flywheel TORX BOLTS using the special tool. TOOL: Flywheel holder 07725-0040001 or equivalent commer- cially available Remove the clutch outer and one-way clutch from FLYWHEEL CLUTCH OUTER the flywheel. ONE-WAY CLUTCH STARTER CLUTCH INSPECTION NEEDLE BEARING Check the needle bearing for abnormal wear or…

• Page 324
  ALTERNATOR/STARTER CLUTCH STARTER DRIVEN GEAR Check the one-way clutch sprag contact surface, teeth and sliding surface for wear or damage. Measure the driven gear O.D. SERVICE LIMIT: 57.73 mm (2.273 in) Measure the driven gear I.D. SERVICE LIMIT: 37.10 mm (1.461 in) STARTER DRIVEN GEAR/STARTER CLUTCH INSTALLATION CLUTCH OUTER…

• Page 325: Flywheel Installation

  ALTERNATOR/STARTER CLUTCH Install the clutch outer and one-way clutch to the fly- CLUTCH OUTER/ONE-WAY CLUTCH wheel. FLYWHEEL Hold the flywheel using the special tool. TORX BOLTS TOOL: Flywheel holder 07725-0040001 or equivalent commer- cially available Clean and apply a locking agent to the torx bolt threads (page 1-18).

• Page 326
  ALTERNATOR/STARTER CLUTCH Wipe any oil off the mating surface of the flywheel FLYWHEEL Align with crankshaft. Install the flywheel to the crankshaft, aligning its key groove with the woodruff key. Hold the flywheel using the special tool. FLYWHEEL HOLDER TOOL: Flywheel holder 07725-0040001 or equivalent commer-…

• Page 327: Stator Installation

  ALTERNATOR/STARTER CLUTCH STATOR INSTALLATION 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) WIRE HOLDER STATOR LEFT CRANKCASE COVER Install the stator to the left crankcase cover. STATOR Clean and apply a locking agent to the bolt threads (page 1-18).

• Page 328
  ALTERNATOR/STARTER CLUTCH Clean off the sealant from the left crankcase cover mating surface. Apply liquid sealant (Three Bond 1207B or equiva- Do not use an lent) to the left crankcase cover mating surface. organic solvent when wiping off the excessive sealant. Install the dowel pins.
• Page 329
  ALTERNATOR/STARTER CLUTCH Install the alternator wire to the wire guide. WIRE GUIDE ALTERNATOR WIRE Connect the alternator 3P (Natural) connector. WIRE BAND HARNESS CLAMP Install the alternator wire to the wire band and har- Route the wire ness clamp. harness properly (page 1-21).

• Page 330: Crankcase/Crankshaft/Transmission

  12. CRANKCASE/CRANKSHAFT/TRANSMISSION COMPONENT LOCATION ························ 12-2 CRANKPIN BEARING ····························· 12-11 SERVICE INFORMATION ························· 12-3 MAIN JOURNAL BEARING ··················· 12-14 TROUBLESHOOTING ······························· 12-6 TRANSMISSION····································· 12-19 CRANKCASE SEPARATION····················· 12-7 CRANKCASE BEARING REPLACEMENT ······································ 12-27 CRANKSHAFT/CONNECTING ROD ········ 12-8 CRANKCASE ASSEMBLY ······················ 12-29 12-1…

• Page 331: Component Location

  CRANKCASE/CRANKSHAFT/TRANSMISSION COMPONENT LOCATION CRANKCASE/CRANKSHAFT/TRANSMISSION 12 N·m (1.2 kgf·m, 9 lbf·ft) 42 N·m (4.3 kgf·m, 31 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) CRANKCASE BOLT (8 mm): 23 N·m (2.3 kgf·m, 17 lbf·ft) 12-2…

• Page 332: Service Information

  CRANKCASE/CRANKSHAFT/TRANSMISSION SERVICE INFORMATION GENERAL • The crankcase must be separated to service the following: – Oil pump (page 4-5) – Crankshaft/connecting rod (page 12-8) – Transmission (page 12-19) • The following parts must be removed before separating the crankcase: – Oil filter (page 3-13) –…

• Page 333
  CRANKCASE/CRANKSHAFT/TRANSMISSION TORQUE VALUES Crankcase bolt (8 mm) 23 N·m (2.3 kgf·m, 17 lbf·ft) Crank pin bearing cap nut 42 N·m (4.3 kgf·m, 31 lbf·ft) Apply engine oil to the threads and seating surface. Oil seal setting plate bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply locking agent.
• Page 334
  CRANKCASE/CRANKSHAFT/TRANSMISSION TOOLS Driver Attachment, 42 x 47 mm Attachment, 52 x 55 mm 07749-0010000 07746-0010300 07746-0010400 Pilot, 22 mm Pilot, 25 mm Pilot, 20 mm 07746-0041000 07746-0040600 07746-0040500 Remover handle Bearing remover, 20 mm Remover weight 07936-3710100 07936-3710600 07741-0010201 Driver, 57 mm Metal installer set 070MF-MEG0100 070MF-MEG0200…

• Page 335: Troubleshooting

  CRANKCASE/CRANKSHAFT/TRANSMISSION TROUBLESHOOTING Excessive engine noise • Worn main journal bearings • Worn crankpin bearings • Worn or damaged transmission gear • Worn or damaged transmission bearings Hard to shift • Improper clutch operation (page 10-4) • Incorrect engine oil viscosity •…

• Page 336: Crankcase Separation

  CRANKCASE/CRANKSHAFT/TRANSMISSION CRANKCASE SEPARATION Remove the engine from the frame (page 7-4). LEFT: RIGHT: BOLT CHAIN For Service Information for removal of necessary parts before separating the crankcase (page 12-3). CHAIN Remove the bolts and cam chain tensioner setting plates. Remove the cam chains. SETTING PLATE SETTING PLATE BOLT…

• Page 337: Crankshaft Removal

  CRANKCASE/CRANKSHAFT/TRANSMISSION Loosen the 6 mm and 8 mm bolts with washer in a 8 mm BOLTS 8 mm BOLT/WASHER crisscross pattern in several steps, then remove them. Set the shift drum to the position as shown. SHIFT DRUM 6 mm BOLTS Place the crankcase with the left crankcase down RIGHT CRANKCASE and remove the right crankcase.

• Page 338: Connecting Rod Removal

  CRANKCASE/CRANKSHAFT/TRANSMISSION SIDE CLEARANCE INSPECTION Before removing the connecting rods, check the big FEELER GAUGE end side clearance. Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big end. SERVICE LIMIT: 0.40 mm (0.016 in) CONNECTING ROD REMOVAL Remove the crankpin bearing cap nuts and the bear- Tap the side of the…

• Page 339: Crankshaft Inspection

  CRANKCASE/CRANKSHAFT/TRANSMISSION CRANKSHAFT INSPECTION Check the crankshaft journal surfaces for damage, discoloration or scratch. CRANKSHAFT RUNOUT Place the crankshaft on a stand or V-blocks. SUPPORTING POINTS Set a dial indicator on the measurement point. Rotate the crankshaft two revolutions and read the runout.

• Page 340: Crankpin Bearing

  CRANKCASE/CRANKSHAFT/TRANSMISSION CRANKSHAFT INSTALLATION Apply molybdenum disulfide oil solution to the crankshaft main journals and install the crankshaft into the left crankcase. CRANKSHAFT Assemble the crankcase (page 12-29). CRANKPIN BEARING Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage.

• Page 341
  CRANKCASE/CRANKSHAFT/TRANSMISSION Apply engine oil to the bearing cap nut threads and Do not rotate the seating surfaces, then tighten them to the specified crankshaft during torque in several steps alternately. inspection. TORQUE: 42 N·m (4.3 kgf·m, 31 lbf·ft) Remove the bearing caps and measure the com- PLASTIGAUGES pressed plastigauge at its widest point on each crankpin to determine the oil clearance.
• Page 342
  CRANKCASE/CRANKSHAFT/TRANSMISSION Record the crankpin O.D. code letter. CRANKPIN O.D. CODE LETTERS Letters A or B on each crank weight is the code for the crankpin O.D. Cross reference the connecting rod and crankpin codes to determine the replacement bearing color code.

• Page 343: Bearing Inspection

  CRANKCASE/CRANKSHAFT/TRANSMISSION CONNECTING ROD SELECTION An alphabetical weight code is stamped on the cap. WEIGHT CODE LETTER If a connecting rod requires replacement, you should select a rod with the same weight code as the original. But if that is unavailable, you may use one of the others specified in the following chart.

• Page 344
  CRANKCASE/CRANKSHAFT/TRANSMISSION Clean off any oil from the crankshaft journals. Measure and record the crankshaft main journal O.D. SERVICE LIMIT: 52.976 mm (2.0857 in) Calculate the main journal oil clearance. SERVICE LIMIT: 0.07 mm (0.003 in) If the clearance exceeds the service limit, select the bearing.
• Page 345
  CRANKCASE/CRANKSHAFT/TRANSMISSION Depending upon the results of the above measure- ments there are four possible scenarios for main bearing selection: • Crankshaft and crankcase are replaced • Crankcase only is replaced • Crankshaft only is replaced • Main bearings only are replaced Carefully refer to the following instructions and tables for main bearing selection.
• Page 346
  CRANKCASE/CRANKSHAFT/TRANSMISSION In case the crankshaft and crankcase are replaced: MAIN JOURNAL O.D. CODE NUMBER 52.988 – 52.994 mm 52.982 – 52.988 mm 52.976 – 52.982 mm (2.0861 – 2.0864 in) (2.0859 – 2.0861 in) (2.0857 – 2.0859 in) BEARING 58.016 – 58.022 mm SUPPORT (2.2841 –…

• Page 347: Bearing Installation

  CRANKCASE/CRANKSHAFT/TRANSMISSION BEARING THICKNESS: O.S. E (Yellow): Thick O.S. F (Pink): O.S. G (Red): A (Blue): Middle B (Black): C (Brown): D (Green): Thin After selecting new bearings, recheck the clearance with a plastigauge. Incorrect clearance can cause severe engine damage. IDENTIFICATION COLOR BEARING INSTALLATION Apply engine oil to new bearing surface.

• Page 348: Transmission

  CRANKCASE/CRANKSHAFT/TRANSMISSION Press the new bearings until the metal installer INSTALLER SET flange fully seat. BEARING Make sure the bearing mating line aligns with the INDEX MARK index mark on the crankcase. Check the oil clearance (page 12-14). • After selecting new bearings, recheck the clear- ance.

• Page 349
  CRANKCASE/CRANKSHAFT/TRANSMISSION Remove the mainshaft and countershaft together. MAINSHAFT COUNTERSHAFT TRANSMISSION DISASSEMBLY Disassemble the mainshaft and countershaft. MAINSHAFT COUNTERSHAFT INSPECTION GEARS Check the gear dogs, dog holes and teeth for dam- age or excessive wear. Measure the I.D. of each gear. SERVICE LIMITS: M3, M5 gears: 28.04 mm (1.104 in)
• Page 350
  CRANKCASE/CRANKSHAFT/TRANSMISSION BUSHINGS Check the bushings for wear or damage. Measure the O.D. of each bushing. SERVICE LIMITS: M3, M5 gear bushings: 27.940 mm (1.1000 in) C1, C2, C4 gear bushings: 30.93 mm (1.218 in) Measure the I.D. of the each gear bushing. SERVICE LIMITS: M3 gear bushing: 25.04 mm (0.986 in) C2 gear bushing: 28.03 mm (1.104 in)
• Page 351
  CRANKCASE/CRANKSHAFT/TRANSMISSION SHIFT FORK SHAFT Check the shaft for bend, abnormal wear or dam- age. Measure the shift fork shaft O.D. SERVICE LIMIT: 12.90 mm (0.508 in) SHIFT DRUM/SHIFT DRUM BEARING Remove the bolt and gearshift cam plate. CAM PLATE BOLT Remove the dowel pin and bearing.
• Page 352
  CRANKCASE/CRANKSHAFT/TRANSMISSION Temporarily install the bearing on the shift drum. BEARING Turn the outer race of the bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the shift drum. Remove and discard the bearing if the races do not turn smoothly, quietly, or if it fits loosely on the shift drum.
• Page 353
  CRANKCASE/CRANKSHAFT/TRANSMISSION Install the bearing on the shift drum. BEARING Install the dowel pin into the shift drum hole. DRUM DOWEL PIN Install the gearshift cam plate by aligning the hole CAM PLATE on the cam plate with the dowel pin. Align Clean and apply locking agent to the gearshift cam CAM PLATE…

• Page 354: Transmission Assembly

  CRANKCASE/CRANKSHAFT/TRANSMISSION TRANSMISSION ASSEMBLY Clean all parts in solvent. Apply engine oil to the all gear teeth and main and countershaft spline area. Apply molybdenum disulfide oil solution to the each bushing sliding surface and shift fork grooves to ensure initial lubrication. Assemble all parts into their original positions.

• Page 355
  CRANKCASE/CRANKSHAFT/TRANSMISSION COUNTERSHAFT COUNTERSHAFT C2 GEAR (31T) C4 GEAR SPLINE BUSHING C2 GEAR BUSHING SPLINE WASHER SNAP RING C5 GEAR (25T) C4 GEAR (30T) SPLINE WASHER SPLINE WASHER LOCK WASHER SNAP RING C3 GEAR (28T) SNAP RING SPLINE WASHER C1 GEAR SPLINE BUSHING THRUST WASHER C1 GEAR (35T) INSTALLATION…

• Page 356: Crankcase Bearing Replacement

  CRANKCASE/CRANKSHAFT/TRANSMISSION Apply engine oil to the shift fork sliding surface and SHIFT DRUM install the shift forks into the shifter gear grooves with the markings facing up (right crankcase side). Install the shift drum by aligning the shift fork guide pins with the shift drum guide grooves.

• Page 357: Left Crankcase Bearings

  CRANKCASE/CRANKSHAFT/TRANSMISSION LEFT CRANKCASE BEARINGS Remove the mainshaft bearings using the special MAINSHAFT BEARING tools. COUNTERSHAFT BEARING TOOLS: Bearing remover, 20 mm 07936-3710600 Remover handle 07936-3710100 Remover weight 07741-0010201 Drive the countershaft bearing out of the left crank- case. BEARING REMOVER WEIGHT HANDLE Drive new bearings into the left crankcase with the…

• Page 358: Crankcase Assembly

  CRANKCASE/CRANKSHAFT/TRANSMISSION Drive new bearings into the right crankcase with the DRIVER marked side facing up until they are fully seated. TOOLS: Mainshaft bearing: Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 Pilot, 22 mm 07746-0041000 Countershaft bearing: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 20 mm 07746-0040500…

• Page 359
  CRANKCASE/CRANKSHAFT/TRANSMISSION Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Make sure the all parts are installed in the left crank- case. Apply liquid sealant (Three Bond 1207B or equiva- lent) to the crankcase mating surfaces. Install the dowel pins into the left crankcase.
• Page 360
  CRANKCASE/CRANKSHAFT/TRANSMISSION Set the shift drum to the position as shown. 8 mm BOLTS 8 mm BOLT/WASHER Install the right crankcase bolts with the washer. Tighten the 8 mm bolts in a crisscross pattern in several steps. TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft) Tighten the 6 mm bolts securely.
• Page 361
  CRANKCASE/CRANKSHAFT/TRANSMISSION Install the cam chains. LEFT: RIGHT: CHAIN Clean and apply locking agent to the bolt threads BOLT (page 1-18). CHAIN Install the cam chain tensioner setting plates and tighten the bolts to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the remaining parts (page 12-3).

• Page 362: Front Wheel/Suspension/Steering

  13. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION ························ 13-2 FRONT WHEEL ······································· 13-15 SERVICE INFORMATION ························· 13-4 FORK ······················································· 13-21 TROUBLESHOOTING ······························· 13-6 STEERING STEM···································· 13-31 HANDLEBAR ············································· 13-7 13-1…

• Page 363: Component Location

  FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION FRONT WHEEL/SUSPENSION/STEERING XL700V: 27 N·m (2.8 kgf·m, 20 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 13-2…

• Page 364
  FRONT WHEEL/SUSPENSION/STEERING XL700VA: 27 N·m (2.8 kgf·m, 20 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 13-3…
• Page 365
  – max. Fork Spring free length 621.4 (24.47) 609.0 (23.97) Tube runout – 0.20 (0.008) Honda ULTRA CUSHION OIL 10W or Recommended fork fluid – equivalent Fluid level 104 (4.1) – 598 ± 2.5 cm (20.2 ± 0.08 US oz, Fluid capacity –…
• Page 366
  FRONT WHEEL/SUSPENSION/STEERING TOOLS Driver Attachment, 37 x 40 mm Attachment, 42 x 47 mm 07749-0010000 07746-0010200 07746-0010300 Pilot, 17 mm Bearing remover shaft Bearing remover head, 17 mm 07746-0040400 07GGD-0010100 07746-0050500 Slider weight Driver attachment Inner driver, 28 mm I.D. 07947-KA50100 07947-KF00100 07946-4300101…
• Page 367
  FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING Hard steering • Steering top thread too tight • Worn or damaged steering head bearings • Bent steering stem • Insufficient tire pressure • Faulty tire Steers to one side or does not track straight • Bent fork leg •…
• Page 368
  FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the following: BRAKE LEVER – Nut – Pivot bolt – Knuckle guard – Brake lever KNUCKLE GUARD PIVOT BOLT Remove the following: WASHER/COLLAR – Bolt – Collar BOLT – Washer/collar – Nut COLLAR – Pivot bolt –…
• Page 369
  FRONT WHEEL/SUSPENSION/STEERING Remove the screws, holder and clutch lever bracket. BRACKET SCREWS HOLDER Remove the screws and left handlebar switch hous- SCREWS ing. SWITCH HOUSING Remove the left handlebar grip. GRIP Disconnect the front brake light switch wire connec- MASTER CYLINDER HOLDER tors from the switch.
• Page 370
  FRONT WHEEL/SUSPENSION/STEERING Remove the screws and right handlebar switch SWITCH HOUSING housing. SCREWS Remove the screws and separate the throttle hous- THROTTLE HOUSING ing. SCREWS Disconnect the throttle cables from the throttle pipe CABLES and remove the throttle pipe from the right handle- bar.
• Page 371
  FRONT WHEEL/SUSPENSION/STEERING Remove the bolt caps. BOLT CAPS Remove the bolts, upper holders and handlebar. BOLTS HANDLEBAR UPPER HOLDERS Remove the lower holder nuts, washers, setting LOWER HOLDERS SETTING PLATES plates and handlebar lower holders. NUTS/ WASHERS INNER WEIGHT REMOVAL/ INSTALLATION Remove the grip or throttle pipe from the handle- RETAINER RING…
• Page 372
  FRONT WHEEL/SUSPENSION/STEERING Remove the inner weight assembly from the han- INNER WEIGHT dlebar. Discard the retainer ring. Check the rubber cushions for wear or damage. RETAINER RING Install a new retainer ring onto the inner weight. RUBBER CUSHIONS Insert the inner weight assembly into the handlebar Hook RETAINER RING by hooking the retainer ring tabs with the holes in…
• Page 373
  Tighten the handlebar lower holder nuts to the specified torque. TORQUE: 26.5 N·m (2.7 kgf·m, 20 lbf·ft) NUTS Apply Honda bond A or equivalent adhesive to the GRIP inside surface of the handlebar grip and to the clean surfaces of the left handlebar and throttle pipe.
• Page 374
  FRONT WHEEL/SUSPENSION/STEERING Install and tighten the front screw first, then tighten the rear screw to the specified torque. TORQUE: 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) SCREWS Install the right handlebar switch housing, aligning SWITCH HOUSING the locating pin with the hole in the handlebar. Align Install and tighten the front long screw first, then SWITCH HOUSING…
• Page 375
  FRONT WHEEL/SUSPENSION/STEERING Install the left handlebar switch housing, aligning SWITCH HOUSING the locating pin with the hole in the handlebar. Align Install the screws. SCREWS Tighten the front short screw first, then tighten the rear long screw. SWITCH HOUSING Install the clutch lever bracket, holder and screws. BRACKET Align Align the edge of the bracket with the punch mark…

• Page 376: Front Wheel

  FRONT WHEEL/SUSPENSION/STEERING Install the rearview mirrors and handlebar switch REARVIEW MIRRORS wire clamps to the handlebar. WIRE CLAMPS Install the clutch lever after connecting the clutch WASHER/COLLAR cable. CLUTCH CABLE Apply grease to the clutch lever pivot bolt sliding surface. BOLT Install the knuckle guard, washer/collar and pivot bolt, then tighten it securely.

• Page 377
  FRONT WHEEL/SUSPENSION/STEERING Loosen the axle holder nuts. AXLE Loosen the front axle. Support the motorcycle securely and raise the front wheel off the ground. Remove the axle and front wheel. • Be careful not to damage the wheel speed sensor when removing the wheel.
• Page 378
  FRONT WHEEL/SUSPENSION/STEERING WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that each bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not Replace the wheel turn smoothly and quietly, or if they fit loosely in the bearings in pairs.
• Page 379
  FRONT WHEEL/SUSPENSION/STEERING To balance the wheel, install a new balance weight BALANCE WEIGHT on the lightest side of the spoke, the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it is spun.
• Page 380
  FRONT WHEEL/SUSPENSION/STEERING Drive in a new left bearing squarely with the marked DRIVER side facing up until it is fully seated. Install the distance collar. Drive in a new right bearing squarely with the marked side facing up until it is seated on the collar. TOOLS: Left side: Driver…
• Page 381
  FRONT WHEEL/SUSPENSION/STEERING Install the hub covers and brake discs with the Do not get grease BRAKE DISC STAMP stamped side facing out. on the brake disc or Install new bolts and tighten them in a crisscross stopping power will pattern in several steps. be reduced.

• Page 382: Fork

  FRONT WHEEL/SUSPENSION/STEERING Install the brake calipers. BOLTS Install and tighten new mounting bolts to the speci- fied torque. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) BRAKE CALIPERS With the front brake applied, pump the forks up and down several times to seat the axle and check brake operation.

• Page 383
  FRONT WHEEL/SUSPENSION/STEERING Remove the bolts and brake hose joints. XL700VA: BRAKE PIPE CLAMPS Remove the bolts and brake pipe clamps. Support the brake caliper with a piece of wire so that it does not hang from the brake hose and pipe. BOLTS BRAKE HOSE JOINTS Remove the bolts and brake hose clamps.
• Page 384
  FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY Remove the dust seal. DUST SEAL Remove the oil seal stopper ring. Do not scratch the fork tube sliding surface. STOPPER RING Remove the fork cap and O-ring. The fork cap is FORK CAP/O-RING under spring pressure; use care when loosening it.
• Page 385
  FRONT WHEEL/SUSPENSION/STEERING Remove the fork piston and rebound spring. Do not remove the REBOUND SPRING fork piston ring, unless it is necessary to replace with a new one. FORK PISTON PISTON RING Using quick successive motions, pull the fork tube out of the fork slider.
• Page 386
  FRONT WHEEL/SUSPENSION/STEERING Carefully remove the fork tube bushing by prying Do not damage the the slot with a screwdriver until the bushing can be fork tube bushing, pulled off by hand. especially the sliding surface. To prevent loss of tension, do not open the bushing more than necessary.
• Page 387
  FRONT WHEEL/SUSPENSION/STEERING Set the fork tube in V-blocks and measure the fork tube runout with a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) Visually inspect the slider and tube bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so the copper sur- BUSHING face appears on more than 3/4 of the entire surface.
• Page 388
  FRONT WHEEL/SUSPENSION/STEERING Install the fork tube bushing, being careful not to Do not open the OIL SEAL damage the coating of the bushing if it has been bushing slit more removed. than necessary. Remove the burrs from the bushing mating surface, TUBE BUSHING being careful not to peel off the coating.
• Page 389
  Pour the specified amount of the recommended fork FORK FLUID fluid into the fork tube. RECOMMENDED FORK FLUID: Honda ULTRA CUSHION OIL 10W or equivalent FORK FLUID CAPACITY: 104 mm 598 ± 2.5 cm (20.2 ± 0.08 US oz, 21.0 ± 0.09 Imp oz) (4.1 in)
• Page 390
  FRONT WHEEL/SUSPENSION/STEERING Coat a new O-ring with fork fluid and install it into FORK CAP the fork cap groove. Hold the fork cap securely and install it into the fork Be careful not to O-RING tube. cross-thread the fork cap. Tighten the fork cap after installing the fork tube into the…
• Page 391
  FRONT WHEEL/SUSPENSION/STEERING Tighten the fork cap to the specified torque if it was FORK CAP removed. TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) Tighten the fork top bride pinch bolt to the specified torque. TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft) PINCH BOLT Install the brake hose joints and bolts.

• Page 392: Steering Stem

  FRONT WHEEL/SUSPENSION/STEERING STEERING STEM REMOVAL Remove the following: 4P (NATURAL) CONNECTOR – Right front side cowl (page 2-9) – Handlebar (page 13-7) – Front fender (page 2-13) – Front wheel (page 13-15) Release the wire clamp and disconnect the ignition switch 2P (Brown) connector and immobilizer 4P CLAMP (Natural) connector.

• Page 393
  FRONT WHEEL/SUSPENSION/STEERING Remove the bolts and brake hose clamp. XL700VA only: XL700VA: BOLTS CLAMP Loosen the steering top thread. TOP THREAD While holding the steering stem, remove the top thread. Remove the dust seal. DUST SEAL Remove the following: STEM –…
• Page 394
  FRONT WHEEL/SUSPENSION/STEERING Install the stem nut onto the stem to prevent the INNER RACE DUST SEAL threads from being damaged while removing the lower bearing inner race. Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the stem.
• Page 395
  FRONT WHEEL/SUSPENSION/STEERING INSTALLATION TOP THREAD LOWER INNER RACE LOWER STEERING BEARING DUST SEAL UPPER INNER RACE LOWER OUTER RACE UPPER STEERING BEARING DUST SEAL UPPER OUTER RACE XL700VA: XL700VA: XL700VA: BRAKE HOSE CLAMP STEERING STEM : BEARINGS : BEARING RACES : DUST SEALS 13-34…
• Page 396
  FRONT WHEEL/SUSPENSION/STEERING Apply 3 – 5 g of specified grease to each new steer- STEM ing bearing and fill it up (page 1-18). Install the lower steering bearing onto the stem. Apply specified grease to a new upper dust seal lip (page 1-18).
• Page 397
  FRONT WHEEL/SUSPENSION/STEERING Retighten the top thread to the specified torque. LOCK NUT WRENCH TOOL: Lock nut wrench 07916-KA50100 TORQUE: 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) TOP THREAD Install the top bridge, washer and stem nut. TOP BRIDGE Install the fork legs into the steering stem and top bridges (page 13-29).

• Page 398: Handlebar

  FRONT WHEEL/SUSPENSION/STEERING Install the front brake hose clamp and tighten the CLAMP bolt securely. Route the hose, wires and cables into the cable guides properly (page 1-21). BOLT Connect the immobilizer 4P (Natural) connector and 4P (NATURAL) CONNECTOR ignition switch 2P (Brown) connector. Install the wires to the clamp.

• Page 399
  MEMO…
• Page 400
  14. REAR WHEEL/SUSPENSION COMPONENT LOCATION ························ 14-2 SHOCK ABSORBER································ 14-13 SERVICE INFORMATION ························· 14-3 SUSPENSION LINKAGE ························ 14-16 TROUBLESHOOTING ······························· 14-5 SWINGARM ············································ 14-21 REAR WHEEL ············································ 14-6 14-1…

• Page 401: Component Location

  REAR WHEEL/SUSPENSION COMPONENT LOCATION REAR WHEEL/SUSPENSION 88 N·m (9.0 kgf·m, 65 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 44 N·m (4.5 kgf·m, 64 N·m (6.5 kgf·m, 47 lbf·ft) 32 lbf·ft) 88 N·m (9.0 kgf·m, 65 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 14-2…

• Page 402
  • When servicing the rear wheel, suspension, or swingarm, raise the rear wheel off the ground by supporting the frame securely. • Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points. SPECIFICATIONS Unit: mm (in)
• Page 403
  REAR WHEEL/SUSPENSION TOOLS Driver Attachment, 37 x 40 mm Attachment, 42 x 47 mm 07749-0010000 07746-0010200 07746-0010300 Pilot, 20 mm Bearing remover shaft Bearing remover head, 17 mm 07746-0040500 07GGD-0010100 07746-0050500 Driver handle Pilot, 17mm Attachment, 22 x 24 mm 070GD-0010100 07746-0040400 07746-0010800…
• Page 404
  REAR WHEEL/SUSPENSION Attachment, 32 x 35 mm Pilot, 25 mm Pilot, 22 mm 07746-0010100 07746-0040600 07746-0041000 Pilot, 16 mm Bearing remover shaft, 25 mm Spoke wrench, 6.1 mm 07746-0041300 07936-ZV10100 07JMA-MR60100 TROUBLESHOOTING Soft suspension • Incorrect suspension adjustment • Weak shock absorber spring •…
• Page 405
  REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle securely and raise the rear AXLE NUT wheel off the ground. Fully slacken the drive chain (page 3-17). Remove the axle nut and setting plate. • Do not operate the brake pedal after removing the wheel.
• Page 406
  REAR WHEEL/SUSPENSION WHEEL RIM Check the rim runout by placing the wheel in a true- ing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) WHEEL BALANCE…
• Page 407
  REAR WHEEL/SUSPENSION DISASSEMBLY If you replace the driven sprocket, loosen the driven sprocket nuts before removing the driven flange from the wheel hub. Remove the dust seal. NUTS DUST SEAL Remove the driven flange assembly from the left wheel hub. DRIVEN FLANGE If you replace the driven sprocket, remove the nuts, BOLTS/NUTS/WASHERS…
• Page 408
  REAR WHEEL/SUSPENSION Remove the torx bolts and pulser ring. TORX BOLTS Remove the dust seal. PULSER RING DUST SEAL Remove the bolts and brake disc. Do not reuse the BOLTS bolts. BRAKE DISC DRIVEN FLANGE BEARING REPLACEMENT Remove the driven flange collar out of the driven Replace the wheel/ DRIVER flange bearing.
• Page 409
  REAR WHEEL/SUSPENSION Install the driven flange collar in a new driven flange DRIVER ATTACHMENT bearing until it is fully seated. TOOLS: Driver 07749-0010000 Attachment, 37 x 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 COLLAR PILOT Install the driven flange bearing/collar into the DRIVER ATTACHMENT driven flange using the special tools.
• Page 410
  REAR WHEEL/SUSPENSION ASSEMBLY 8 N·m (0.8 kgf·m, 5.9 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) REAR PULSER RING 42 N·m (4.3 kgf·m, 31 lbf·ft) REAR BRAKE DISC BEARING (6304UU) DUST SEAL DRIVEN FLANGE BEARING (6303UU) COLLAR DUST SEAL DISTANCE COLLAR DRIVEN SPROCKET O-RING BEARING (6203UU)
• Page 411
  REAR WHEEL/SUSPENSION Install the brake disc with its rotating direction mark Do not get grease DIRECTION MARK BRAKE DISC facing out. on the brake disc or stopping power will Install new bolts and tighten them in a crisscross be reduced. pattern in several steps.

• Page 412: Shock Absorber

  REAR WHEEL/SUSPENSION INSTALLATION Install the side collars. COLLAR Place the rear wheel into the swingarm. Be careful not to SETTING PLATE AXLE damage the VS Install the drive chain over the driven sprocket. sensor when Apply a thin coat of grease to the rear axle surface. installing the wheel.

• Page 413
  REAR WHEEL/SUSPENSION Remove the lower mounting bolt. LOWER MOUNTING BOLT Remove the upper mounting bolt and nut. UPPER MOUNTING BOLT/NUT Remove the shock absorber. INSPECTION Visually inspect the damper unit for damage. 197.4 mm (7.77 in) Check for the: – Damper rod for bend or damage –…

• Page 414: Needle Bearing Replacement

  REAR WHEEL/SUSPENSION NEEDLE BEARING REPLACEMENT Remove the pivot collars and dust seals. PIVOT COLLARS DUST SEALS Set the shock absorber in a hydraulic press. DRIVER ATTACHMENT/PILOT Press the needle bearing out from the upper joint. TOOLS: Driver 07749-0010000 Attachment, 22 x 24 mm 07746-0010800 Pilot, 22 mm 07746-0041000…

• Page 415: Suspension Linkage

  REAR WHEEL/SUSPENSION INSTALLATION Install the shock absorber into the frame. UPPER MOUNTING BOLT/NUT Install the upper mounting bolt and nut. Tighten the upper mounting nut to the specified torque. TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft) Install and tighten the lower mounting bolt to the BOLT specified torque.

• Page 416
  REAR WHEEL/SUSPENSION Remove the cushion connecting rod nut and bolt. BOLT/NUT Remove the drive chain slider upper side screw and collar. SCREW/COLLAR Remove the shock absorber lower mounting bolt BOLT and cushion arm nut. Remove the cushion arm bolt and suspension link- When removing the age assembly downward.

• Page 417: Bearing Replacement

  REAR WHEEL/SUSPENSION BEARING REPLACEMENT CUSHION CONNECTING ROD Remove the pivot collars and dust seals. DUST SEALS COLLARS DUST SEALS Press the needle bearings out of the cushion con- ATTACHMENT DRIVER HANDLE necting rod using special tools. TOOLS: Driver handle 070GD-0010100 Attachment, 22 x 24 mm 07746-0010800 Pilot, 17 mm…

• Page 418
  REAR WHEEL/SUSPENSION CUSHION ARM Remove the pivot collars and dust seals. DUST SEALS COLLARS DUST SEALS Press the needle bearings out of the cushion arm SHOCK ABSORBER SWINGARM SIDE: using the special tools. SIDE: TOOLS: Shock absorber side: Driver handle 070GD-0010100 Attachment, 22 x 24 mm 07746-0010800…
• Page 419
  REAR WHEEL/SUSPENSION Apply specified grease to new dust seal lips (page 1- DUST SEALS COLLARS 18). Install the dust seals and pivot collars. DUST SEALS ASSEMBLY Install the cushion connecting rod, bolt and nut to CUSHION ARM CUSHION CONNECTING ROD the cushion arm.

• Page 420: Swingarm

  REAR WHEEL/SUSPENSION Install the cushion connecting rod bolt and nut. Tighten the nut to the specified torque. TORQUE: 64 N·m (6.5 kgf·m, 47 lbf·ft) BOLT/NUT Install the lower drive chain slider and bolt. Install the exhaust system (page 2-18). BOLT SLIDER SWINGARM REMOVAL…

• Page 421
  REAR WHEEL/SUSPENSION Remove the bolts and brake hose clamps. CLAMPS BOLTS Remove the screws and mud guard. SCREWS MUD GUARD Remove the drive chain slider upper side screw and collar. SCREW/COLLAR Remove the cushion arm nut and bolt. When removing the BOLT cushion arm bolt, lift the drive chain…
• Page 422
  REAR WHEEL/SUSPENSION Remove the swingarm pivot covers. PIVOT COVERS Remove the swingarm pivot nut, swingarm pivot PIVOT NUT SWINGARM bolt and swingarm. PIVOT BOLT DISASSEMBLY/INSPECTION Remove the screw, collar and drive chain slider. CHAIN SLIDER Check the drive chain slider for wear or damage (page 3-21).
• Page 423
  REAR WHEEL/SUSPENSION Remove the side collars and dust seals from the Right side: DUST SEALS swingarm right side pivot. Check the dust seals and side collars for damage or fatigue. SIDE COLLARS Remove the pivot collar and dust seals from the Left side: DUST SEALS swingarm left side pivot.
• Page 424
  REAR WHEEL/SUSPENSION Press the right side pivot bearings and distance col- DRIVER HANDLE ATTACHMENT/PILOT lar out of the swingarm pivot using the special tools. TOOLS: Driver handle 070GD-0010100 Attachment, 22 x 24 mm 07746-0010800 Pilot, 17 mm 07746-0040400 BEARINGS Pack new bearings with specified grease (page 1- DRIVER ATTACHMENT/PILOT 18).
• Page 425
  REAR WHEEL/SUSPENSION Pack new needle bearing with specified grease DRIVER 4.0 – 4.5 mm (page 1-18). (0.16 – 0.18 in) Press the needle bearing in left side pivot with the marking side facing up until the depth from the swingarm outer surface is 4.0 – 4.5 mm (0.16 – 0.18 in), using the special tools.
• Page 426
  REAR WHEEL/SUSPENSION Apply specified grease to the dust seal lips (page 1- Right side: DUST SEALS 18). Install new dust seals into the right side pivot. Install the side collars to the right side pivot. SIDE COLLAR Install the drive chain guide, washers and bolts. CHAIN GUIDE BOLTS/WASHERS Install the drive chain slider, collar and screw.
• Page 427
  REAR WHEEL/SUSPENSION Install the pivot nut. PIVOT NUT Tighten the pivot nut to the specified torque. TORQUE: 88 N·m (9.0 kgf·m, 65 lbf·ft) Install the swingarm pivot covers. PIVOT COVER Install the cushion arm bolt and nut. When installing the BOLT cushion arm bolt, Tighten the nut to the specified torque.
• Page 428
  REAR WHEEL/SUSPENSION Install the mud guard and tighten the screws. SCREWS MUD GUARD Install the brake hose clamps and bolts securely. CLAMPS BOLTS Install the rear brake caliper/bracket onto the guide CALIPER/ rail of the swingarm. BRACKET GUIDE RAIL Install the drive chain case aligning its slit with the CHAIN CASE swingarm tab.
• Page 429
  MEMO…
• Page 430
  15. HYDRAULIC BRAKE COMPONENT LOCATION ························ 15-2 FRONT MASTER CYLINDER·················· 15-21 SERVICE INFORMATION ························· 15-4 FRONT BRAKE CALIPER (XL700V) ······· 15-25 TROUBLESHOOTING ······························· 15-6 FRONT BRAKE CALIPER (XL700VA)····· 15-29 BRAKE FLUID REPLACEMENT/ REAR MASTER CYLINDER ···················· 15-34 AIR BLEEDING (XL700V)·························· 15-7 REAR BRAKE CALIPER ··························…

• Page 431: Component Location

  HYDRAULIC BRAKE COMPONENT LOCATION HYDRAULIC BRAKE FRONT: 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) XL700VA: 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) XL700V: 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 15-2…

• Page 432
  HYDRAULIC BRAKE REAR: 34 N·m (3.5 kgf·m, 25 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) XL700V: 63.7 N·m (6.5 kgf·m, 47 lbf·ft) 88 N·m (9.0 kgf·m, 65 lbf·ft) XL700V: 18 N·m (1.8 kgf·m, 13 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 15-3…

• Page 433: Service Information

  HYDRAULIC BRAKE SERVICE INFORMATION GENERAL Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilled brake fluid will severely damage instrument lenses and painted surfaces.

• Page 434
  HYDRAULIC BRAKE TORQUE VALUES Brake caliper bleed valve 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) Front/rear master cylinder reservoir cap screw 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Brake pad pin 18 N·m (1.8 kgf·m, 13 lbf·ft) Front brake pad pin plug screw (STD type) 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)

• Page 435: Troubleshooting

  HYDRAULIC BRAKE TROUBLESHOOTING Brake lever soft or spongy • Air in hydraulic system • Leaking hydraulic system • Contaminated brake pad/disc • Worn caliper piston seals • Worn master cylinder piston cups • Worn brake pad/disc • Contaminated caliper • Caliper not sliding properly •…

• Page 436: Brake Fluid Replacement

  HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING (XL700V) • Do not allow foreign material to enter the system when filling the reservoir. • When using a commercially available brake bleeder, follow the manufacturer’s operating instructions. BRAKE FLUID DRAINING LEVER BRAKE LINE Turn the handlebar until the front master cylinder RESERVOIR CAP/SET PLATE/DIAPHRAGM reservoir is parallel to the ground, before removing…

• Page 437
  HYDRAULIC BRAKE Connect a commercially available brake bleeder to BLEED VALVE the rear brake caliper bleed valve. Loosen the bleed valve and operate a air bleed tool. Drain the brake fluid. BRAKE BLEEDER BRAKE FLUID FILLING/BLEEDING LEVER BRAKE LINE Fill the reservoir with DOT 4 brake fluid from a BLEED VALVE sealed container.
• Page 438
  HYDRAULIC BRAKE 1. Squeeze the brake lever, open the bleed valve 1/4 turn and then close it. 2. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. • Do not release the lever until the bleed valve has been closed.
• Page 439
  HYDRAULIC BRAKE Connect a commercially available brake bleeder to BLEED VALVE the rear caliper bleed valve. • If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape. 1. Pump the brake bleeder and loosen the bleed valve.

• Page 440: Brake Fluid Replacement/Air Bleeding (Xl700Va)

  HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING (XL700VA) • Do not allow foreign material to enter the system when filling the reservoir. • When using a commercially available brake bleeder, follow the manufacturer’s operating instructions. BRAKE FLUID DRAINING LEVER BRAKE LINE Turn the handlebar until the front master cylinder RESERVOIR CAP/SET PLATE/DIAPHRAGM reservoir is parallel to the ground, before removing…

• Page 441
  HYDRAULIC BRAKE Connect a commercially available brake bleeder to BLEED VALVE the left front brake caliper lower bleed valve. Loosen the bleed valve and operate a air bleed tool. Drain the brake fluid. BRAKE BLEEDER Connect a commercially available brake bleeder to BLEED VALVE the rear brake caliper bleed valve.
• Page 442
  HYDRAULIC BRAKE LEVER BRAKE LINE Fill the reservoir with DOT 4 brake fluid from a BLEED VALVE sealed container. • Use only DOT 4 brake fluid from a sealed con- tainer. • Do not mix different types of fluid since they are not compatible.
• Page 443
  HYDRAULIC BRAKE Repeat steps 1and 2 until air bubbles do not appear BLEED VALVE in the bleed hose. After bleeding the air completely, tighten the bleed valve to the specified torque. TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) BLEED HOSE Fill the reservoir to the upper level line with DOT 4 RESERVOIR CAP SET PLATE…
• Page 444
  HYDRAULIC BRAKE Connect a commercially available brake bleeder to BLEED VALVE the rear caliper bleed valve. Repeat step 1 and 2 for rear caliper bleed valve. Bleed the hydraulic system. BRAKE BLEEDER If a brake bleeder is not available, perform the fol- BLEED VALVE lowing procedure.
• Page 445
  HYDRAULIC BRAKE Connect a bleed hose to the left front caliper lower BLEED VALVE bleed valve. 1. Pump the brake pedal several times quickly, then push the brake pedal all the way down, loosen the left front caliper center bleed valve and loosen the bleed valve 1/4 of a turn.

• Page 446: Brake Pad Replacement

  HYDRAULIC BRAKE BRAKE PAD/DISC BRAKE PAD REPLACEMENT FRONT (XL700V) Push the caliper piston all the way in to allow instal- Check the brake lation of new brake pads. fluid level in the reservoir as this operation causes the level to rise. Remove the pad pin plug.

• Page 447
  HYDRAULIC BRAKE Install the pad pin by pushing in the pads against Always replace the the pad spring to align the pad pin holes in the pads brake pads in pairs and caliper body. to ensure even disc pressure. Tighten the pad pin to the specified torque. TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft) Operate the brake lever to seat the caliper piston against the pads.
• Page 448
  HYDRAULIC BRAKE Install new brake pads into the caliper so their ends Make sure the pad PADS rest into the pad retainer on the bracket properly. spring is installed correctly. RETAINER Apply silicone grease to the pad pin stopper ring PAD PIN sliding surface.

• Page 449: Brake Disc Inspection

  HYDRAULIC BRAKE Pivot the caliper up, and remove the pad pin and the PADS PAD PIN brake pads. Install new brake pads into the caliper so their ends Make sure the pad PADS STOPPER RING rest into the pad retainer on the bracket properly. spring is installed correctly.

• Page 450: Front Master Cylinder

  HYDRAULIC BRAKE Measure the brake disc warpage with a dial indica- tor. SERVICE LIMITS: FRONT: 0.30 mm (0.012 in) REAR: 0.30 mm (0.012 in) Check the bearing for excessive play, if the warpage exceeds the service limit. Replace the brake disc if the bearings are normal. For brake disc replacement (page 13-15).

• Page 451
  HYDRAULIC BRAKE Remove the boot. BOOT Remove the snap ring using a special tool. SNAP RING TOOL: Snap ring pliers 07914-SA50001 PLIERS Remove the master piston and spring. SPRING Clean the master cylinder, reservoir and master pis- ton in clean brake fluid. MASTER PISTON INSPECTION Check the piston cups for wear, deterioration or…
• Page 452
  HYDRAULIC BRAKE Measure the master cylinder I.D. SERVICE LIMIT: 12.755 mm (0.5022 in) Measure the master piston O.D. SERVICE LIMIT: 12.645 mm (0.4978 in) ASSEMBLY Replace the piston, spring, cups and snap ring as a set. 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) RESERVOIR CAP SET PLATE MASTER PISTON…
• Page 453
  HYDRAULIC BRAKE Coat the master piston and piston cups with clean SPRING brake fluid. Install the spring onto the piston end. Install the master piston/spring into the master cyl- Do not allow the inder. piston cup lips to turn inside out. CUPS MASTER PISTON Install the snap ring into the groove in the master…

• Page 454: Front Brake Caliper (Xl700V)

  HYDRAULIC BRAKE Connect the brake hose to the master cylinder with Be sure to rest the BRAKE HOSE CONNECTORS the oil bolt and new sealing washers. hose joint against Tighten the oil bolt to the specified torque. the stopper. TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Connect the brake light switch connectors.

• Page 455
  HYDRAULIC BRAKE Remove the bracket pin boot and pad spring from BOOT the caliper. PAD SPRING Remove the caliper pin boot and pad retainer from BOOT PAD RETAINER the bracket Clean the retainer and bracket mating surfaces. Place a shop towel over the pistons. Do not use high Position the caliper body with the piston facing pressure air or bring…
• Page 456
  HYDRAULIC BRAKE INSPECTION Check the caliper cylinders for scoring, scratches or damage. Measure the caliper cylinder I.D. SERVICE LIMIT: 27.060 mm (1.0654 in) Check the caliper pistons for scoring, scratches or damage. Measure the caliper piston O.D. SERVICE LIMIT: 26.910 mm (1.0594 in) ASSEMBLY CALIPER BRACKET CALIPER PIN BOOT…
• Page 457
  HYDRAULIC BRAKE Coat new piston seals with clean brake fluid, and PISTON SEALS install them into the seal grooves in the caliper. Coat new dust seals with silicone grease and install them into the seal grooves in the caliper. Coat the caliper pistons with clean brake fluid and install them into the caliper cylinders with the open- ing toward the pads.

• Page 458: Front Brake Caliper (Xl700Va)

  HYDRAULIC BRAKE INSTALLATION Install the brake caliper onto the fork leg. BOLTS Install new mounting bolts and tighten them to the specified torque. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) CALIPER Connect the brake hose to the caliper with the oil bolt and new sealing washers.

• Page 459
  HYDRAULIC BRAKE DISASSEMBLY Disassemble the bracket from the caliper. CALIPER BRACKET Remove the bracket pin boot and pad spring from BOOT the caliper. PAD SPRING Remove the caliper pin boot and pad retainer from PAD RETAINER the bracket Clean the retainer and bracket mating surfaces. BOOT Place a shop towel over the pistons.
• Page 460
  HYDRAULIC BRAKE Push the dust and piston seals in and lift them out. Be careful not to PISTON SEAL damage the piston Clean the seal grooves, caliper cylinders and pis- sliding surface. tons with clean brake fluid. DUST SEAL INSPECTION Check the caliper cylinders for scoring, scratches or damage.
• Page 461
  HYDRAULIC BRAKE ASSEMBLY CALIPER BRACKET CALIPER PIN BOOT 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) PISTON SEAL PAD REATAINER BRAKE PADS BRACKET PIN BOOT PISTON DUST SEAL PAD SPRING 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) 18 N·m (1.8 kgf·m, 13 lbf·ft) Coat new piston seals with clean brake fluid, and PISTON SEALS install them into the seal grooves in the caliper.
• Page 462
  HYDRAULIC BRAKE Check the bracket pin boot and replace it if it is hard, BOOT deteriorated or damaged. Install the bracket pin boot and pad spring in the cal- iper. If the caliper pin is removed, apply locking agent to the threads and tighten it.

• Page 463: Rear Master Cylinder

  HYDRAULIC BRAKE REAR MASTER CYLINDER REMOVAL Remove the battery tray (page 17-6). OIL BOLT SEALING WASHERS Drain the brake fluid from the hydraulic system. – XL700V (page 15-7) – XL700VA (page 15-11) Remove the brake hose oil bolt, sealing washers When removing the and brake hose.

• Page 464
  HYDRAULIC BRAKE Release the rear brake light switch spring. STEP HOLDER Remove the rear master cylinder and step holder. MASTER CYLINDER SPRING Remove the cotter pin and joint pin. COTTER PIN JOINT PIN DISASSEMBLY Remove the screw, reservoir hose joint and O-ring. HOSE JOINT/O-RING SCREW Remove the boot.
• Page 465
  HYDRAULIC BRAKE Remove the push rod/master piston, primary cup XL700VA: XL700VA: SPRING PRIMARY CUP and spring. MASTER CYLINDER PUSH ROD/MASTER PISTON Remove the push rod, master piston, primary cup XL700V: XL700V: SPRING and spring. PRIMARY CUP PUSH ROD MASTER CYLINDER MASTER PISTON INSPECTION Check the primary cup, piston cup and boot for…
• Page 466
  HYDRAULIC BRAKE Measure the master cylinder I.D. XL700VA: SERVICE LIMITS: XL700VA: 17.515 mm (0.6896 in) XL700V: 14.055 mm (0.5533 in) XL700V: Measure the master piston O.D. XL700VA: SERVICE LIMITS: XL700VA: 17.405 mm (0.6852 in) XL700V: 13.945 mm (0.5490 in) XL700V: 15-37…
• Page 467
  HYDRAULIC BRAKE ASSEMBLY Replace the piston, spring, primary cup and piston cup as a set. 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) HOSE JOINT RESERVOIR CAP O-RING SET PLATE DIAPHGRAM HOSE JOINT O-RING…
• Page 468
  HYDRAULIC BRAKE Install the snap ring into the groove in the master SNAP RING PLIERS cylinder using a special tool. BOOT TOOL: Snap ring pliers 07914-SA50001 • Install the snap ring with the chamfered edges facing the thrust load side. •…
• Page 469
  HYDRAULIC BRAKE INSTALLATION Install the joint pin. COTTER PIN Secure the joint pin using a new the cotter pin. JOINT PIN Install the rear master cylinder to the inside of frame. Hook the rear brake light switch spring. MASTER CYLINDER Hook Install the step holder, swingarm pivot nut and step STEP HOLDER…

• Page 470: Rear Brake Caliper

  HYDRAULIC BRAKE Install the rear master cylinder assembly and MASTER CYLINDER tighten the bolts to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) BOLTS Install the brake hose with the oil bolt and new seal- OIL BOLT SEALING WASHERS ing washers.

• Page 471
  HYDRAULIC BRAKE DISASSEMBLY Remove the slide pin boot from the caliper bracket. BRACKET BOOT If the boot is hard, damaged or deteriorated, replace it with a new one. Remove the caliper boot, sleeve and pad spring BOOT from the caliper. SLEEVE PAD SPRING Place a shop towel over the piston.
• Page 472
  HYDRAULIC BRAKE INSPECTION Check the caliper cylinders for scoring, scratches or damage. Measure the caliper cylinder I.D. SERVICE LIMIT: 38.240 mm (1.5055 in) Check the caliper pistons for scoring, scratches or damage. Measure the caliper piston O.D. SERVICE LIMIT: 38.090 mm (1.4996 in) ASSEMBLY BRAKE PADS DUST SEAL…
• Page 473
  HYDRAULIC BRAKE Coat a new piston seal with clean brake fluid and PISTON SEAL install it into the seal groove in the caliper. Coat a new dust seal with silicone grease and install into the seal groove in the caliper. Coat the caliper pistons with clean brake fluid and install them into the caliper cylinders with the open- PISTON…

• Page 474: Brake Pedal

  HYDRAULIC BRAKE Install the brake pad (page 15-17). SEALING WASHERS OIL BOLT Install the brake hose with new sealing washers and oil bolt. Push the brake hose stopper on the caliper, then tighten the oil bolt to the specified torque. TORQUE: 34 N·m (3.5 kgf·m, 24 lbf·ft) Fill and bleed the hydraulic system.

• Page 475
  HYDRAULIC BRAKE Install the spring rod to the brake pedal pivot, align- BOLT ing the punch marks on the rod and pivot. Install and tighten the pinch bolt securely. Align SPRING ROD Install the return spring. RETURN SPRING Install the rear master cylinder (page 15-40). 15-46…

• Page 476: Abs Troubleshooting

  16. ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM LOCATION ························ 16-2 ABS INDICATOR CIRCUIT TROUBLESHOOTING····························· 16-11 ABS SYSTEM DIAGRAM ························· 16-3 ABS TROUBLESHOOTING ···················· 16-13 SERVICE INFORMATION ························· 16-4 FRONT WHEEL SPEED SENSOR ·········· 16-21 ABS CONNECTOR LOCATIONS ·············· 16-5 REAR WHEEL SPEED SENSOR/ VS SENSOR ············································…

• Page 477: Abs System Location

  ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM LOCATION ANTI-LOCK BRAKE SYSTEM (ABS) FRONT BRAKE MASTER CYLINDER ABS MODULATOR FRONT PULSER RING REAR WHEEL SPEED SENSOR/ VS SENSOR REAR PULSER RING REAR BRAKE CALIPER REAR BRAKE MASTER CYLINDER FRONT BRAKE CALIPER FRONT WHEEL SPEED SENSOR 16-2…

• Page 478: Abs System Diagram

  ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM DIAGRAM ABS MODULATOR 1. MOTOR GND 4. GND ABS MOTOR 30A 2. +MOTOR ABS FAIL SAFE RELAY 30A ABS 54 3. FAIL SAFE RELAY MAIN FUSE 30A ABS MAIN 10A ABS 61/62 R/Bl R/Br 18.

• Page 479: Service Information

  ANTI-LOCK BRAKE SYSTEM (ABS) SERVICE INFORMATION GENERAL The ABS control module may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the control module. Always turn the ignition switch OFF before servicing. •…

• Page 480: Abs Connector Locations

  ANTI-LOCK BRAKE SYSTEM (ABS) ABS CONNECTOR LOCATIONS Note 1: Remove the air cleaner housing (page 5-62). FRONT WHEEL SPEED SENSOR 2P (ORANGE) CONNECTOR (Note 1) Note 2: Remove the battery tray (page 17-6). REAR WHEEL SPEED SENSOR/VS SENSOR 2P (ORANGE) CONNECTOR (Note 1) 16-5…

• Page 481
  ANTI-LOCK BRAKE SYSTEM (ABS) Note 3: Remove the seat (page 2-4). Note 4: Remove the left side cover (page 2-4). ABS SERVICE CHECK 3P (NATURAL) CONNECTOR (Note 3) ABS MODULATOR 26P CONNECTOR (Note 4) 16-6…

• Page 482: System Description

  ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the problematic part can be detected by outputting the problem code.

• Page 483: Abs Indicator Problem Code

  ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE INDICATION PATTERN • The ABS indicator indicates the problem code by blinking a specified number of times. The indicator has two types of blinkings, a long blink and short blink. The long blink lasts for 1.3 sec- onds, the short blink lasts for 0.3 seconds.

• Page 484
  ANTI-LOCK BRAKE SYSTEM (ABS) 3. Turn the ignition switch OFF and remove the ABS SERVICE CHECK jumper wire. CONNECTOR JUMPER WIRE CLEANING PROBLEM CODE 1. Short the wire terminals of the ABS service check ABS SERVICE CHECK 3P (Natural) connector with a jumper wire with CONNECTOR the ignition switch turned OFF in the same man- ner as retrieval.

• Page 485: Abs Indicator Problem Code Index

  ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR PROBLEM CODE INDEX • The ABS indicator might blink in the following cases. Correct the faulty part. – Incorrect tire pressure. – Tires not recommended for the motorcycle were installed (incorrect tire size). – Deformation of the wheel or tire. •…

• Page 486: Abs Indicator Circuit

  ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) 1. Combination Meter Power/ground Line Inspection Check the combination meter power and ground lines (page 20-9). Are the wires normal? –…

• Page 487
  ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR STAYS ON (–Indicator does not go off when the motorcycle is running, –Problem code is not indicated by the retrieval procedure) 1. Service Check Line Short Circuit Inspection Disconnect the ABS modulator 26P connector. Check for continuity between the ABS modulator 26P connector of the wire harness side and Br/W…

• Page 488: Abs Troubleshooting

  ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING • Perform inspection with the ignition switch turned OFF, unless otherwise specified. • Refer to the ABS Connector Locations (page 16- 5). All connector diagrams in the troubleshooting are viewed from the terminal side. •…

• Page 489
  ANTI-LOCK BRAKE SYSTEM (ABS) 2. Speed Sensor Condition Inspection Inspect the area around the front wheel speed SPEED SENSOR sensor: Check that there is iron or other magnetic depos- its between the pulser ring and wheel speed sen- sor, and the pulser ring slots for obstructions. Check installation condition of the pulser ring or wheel speed sensor for looseness.
• Page 490
  ANTI-LOCK BRAKE SYSTEM (ABS) 6. Failure Reproduction With A New Speed Sensor Replace the front wheel speed sensor with a new ABS INDICATOR one (page 16-21). Connect the ABS modulator 26P connector. Erase the problem code (page 16-9). Test ride the motorcycle above 5 km/h (3 mph). Retrieve the problem code (page 16-8).
• Page 491
  ANTI-LOCK BRAKE SYSTEM (ABS) 3. Speed Sensor Input Voltage Inspection Disconnect the rear wheel speed sensor/VS sen- REAR WHEEL SPEED SENSOR/ sor 2P (Orange) connector. VS SENSOR 2P (ORANGE) CONNECTOR Measure the voltage at the rear wheel speed (Wire side/female terminal) sensor/VS sensor 2P (Orange) connector of the wire harness side with the ignition switch turned Connection: Pink/white (+) –…
• Page 492
  ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 21 (Wheel slipping) • The ABS indicator might blink under unusual riding or conditions (page 16-10). This is temporary failure. Erase the problem code (page 16-9). Then test ride the motorcycle above 5 km/h (3 mph) and check the problem code by retrieving the self-diagnosis system (page 16-8).
• Page 493
  ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 51, 52 or 53 (Pump Motor) 1. Motor Power Input Line Open Circuit Inspection Disconnect the ABS modulator 26P connector. Measure the voltage between the ABS modula- tor 26P connector of the wire harness side and ground.
• Page 494
  ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 54 (Valve Relay) 1. Relay Power Input Line Open Circuit Inspection Disconnect the ABS modulator 26P connector. Measure the voltage between the ABS modula- tor 26P connector of the wire harness side and ground. There should be battery voltage at all times.
• Page 495
  ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 61 or 62 (Power Circuit) 1. ABS Power Input Line Short Circuit Inspection Disconnect the ABS modulator 26P connector. Check for continuity between the ABS modulator 26P connector of the wire harness side and R/Br ground.

• Page 496: Front Wheel Speed Sensor

  ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 81 (CPU; ABS Control Unit) 1. Failure Reproduction Erase the problem code (page 16-9). ABS INDICATOR Test ride the motorcycle above 5 km/h (3 mph). Retrieve the problem code (page 16-8). Does the indicator blink 81 times? –…

• Page 497: Rear Wheel Speed Sensor

  ANTI-LOCK BRAKE SYSTEM (ABS) Remove the bolt, then release the wheel speed sen- CLAMP WIRE sor wire from the clamp. BOLT Remove the bolts, sensor cover, wire clamp and FRONT WHEEL SPEED SENSOR front wheel speed sensor. WIRE CLAMP BOLTS Check that there is iron or other magnetic deposits between the pulser ring and front wheel speed sen- sor.

• Page 498
  ANTI-LOCK BRAKE SYSTEM (ABS) REMOVAL/INSTALLATION Remove the battery tray (page 17-6). Disconnect the rear wheel speed sensor/VS sensor 2P (Orange) connector. Remove the wire harness from the clamps (page 1- 21). 2P (ORANGE) CONNECTOR Remove the bolts, wire clamp and rear wheel speed BOLTS sensor/VS sensor.

• Page 499: Pcv

  ANTI-LOCK BRAKE SYSTEM (ABS) REMOVAL/INSTALLATION Drain the brake fluid from the front and rear hydrau- lic systems (page 15-11). Remove the battery tray (page 17-6). Loosen the joint nuts and remove the brake pipe. When loosening the brake pipe joint nuts, cover the end of the brake pipes to prevent…

• Page 500
  ANTI-LOCK BRAKE SYSTEM (ABS) POWER INPUT LINE OPEN CIRCUIT INSPECTION Measure the voltage between the Red/brown wire terminal (+) and ground (–). There should be battery voltage with the ignition switch ON. If there is no voltage, check for ABS MAIN fuse. R/Br TOOL: Test probe…
• Page 501
  ANTI-LOCK BRAKE SYSTEM (ABS) Loosen the brake pipe joint nuts and disconnect the When loosening brake pipes. the brake pipe joint Remove the bolts/washers, bolt and brake joints nuts, cover the end from the modulator stay. of the brake pipes to prevent contamination.
• Page 502
  ANTI-LOCK BRAKE SYSTEM (ABS) Remove the bolts and modulator stay from the modulator. Installation is in the reverse order of removal. Apply brake fluid to the brake pipe joint nut threads. Tighten the brake pipe joint nuts to the specified torque.
• Page 503
  MEMO…
• Page 504
  17. BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM·································· 17-2 CHARGING SYSTEM INSPECTION········· 17-7 SERVICE INFORMATION ························· 17-3 REGULATOR/RECTIFIER ························· 17-8 TROUBLESHOOTING ······························· 17-5 ALTERNATOR CHARGING COIL ············· 17-9 BATTERY··················································· 17-6 17-1…

• Page 505: System Diagram

  BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM MAIN FUSE (30 A) BATTERY ALTERNATOR REGULATOR/RECTIFIER Yellow Green MAIN FUSE REGULATOR/RECTIFIER BATTERY ALTERNATOR 17-2…

• Page 506: Service Information

  BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.

• Page 507
  BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V – 11.2 Ah Current leakage 2 mA max. Voltage Fully 13.0 – 13.2 V (20°C/68°F) charged Needs Below 12.4 V charging Charging current Normal 1.1 A/5 – 10 h Quick 5.5 A/1.0 h Alternator Capacity 396 W/5,000 min…
• Page 508
  BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. Battery Test Remove the battery (page 17-6). Check the battery condition using the recommended battery tester (page 17-6). RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent Is the battery good condition? –…

• Page 509: Voltage Inspection

  BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the right side cover (page 2-4). Always turn the POSITIVE (+) CABLE ignition switch OFF Disconnect the battery negative (–) cable first, then before removing disconnect the battery positive (+) cable. BATTERY the battery. Remove the nut and battery holder. Remove the battery.

• Page 510: Charging System Inspection

  BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Remove the right side cover (page 2-4). NEGATIVE (–) TERMINAL: (–) PROBE With the ignition switch turned OFF, disconnect the negative (–) cable from the battery. Connect the ammeter (+) probe to the negative (–) cable and the ammeter (–) probe to the battery (–) terminal.

• Page 511: Regulator/Rectifier

  BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER WIRE HARNESS INSPECTION BATTERY CHARGING LINE Remove the left side cover (page 2-4). 2P (NATURAL) CONNECTOR With the ignition switch turned OFF, disconnect the regulator/rectifier 2P (Natural) connector. Measure the voltage between the Red wire terminal (+) of the wire harness side 2P (Natural) connector and ground (–).

• Page 512: Alternator Charging Coil

  BATTERY/CHARGING SYSTEM Remove the bolts and regulator/rectifier. Install the regulator/rectifier in the reverse order of removal. BOLTS REGULATOR/RECTIFIER ALTERNATOR CHARGING COIL INSPECTION Remove the left side cover (page 2-4). 3P (NATURAL) CONNECTOR With the ignition switch turned OFF, disconnect the alternator 3P (Natural) connector.

• Page 513
  MEMO…
• Page 514
  18. IGNITION SYSTEM SYSTEM DIAGRAM·································· 18-2 IGNITION SYSTEM INSPECTION············ 18-5 SERVICE INFORMATION ························· 18-3 IGNITION COIL ········································· 18-8 TROUBLESHOOTING ······························· 18-4 IGNITION TIMING ···································· 18-8 18-1…

• Page 515: Battery

  IGNITION SYSTEM SYSTEM DIAGRAM IGNITION SYSTEM ENGINE STOP SWITCH IGNITION SWITCH TP SENSOR CLUTCH SWITCH REAR IGNITION COIL FUSE BOX FRONT IGNITION COIL BATTERY SPARK PLUG CMP SENSOR CKP SENSOR NEUTRAL SWITCH SIDESTAND SWITCH ENGINE STOP IGNITION SWITCH SWITCH MAIN FUSE 10A FUSE 30A CLUTCH…

• Page 516: Service Information

  IGNITION SYSTEM SERVICE INFORMATION GENERAL • The ECM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive volt- age may damage the ECM. Always turn OFF the ignition switch before servicing. • Use spark plugs of the correct heat range. Using spark plugs with an incorrect heat range can damage the engine. •…

• Page 517: Ignition Coil

  IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. – Faulty spark plug – Loose spark plug cap or spark plug wire connection – Water in the spark plug cap (Leaking the ignition coil secondary voltage) • If there is no spark at either cylinder, temporarily exchange the ignition coil with a known-good one and perform the spark test.

• Page 518
  IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If no spark jumps at the plug, check all connec- tions for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. •…
• Page 519
  IGNITION SYSTEM Lift and support the fuel tank (page 3-5). Rear side: Front: With the ignition coil primary wires connected, con- nect the peak voltage tester or adaptor probes to the ignition coil primary terminal and ground. TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimeter…
• Page 520
  IGNITION SYSTEM CKP SENSOR PEAK VOLTAGE Check that the cylinder compression is normal for each cylinder and the spark plug is installed cor- rectly in the cylinder head. Remove the left side cover (page 2-4). ECM 33P (BLACK) CONNECTOR Disconnect the ECM 33P connectors (page 5-77). (Wire side/female terminal) Connect the peak voltage tester or adaptor probes to the wire harness side ECM 33P connector termi-…

• Page 521: Ignition Timing

  IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Turn the ignition switch OFF. FRONT IGNITION COIL Remove the right air guard (page 2-10). CONNECTORS FRONT IGNITION COIL Disconnect the spark plug cap (page 3-8). Disconnect the ignition coil primary wire connec- tors. Remove the bolts, collars, washers and front igni- tion coil from the frame.

• Page 522
  IGNITION SYSTEM Connect the timing light to the front spark plug wire. Read the TIMING LIGHT INDEX NOTCH manufacturer’s Start the engine, let it idle and check the ignition instructions for timing. timing light IDLE SPEED: 1,200 ± 100 min operation.
• Page 523
  MEMO…
• Page 524
  19. ELECTRIC STARTER SYSTEM DIAGRAM·································· 19-2 STARTER MOTOR ···································· 19-6 SERVICE INFORMATION ························· 19-3 STARTER RELAY SWITCH····················· 19-15 TROUBLESHOOTING ······························· 19-4 DIODE······················································ 19-16 19-1…

• Page 525: System Diagram

  ELECTRIC STARTER SYSTEM DIAGRAM ELECTRIC STARTER IGNITION SWITCH ENGINE STOP SWITCH CLUTCH SWITCH STARTER SWITCH FUSE BOX · DIODE BATTERY · FUSE 20 A STARTER MOTOR NEUTRAL SWITCH SIDESTAND SWITCH MAIN FUSE 30 A/ STARTER RELAY SWITCH STARTER MAIN FUSE MOTOR BATTERY IGNITION…

• Page 526: Service Information

  ELECTRIC STARTER SERVICE INFORMATION GENERAL If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. • Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.

• Page 527
  ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 1. Fuse Inspection Check for blown main fuse or sub fuse. Is the fuse blown? – Replace the fuse – GO TO STEP 2. 2. Battery Inspection Make sure the battery is fully charged and in good condition (page 17-6). Is the battery in good condition? –…
• Page 528
  ELECTRIC STARTER 7. Starter Relay Switch Continuity Inspection • Remove and check the operation of the starter relay switch (page 19-15). Is there continuity? – Faulty starter relay switch – Loose or poor contact starter relay switch connector The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position except neutral, with the sidestand up and the clutch lever pulled in.
• Page 529
  ELECTRIC STARTER STARTER MOTOR REMOVAL • With the ignition switch OFF, disconnect the bat- tery negative (–) cable before servicing the starter motor. Remove the rear exhaust pipe protector A and RUBBER CAP TERMINAL NUT exhaust pipe protector B (page 2-15). Remove the rubber cap and terminal nut.
• Page 530
  ELECTRIC STARTER DISASSEMBLY/INSPECTION Remove the bolts and O-rings. BOLTS/O-RINGS Remove the front cover and O-ring. FRONT COVER O-RING Remove the starter motor case and O-ring. O-RING Remove the armature from the rear cover. ARMATURE STARTER MOTOR CASE Remove the brushes and springs from the brush BRUSHES/SPRINGS holder.
• Page 531
  ELECTRIC STARTER Check for continuity between starter motor cable CONTINUITY: POSITIVE BRUSHES terminal and positive brushes. There should be continuity. STARTER MOTOR CABLE TERMINAL Check for continuity between positive brushes and NO CONTINUITY: REAR COVER rear cover. There should be no continuity. Check for continuity between positive and negative brushes.
• Page 532
  ELECTRIC STARTER Remove the washer, insulator, terminal stopper and TERMINAL STOPPER INSULATOR O-ring. O-RING WASHER Remove the terminal bolt, positive brushes and BRUSH HOLDER TERMINAL BOLT brush holder. POSITIVE BRUSHES Measure each brush length. SERVICE LIMIT: 6.5 mm (0.26 in) Check the commutator for damage or abnormal ARMATURE wear.
• Page 533
  ELECTRIC STARTER Check for continuity between pairs of commutator CONTINUITY: bars. There should be continuity. Check for continuity between each individual com- NO CONTINUITY: mutator bar and the armature shaft. There should be no continuity. Check the dust seal and bearing for wear or dam- DUST SEAL BEARING age.
• Page 534
  ELECTRIC STARTER ASSEMBLY O-RING 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) FRONT COVER O-RING O-RING MOTOR CASE O-RING ARMATURE POSITIVE BRUSHES INSULATOR 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft) SPRING WASHER NEGATIVE BRUSHES BRUSH HOLDER STOPPER REAR COVER O- RING TERMINAL STOPPER Install the brush holder, positive brushes and termi- BRUSH HOLDER TERMINAL BOLT…
• Page 535
  ELECTRIC STARTER Install and tighten the terminal nut securely. Install the negative brushes and tighten the screw to NEGATIVE BRUSHES SCREW the specified torque. TORQUE: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft) Install the brush springs to the brush holder SPRINGS grooves.
• Page 536
  ELECTRIC STARTER Install the armature to the rear cover assembly. ARMATURE REAR COVER ASSEMBLY Install a new O-ring to the starter motor case. O-RING Install the starter motor case with its groove to the stopper on the rear cover assembly. The coil may be damaged if the magnet pulls the armature against the case.
• Page 537
  ELECTRIC STARTER Install a new O-rings to the bolts. O-RINGS Install and tighten the bolts to the specified torque. TORQUE: 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) BOLTS INSTALLATION Apply engine oil to a new O-ring and install it to the starter motor groove.

• Page 538: Starter Relay Switch

  ELECTRIC STARTER STARTER RELAY SWITCH INSPECTION Remove the left side cover (page 2-4). STARTER RELAY SWITCH Shift the transmission into neutral. Turn the ignition switch ON with the engine stop switch at » «. Push the starter switch button. The coil is normal if the starter relay switch clicks. If you do not hear the switch click, inspect the relay switch using the procedure below.

• Page 539
  ELECTRIC STARTER OPERATION CHECK Remove the starter relay switch (page 19-16). CABLE TERMINALS 4P (RED) CONNECTOR Connect an ohmmeter to the starter relay switch large terminals. Connect a fully charged 12 V battery positive (+) wire to the starter relay switch Yellow/red wire ter- minal and negative (–) wire to Green/red wire termi- nal.
• Page 540
  ELECTRIC STARTER Check for continuity between the diode terminals. DIODE When there is continuity, a small resistance value will register. If there is continuity in one direction, the diode is normal. 19-17…
• Page 541
  MEMO…
• Page 542
  20. LIGHTS/METERS/SWITCHES COMPONENT LOCATION ························ 20-2 FUEL LEVEL SENSOR/FUEL METER ···· 20-16 SERVICE INFORMATION ························· 20-3 EOP SWITCH ·········································· 20-18 TROUBLESHOOTING ······························· 20-4 IGNITION SWITCH ································· 20-20 HEADLIGHT··············································· 20-6 HANDLEBAR SWITCH ··························· 20-21 POSITION LIGHT ······································ 20-7 BRAKE LIGHT SWITCH ·························· 20-23 TURN SIGNAL LIGHT·······························…
• Page 543
  LIGHTS/METERS/SWITCHES COMPONENT LOCATION LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCH IGNITION SWITCH SPEEDOMETER FRONT BRAKE LIGHT SWITCH CLUTCH SWITCH RIGHT HANDLEBAR SWITCH REAR BRAKE LIGHT SWITCH FUSE BOX (HEADLIGHT RELAY) ECT SENSOR HORN NEUTRAL SWITCH EOP SWITCH SIDESTAND SWITCH VS SENSOR TURN SIGNAL RELAY 20-2…
• Page 544
  LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL Note the following when replacing the halogen headlight bulb. – Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail. –…

• Page 545: Troubleshooting

  LIGHTS/METERS/SWITCHES TROUBLESHOOTING VS SENSOR/SPEEDOMETER The speedometer and odometer/trip meter indicates «– – – –». Faulty EEPROM in ECM The odometer/trip meter operate normally, but the speedometer does not operate Faulty speedometer in combination meter The speedometer operates normally, but the odometer/trip meter does not operate Faulty odometer/trip meter in combination meter The speedometer operates abnormally 1.

• Page 546
  LIGHTS/METERS/SWITCHES 6. VS Sensor Line Open Circuit Inspection (XL700V) Disconnect the combination meter 20P connector. Check for continuity of the Pink/white and Green/red wires between the combination meter 20P and VS sensor 2P (Orange) connector terminals. Is there continuity? – Open circuit in Pink/white and/or Green/red wires between the combination meter 20P and VS sensor 2P (Orange) connector –…

• Page 547: Headlight

  LIGHTS/METERS/SWITCHES HEADLIGHT BULB REPLACEMENT Disconnect the headlight 2P connectors. Turn the headlight bulb counterclockwise and remove the headlight bulb. Avoid touching the halogen headlight bulb. Finger BULB prints can create hot spots that cause a bulb to break. If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent early bulb failure.

• Page 548: Position Light

  LIGHTS/METERS/SWITCHES POSITION LIGHT BULB REPLACEMENT Pull out the position light bulb socket. BULB Remove the bulb from the bulb socket and replace it with a new one. Installation is in the reverse order of removal. BULB SOCKET TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw, turn signal light lens and gasket.

• Page 549: Brake/Tail Light

  LIGHTS/METERS/SWITCHES REAR Remove the fender cover (page 2-6). TURN SIGNAL LIGHT Remove the nut and turn signal light. Installation is in the reverse order of removal. BRAKE/TAIL LIGHT BULB REPLACEMENT Remove the seat (page 2-4). Turn the bulb socket counterclockwise, then remove it from the brake/tail light unit.

• Page 550: License Light

  LIGHTS/METERS/SWITCHES LICENSE LIGHT BULB REPLACEMENT Remove the screw and license light unit. BULB SOCKET LICENSE LIGHT UNIT Pull out the license light bulb socket. Remove bulb from the bulb socket, and replace it with a new one. Install the removed parts in the reverse order of removal.

• Page 551
  LIGHTS/METERS/SWITCHES GROUND LINE Check for continuity between the Green/black wire terminal and ground. There should be continuity at all times. If there is no continuity, check for an open circuit in the Green/black wire. G/Bl 20P (GRAY) CONNECTOR (Viewed from harness side) BACK-UP VOLTAGE LINE Check this line if the odometer/trip meter does not function.

• Page 552: Speedometer/Vs Sensor

  LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY Remove the screws and combination meter case. SCREWS CASE Remove the combination meter print board assem- PRINT BOARD ASSEMBLY bly. Assembly is in the reverse order of disassembly. SPEEDOMETER/VS SENSOR SYSTEM INSPECTION Check the following: XL700VA: – Combination meter power/ground line (page 20- 20P (GRAY) CONNECTOR (viewed from harness side) –…

• Page 553
  LIGHTS/METERS/SWITCHES VS SENSOR INSPECTION Support the motorcycle securely and raise the rear wheel off the ground. Measure the clearance (air gap) between the VS sensor and pulser ring at several points by turning the wheel slowly. It must be within specification. STANDARD: 0.2 –…

• Page 554: Tachometer

  LIGHTS/METERS/SWITCHES Check that there is iron or other magnetic deposits VS SENSOR between the pulser ring and VS sensor. Remove any deposits. Check the sensor tip for deformation or damage Route the sensor (e.g., chipped pulser ring teeth). wire properly (page Replace the VS sensor if necessary.

• Page 555: Coolant Temperature Gauge

  LIGHTS/METERS/SWITCHES If the value is 0 V, check for continuity between the 20P (GRAY) CONNECTOR combination meter 20P connector and ECM 33P (Viewed from harness side) (Gray) connector Yellow/green terminals. TOOL: Test probe 07ZAJ-RDJA110 If there is no continuity, check the wire harness for an open circuit.

• Page 556
  LIGHTS/METERS/SWITCHES 2. ECT Sensor Line Open Circuit Inspection Disconnect the combination meter 20P (Gray) 20P (GRAY) CONNECTOR connector. (Wire side/female terminal) Check the continuity between the ECT sensor 3P (Gray) and combination meter 20P (Gray) con- nectors. Connection: Green/blue – Green/blue G/Bu Is there continuity? –…

• Page 557: Fuel Level Sensor/Fuel Meter

  LIGHTS/METERS/SWITCHES ECT SENSOR INSPECTION Drain the coolant from by removing the water pump THERMOMETER drain bolt (page 6-7). Remove the ECT sensor (page 5-72). Heat the coolant (1:1mixture) with an electric heat- Wear insulated ing element. gloves and Suspend the ECT sensor in heated coolant and adequate eye check the continuity through the sensor as the cool- protection.

• Page 558: Fuel Level Sensor Inspection

  LIGHTS/METERS/SWITCHES FUEL LEVEL SENSOR INSPECTION Remove the fuel pump (page 5-59). FLOAT Connect an ohmmeter to the fuel pump 3P (Natural) connector Black/white and Red/black terminals. Inspect the resistance of the float at the full and empty positions. Position FULL EMPTY 8 –…

• Page 559: Eop Switch

  LIGHTS/METERS/SWITCHES EOP SWITCH INSPECTION Indicator does not come on with the ignition switch turned ON Check that the neutral and high beam indicators OIL PRESSURE INDICATOR function properly. If they do not function properly, check the power input line of the combination meter (page 20-9). Remove the under cowl (page 2-13).

• Page 560
  LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the under cowl (page 2-13). TERMINAL SCREW EOP SWITCH Remove the dust cover. Remove the terminal screw and disconnect the EOP switch wire. Remove the EOP switch while holding the switch base. DUST COVER SWITCH BASE Apply liquid sealant (Three Bond 1207B or equiva- 3 –…

• Page 561: Ignition Switch

  LIGHTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Remove the right front side cowl (page 2-9). 2P (BROWN) CONNECTOR Disconnect the ignition switch 2P (Brown) connec- tor. Check for continuity between the switch side con- IGNITION SWITCH nector terminals in each switch position. Continuity should exist between the color coded wires as follow: IGNITION SWITCH LOCK…

• Page 562: Handlebar Switch

  LIGHTS/METERS/SWITCHES HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH Lift and support the fuel tank (page 3-5). 8P (GRAY) CONNECTOR Disconnect the right handlebar switch 8P (Gray) connector. Check for continuity between the connector termi- ENGINE STOP SWITCH nals in each switch position. Continuity should exist between the wires as fol- lows: ENGINE STOP SWITCH…

• Page 563
  LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCH Lift and support the fuel tank (page 3-5). 10P (GRAY) CONNECTOR Disconnect the left handlebar switch 10P (Gray) con- nector. Check for continuity between the connector termi- DIMMER SWITCH PASSING SWITCH nals in each switch position. Continuity should exist between the wires as fol- lows: TURN SIGNAL SWITCH…

• Page 564: Brake Light Switch

  LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT Disconnect the brake light switch connectors and FRONT BRAKE LIGHT SWITCH check for continuity between the switch terminals. There should be continuity with the brake lever squeezed and no continuity with the lever released. REAR Remove the battery tray (page 17-6).

• Page 565: Clutch Switch

  LIGHTS/METERS/SWITCHES CLUTCH SWITCH Disconnect the clutch switch wire connectors and CLUTCH SWITCH check for continuity between the switch terminals. There should be continuity with the clutch lever squeezed and no continuity with the lever released. NEUTRAL SWITCH INSPECTION Remove the under cowl (page 2-13). NEUTRAL SWITCH Disconnect the neutral switch connector.

• Page 566: Sidestand Switch

  LIGHTS/METERS/SWITCHES Install the neutral switch with a new sealing washer NEUTRAL SWITCH and tighten it to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Connect the neutral switch connector. Install the under cowl (page 2-13). SEALING WASHER CONNECTOR SIDESTAND SWITCH INSPECTION Remove the under cowl (page 2-13).

• Page 567: Horn

  LIGHTS/METERS/SWITCHES HORN INSPECTION Disconnect the connectors from the horn. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V bat- tery is connected across the horn terminals. REMOVAL/INSTALLATION Remove the under cowl (page 2-13). HORN CONNECTORS Disconnect the connectors from the horn.

• Page 568: Headlight Relay

  LIGHTS/METERS/SWITCHES HEADLIGHT RELAY INSPECTION Remove the seat (page 2-4). HEADLIGHT RELAY Open the fuse/relay box and remove the headlight relay. Connect an ohmmeter to the headlight relay con- HEADLIGHT RELAY nector terminals. Connect a 12 V battery to the headlight relay con- nector terminals as shown.

• Page 569
  MEMO…

• Page 570: Immobilizer System (Hiss)

  21. IMMOBILIZER SYSTEM (HISS) SYSTEM DIAGRAM·································· 21-2 TROUBLESHOOTING······························· 21-9 SERVICE INFORMATION ························· 21-3 HISS INDICATOR···································· 21-12 KEY REGISTRATION PROCEDURES ······· 21-4 ECM ························································· 21-12 DIAGNOSTIC CODE INDICATION ··········· 21-7 IMMOBILIZER RECEIVER······················· 21-14 21-1…

• Page 571: System Diagram

  IMMOBILIZER SYSTEM (HISS) SYSTEM DIAGRAM IMMOBILIZER SYSTEM (HISS) IGNITION SWITCH IMMOBILIZER RECEIVER CKP SENSOR FUSE BOX BATTERY MAIN FUSE 30A Black FUSE 10A Blue Yellow IMMOBILIZER Green INDICATOR White ENGINE STOP Orange RELAY Pink MAIN FUSE 30A IMMOBILIZER RECEIVER FUSE 20A SENSOR BATTERY 21-2…

• Page 572: Service Information

  IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION GENERAL • When checking the immobilizer system (HISS), follow the steps in the troubleshooting flow chart (page 21-9). • Keep the immobilizer key away from the other vehicle’s immobilizer key when using it. The jamming of the key code signal may occur and the proper operation of the system will be obstructed.

• Page 573: Key Registration Procedures

  IMMOBILIZER SYSTEM (HISS) KEY REGISTRATION PROCEDURES When the key has been lost, or additional spare key is required: 1. Obtain a new transponder key. 2. Grind the key in accordance with the shape of the original key. 3. Apply 12 V battery voltage to the CKP sensor lines of the ECM using the special tool (page 21-7). 4.

• Page 574
  IMMOBILIZER SYSTEM (HISS) When the ignition switch is faulty: 1. Obtain a new ignition switch and two new transponder keys. 2. Remove the ignition switch (page 20-20). 3. Apply 12 V battery voltage to the CKP sensor lines of the ECM using the special tool (page 21-7). 4.
• Page 575
  IMMOBILIZER SYSTEM (HISS) 15.Turn the ignition switch OFF and remove the key. 16.Turn the ignition switch ON with a second new key. (Never use the key registered in previous step.) The indicator comes on for two seconds then it blinks four times repeatedly. •…

• Page 576: Diagnostic Code Indication

  IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE INDICATION Remove the under cowl (page 2-13). INSPECTION 2P (RED) Disconnect the CKP sensor 2P (Red) connector. TEST HARNESS CONNECTOR Connect the inspection adaptor to the wire harness side connector. Connect the Red clip of the adaptor to the 12 V bat- tery positive (+) terminal and Black clip to the nega- tive (–) terminal.

• Page 577
  IMMOBILIZER SYSTEM (HISS) When the system (ECM) enters the diagnostic mode from the registration mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Registration is The key is Use a new key or overlapped. already regis- cancelled key. tered properly. Code signals Communication Follow the cannot send or fails.
• Page 578
  IMMOBILIZER SYSTEM (HISS) TROUBLESHOOTING The HISS indicator comes on for approx. two seconds then it goes off, when the ignition switch is turned ON with the properly registered key and the immobilizer system (HISS) functions normally. If there is any problem or the properly registered key is not used, the indicator will remains on. HISS indicator does not come on when the ignition switch is turned ON 1.
• Page 579
  IMMOBILIZER SYSTEM (HISS) HISS indicator remains on with the ignition switch ON 1. Immobilizer Receiver Jamming Inspection Check that there is any metal obstruction or the other vehicle’s transponder key near the immobilizer receiver and key. Is there any metal obstruction or the other key? –…
• Page 580
  IMMOBILIZER SYSTEM (HISS) Diagnostic code is indicated (Code signals cannot send or receive) 1. Immobilizer Receiver Power Input Line Inspection Check the power input line (Yellow/red) at the immobilizer receiver 4P (Natural) connector (page 21- 15). Is there approx. 5 V? –…

• Page 581: Hiss Indicator

  IMMOBILIZER SYSTEM (HISS) HISS INDICATOR Remove the front center cowl (page 2-12). COMBINATION METER Perform the following inspections. 20P CONNECTOR BACK-UP VOLTAGE LINE INSPECTION Measure the voltage between the Red/green wire terminal (+) and ground (–). There should be battery voltage at all times. 20P CONNECTOR (Viewed from harness side) HISS INDICATOR LINE INSPECTION…

• Page 582
  IMMOBILIZER SYSTEM (HISS) HISS INDICATOR LINE INSPECTION Measure the voltage between the B12 (White/red) 33P (GRAY) CONNECTOR wire terminal (+) and ground (–). (Wire side/female terminal) TOOL: Test probe 07ZAJ-RDJA110 Turn the ignition switch ON. There should be battery voltage. POWER INPUT LINE INSPECTION Measure the voltage between the A4 (Black/white) 33P (BLACK) CONNECTOR…
• Page 583
  IMMOBILIZER SYSTEM (HISS) CKP SENSOR LINE INSPECTION Remove the under cowl (page 2-13). Disconnect the CKP sensor 2P (Red) connector. 3P (BLACK) CONNECTOR (Wire side/female terminal) Check the Yellow and White/yellow wire for continu- ity between the ECM and CKP sensor connectors. There should be continuity between the same color wire terminals.
• Page 584
  IMMOBILIZER SYSTEM (HISS) POWER INPUT LINE INSPECTION Measure the voltage between the Yellow/red wire 4P (NATURAL) CONNECTOR terminal (+) of the wire harness side connector and (Wire side/male terminal) ground (–). Turn the ignition switch ON. There should be approx. 5 V. GROUND LINE INSPECTION Check for continuity between the Green/orange wire terminal of the wire harness side connector and…
• Page 585
  IMMOBILIZER SYSTEM (HISS) REPLACEMENT Remove the ignition switch (page 20-20). IMMOBILIZER Remove the screws and the immobilizer receiver. RECEIVER Install a new receiver and tighten the screws securely. Route the receiver wire properly (page 1-21). Install the ignition switch (page 20-20). SCREWS REPLACEMENT PARTS FOR PROBLEM Replacement parts…

• Page 586: Wiring Diagrams

  22. WIRING DIAGRAMS XL700V ······················································ 22-3 XL700VA ··················································· 22-4 22-1…

• Page 587: Immobilizer Receiver

  WIRING DIAGRAMS XL700V WIRING DIAGRAMS FRONT BRAKE LIGHT SWITCH ENGINE STOP •STARTER SWITCH FAN MOTOR VS SENSOR SERVICE CHECK CONNECTOR 33P Bl 33P GRAY COMBINATION METER IGNITION SWITCH IMMOBILIZER Bl/W PAIR CONTROL SOLENOID VALVE O/Bl RECEIVER IAT SENSOR Bl/W INJECTOR 1 P/Bu Gr/Bu Bl/W…

• Page 588
  WIRING DIAGRAMS XL700VA SERVICE CHECK CONNECTOR REAR WHEEL SPEED SENSOR / VS SENSOR FRONT WHEEL SPEED SENSOR SERVICE CHECK CONNECTOR ABS MODULATOR FRONT BRAKE LIGHT SWITCH ENGINE STOP •STARTER SWITCH FAN MOTOR 33P Bl 33P GRAY COMBINATION METER IGNITION SWITCH IMMOBILIZER Bl/W PAIR CONTROL SOLENOID VALVE…

• Page 589: Engine Does Not Start Or

  23. TROUBLESHOOTING ENGINE DOES NOT START OR POOR PERFORMANCE AT IS HARD TO START·································· 23-2 HIGH SPEED ············································· 23-6 ENGINE LACKS POWER ·························· 23-3 POOR HANDLING ···································· 23-7 POOR PERFORMANCE AT LOW AND IDLE SPEED ···························· 23-5 23-1…

• Page 590
  TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START TROUBLESHOOTING 1. Fuel Line Inspection Check fuel flow to throttle body. Does fuel reach the throttle body? – • Clogged fuel line and strainer • Clogged fuel tank breather • Faulty fuel pump unit (page 5-58) –…

• Page 591: Engine Lacks Power

  TROUBLESHOOTING ENGINE LACKS POWER 1. Drive Train Inspection Raise wheel off the ground and spin it by hand. Does the wheel spin freely? – • Brake dragging • Worn or damaged wheel bearings – GO TO STEP 2. 2. Tire Pressure Inspection Check tire pressure.

• Page 592
  TROUBLESHOOTING 7. Engine Oil Inspection Check oil level and condition. Is there correct level and good condition? – • Oil level too high • Oil level too low • Contaminated oil – GO TO STEP 8. 8. Ignition Timing Inspection Check ignition timing.
• Page 593
  TROUBLESHOOTING 13. Engine Knocking Inspection Accelerate or run at high speed. Is the engine knocking? – • Worn piston and cylinder • Wrong type of fuel • Thermostat stuck closed • Excessive carbon build-up in combustion chamber • Ignition timing too advance (Faulty ECM) •…

• Page 594: Poor Performance At High Speed

  TROUBLESHOOTING 6. IACV Inspection Check the IACV operation. Does the IACV operates normally? – Faulty IACV POOR PERFORMANCE AT HIGH SPEED 1. Ignition Timing Inspection Check ignition timing. Is the ignition timing correct? – • Faulty ECM • Faulty CKP sensor •…

• Page 595: Poor Handling

  TROUBLESHOOTING POOR HANDLING Steering is heavy • Steering top thread too tight • Damaged steering head bearings • Low tire pressure Either wheel is wobbling • Excessive wheel bearing play • Bent rim • Improperly installed wheel hub • Excessively worn swingarm pivot bearings •…

• Page 596
  MEMO…
• Page 597
  24. INDEX ABS CONNECTOR LOCATIONS ·································16-5 CYLINDER HEAD ASSEMBLY ···································· 8-23 ABS INDICATOR CIRCUIT TROUBLESHOOTING····16-11 CYLINDER HEAD COVER INSTALLATION ················ 8-33 ABS INDICATOR PROBLEM CODE INDEX ··············16-10 CYLINDER HEAD COVER REMOVAL ··························· 8-6 ABS MODULATOR ····················································16-24 CYLINDER HEAD DISASSEMBLY ······························ 8-15 ABS SYSTEM DIAGRAM ············································16-3 CYLINDER HEAD INSTALLATION······························…
• Page 598
  INDEX IGNITION TIMING ······················································· 18-8 SHOCK ABSORBER··················································· 14-13 IMMOBILIZER RECEIVER·········································· 21-14 SIDE COVER··································································· 2-4 INJECTOR···································································· 5-69 SIDESTAND INNER CENTER COWL ················································· 2-9 FRAME/BODY PANELS/EXHAUST SYSTEM ········ 2-23 KEY REGISTRATION PROCEDURES ························· 21-4 MAINTENANCE ······················································ 3-27 LICENSE LIGHT ··························································· 20-9 SIDESTAND SWITCH ················································ 20-25 LIGHTS/METERS/SWITCHES SPECIFICATIONS·······…

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