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Honda NC700 2012 User Manual
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19-2
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HYDRAULIC BRAKE
HYDRAULIC BRAKE
COMPONENT LOCATION
34 N·m (3.5 kgf·m, 25 lb
f·ft)
30 N·m (3.1 kgf·m, 22
lbf·ft)
12 N·m (1.2 kgf·m,
9 lbf·ft)
34 N·m (3.5 kgf·m, 25
lbf·ft)
34 N·m (3.5 kgf·m, 25 lb
f·ft)
NC700X/S:
17 N·m (1.7 kg
f·m, 13 lbf·ft)
NC700XA/SA
shown:
640
642
Table of Contents
A Few Words About Safety
1
Service Information
1
For Your Customer’s Safety
1
For Your Safety
1
Important Safety Precautions
1
How To Use This Manual
2
SYMBOLS
3
1. GENERAL INFORMATION
6
SERVICE RULES
7
ABBREVIATION
7
DESTINATION CODE
7
MODEL IDENTIFICATION
8
SERIAL NUMBERS
9
LABELS
10
SPECIFICATIONS
11
GENERAL SPECIFICATIONS
11
PGM-FI SPECIFICATIONS
13
IGNITION SYSTEM SPECIFICATIONS
13
ELECTRIC STARTER SPECIFICATION
13
FUEL SYSTEM SPECIFICATIONS
13
COOLING SYSTEM SPECIFICATIONS
13
LUBRICATION SYSTEM SPECIFICATIONS
14
CYLINDER HEAD/VALVES SPECIFICATIONS
14
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (NC700X/XA/S/SA)
15
DUAL CLUTCH TRANSMISSION SPECIFICATIONS (NC700XD/SD)
15
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
15
CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS
15
NC700X/XA/S/SA
15
NC700XD/SD
16
CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS
16
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
17
REAR WHEEL/SUSPENSION SPECIFICATIONS
17
HYDRAULIC BRAKE SPECIFICATIONS
18
BATTERY/CHARGING SYSTEM SPECIFICATIONS
18
LIGHTS/METERS/SWITCHES SPECIFICATIONS
19
TORQUE VALUES
20
STANDARD TORQUE VALUES
20
ENGINE & FRAME TORQUE VALUES
20
LUBRICATION & SEAL POINTS
28
ENGINE
28
FRAME
29
CABLE & HARNESS ROUTING
30
EMISSION CONTROL SYSTEMS
91
SOURCE OF EMISSIONS
91
CRANKCASE EMISSION CONTROL SYSTEM
91
EXHAUST EMISSION CONTROL SYSTEM
92
THREE-WAY CATALYTIC CONVERTER
92
NOISE EMISSION CONTROL SYSTEM
92
TECHNICAL FEATURES
92
CRACKING CONNECTING ROD
92
ECM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION (NC700X/XA/S/SA)
93
WHEN THERE IS A PROBLEM IN THE TXD/RXD LINE
93
PCM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION (NC700XD/SD)
94
WHEN THE SERIAL COMMUNICATION IS ABNORMAL
94
DUAL CLUTCH TRANSMISSION
95
2. FRAME/BODY PANELS/EXHAUST SYSTEM
96
BODY PANEL LOCATIONS (NC700X/XA)
97
BODY PANEL REMOVAL CHART
97
BODY PANEL LOCATIONS (NC700XD)
98
BODY PANEL REMOVAL CHART
98
BODY PANEL LOCATIONS (NC700S/SA)
99
BODY PANEL REMOVAL CHART
99
BODY PANEL LOCATIONS (NC700SD)
100
BODY PANEL REMOVAL CHART
100
SERVICE INFORMATION
101
GENERAL
101
TORQUE VALUES
101
TROUBLESHOOTING
101
Excessive exhaust noise
101
Poor performance
101
PILLION SEAT
102
REMOVAL/INSTALLATION
102
SINGLE SEAT
102
REMOVAL/INSTALLATION (NC700X/ XA/XD)
102
REMOVAL/INSTALLATION (NC700S/ SA/SD)
102
GRAB RAIL
103
REMOVAL/INSTALLATION
103
CENTER SEAT COWL
103
REMOVAL/INSTALLATION
103
SEAT COWL
104
REMOVAL/INSTALLATION
104
DISASSEMBLY/ASSEMBLY
104
REAR FENDER MUD GUARD (U type)
105
REMOVAL/INSTALLATION
105
BRAKE/TAIL/LICENSE LIGHT/TAIL LIGHT COVER
105
REMOVAL/INSTALLATION
105
DISASSEMBLY/ASSEMBLY
106
MUD GUARD
106
REMOVAL/INSTALLATION
106
REAR FENDER A
107
REMOVAL/INSTALLATION
107
REAR FENDER B
107
REMOVAL/INSTALLATION
107
AIR DUCT (NC700X/XA/XD)
108
REMOVAL/INSTALLATION
108
SIDE COWL (NC700S/SA/SD)
108
LEFT SIDE COWL REMOVAL/INSTALLATION
108
RIGHT SIDE COWL REMOVAL/INSTALLATION
109
SHROUD/SIDE COVER (NC700X/XA/XD)
109
REMOVAL/INSTALLATION
109
DISASSEMBLY/ASSEMBLY
110
SHELTER/SIDE COVER (NC700S/SA/SD)
110
REMOVAL/INSTALLATION
110
DISASSEMBLY/ASSEMBLY
111
CENTER COVER (NC700X/XA/XD)
111
REMOVAL/INSTALLATION
111
DISASSEMBLY/ASSEMBLY
112
LUGGAGE BOX LID
112
REMOVAL/INSTALLATION (NC700X/XA/XD)
112
REMOVAL/INSTALLATION (NC700S/SA/SD)
113
LUGGAGE BOX LID/HINGE ASSEMBLY
114
REMOVAL/INSTALLATION
114
LUGGAGE BOX
114
REMOVAL/INSTALLATION (NC700X/XA/XD)
114
REMOVAL/INSTALLATION (NC700S/SA/SD)
115
DISASSEMBLY/ASSEMBLY (NC700X/XA/XD)
116
DISASSEMBLY/ASSEMBLY (NC700S/SA/SD)
117
WINDSCREEN
118
REMOVAL/INSTALLATION (NC700X/XA/XD)
118
REMOVAL/INSTALLATION (NC700S/SA/SD)
118
FRONT SIDE COWL (NC700X/XA/XD)
119
REMOVAL/INSTALLATION
119
METER STAY (NC700X/XA/XD)
119
REMOVAL/INSTALLATION
119
FRONT UNDER COVER (NC700X/XA/ XD)
120
REMOVAL/INSTALLATION
120
INNER UPPER COVER (NC700X/XA/XD)
120
REMOVAL/INSTALLATION
120
HEADLIGHT/FRONT CENTER COWL (NC700X/XA/XD)
121
REMOVAL/INSTALLATION
121
DISASSEMBLY/ASSEMBLY
121
HEADLIGHT/HEADLIGHT STAY (NC700S/SA/SD)
122
REMOVAL/INSTALLATION
122
DISASSEMBLY/ASSEMBLY
122
HEADLIGHT COVER (NC700S/SA/SD)
122
REMOVAL/INSTALLATION
122
FRONT FENDER
123
REMOVAL/INSTALLATION
123
LOWER COWL
123
REMOVAL/INSTALLATION (NC700X/ XA/S/SA)
123
REMOVAL/INSTALLATION (NC700XD/ SD)
124
DISASSEMBLY/ASSEMBLY
124
LEFT REAR COVER
124
REMOVAL/INSTALLATION (NC700X/ XA/S/SA)
124
REMOVAL/INSTALLATION (NC700XD/ SD)
125
RIGHT ENGINE SIDE COVER (NC700XD/SD)
125
REMOVAL/INSTALLATION
125
GUARD PIPE (NC700XD/SD)
125
REMOVAL/INSTALLATION
125
BATTERY BOX
126
REMOVAL/INSTALLATION
126
CENTER CROSS PLATE
127
REMOVAL/INSTALLATION
127
EXHAUST PIPE/MUFFLER
127
MUFFLER REMOVAL/INSTALLATION
127
EXHAUST PIPE
129
REMOVAL
129
INSTALLATION
129
STUD BOLT REPLACEMENT
130
3. MAINTENANCE
132
SERVICE INFORMATION
133
GENERAL
133
TORQUE VALUES
133
MAINTENANCE SCHEDULE
134
NC700X/XA/S/SA
134
NC700XD/SD
135
FUEL LINE
136
INSPECTION
136
THROTTLE OPERATION
136
AIR CLEANER
138
REMOVAL/INSTALLATION (NC700X/ XA/XD)
138
REMOVAL/INSTALLATION (NC700S/ SA/SD)
138
CRANKCASE BREATHER
139
SPARK PLUG
139
REMOVAL/INSTALLATION
139
INSPECTION
140
VALVE CLEARANCE
141
INSPECTION
141
ADJUSTMENT
142
ENGINE OIL
143
OIL LEVEL INSPECTION
143
ENGINE OIL CHANGE
144
ENGINE OIL FILTER
144
CLUTCH OIL FILTER (NC700XD/SD)
145
ENGINE IDLE SPEED
146
RADIATOR COOLANT
146
COOLING SYSTEM
147
DRIVE CHAIN
147
DRIVE CHAIN SLACK INSPECTION
147
ADJUSTMENT
148
CLEANING AND LUBRICATION
148
SPROCKET INSPECTION
149
REPLACEMENT
150
DRIVE CHAIN SLIDER
151
BRAKE FLUID
152
FRONT BRAKE
152
REAR BRAKE
152
BRAKE PADS WEAR
153
FRONT BRAKE PADS
153
REAR BRAKE PADS
153
BRAKE SYSTEM
154
INSPECTION
154
BRAKE PEDAL HEIGHT ADJUSTMENT
154
BRAKE LIGHT SWITCH
155
BRAKE LOCK OPERATION (NC700XD/ SD)
155
INSPECTION
155
ADJUSTMENT
156
HEADLIGHT AIM
156
CLUTCH SYSTEM (NC700X/XA/S/SA)
157
SIDESTAND
158
INSPECTION
158
REMOVAL/INSTALLATION
158
SUSPENSION
159
FRONT SUSPENSION INSPECTION
159
REAR SUSPENSION INSPECTION
160
NUTS, BOLTS, FASTENERS
160
WHEELS/TIRES
160
STEERING HEAD BEARINGS
161
4. PGM-FI SYSTEM
162
PGM-FI SYSTEM LOCATION
163
PGM-FI SYSTEM DIAGRAM
165
SERVICE INFORMATION
167
GENERAL
167
SPECIFICATIONS
167
TORQUE VALUES
167
PGM-FI SYMPTOM TROUBLESHOOTING
168
PGM-FI CONNECTOR LOCATIONS
169
PGM-FI TROUBLESHOOTING INFORMATION
172
GENERAL TROUBLESHOOTING
172
Intermittent Failure
172
Opens and Shorts
172
If the MIL has come on
172
If the MIL did not stay on
172
SYSTEM DESCRIPTION
172
SELF-DIAGNOSIS SYSTEM
172
FAIL-SAFE FUNCTION
172
DTC
172
MIL Blink Pattern
172
MIL Check
172
CURRENT DTC/FREEZE DTC
173
HDS POCKET TESTER INFORMATION
173
How to connect the HDS pocket tester
173
ECM/PCM reset
173
DTC READOUT
173
Reading DTC with the MIL
173
ERASING DTC
174
How to erase the DTC with SCS connector
174
CIRCUIT INSPECTION
174
INSPECTION AT ECM/PCM CONNECTOR
174
TEST HARNESS CONNECTION (NC700X/XA/S/SA)
174
TEST HARNESS CONNECTION (NC700XD/SD)
175
TEST HARNESS TERMINAL LAYOUT
175
DTC INDEX
176
SENSOR UNIT POWER LINE INSPECTION
178
BEFORE DTC TROUBLESHOOTING
178
1. Sensor Unit Power Input Voltage Inspection
178
1. Sensor Unit Power Input Voltage Inspection
178
2. Sensor Unit Input Voltage Line Short Circuit Inspection
178
3. Sensor Unit Power Line Open Circuit Inspection
179
BEFORE MIL TROUBLESHOOTING
180
1. Sensor Unit Power Input Voltage Inspection 1
180
1. Sensor Unit Power Input Voltage Inspection 1
180
2. Sensor Unit Power Input Voltage Inspection 2
180
3. Sensor Unit Input Voltage Line Short Circuit Inspection
181
4. Sensor Unit Input Voltage Line Open Circuit Inspection
181
DTC TROUBLESHOOTING
182
DTC 1-1 (MAP SENSOR LOW VOLTAGE)
182
1. MAP Sensor System Inspection
182
1. MAP Sensor System Inspection
182
2. Sensor Unit Power Line Inspection
182
3. MAP Sensor Output Voltage Inspection
182
4. MAP Sensor Output Line Short Circuit Inspection
182
5. MAP Sensor Inspection
183
DTC 1-2 (MAP SENSOR HIGH VOLTAGE)
183
1. MAP Sensor System Inspection 1
183
1. MAP Sensor System Inspection 1
183
2. Sensor Unit Power Line Inspection
183
3. MAP Sensor System Inspection 2
183
4. MAP Sensor Output Line Open Circuit Inspection
184
DTC 7-1 (ECT SENSOR LOW VOLTAGE)
184
1. ECT Sensor System Inspection
184
1. ECT Sensor System Inspection
184
2. ECT Sensor Inspection
184
3. ECT Sensor Resistance Inspection
185
4. ECT Sensor Output Line Short Circuit Inspection
185
DTC 7-2 (ECT SENSOR HIGH VOLTAGE)
185
1. ECT Sensor System Inspection
185
1. ECT Sensor System Inspection
185
2. ECT Sensor Inspection
186
3. ECT Sensor Line Open Circuit Inspection
186
DTC 8-1 (TP SENSOR LOW VOLTAGE)
187
1. TP Sensor System Inspection
187
1. TP Sensor System Inspection
187
2. Sensor Unit Power Line Inspection
187
3. TP Sensor Output Line Short Circuit Inspection
187
4. TP Sensor Output Line Open Circuit Inspection
188
5. TP Sensor Inspection
188
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
188
1. TP Sensor System Inspection
188
1. TP Sensor System Inspection
188
2. TP Sensor Inspection
188
3. TP Sensor Resistance Inspection
189
4. TP Sensor Power Input Voltage Inspection
189
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
189
1. IAT Sensor System Inspection
189
1. IAT Sensor System Inspection
189
2. IAT Sensor Inspection
189
3. IAT Sensor Voltage Output Line Short Circuit Inspection
190
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)
190
1. IAT Sensor System Inspection
190
1. IAT Sensor System Inspection
190
2. IAT Sensor Inspection
190
3. IAT Sensor Line Open Circuit Inspection
191
DTC 11-1 (VS SENSOR)
191
1. VS Sensor System Inspection
191
1. VS Sensor System Inspection
191
2. Speedometer Inspection
191
3. VS Sensor Input Voltage Inspection
192
4. VS Sensor Signal Line Short Circuit Inspection
192
5. VS Sensor Signal Line Open Circuit Inspection
192
6. VS Sensor Inspection
193
DTC 12-1 (No.1 INJECTOR)
193
1. Injector System Inspection
193
1. Injector System Inspection
193
2. Injector Input Voltage Inspection
193
3. Injector Signal Line Short Circuit Inspection
194
4. Injector Resistance Inspection
194
5. Injector Signal Line Open Circuit Inspection
194
DTC 13-1 (No.2 INJECTOR)
194
DTC 21-1 (O2 SENSOR)
195
1. O2 Sensor System Inspection
195
1. O2 Sensor System Inspection
195
2. O2 Sensor Short Circuit Inspection
195
3. O2 Sensor Line Open Circuit Inspection 1
195
4. O2 Sensor Line Open Circuit Inspection 2
196
5. O2 Sensor Inspection
196
DTC 29-1 (IACV)
196
1. Recheck DTC
196
1. Recheck DTC
196
2. IACV Short Circuit Inspection
197
3. IACV Open Circuit Inspection
197
4. IACV Resistance Inspection
197
DTC 33-2 (EEPROM)
198
1. Recheck DTC
198
1. Recheck DTC
198
DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)
198
1. Recheck DTC
198
1. Recheck DTC
198
2. Bank Angle Sensor Power Input Line Short Circuit Inspection
198
3. Bank Angle Sensor Output Line Short Circuit Inspection
199
4. Bank Angle Sensor Inspection
199
DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)
199
1. Recheck DTC
199
1. Recheck DTC
199
2. Bank Angle Sensor Power Input Voltage Inspection
200
3. Bank Angle Sensor Output Line Short Circuit Inspection
200
4. Bank Angle Sensor Output Line Open Circuit Inspection
200
DTC 84-1 (CPU IN THE PCM MALFUNCTION) (NC700XD/SD)
201
1. DTC Recheck
201
1. DTC Recheck
201
DTC 86-1 (METER COMMUNICATION MALFUNCTION)
201
1. Recheck DTC
201
1. Recheck DTC
201
2. Combination Meter Serial Line Short Circuit Inspection
201
3. Combination Meter Serial Line Open Circuit Inspection
202
4. Combination Meter Serial Line Output Voltage Inspection
202
5. ECM Serial Line Output Voltage Inspection
202
DTC 87-1 (EOP SWITCH MALFUNCTION)
203
1. EOP Switch System Inspection
203
1. EOP Switch System Inspection
203
2. EOP Switch Output Line Open Circuit Inspection
204
3. EOP Switch Inspection
204
MIL TROUBLESHOOTING
204
MIL 1 BLINK (MAP SENSOR)
204
1. Sensor Unit Power Line Inspection
204
1. Sensor Unit Power Line Inspection
204
2. MAP Sensor Output Voltage Inspection 1
205
3. MAP Sensor Output Voltage Inspection 2
205
4. MAP Sensor Output Line Short Circuit Inspection
205
5. MAP Sensor Output Line Open Circuit Inspection
206
MIL 7 BLINKS (ECT SENSOR)
206
1. ECT Sensor Output Voltage Inspection
206
1. ECT Sensor Output Voltage Inspection
206
2. ECT Sensor Input Voltage Inspection
207
3. ECT Sensor Resistance Inspection
207
4. ECT Sensor Line Open Circuit Inspection
207
5. ECT Sensor Output Line Short Circuit Inspection
208
MIL 8 BLINKS (TP SENSOR)
208
1. Sensor Unit Power Line Inspection
208
1. Sensor Unit Power Line Inspection
208
2. TP Sensor Output Voltage Inspection
208
3. TP Sensor Output Line Short Circuit Inspection
208
4. TP Sensor Output Line Open Circuit Inspection
209
MIL 9 BLINKS (IAT SENSOR)
209
1. IAT Sensor Output Voltage Inspection
209
1. IAT Sensor Output Voltage Inspection
209
2. IAT Sensor Input Voltage Inspection
210
3. IAT Sensor Resistance Inspection
210
4. IAT Sensor Line Open Circuit Inspection
210
5. IAT Sensor Output Line Short Circuit Inspection
211
MIL 11 BLINKS (VS SENSOR) (NC700X/ XA/S/SA)
211
1. Speedometer Inspection
211
1. Speedometer Inspection
211
2. VS Sensor Pulse Inspection
211
3. VS Sensor Input Voltage Inspection
211
4. VS Sensor Signal Line Open Circuit Inspection
212
5. VS Sensor Signal Line Short Circuit Inspection
212
MIL 11 BLINKS (VS SENSOR) (NC700XD/SD)
212
1. VS Sensor Pulse Inspection
212
1. VS Sensor Pulse Inspection
212
2. VS Sensor Input Voltage Inspection
213
3. VS Sensor Signal Line Open Circuit Inspection
213
4. VS Sensor Signal Line Short Circuit Inspection
213
5. VS Sensor Inspection
213
MIL 12 BLINKS (No.1 INJECTOR)
214
1. Injector Input Voltage Inspection
214
1. Injector Input Voltage Inspection
214
2. Injector Signal Line Short Circuit Inspection
214
3. Injector Resistance Inspection
214
4. Injector Signal Line Open Circuit Inspection
215
MIL 13 BLINKS (No.2 INJECTOR)
215
MIL 21 BLINKS (O2 SENSOR)
215
1. O2 Sensor System Inspection
215
1. O2 Sensor System Inspection
215
2. O2 Sensor Line Short Circuit Inspection
216
3. O2 Sensor Line Open Circuit Inspection 1
216
4. O2 Sensor Line Open Circuit Inspection 2
216
5. O2 Sensor Inspection
217
MIL 29 BLINKS (IACV)
217
1. IACV Resistance Inspection
217
1. IACV Resistance Inspection
217
2. IACV Short Circuit Inspection
218
3. IACV Open Circuit Inspection
218
MIL 54 BLINKS (BANK ANGLE SENSOR)
219
1. Bank Angle Sensor Power Input Voltage Inspection
219
1. Bank Angle Sensor Power Input Voltage Inspection
219
2. Bank Angle Sensor Output Line Short Circuit Inspection
219
3. Bank Angle Sensor Output Line Open Circuit Inspection
220
4. Bank Angle Sensor Inspection
220
MIL 84 BLINKS (CPU IN THE PCM MALFUNCTION) (NC700XD/SD)
220
1. DTC Recheck
220
1. DTC Recheck
220
MIL 86 BLINKS (METER COMMUNICATION MALFUNCTION)
221
1. Combination Meter Serial Line Output Voltage Inspection
221
1. Combination Meter Serial Line Output Voltage Inspection
221
2. ECM/PCM Serial Line Output Voltage Inspection
221
MIL 87 BLINKS (EOP SWITCH MALFUNCTION)
223
1. EOP Switch Output Line Open Circuit Inspection
223
1. EOP Switch Output Line Open Circuit Inspection
223
2. EOP Switch Inspection
223
MIL CIRCUIT TROUBLESHOOTING
224
FUEL CUT RELAY
225
INSPECTION
225
ECT SENSOR
225
REMOVAL/INSTALLATION
225
BANK ANGLE SENSOR
226
REMOVAL/INSTALLATION
226
SYSTEM INSPECTION WITH HDS POCKET TESTER
227
SYSTEM INSPECTION WITH ECM TEST HARNESS
227
ECM (NC700X/XA/S/SA)/PCM (NC700XD/SD)
228
REMOVAL/INSTALLATION (NC700X/ XA/S/SA)
228
REMOVAL/INSTALLATION (NC700XD/ SD)
228
ECM/PCM POWER/GROUND LINE INSPECTION
229
ENGINE DOES NOT START (MIL does not blink)
229
1. ECM/PCM Power Input Voltage Inspection
229
2. ECM/PCM Ground Line Inspection
230
O2 SENSOR
230
REMOVAL
230
INSTALLATION
231
5. IGNITION SYSTEM
232
SYSTEM LOCATION
233
SYSTEM DIAGRAM
234
SERVICE INFORMATION
235
GENERAL
235
SPECIFICATIONS
235
TORQUE VALUE
235
TROUBLESHOOTING
236
IGNITION SYSTEM INSPECTION
237
IGNITION COIL PRIMARY PEAK VOLTAGE
237
CKP SENSOR PEAK VOLTAGE (NC700X/XA/S/SA)
238
CKP SENSOR PEAK VOLTAGE (NC700XD/SD)
239
IGNITION TIMING
240
IGNITION COIL
241
REMOVAL/INSTALLATION
241
No.1 IGNITION COIL
241
No.2 IGNITION COIL
241
CKP SENSOR
242
REMOVAL/INSTALLATION (NC700X/ XA/S/SA)
242
REMOVAL/INSTALLATION (NC700XD/ SD)
242
6. ELECTRIC STARTER
244
SYSTEM LOCATION
245
SYSTEM DIAGRAM
246
SERVICE INFORMATION
247
GENERAL
247
SPECIFICATION
247
TORQUE VALUE
247
TROUBLESHOOTING
248
Starter motor does not turn (NC700X/XA/S/SA)
248
1. Fuse Inspection
248
2. Battery Inspection
248
3. Starter Relay Switch Operation
248
4. Starter Motor Inspection
248
5. Relay Coil Ground Lines Inspection
248
6. Starter Relay Input Voltage Inspection
248
7. Starter Relay Switch Continuity Inspection
249
Starter motor does not turn (NC700XD/SD)
249
1. Fuse Inspection
249
2. Battery Inspection
249
3. Starter Relay Switch Operation Inspection
249
4. Starter Motor Inspection
249
5. Relay Coil Input Line Inspection
249
6. Relay Coil Ground Line Inspection
249
7. Starter Relay Switch Continuity Inspection
249
8. Starter Relay Inspection
250
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. (NC700X/XA/S/SA)
250
1. Clutch Switch Inspection
250
2. Sidestand Switch Inspection
250
Starter motor turns slowly
250
Starter motor turns, but engine does not turn
250
Starter relay switch "Clicks", but engine does not turn over
250
STARTER MOTOR
251
REMOVAL/INSTALLATION
251
DISASSEMBLY/ASSEMBLY
251
INSPECTION
252
FRONT COVER
252
REAR COVER
252
ARMATURE
252
STARTER RELAY SWITCH
253
INSPECTION
253
STARTER RELAY INPUT VOLTAGE
253
GROUND LINE (NC700X/XA/S/SA)
253
GROUND LINE (NC700XD/SD)
254
OPERATION CHECK
254
REMOVAL/INSTALLATION
254
NEUTRAL DIODE (NC700X/XA/S/SA)
255
INSPECTION
255
STARTER RELAY (NC700XD/SD)
255
INSPECTION
255
7. FUEL SYSTEM
256
COMPONENT LOCATION
257
SERVICE INFORMATION
258
GENERAL
258
SPECIFICATIONS
258
TORQUE VALUES
258
FUEL LINE REPLACEMENT
259
FUEL PRESSURE RELIEVING
259
QUICK CONNECT FITTING REMOVAL
259
FUEL PUMP SIDE
259
INJECTOR SIDE
259
QUICK CONNECT FITTING INSTALLATION
260
FUEL PUMP SIDE
260
INJECTOR SIDE
260
FUEL PRESSURE NORMALIZATION
261
FUEL PRESSURE TEST
262
FUEL FLOW INSPECTION
262
FUEL TANK
263
REMOVAL/INSTALLATION
263
FUEL PUMP SIDE QUICK CONNECT FITTING REMOVAL
263
FUEL PUMP SIDE QUICK CONNECT FITTING INSTALLATION
264
FUEL PUMP UNIT
265
INSPECTION
265
REMOVAL
266
DISASSEMBLY/INSPECTION
266
ASSEMBLY
267
INSTALLATION
268
AIR CLEANER HOUSING
269
REMOVAL/INSTALLATION
269
THROTTLE BODY
270
REMOVAL
270
DISASSEMBLY
271
ASSEMBLY
272
INSTALLATION
273
THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE
274
INJECTOR
275
REMOVAL
275
INSTALLATION
276
IACV
277
REMOVAL/INSPECTION
277
INSTALLATION
278
8. COOLING SYSTEM
280
SYSTEM FLOW PATTERN
281
SERVICE INFORMATION
282
GENERAL
282
SPECIFICATIONS
282
TORQUE VALUES
282
TROUBLESHOOTING
283
Engine temperature too high
283
Engine temperature too low
283
Coolant leak
283
SYSTEM TESTING
284
COOLANT (HYDROMETER TEST)
284
RADIATOR CAP/SYSTEM PRESSURE INSPECTION
285
COOLANT REPLACEMENT
285
PREPARATION
285
REPLACEMENT/AIR BLEEDING
285
THERMOSTAT/THERMOSTAT HOUSING
286
REMOVAL/INSTALLATION
286
INSPECTION
288
RADIATOR
288
REMOVAL/INSTALLATION
288
DISASSEMBLY/ASSEMBLY
290
WATER PUMP
291
MECHANICAL SEAL INSPECTION
291
REMOVAL/INSTALLATION
291
DISASSEMBLY/ASSEMBLY
293
RADIATOR RESERVE TANK
293
REMOVAL/INSTALLATION
293
FAN CONT. RELAY
294
INSPECTION
294
9. LUBRICATION SYSTEM
296
LUBRICATION SYSTEM DIAGRAM
297
SERVICE INFORMATION
299
GENERAL
299
SPECIFICATIONS
299
TORQUE VALUE
299
TROUBLESHOOTING
300
Oil level too low
300
Low oil pressure
300
No oil pressure
300
High oil pressure
300
Oil contamination
300
Oil emulsification
300
OIL PRESSURE INSPECTION
301
OIL PUMP (NC700X/XA/S/SA)
301
REMOVAL/INSTALLATION
301
DISASSEMBLY/ASSEMBLY
302
INSPECTION
302
OIL PUMP (NC700XD/SD)
303
REMOVAL/INSTALLATION
303
DISASSEMBLY
304
INSPECTION
305
ASSEMBLY
306
OIL STRAINER
306
REMOVAL
306
INSTALLATION
307
10. CYLINDER HEAD/VALVES
308
COMPONENT LOCATION
309
SERVICE INFORMATION
310
GENERAL
310
SPECIFICATIONS
310
TORQUE VALUES
310
TROUBLESHOOTING
311
Compression too low, hard starting or poor performance at low speed
311
Compression too high, overheating or knocking
311
Excessive smoke
311
Excessive noise
311
Rough idle
311
CYLINDER COMPRESSION TEST
312
CYLINDER HEAD COVER
312
REMOVAL/INSTALLATION
312
DISASSEMBLY/ASSEMBLY
314
ROCKER ARM
315
REMOVAL
315
DISASSEMBLY/ASSEMBLY
316
INSPECTION
316
INSTALLATION
317
CAM CHAIN TENSIONER
318
CAM CHAIN INSPECTION
318
RELEASING CAM CHAIN TENSION
318
REMOVAL/INSTALLATION
319
INSPECTION
319
APPLYING CAM CHAIN TENSION
319
CAMSHAFT
320
REMOVAL
320
INSPECTION
320
CAMSHAFT
320
CYLINDER HEAD
321
CAM SPROCKET
321
INSTALLATION
322
CYLINDER HEAD
323
REMOVAL
323
DISASSEMBLY
326
INSPECTION
326
CYLINDER HEAD
326
VALVE SPRING
327
VALVE/VALVE GUIDE
327
VALVE GUIDE REPLACEMENT
328
VALVE SEAT INSPECTION/REFACING
329
VALVE SEAT REFACING
330
ASSEMBLY
331
INSTALLATION
332
11. CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA)
336
COMPONENT LOCATION
337
SERVICE INFORMATION
338
GENERAL
338
SPECIFICATIONS
338
TORQUE VALUES
338
TROUBLESHOOTING
339
Clutch lever is too hard to pull in
339
Clutch slips when accelerating
339
Clutch will not disengage or motorcycle creeps with clutch disengaged
339
Hard to shift
339
Transmission jumps out of gear
339
Gearshift pedal will not return
339
RIGHT CRANKCASE COVER
340
REMOVAL/INSTALLATION
340
CLUTCH LIFTER ARM REMOVAL/ INSTALLATION
341
CLUTCH
342
REMOVAL
342
INSPECTION
344
CLUTCH LIFTER BEARING
344
CLUTCH SPRING
344
CLUTCH CENTER
344
CLUTCH LIFTER ROD B
345
CLUTCH DISC
345
CLUTCH PLATE
345
JUDDER SPRING/SPRING SEAT
345
CLUTCH OUTER/PRIMARY DRIVEN GEAR/CLUTCH OUTER GUIDE
346
MAINSHAFT
346
INSTALLATION
347
PRIMARY DRIVE GEAR/CKP SENSOR ROTOR
350
REMOVAL
350
INSPECTION
350
INSTALLATION
350
GEARSHIFT LINKAGE
351
REMOVAL
351
INSPECTION
352
INSTALLATION
352
GEARSHIFT PEDAL
354
REMOVAL/INSTALLATION
354
12. DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD)
356
COMPONENT LOCATION
357
SERVICE INFORMATION
358
GENERAL
358
For DCT System Troubleshooting
358
Shift Control Motor Function Procedures
358
Linear Solenoid Valve Function Procedures
359
SPECIFICATIONS
359
TORQUE VALUES
359
DCT SYMPTOM TROUBLESHOOTING
360
CLUTCH SLIPS AND MOTORCYCLE DOES NOT ACCELERATE
360
EXCESSIVE NOISE OR VIBRATION AROUND THE DCT SYSTEM
360
DCT ELECTRICAL SYSTEM LOCATION
361
DCT SYSTEM DIAGRAM
362
DCT CONNECTOR LOCATIONS
363
DCT TROUBLESHOOTING INFORMATION
366
GENERAL TROUBLESHOOTING
366
Intermittent Failure
366
Opens and Shorts
366
If the shift indicator "–" has come on
366
If the shift indicator "–" did not stay on
366
SYSTEM DESCRIPTION
366
SELF-DIAGNOSIS SYSTEM
366
FAIL-SAFE FUNCTION
366
DTC (Diagnostic Trouble Code)
366
Shift indicator "–" Blink Pattern
367
Shift indicator Check
367
CURRENT DTC/STORED DTC
367
HDS POCKET TESTER INFORMATION
367
DTC READOUT
367
Reading DTC with the shift indicator "–"
368
ERASING DTC
368
How to erase the DTC without HDS
368
DTC INDEX
370
DTC TROUBLESHOOTING
375
DTC 8-1 (TP SENSOR ABNORMAL VOLTAGE)
375
1. TP Sensor System Inspection
375
1. TP Sensor System Inspection
375
DTC 9-1 (CLUTCH LINE EOP SENSOR LOW VOLTAGE)
375
1. Clutch Line EOP Sensor System Inspection
375
1. Clutch Line EOP Sensor System Inspection
375
2. Clutch Line EOP Sensor Inspection
375
3. Clutch Line EOP Sensor Input Line Open Circuit Inspection
375
4. Clutch Line EOP Sensor Output Line Short Circuit Inspection
376
DTC 9-2 (CLUTCH LINE EOP SENSOR HIGH VOLTAGE)
376
1. Clutch Line EOP Sensor System Inspection
376
1. Clutch Line EOP Sensor System Inspection
376
2. Clutch Line EOP Sensor Inspection
376
3. Clutch Line EOP Sensor Ground Line Open Circuit Inspection
377
4. Clutch Line EOP Sensor Output Line Open Circuit Inspection
377
DTC 19-1 (CKP SENSOR NO SIGNAL)
377
1. CKP sensor Peak Voltage Inspection
377
1. CKP sensor Peak Voltage Inspection
377
2. CKP sensor Circuit Inspection
378
DTC 21-1 (SHIFT SPINDLE ANGLE SENSOR LOW VOLTAGE)
378
1. Shift Spindle Angle Sensor System Inspection
378
1. Shift Spindle Angle Sensor System Inspection
378
2. Shift Spindle Angle Sensor Input Line Open Circuit Inspection
378
3. Shift Spindle Angle Sensor Output Line Open Circuit Inspection
379
4. Shift Spindle Angle Sensor Output Line Short Circuit Inspection
379
5. Shift Spindle Angle Sensor Inspection
379
DTC 21-2 (SHIFT SPINDLE ANGLE SENSOR HIGH VOLTAGE)
379
1. Shift Spindle Angle Sensor System Inspection
379
1. Shift Spindle Angle Sensor System Inspection
379
2. Shift Spindle Angle Sensor Ground Line Open Circuit Inspection
380
3. Shift Spindle Angle Sensor System Inspection
380
DTC 22-1 (SHIFT SPINDLE OPERATION MALFUNCTION: AFTER OPERATING GEARSHIFT MECHANISM)
380
1. Shift Spindle Angle Sensor System Inspection
380
1. Shift Spindle Angle Sensor System Inspection
380
2. Shift Control Motor/Reduction Gear Condition
380
3. Shift Control Motor Condition Inspection
381
4. Shift Spindle Angle Sensor System Inspection
381
5. Shift Spindle Angle Sensor Condition Inspection
381
6. DTC Recheck
381
DTC 23-1 (SHIFT SPINDLE OPERATION MALFUNCTION: WHILE OPERATING GEARSHIFT MECHANISM)
381
DTC 24-1 (SHIFT CONTROL MOTOR DRIVE CIRCUIT)
382
1. Shift Control Motor Line Open Circuit Inspection
382
1. Shift Control Motor Line Open Circuit Inspection
382
2. Shift Control Motor Line Short Circuit Inspection
382
3. Shift Control Motor Inspection
382
DTC 27-1 (SHIFT DRUM POSITION MALFUNCTION)
383
1. TR Sensor System Inspection
383
1. TR Sensor System Inspection
383
2. Shift Control Motor/Reduction gear condition
383
3. Shift Control Motor Condition Inspection
383
4. TR Sensor System Inspection
383
5. TR Sensor Condition Inspection
384
6. DTC Recheck
384
DTC 31-1 (SHIFT CONTROL MOTOR LOW VOLTAGE)
384
1. DTC Recheck
384
1. DTC Recheck
384
2. Shift Control Motor Line Open Circuit Inspection
384
DTC 32-1 (FAIL SAFE RELAY CIRCUIT MALFUNCTION)
385
1. Shift Control Motor Power Supply Voltage Inspection
385
1. Shift Control Motor Power Supply Voltage Inspection
385
2. DTC Recheck
385
DTC 37-1 (IGNITION HOLD RELAY MALFUNCTION)
385
1. PCM (DCT Drive Circuit) Sub Power Voltage Inspection
385
1. PCM (DCT Drive Circuit) Sub Power Voltage Inspection
385
2. DTC Recheck
386
DTC 41-1 (N-D SHIFT SWITCH MALFUNCTION)
386
1. N-D Shift Switch Power Input Voltage Inspection
386
1. N-D Shift Switch Power Input Voltage Inspection
386
2. N-D Shift Switch Inspection
386
3. N-D Shift Switch Input Line Open Circuit Inspection
387
4. N-D Shift Switch Input Line Short Circuit Inspection
387
DTC 42-1 (SHIFT SWITCH MALFUNCTION)
388
1. Shift Switch Power Input Voltage Inspection
388
1. Shift Switch Power Input Voltage Inspection
388
2. Shift Switch Inspection
388
3. Shift Switch Input Line Open Circuit Inspection
389
4. Shift Switch Input Line Short Circuit Inspection
389
DTC 44-1 (EOT SENSOR LOW VOLTAGE)
389
1. EOT Sensor System Inspection
389
1. EOT Sensor System Inspection
389
2. EOT Sensor Inspection
390
3. EOT Sensor Resistance Inspection
390
4. EOT Sensor Input Line Short Circuit Inspection
390
DTC 44-2 (EOT SENSOR HIGH VOLTAGE)
390
1. EOT Sensor System Inspection
390
1. EOT Sensor System Inspection
390
2. EOT Sensor Inspection
391
3. EOT Sensor Input Line Open Circuit Inspection
391
4. EOT Sensor Ground Line Open Circuit Inspection
391
DTC 47-1 or 48-1 (No.1 or No.2 CLUTCH EOP SENSOR LOW VOLTAGE)
392
1. Clutch EOP Sensor System Inspection
392
1. Clutch EOP Sensor System Inspection
392
2. Clutch EOP Sensor Inspection
392
3. Clutch EOP Sensor Input Line Open Circuit Inspection
392
4. Clutch EOP Sensor Output Line Short Circuit Inspection
392
DTC 47-2 or 48-2 (No.1 or No.2 CLUTCH EOP SENSOR HIGH VOLTAGE)
393
1. Clutch EOP Sensor System Inspection
393
1. Clutch EOP Sensor System Inspection
393
2. Clutch EOP Sensor Inspection
393
3. Clutch EOP Sensor Ground Line Open Circuit Inspection
393
4. Clutch EOP Sensor Output Line Open Circuit Inspection
394
DTC 49-1, 49-2 (CLUTCH LINE LOW OIL PRESSURE)
394
1. Clutch Line EOP Sensor System Inspection
394
1. Clutch Line EOP Sensor System Inspection
394
2. Engine Oil Level Inspection
394
3. Clutch Line Oil Filter Condition Inspection
394
4. Clutch Line EOP Sensor Inspection
395
5. PCM Inspection
395
DTC 51-1 (TR SENSOR LOW VOLTAGE)
395
1. TR Sensor System Inspection
395
1. TR Sensor System Inspection
395
2. TR Sensor Input Line Open Circuit Inspection
395
3. TR Sensor Output Line Open Circuit Inspection
396
4. TR Sensor Output Line Short Circuit Inspection
396
5. TR Sensor Inspection
396
DTC 51-2 (TR SENSOR HIGH VOLTAGE)
396
1. TR Sensor System Inspection
396
1. TR Sensor System Inspection
396
2. TR Sensor Ground Line Open Circuit Inspection
397
3. TR Sensor Inspection
397
DTC 52-1 (NEUTRAL SWITCH STUCK OFF)
397
1. DTC Recheck
397
1. DTC Recheck
397
2. Neutral Switch Line Open Circuit Inspection
397
3. Neutral Switch Inspection
398
DTC 52-2 (NEUTRAL SWITCH STUCK ON)
398
1. Neutral Switch Line Short Circuit Inspection
398
1. Neutral Switch Line Short Circuit Inspection
398
2. Neutral Switch Inspection
398
DTC 53-1 (INNER MAINSHAFT SENSOR SPEED LOW)
398
1. DTC Recheck
398
1. DTC Recheck
398
2. Inner Mainshaft Sensor Input Voltage Inspection
399
3. Inner Mainshaft Sensor Output Line Inspection
399
4. Inner Mainshaft Sensor Input Line Open Circuit Inspection
399
5. Inner Mainshaft Sensor Ground Line Open Circuit Inspection
400
6. Inner Mainshaft Sensor Output Line Open Circuit Inspection
400
7. Inner Mainshaft Sensor Output Line Short Circuit Inspection
400
8. Inner Mainshaft Sensor Inspection
400
DTC 54-1 (OUTER MAINSHAFT SENSOR SPEED LOW)
401
1. DTC Recheck
401
1. DTC Recheck
401
2. Outer Mainshaft Sensor Input Voltage Inspection
401
3. Outer Mainshaft Sensor Output Line Inspection
401
4. Outer Mainshaft Sensor Input Line Open Circuit Inspection
402
5. Outer Mainshaft Sensor Ground Line Open Circuit Inspection
402
6. Outer Mainshaft Sensor Output Line Open Circuit Inspection
402
7. Outer Mainshaft Sensor Output Line Short Circuit Inspection
403
8. Outer Mainshaft Sensor Condition Inspection
403
DTC 55-1, 55-2 (No.1 LINEAR SOLENOID VALVE)
403
1. DTC Recheck
403
1. DTC Recheck
403
2. No.1 Linear Solenoid Valve Inspection
403
3. No.1 Linear Solenoid Valve Input/ground Line Open Circuit Inspection
404
4. No.1 Linear Solenoid Valve Input/ground Line Short Circuit Inspection
404
DTC 56-1, 56-2 (No.2 LINEAR SOLENOID VALVE)
404
1. DTC Recheck
404
1. DTC Recheck
404
2. No.2 Linear Solenoid Valve Inspection
405
3. No.2 Linear Solenoid Valve Input/ground Line Open Circuit Inspection
405
4. No.2 Linear Solenoid Valve Input/ground Line Short Circuit Inspection
405
DTC 57-1 (GEARSHIFT MECHANISM MALFUNCTION)
405
DTC 57-2 (GEAR POSITION MALFUNCTION; JUMPS OUT OF GEAR)
405
DTC 58-1 (No.1 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR)
406
1. Clutch Condition Inspection
406
1. Clutch Condition Inspection
406
2. Clutch Oil Line Inspection
406
DTC 59-1 (No.2 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR)
406
DTC 61-1, 61-2, 61-3, 61-4, 62-1, 62-2 (No.1 CLUTCH OIL PRESSURE MALFUNCTION)
406
1. DTC Recheck
406
1. DTC Recheck
406
2. No.1 Clutch EOP Sensor Inspection
406
3. PCM Inspection
407
DTC 63-1, 63-2, 63-3, 63-4, 64-1, 64-2 (No.2 CLUTCH OIL PRESSURE MALFUNCTION)
407
1. DTC Recheck
407
1. DTC Recheck
407
2. No.2 Clutch EOP Sensor Inspection
407
3. PCM Inspection
407
DTC 65-1 (FRONT AND REAR WHEEL SPEED SIGNAL MALFUNCTION)
408
1. DTC Recheck
408
1. DTC Recheck
408
2. Front Wheel Speed Sensor Air Gap Inspection
408
3. Front Wheel Speed Sensor Condition Inspection
408
4. VS Sensor Condition Inspection
408
DTC 66-1 (VS SENSOR NO SIGNAL)
409
1. DTC Recheck
409
1. DTC Recheck
409
2. VS Sensor Input Voltage Inspection
409
3. VS Sensor Output Line Inspection
409
4. VS Sensor Output Line Open Circuit Inspection
410
5. VS Sensor Output Line Short Circuit Inspection
410
6. VS Sensor Inspection
410
DTC 67-1 (FRONT WHEEL SPEED SENSOR NO SIGNAL)
410
1. DTC Recheck
410
1. DTC Recheck
410
2. ABS Problem Code Inspection
411
3. Front Wheel Speed Sensor Line Open Circuit Inspection
411
4. Front Wheel Speed Sensor Line Short Circuit Inspection
411
DTC 68-1 (No.1 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS)
411
1. DTC Recheck
411
1. DTC Recheck
411
2. Clutch Clearance Inspection
412
DTC 69-1 (No.2 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS)
412
1. DTC Recheck
412
1. DTC Recheck
412
2. Clutch Condition Inspection
412
DTC 71-1, 72-1 (INNER, OUTER MAINSHAFT/COUNTERSHAFT SPEED RATIO FAILURE)
412
1. DTC Recheck 1
412
1. DTC Recheck 1
412
2. DTC Recheck 2
413
DTC 84-1 (CPU IN THE PCM MALFUNCTION)
413
1. DTC Recheck
413
1. DTC Recheck
413
DTC 1-1 (SHIFT PEDAL ANGLE SENSOR (OPTIONAL) MALFUNCTION)
413
1. Recheck the DTC
413
1. Recheck the DTC
413
2. Shift Pedal Angle Sensor Input Voltage Inspection
414
3. Shift Pedal Angle Sensor Open Circuit Inspection
414
4. Shift Pedal Angle Sensor Output Line Open Circuit Inspection
414
5. Shift Pedal Angle Sensor Output Line Short Circuit Inspection
415
6. Shift Pedal Angle Sensor Resistance Inspection
415
SHIFT INDICATOR TROUBLESHOOTING
416
DTC 9 (CLUTCH LINE EOP SENSOR)
416
1. Clutch Line EOP Sensor Input Voltage Inspection
416
1. Clutch Line EOP Sensor Input Voltage Inspection
416
2. Clutch Line EOP Sensor Output Line Open Circuit Inspection
416
3. Clutch Line EOP Sensor Output Line Short Circuit Inspection
416
4. Clutch Line EOP Sensor Inspection
417
5. Clutch Line EOP Sensor Power/Ground Line Open Circuit Inspection
417
DTC 19 (CKP SENSOR)
417
1. CKP Sensor Peak Voltage Inspection at PCM
417
1. CKP Sensor Peak Voltage Inspection at PCM
417
2. CKP Sensor Peak Voltage Inspection
418
DTC 21 (SHIFT SPINDLE ANGLE SENSOR)
418
1. Shift Spindle Angle Sensor Input Voltage Inspection
418
1. Shift Spindle Angle Sensor Input Voltage Inspection
418
2. Shift Spindle Angle Sensor Output Line Open Circuit Inspection
418
3. Shift Spindle Angle Sensor Output Line Short Circuit Inspection
419
4. Shift Spindle Angle Sensor Inspection
419
5. Shift Spindle Angle Sensor Power/Ground Line Open Circuit Inspection
419
DTC 22, 23 (SHIFT SPINDLE OPERATION MALFUNCTION)
419
1. Shift Control Motor/Reduction gear condition
419
1. Shift Control Motor/Reduction gear condition
419
2. Shift Control Motor Condition Inspection
420
3. Shift Spindle Angle Sensor Condition Inspection
420
DTC 24 (SHIFT CONTROL MOTOR DRIVE CIRCUIT)
420
1. Shift Control Motor Line Open Circuit Inspection
420
1. Shift Control Motor Line Open Circuit Inspection
420
2. Shift Control Motor Line Short Circuit Inspection
421
3. Shift Control Motor Inspection
421
DTC 27 (SHIFT DRUM POSITION)
421
1. Shift Control Motor/Reduction gear condition
421
1. Shift Control Motor/Reduction gear condition
421
2. Shift Control Motor Condition Inspection
421
3. TR Sensor Condition Inspection
422
4. DTC Recheck
422
DTC 31 (SHIFT CONTROL MOTOR)
422
1. PVB Fuse Inspection
422
1. PVB Fuse Inspection
422
2. Shift Control Motor Line Open Circuit Inspection
422
DTC 32 (FAIL SAFE RELAY)
423
1. PVB Fuse Inspection
423
1. PVB Fuse Inspection
423
2. Shift Control Motor Power Supply Voltage Inspection
423
DTC 37 (IGNITION HOLD RELAY)
423
1. SUB PVB Fuse Inspection
423
1. SUB PVB Fuse Inspection
423
2. PCM (DCT Drive Circuit) Sub Power Voltage Inspection
424
DTC 41 (N-D SHIFT SWITCH)
424
1. N-D Shift Switch Power Input Voltage Inspection
424
1. N-D Shift Switch Power Input Voltage Inspection
424
2. N-D Shift Switch Inspection
425
3. N-D Shift Switch Input Line Open Circuit Inspection
425
4. N-D Shift Switch Input Line Short Circuit Inspection
426
DTC 42 (SHIFT SWITCH)
426
1. Shift Switch Power Input Voltage Inspection
426
1. Shift Switch Power Input Voltage Inspection
426
2. Shift Switch Inspection
427
3. Shift Switch Input Line Open Circuit Inspection
427
4. Shift Switch Input Line Short Circuit Inspection
428
DTC 44 (EOT SENSOR)
428
1. EOT Sensor Input Line Open Circuit Inspection
428
1. EOT Sensor Input Line Open Circuit Inspection
428
2. EOT Sensor Input Line Short Circuit Inspection
428
3. EOT Sensor Ground Line Open Circuit Inspection
429
4. EOT Sensor Resistance Inspection
429
DTC 47 or 48 (No.1 or No.2 CLUTCH EOP SENSOR)
429
1. Clutch EOP Sensor Input Voltage Inspection
429
1. Clutch EOP Sensor Input Voltage Inspection
429
2. Clutch EOP Sensor Output Line Open Circuit Inspection
430
3. Clutch EOP Sensor Output Line Short Circuit Inspection
430
4. Clutch EOP Sensor Inspection
430
5. Clutch EOP Sensor Power/Ground Line Open Circuit Inspection
430
DTC 49 (CLUTCH LINE LOW OIL PRESSURE)
431
1. Engine Oil Level Inspection
431
1. Engine Oil Level Inspection
431
2. Clutch Line Oil Filter Condition Inspection
431
3. Clutch Line EOP Sensor Inspection
431
4. PCM Inspection
431
DTC 51 (TR SENSOR)
432
1. TR Sensor Input Voltage Inspection
432
1. TR Sensor Input Voltage Inspection
432
2. TR Sensor Output Line Open Circuit Inspection
432
3. TR Sensor Output Line Short Circuit Inspection
432
4. TR Sensor Inspection
433
5. TR Sensor Power/Ground Line Open Circuit Inspection
433
DTC 52 (NEUTRAL SWITCH)
433
1. DTC Recheck
433
1. DTC Recheck
433
2. Neutral Switch Line Open Circuit Inspection
433
3. Neutral Switch Line Short Circuit Inspection
434
4. Neutral Switch Inspection
434
DTC 53 (INNER MAINSHAFT SENSOR SPEED LOW)
434
1. Inner Mainshaft Sensor Input Voltage Inspection
434
1. Inner Mainshaft Sensor Input Voltage Inspection
434
2. Inner Mainshaft Sensor Output Line Inspection
435
3. Inner Mainshaft Sensor Input Line Open Circuit Inspection
435
4. Inner Mainshaft Sensor Ground Line Open Circuit Inspection
435
5. Inner Mainshaft Output Line Open Circuit Inspection
436
6. Inner Mainshaft Sensor Output Line Short Circuit Inspection
436
7. Inner Mainshaft Sensor Inspection
436
DTC 54 (OUTER MAINSHAFT SENSOR SPEED LOW)
437
1. Outer Mainshaft Sensor Input Voltage Inspection
437
1. Outer Mainshaft Sensor Input Voltage Inspection
437
2. Outer Mainshaft Sensor Output Line Inspection
437
3. Outer Mainshaft Sensor Input Line Open Circuit Inspection
437
4. Outer Mainshaft Sensor Ground Line Open Circuit Inspection
438
5. Outer Mainshaft Output Line Open Circuit Inspection
438
6. Outer Mainshaft Sensor Output Line Short Circuit Inspection
438
7. Outer Mainshaft Sensor Inspection
438
DTC 55 (No.1 LINEAR SOLENOID VALVE)
439
1. No.1 Linear Solenoid Valve Inspection
439
1. No.1 Linear Solenoid Valve Inspection
439
2. No.1 Linear Solenoid Valve Input/ground Line Open Circuit Inspection
439
3. No.1 Linear Solenoid Valve Input/ground Line Short Circuit Inspection
439
DTC 56 (No.2 LINEAR SOLENOID VALVE)
440
1. No.2 Linear Solenoid Valve Inspection
440
1. No.2 Linear Solenoid Valve Inspection
440
2. No.2 Linear Solenoid Valve Input/ground Line Open Circuit Inspection
440
3. No.2 Linear Solenoid Valve Input/ground Line Short Circuit Inspection
440
DTC 57 (GEARSHIFT MECHANISM/ GEAR POSITION MALFUNCTION)
441
DTC 58 (No.1 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR)
441
1. Clutch Condition Inspection
441
1. Clutch Condition Inspection
441
2. Clutch Oil Line Inspection
441
DTC 59 (No.2 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR)
441
DTC 61, 62 (No.1 CLUTCH OIL PRESSURE MALFUNCTION)
441
1. DTC Recheck
441
1. DTC Recheck
441
2. No.1 Clutch EOP Sensor Inspection
441
3. PCM Inspection
442
DTC 63, 64 (No.2 CLUTCH OIL PRESSURE MALFUNCTION)
442
1. DTC Recheck
442
1. DTC Recheck
442
2. No.2 Clutch EOP Sensor Inspection
442
3. PCM Inspection
442
DTC 65 (FRONT AND REAR WHEEL SPEED SENSOR SIGNAL MALFUNCTION)
443
1. DTC Recheck
443
1. DTC Recheck
443
2. Speed Sensor Air Gap Inspection
443
3. Speed Sensor Condition Inspection
443
4. VS Sensor Condition Inspection
443
DTC 66 (VS SENSOR NO SIGNAL)
444
1. DTC Recheck
444
1. DTC Recheck
444
2. VS Sensor Input Voltage Inspection
444
3. VS Sensor Output Line Inspection
444
4. VS Sensor Output Line Open Circuit Inspection
445
5. VS Sensor Output Line Short Circuit Inspection
445
6. VS Sensor Inspection
445
DTC 67 (FRONT WHEEL SPEED SENSOR NO SIGNAL)
445
1. DTC Recheck
445
1. DTC Recheck
445
2. ABS Problem Code Inspection
446
3. Front Wheel Speed Sensor Line Open Circuit Inspection
446
4. Front Wheel Speed Sensor Line Short Circuit Inspection
446
DTC 68 (No.1 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS)
446
1. DTC Recheck
446
1. DTC Recheck
446
2. Clutch Condition Inspection
447
DTC 69 (No.2 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS)
447
1. DTC Recheck
447
1. DTC Recheck
447
2. Clutch Condition Inspection
447
DTC 71, 72 (INNER, OUTER MAINSHAFT/COUNTERSHAFT SPEED RATIO FAILURE)
447
1. DTC Recheck 1
447
1. DTC Recheck 1
447
2. DTC Recheck 2
448
DTC 84 (CPU IN THE PCM MALFUNCTION)
448
1. DTC Recheck
448
1. DTC Recheck
448
DTC 1 (SHIFT PEDAL ANGLE SENSOR (OPTIONAL) MALFUNCTION)
448
1. DTC Recheck
448
1. DTC Recheck
448
2. Shift Pedal Angle Sensor Input Voltage Inspection
449
3. Shift Pedal Angle Sensor Open Circuit Inspection
449
4. Shift Pedal Angle Sensor Output Line Open Circuit Inspection
449
5. Shift Pedal Angle Sensor Output Line Short Circuit Inspection
450
6. Shift Pedal Angle Sensor Resistance Inspection
450
MODE/SHIFT INDICATOR CIRCUIT TROUBLESHOOTING
450
AT/MT MODE SWITCH TROUBLESHOOTING
451
1. AT/MT mode switch Power Input Voltage Inspection
451
1. AT/MT mode switch Power Input Voltage Inspection
451
2. AT/MT mode switch Inspection
451
3. AT/MT mode switch Input Line Open Circuit Inspection
452
RIGHT CRANKCASE COVER
452
REMOVAL
452
LINEAR SOLENOID VALVE BODY DISASSEMBLY
453
LINEAR SOLENOID VALVE BODY ASSEMBLY
455
OIL GUIDE COLLAR REMOVAL/ INSTALLATION
457
INSTALLATION
458
DUAL CLUTCH
460
REMOVAL
460
DISASSEMBLY
461
CLUTCH CLEARANCE INSPECTION
461
ASSEMBLY
461
INSTALLATION
462
PRIMARY DRIVE GEAR/CKP SENSOR ROTOR
463
REMOVAL
463
INSTALLATION
463
SHIFT CONTROL MOTOR/REDUCTION GEARS
464
REMOVAL
464
INSTALLATION
465
GEARSHIFT LINKAGE
467
REMOVAL
467
INSPECTION
468
INSTALLATION
468
MAINSHAFT SENSOR
470
REMOVAL/INSTALLATION
470
TR SENSOR
470
REMOVAL/INSTALLATION
470
SHIFT SPINDLE ANGLE SENSOR
471
REMOVAL/INSTALLATION
471
CLUTCH EOP SENSOR
472
REMOVAL/INSTALLATION
472
EOT SENSOR
473
REMOVAL/INSTALLATION
473
DCT SHIFT PEDAL (OPTIONAL)
473
REGISTRATION (TO ENABLE THE PEDAL)
473
REGISTRATION CANCELLATION (TO DISABLE THE PEDAL)
474
CLUTCH INITIALIZE LEARNING (PCM)
475
13. ALTERNATOR/STARTER CLUTCH
478
COMPONENT LOCATION
479
SERVICE INFORMATION
481
GENERAL
481
SPECIFICATIONS
481
TORQUE VALUES
481
TROUBLESHOOTING
481
Starter motor turns, but engine does not turn
481
ALTERNATOR COVER
482
REMOVAL/INSTALLATION
482
FLYWHEEL
484
REMOVAL
484
INSPECTION
485
STARTER REDUCTION GEAR/STARTER IDLE GEAR
485
NEEDLE BEARING
485
STARTER CLUTCH OPERATION
485
INSTALLATION
486
STARTER CLUTCH
487
REMOVAL
487
INSPECTION
488
INSTALLATION
488
STATOR
490
REMOVAL
490
INSTALLATION
490
14. CRANKCASE/TRANSMISSION/BALANCER
492
COMPONENT LOCATION
493
SERVICE INFORMATION
495
GENERAL (NC700X/XA/S/SA)
495
GENERAL (NC700XD/SD)
495
SPECIFICATIONS (NC700X/XA/S/SA)
496
SPECIFICATIONS (NC700XD/SD)
496
TORQUE VALUES
497
TROUBLESHOOTING
497
Hard to shift
497
Transmission jumps out of gear
497
Excessive engine noise
497
CRANKCASE SEPARATION
498
TRANSMISSION (NC700X/XA/S/SA)
499
REMOVAL/DISASSEMBLY
499
MAINSHAFT/COUNTERSHAFT
499
SHIFT DRUM/SHIFT FORK
500
INSPECTION
501
SHIFT DRUM/SHIFT FORK
501
TRANSMISSION
502
MAINSHAFT BEARING
503
COUNTERSHAFT BEARING
503
LEFT MAINSHAFT BEARING REPLACEMENT
503
TRANSMISSION ASSEMBLY
504
INSTALLATION
506
MAINSHAFT/COUNTERSHAFT
506
SHIFT DRUM/SHIFT FORK
507
TRANSMISSION (NC700XD/SD)
508
REMOVAL/DISASSEMBLY
508
MAINSHAFT/COUNTERSHAFT
508
SHIFT DRUM/SHIFT FORK
509
INSPECTION
509
SHIFT DRUM/SHIFT FORK
509
TRANSMISSION
510
MAINSHAFT BEARING
512
COUNTERSHAFT BEARING
512
LEFT MAINSHAFT BEARING REPLACEMENT
512
TRANSMISSION ASSEMBLY
513
INSTALLATION
515
MAINSHAFT/COUNTERSHAFT
515
SHIFT DRUM/SHIFT FORK
516
BALANCER
517
REMOVAL
517
INSPECTION
517
LEFT BALANCER SHAFT BEARING REPLACEMENT
518
INSTALLATION
519
CRANKCASE ASSEMBLY
519
15. CRANKSHAFT/PISTON/CYLINDER
524
COMPONENT LOCATION
525
SERVICE INFORMATION
526
GENERAL
526
SPECIFICATIONS
526
TORQUE VALUES
526
TROUBLESHOOTING
527
Cylinder compression is too low, hard to starting or poor performance at low speed
527
Cylinder compression too high, overheating or knocking
527
Excessive smoke
527
Abnormal noise
527
Engine vibration
527
CRANKSHAFT
528
SIDE CLEARANCE INSPECTION
528
REMOVAL
528
INSPECTION
529
INSTALLATION
529
MAIN JOURNAL BEARING
531
BEARING INSPECTION
531
OIL CLEARANCE INSPECTION
531
BEARING SELECTION
532
BEARING INSTALLATION
533
CRANKPIN BEARING
534
BEARING INSPECTION
534
OIL CLEARANCE INSPECTION
534
BEARING SELECTION
535
BEARING INSTALLATION
536
PISTON/CYLINDER
537
PISTON/CONNECTING ROD REMOVAL
537
PISTON RING REMOVAL
537
PISTON REMOVAL
538
PISTON INSPECTION
539
CONNECTING ROD INSPECTION
540
CYLINDER INSPECTION
541
PISTON INSTALLATION
541
PISTON RING INSTALLATION
543
PISTON/CONNECTING ROD INSTALLATION
543
16. ENGINE REMOVAL/INSTALLATION
544
COMPONENT LOCATION
545
SERVICE INFORMATION
547
GENERAL
547
SPECIFICATIONS
547
TORQUE VALUES
547
ENGINE REMOVAL (NC700X/XA/S/SA)
548
ENGINE REMOVAL (NC700XD/SD)
552
ENGINE INSTALLATION (NC700X/XA/S/ SA)
558
ENGINE INSTALLATION (NC700XD/SD)
564
17. FRONT WHEEL/SUSPENSION/STEERING
572
COMPONENT LOCATION
573
SERVICE INFORMATION
579
GENERAL
579
SPECIFICATIONS
579
TORQUE VALUES
579
TROUBLESHOOTING
580
Hard steering
580
Steers to one side or does not track straight
580
Front wheel wobbling
580
Wheel hard to turn
580
Soft suspension
580
Stiff suspension
580
Front suspension noisy
580
HANDLEBAR
581
REMOVAL (NC700X/XA/S/SA)
581
REMOVAL (NC700XD/SD)
583
INSTALLATION (NC700X/XA/S/SA)
585
INSTALLATION (NC700XD/SD)
588
INNER WEIGHT REPLACEMENT
591
FRONT WHEEL
591
REMOVAL
591
INSPECTION
592
WHEEL RIM
592
AXLE
592
WHEEL BEARING
593
WHEEL BALANCE
593
DISASSEMBLY/ASSEMBLY
593
WHEEL BEARING REPLACEMENT
595
INSTALLATION
595
FORK
596
REMOVAL
596
DISASSEMBLY
597
INSPECTION
599
FORK SPRING
599
FORK PIPE/SLIDER
599
FORK PISTON/REBOUND SPRING/OIL LOCK PIECE
600
GUIDE BUSHING/SLIDER BUSHING/BACK-UP RING
600
ASSEMBLY
601
INSTALLATION
604
STEERING STEM
604
REMOVAL
604
BEARING REPLACEMENT
607
INSTALLATION
609
CLUTCH LEVER (NC700X/XA/S/SA)
613
REMOVAL/INSTALLATION
613
18. REAR WHEEL/SUSPENSION
614
COMPONENT LOCATION
615
SERVICE INFORMATION
617
GENERAL
617
SPECIFICATIONS
617
TORQUE VALUES
617
TROUBLESHOOTING
618
Steers to one side or does not track straight
618
Rear wheel wobbling
618
Wheel hard to turn
618
Soft suspension
618
Stiff suspension
618
Rear suspension noisy
618
REAR WHEEL
619
REMOVAL
619
INSPECTION
620
WHEEL RIM
620
AXLE
620
WHEEL AND DRIVEN FLANGE BEARINGS
620
WHEEL BALANCE
620
DRIVEN SPROCKET
620
DISASSEMBLY
620
ASSEMBLY
622
INSTALLATION
624
SHOCK LINKAGE
626
REMOVAL/INSTALLATION
626
DISASSEMBLY/INSPECTION/ ASSEMBLY
626
BEARING REPLACEMENT
627
SHOCK ABSORBER
627
REMOVAL/INSTALLATION
627
INSPECTION
628
BEARING REPLACEMENT
628
SHOCK ABSORBER DISPOSAL PROCEDURE
629
SWINGARM
629
REMOVAL
629
DISASSEMBLY/INSPECTION
631
PIVOT BEARING REPLACEMENT
632
ASSEMBLY
635
INSTALLATION
636
19. HYDRAULIC BRAKE
640
COMPONENT LOCATION
641
SERVICE INFORMATION
644
GENERAL
644
SPECIFICATIONS
644
TORQUE VALUES
645
TROUBLESHOOTING
646
Brake lever/pedal soft or spongy
646
Brake lever/pedal hard
646
Brake drags
646
BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700X/S)
647
BRAKE FLUID DRAINING
647
BRAKE FLUID FILLING/AIR BLEEDING
648
BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700XA/XD/SA/SD)
650
BRAKE FLUID DRAINING
650
LEVER BRAKE LINE
650
PEDAL (COMBI) BRAKE LINE
650
BRAKE FLUID FILLING/AIR BLEEDING
651
LEVER BRAKE LINE
652
PEDAL (COMBI) BRAKE FLUID FILLING
653
PEDAL (COMBI) BRAKE AIR BLEEDING
654
BRAKE PAD/DISC
655
FRONT BRAKE PAD REPLACEMENT (NC700X/S)
655
FRONT BRAKE PAD REPLACEMENT (NC700XA/XD/SA/SD)
656
REAR BRAKE PAD REPLACEMENT
657
PARKING BRAKE PAD REPLACEMENT (NC700XD/SD)
658
BRAKE DISC INSPECTION
659
FRONT MASTER CYLINDER
659
REMOVAL/INSTALLATION
659
DISASSEMBLY/ASSEMBLY
661
INSPECTION
662
REAR MASTER CYLINDER
662
REMOVAL/INSTALLATION
662
DISASSEMBLY/ASSEMBLY
664
INSPECTION
665
FRONT BRAKE CALIPER (NC700X/S)
665
REMOVAL/INSTALLATION
665
DISASSEMBLY/ASSEMBLY
666
INSPECTION
667
FRONT BRAKE CALIPER (NC700XA/ XD/SA/SD)
667
REMOVAL/INSTALLATION
667
DISASSEMBLY/ASSEMBLY
668
INSPECTION
669
REAR BRAKE CALIPER
669
REMOVAL/INSTALLATION
669
DISASSEMBLY/ASSEMBLY
670
INSPECTION
671
PARKING BRAKE CALIPER (NC700XD/ SD)
671
REMOVAL/INSTALLATION
671
DISASSEMBLY
672
INSPECTION
673
ASSEMBLY
674
BRAKE PEDAL
676
REMOVAL/INSTALLATION
676
PARKING BRAKE LEVER (NC700XD/ SD)
677
REMOVAL/INSTALLATION
677
DISASSEMBLY
678
ASSEMBLY
679
20. ANTI-LOCK BRAKE SYSTEM (ABS)
682
ABS SYSTEM LOCATION
683
ABS SYSTEM DIAGRAM
684
SERVICE INFORMATION
685
GENERAL
685
TORQUE VALUES
685
ABS CONNECTOR LOCATIONS
686
ABS TROUBLESHOOTING INFORMATION
688
SYSTEM DESCRIPTION
688
SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM
688
PRE-START SELF-DIAGNOSIS PROCEDURE
688
PROBLEM CODE INDICATION PATTERN
689
PROBLEM CODE READOUT
689
ERASING PROBLEM CODE
690
ABS INDICATOR PROBLEM CODE INDEX
691
ABS INDICATOR CIRCUIT TROUBLESHOOTING
693
ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON)
693
1. Combination Meter Power/ground Line Inspection
693
1. Combination Meter Power/ground Line Inspection
693
2. Indicator Operation Inspection
693
3. Indicator Signal Line Short Circuit Inspection
693
ABS INDICATOR STAYS ON (Indicator does not go off when the motorcycle is running, Problem code is not indicated by the retrieval procedure)
694
1. Service Check Line Short Circuit Inspection
694
1. Service Check Line Short Circuit Inspection
694
2. Indicator Operation Inspection
694
3. Indicator Signal Line Open Circuit Inspection
694
4. Logic Ground Line Open Circuit Inspection
695
5. Fuse Inspection
695
6. Power Input Line Short Circuit Inspection
695
7. Power Input Line Open Circuit Inspection
696
ABS TROUBLESHOOTING
696
PROBLEM CODE 11, 12, 21, 41 or 42 (Front Wheel Speed Sensor/Front Pulser Ring/Front Wheel Lock)
696
1. Speed Sensor Air Gap Inspection
696
1. Speed Sensor Air Gap Inspection
696
2. Speed Sensor Condition Inspection
697
3. Front Wheel Speed Sensor Line Short Circuit Inspection (at sensor side)
697
4. Front Wheel Speed Sensor Line Short Circuit Inspection (at wire harness side)
697
5. Speed Sensor Line Open Circuit Inspection
698
6. Failure Reproduction with a New Speed Sensor
698
PROBLEM CODE 13, 14, 23 or 43 (Rear Wheel Speed Sensor/Rear Pulser Ring/ Rear Wheel Lock)
698
1. Speed Sensor Air Gap Inspection
698
1. Speed Sensor Air Gap Inspection
698
2. Speed Sensor Condition Inspection
699
3. Rear Wheel Speed Sensor Line Short Circuit Inspection (at sensor side)
699
4. Rear Wheel Speed Sensor Line Short Circuit Inspection (at wire harness side)
699
5. Speed Sensor Line Open Circuit Inspection
700
6. Failure Reproduction with a New Speed Sensor
700
PROBLEM CODE 31, 32, 33, 34, 37 or 38 (Solenoid Valve)
700
1. Failure Reproduction
700
1. Failure Reproduction
700
PROBLEM CODE 51, 52 or 53 (Pump Motor)
701
1. Fuse Inspection
701
1. Fuse Inspection
701
2. Motor Power Input Line Short Circuit Inspection
701
3. Motor Power Input Line Open Circuit Inspection
701
4. Failure Reproduction
702
PROBLEM CODE 54 (Fail-safe Relay)
702
1. Fuse Inspection
702
1. Fuse Inspection
702
2. Relay Power Input Line Short Circuit Inspection
702
3. Relay Power Input Line Open Circuit Inspection
703
4. Failure Reproduction
703
PROBLEM CODE 61 or 62 (Power Circuit)
703
1. Fuse Inspection
703
1. Fuse Inspection
703
2. Power Input Line Short Circuit Inspection
704
3. Power Input Line Open Circuit Inspection
704
4. Failure Reproduction
704
PROBLEM CODE 71 (Tire Size)
705
1. Failure Reproduction
705
1. Failure Reproduction
705
PROBLEM CODE 81 (ABS Control Unit)
705
1. Failure Reproduction
705
1. Failure Reproduction
705
WHEEL SPEED SENSOR
705
AIR GAP INSPECTION
705
WHEEL SPEED SENSOR REPLACEMENT
706
FRONT WHEEL SPEED SENSOR REMOVAL/ INSTALLATION
706
REAR WHEEL SPEED SENSOR REMOVAL/ INSTALLATION
707
PCV
709
REMOVAL/INSTALLATION
709
DELAY VALVE
709
REMOVAL/INSTALLATION
709
ABS MODULATOR
710
REMOVAL/INSTALLATION (NC700XA/ SA)
710
REMOVAL/INSTALLATION (NC700XD/ SD)
712
21. BATTERY/CHARGING SYSTEM
714
SYSTEM LOCATION
715
SYSTEM DIAGRAM
715
SERVICE INFORMATION
716
GENERAL
716
BATTERY CHARGING
716
BATTERY TESTING
716
SPECIFICATIONS
717
TROUBLESHOOTING
718
BATTERY IS DAMAGED OR WEAK
718
1. BATTERY TEST
718
2. CURRENT LEAKAGE TEST
718
3. CHARGING VOLTAGE INSPECTION
718
4. REGULATOR/RECTIFIER SYSTEM INSPECTION
718
5. ALTERNATOR CHARGING COIL INSPECTION
718
6. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTOR
718
BATTERY
719
REMOVAL/INSTALLATION
719
VOLTAGE INSPECTION
719
BATTERY TESTING
719
CHARGING SYSTEM INSPECTION
720
CURRENT LEAKAGE TEST
720
CHARGING VOLTAGE INSPECTION
720
REGULATOR/RECTIFIER
721
REMOVAL/INSTALLATION
721
SYSTEM INSPECTION
721
BATTERY CHARGING LINE INSPECTION
721
GROUND LINE INSPECTION
722
ALTERNATOR CHARGING COIL
722
CHARGING COIL INSPECTION
722
22. LIGHTS/METERS/SWITCHES
724
SYSTEM LOCATION
725
SERVICE INFORMATION
726
GENERAL
726
SPECIFICATIONS
726
TORQUE VALUES
726
TROUBLESHOOTING
727
SPEED SENSOR/SPEEDOMETER (NC700X/XA/S/SA)
727
The speedometer operation is abnormal
727
1. Fuse Inspection
727
2. Battery Inspection
727
3. VS Sensor Power Input Voltage Inspection
727
4. VS Sensor Signal Line Inspection
727
5. VS Sensor Signal Inspection
727
HEADLIGHT
728
BULB REPLACEMENT (NC700X/XA/ XD)
728
BULB REPLACEMENT (NC700S/SA/ SD)
728
TURN SIGNAL LIGHT
729
BULB REPLACEMENT
729
REMOVAL/INSTALLATION
729
FRONT (NC700X/XA/XD)
729
FRONT (NC700S/SA/SD)
729
REAR
730
POSITION LIGHT
730
BULB REPLACEMENT (NC700X/XA/ XD)
730
BULB REPLACEMENT (NC700S/SA/ SD)
730
BRAKE/TAIL/LICENSE LIGHT
731
BULB REPLACEMENT
731
COMBINATION METER
731
SYSTEM INSPECTION (NC700X/XA/S/ SA)
731
SYSTEM INSPECTION (NC700XD/SD)
732
REMOVAL/INSTALLATION (NC700X/ XA/XD)
732
REMOVAL/INSTALLATION (NC700S/ SA/SD)
732
POWER/GROUND LINE INSPECTION
733
POWER INPUT LINE
733
BACK-UP VOLTAGE LINE
733
GROUND LINE
734
TXD/RXD LINE INSPECTION
734
NC700X/XA/S/SA
734
NC700XD/SD
734
MIL AND ENGINE OIL PRESSURE INDICATOR ARE STAY ON, TACHOMETER, HIGH COOLANT TEMPERATURE INDICATOR AND HISS INDICATOR DOES NOT COME ON AND SHIFT INDICATOR "–" (NC700XD/SD) IS BLINKING (when the ignition switch turned ON)
735
1. Combination Meter Serial Line Short Circuit Inspection
735
1. Combination Meter Serial Line Short Circuit Inspection
735
2. Combination Meter Serial Line Open Circuit Inspection
736
3. Combination Meter Serial Line Output Voltage Inspection
736
4. ECM Serial Line Output Voltage Inspection
737
COMBINATION METER DIGITAL CLOCK SET PROCEDURE
737
SPEEDOMETER/VS SENSOR
739
SYSTEM INSPECTION (NC700X/XA/S/ SA)
739
SYSTEM INSPECTION (NC700XD/SD)
739
VS SENSOR SIGNAL LINE INSPECTION (NC700X/XA/S/SA)
740
VS SENSOR REMOVAL/ INSTALLATION
741
TACHOMETER
741
SYSTEM INSPECTION
741
HIGH COOLANT TEMPERATURE INDICATOR/ECT SENSOR
741
SYSTEM INSPECTION
741
ECT SENSOR UNIT INSPECTION
742
ENGINE OIL PRESSURE INDICATOR/ EOP SWITCH
742
SYSTEM INSPECTION
742
EOP SWITCH LINE INSPECTION
743
EOP SWITCH REMOVAL/ INSTALLATION
743
FUEL LEVEL SENSOR
744
FUEL LEVEL SENSOR INSPECTION
744
FUEL METER INSPECTION
744
PARKING BRAKE INDICATOR/SWITCH (NC700XD/SD)
745
SYSTEM INSPECTION
745
PARKING BRAKE SWITCH INSPECTION
745
PARKING BRAKE SWITCH REMOVAL/ INSTALLATION
746
IGNITION SWITCH
747
INSPECTION
747
REMOVAL/INSTALLATION
747
HANDLEBAR SWITCHES
748
RIGHT HANDLEBAR SWITCH
748
LEFT HANDLEBAR SWITCHES
748
BRAKE LIGHT SWITCH
749
FRONT
749
REAR
749
CLUTCH SWITCH (NC700X/XA/S/SA)
749
NEUTRAL SWITCH
750
INSPECTION (NC700X/XA/S/SA)
750
INSPECTION (NC700XD/SD)
750
REMOVAL/INSTALLATION (NC700X/ XA/S/SA)
751
REMOVAL/INSTALLATION (NC700XD/ SD)
751
SIDESTAND SWITCH
751
INSPECTION
751
REMOVAL/INSTALLATION
752
HORN
752
INSPECTION
752
REMOVAL/INSTALLATION
753
TURN SIGNAL/HAZARD RELAY
753
SYSTEM INSPECTION
753
1. Battery Power Source Line Open Circuit Inspection
753
1. Battery Power Source Line Open Circuit Inspection
753
2. Ground Line Open Circuit Inspection
754
3. Turn Signal/hazard Switch Line Open Circuit Inspection
754
4. Ignition Switch Power Source Line Open Circuit Inspection
754
REMOVAL/INSTALLATION
755
23. IMMOBILIZER SYSTEM (HISS)
756
SYSTEM LOCATION
757
SYSTEM DIAGRAM
757
SERVICE INFORMATION
758
GENERAL
758
KEY REGISTRATION PROCEDURES
758
When the key has been lost, or additional spare key is required:
758
When the ignition switch is faulty:
759
When all keys have been lost:
760
When the ECM/PCM is faulty:
761
DIAGNOSTIC CODE INDICATION
761
DIAGNOSTIC CODE
762
TROUBLESHOOTING
763
Immobilizer indicator does not come on when the ignition switch is turned ON
763
1. Fuse Inspection
763
2. Combination Meter Inspection
763
3. Combination Meter Power Input Line Inspection
763
4. TXD/RXD Line Inspection between The ECM/PCM and Combination Meter
763
5. Power Input Line Inspection at The ECM/PCM Connector
763
6. Ground Line Inspection at The ECM/PCM Connector
763
Immobilizer indicator remains on with the ignition switch turned ON
763
1. Immobilizer Receiver Jamming Inspection
763
2. First Transponder Key Inspection
764
3. Diagnostic Code Inspection
764
4. TXD/RXD Line Inspection between The ECM/PCM and Combination Meter
764
5. CKP sensor Line Inspection
764
Diagnostic code is indicated (Code signals cannot send or receive)
764
1. Immobilizer Receiver Power Input Line Inspection
764
2. Immobilizer Receiver Ground Line Inspection
764
3. Immobilizer Receiver Signal Line Inspection 1
764
4. Immobilizer Receiver Signal Line Inspection 2
764
HISS INDICATOR
765
INSPECTION
765
POWER INPUT LINE INSPECTION
765
TXD/RXD LINE INSPECTION
765
ECM (NC700X/XA/S/SA)/PCM (NC700XD/SD)
766
INSPECTION
766
POWER INPUT LINE INSPECTION
766
GROUND LINE INSPECTION
767
CKP SENSOR LINE INSPECTION
767
IMMOBILIZER RECEIVER
767
INSPECTION
767
POWER INPUT LINE INSPECTION
768
GROUND LINE INSPECTION
768
SIGNAL LINE INSPECTION
768
REMOVAL/INSTALLATION
769
REPLACEMENT PARTS FOR PROBLEM
769
24. WIRING DIAGRAM
770
INDEX
771
5
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Honda NC700 2012 Specifications
General
Brand
Honda
Model
NC700 2012
Category
Motorcycle
Language
English
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