2005 honda nt700v nt700va service repair manual by ujfjisefjj

Paper Book Part No. 62lWEVVOO

ONTENTS

HOW TO USE THlS MANUAL This service manual describes the service procedures for the NT700VI VA. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 4 apply to the whole motorcycle. Section 3 illustrates procedures for remwaVinstallation of components that may be required to perform service described in the following sections. Section 5 through 23 describe parts of the motorcycle, grouped according to location. Find the section you want m this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages If you are not familiar with this motorcycle, read Technical Feature in Section 2. If you don't know the source of the trouble, go to section 25

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not ~racticalor possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: Safety Labels -on the vehicle * Safety Messages - preceded by a safety alert symbol f: and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.

You CAN be HURT if you don't follow instructions.

Instructions - how to service this vehicle correctly and safely.

symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THlS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TlME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TlME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THlS PUBLICATION MAY BE REPRODUCED WITHWRllTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. C t PUUl ICAJlON OFFICE

Date of Issue: November, 2005

O Honda Motor Co., Ltd.

TROUBLESHOOTING INDEX

TYPE CODE Throughout this manual, the following abbreviations are used to identify individual model.

CODE

EUROPEAN DIRECT SALES

(Netherlands, Spain, Germany, Belgium, Portugal, Italy, Switzerland, Austria)

E F

AREATYPE

U.K. (Ireland)

France Australia

A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.

For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

For Your Safety

unsafe condition that can cause your customer or others to be seriously hurt or killed.

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot

recommended that you do not atternpito perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task.

Failure to properly followinstructions and precautions can cause you to be seriously hurt or killed.

Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. Protect yourself and others whenever you have the vehicle up in the air. Any time you Kft the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tens you to do otherwise. 1 his win help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clotl.,ing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. Use only a nonflammable solvent, not gasoline, to clean parts. Never drain or store gasoline in an open container. Keep all cigarettes, sparks and flames away from the battery and an fuel-related parts.

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1).

Use multi-purpose grease (Lithium based multi-purpose grease NLGl #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGl #2 or \

Example: Molykote@BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl #2 or equivalent). Example: Molykote@G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

Apply sealant.

Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use Fork or Suspension Fluid.

1. GENERAL INFORMATION

..................................................................

I FRlNG SPECNCAflONS .................. 1-11

MODEL IBENTFICATION........................... REAR WHEELISUSPENSION ..................................... 1-11 SPtClFlCA IIONS

GENERAL SPECIFICATIONS LUBRICATION SYSTFM SPECIFICATIONS........................................ FUEL SYSTEM (PGM-FI) SPEClmCATlONS ..........................

......... 1-7

HYDRAULIC BRAKE SPECIFICATIONS-.. 1-11 BA ITERYICHARGUVG SYSTEM ..................................... 1-12 SPtClFlCATlONS IGMTION SYSfEM SPECIFICATIONS

1-12

COOLING SYSTEM SPECIFICATIONS ELECTRIC STARTER SPECIFICATIONS 1-12 CYLINDER HEADIVALVE SPEClFlCATlONS........................................1-8 CYLINDERIPISTON SPECIFICATIONS--.-.1-8 CLUTCHIGEARSHIFT LINKAGE SPEClFlCATlONS........................................ 1-9 ALTERNATORISTARTER CLUTCH SPEClFlCATlONS........................................1-9 CRANKSHAFTITRANSMISSION SPECIFICATIONS...............................1-10 1-10 FINAL DRIVE SPECIFICATIONS-.-.-.-.---..--

LIGHTSIMETERSISWITCHES SPEClFlCATlONS ..................................... 1-12 STANDARD TORQUE VALUES *.....-----.--. 1-13 ENGINE & FRAME TORQUE VALUES----1-13 1-18 LUBRICATION & SEAL POINTS ---.....------

CABLE & HARNESS ROUTING ........................... .................... 1-20 (NT~OOVA)

CABLE & HARNESS ROUTING (NT7OOV).............................. .................... 1-35

EMISSION CONTROL SYSTEMS ............ 1-50

GENERAL INFORMATION

SERVICE RULES 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. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, 0-rings, cotter pins, and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. Route all electrical wires as shown in the Cable and Harness-Routing (page 1-35).

ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbrev. term PGM-FI MAP sensor TP sensor ECT sensor IAT sensor CKP sensor

Full term Programmed Fuel Injection Manifold Absolute Pressure sensor Throttle Position sensor Engine Coolant Temperature sensor Intake Air Temperature sensor Crankshaft Position sensor

FP PAIR ABS HISS

Fuel Pump Pulsed Secondary Air Injection Anti-lock Brake System Honda Ignition Security System

GENERAL INFORMATION

MODEL IDENTIFICATION

SERIAL NUMBERS The Vehicle Identification Number (V.1.N) is stamped on the right side of the steering head.

The engine serial number crankcase.

stamped

the right side of the

GENERAL INFORMATION The throttle body identification number is stamped on the throttle oay.

The registered number plate is attached on the right side of the frame.

LABELS The color label is attached on the rear fender. When ordering colorcoded parts, always specify the designated color code.

ENERAL SPECIFICATIONS

FRAME

Overall width Overall height (Windscreen high position) Overall height (Windscreen low position) Wheelbase Seat height Footpeg height Ground clearance Curb weight (NT700V) Curb weight (NT700VA) Maximum weinht ca~acitv Frame type Front suspension Front axle travel Rear suspension Rear axle travel Front tire size Rear tire size T L m b

Bridgestone

ENGINE

SPECIFICATIONS 2215 M? 'cn) 805 m m (31.7 in) 1,480 m m (58.2 in) 1,320 m m (52.0 in) 1,475 m m (58.1 in) 805 m m (31.6 in) 322 m m (12.7 in) 160 m m (6.3 in) 254 kg (560 Ibs) 257 kg (567 Ibs) 197 kg (434 Ibs) Diamond Telescopic fork 115 m m (4.5 in) Swingarm 123 m m (4.8 in) 120ffOZR17M/C (58W) 150ffOZR17M1C (69W)

Front brake Hear brake Caster angle Trail length Fuel tank ca~acitv Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve Exhaust valve

opens closes opens closes

Rear: MACADAMSOXB Front: BT020F RADIAL J/ Rear: BT020R RADIAL U Hydraulic double disc Hydraulic slngle dlsc 28" 50' 115 m m (4.5 in) 19.7 liters (5.2 US gal, 4.3 Imp gal) 2 cylinders 52" V transverse 81.0 X 66.0 m m (3.19 X 2.60 in) 680.2 cm3 (41.6 cu-in) 10.0 : 1 Silent cam chain driven, OHC 10" BTDC (at 1 m m lift) 30" ABDC (at 1 m m lift) 35" BBDC (at 1 m m lift) 5" ATDC (at 1 m m lift)

Oil pump type Cooling system Air filtration Engine dry weight Firing order Cylinder number FUEL DELIVERY SYSTEM DRIVE TRAIN

Throttle bore Clutch system clutch oberation system Transmission Primary reduction Secondary reduction Third reduction (Output drive reduction) Final reduction Gear ratio Ist 2nd

Trochoid Liquid cooled Net and viscous paper element 65.2 kg (144 Ibs) Front - 232" - Rear - 488" - Front Front: #2/Rear: # l PGM-FI (Programmed Fuel Injection) 40 m m (1.6 in) Multi-plate, wet cable 'operating Constant mesh, 5-speeds 1.763 (67138) 0.939 (31133) 1.059 (18117) 3.090 (34111) 2.571 (36114) 1.688 (27116)

3-4

4t h 5th Gearshift pattern

1.074 (29127) 0.955 (21122) Left foot operated return system, 1- N - 2 - 3 - 4 - 5

GENERAL INFORMATION

ELECTRICAL Starting system Charging system Regulatorlrectifier Lighting system

Electric starter motor Triple phase output alternator SCR shortedltriple phase full-wave rectification Battery

GENERAL INFORMATION

LUBRICATION SYSTEM SPECIFICATIONS Unit: m m (ir

FUEL SYSTEM (PGM-FI) SPECIFICATIONS ITEM Throttle body identification number Idle speed Throttle grip free play IAT sensor resistance (at 20 "Cl68 "F) ECT sensor resistance (at 20 "Cl68 "F) 711 O Vl f'lGR

-v

OF\ I

CMP sensor peak voltage (at 20 "Cl68 "F) CKP sensor peak voltage (at 20 "Cl68 "F) Fuel pressure at idle Fuel pump flow (at 12V)

SPECIFICATIONS GQ66A 1,200 f 100 min.' (rpm) 2 - 6 m m (1112 - 114 in) 1-4kR 2.32 - 2.59 kR 70.0 M Q 0.7 V minimum 0.7 V minimum 343 kPa (3.5 kgf/cmz, 50 psi) 200 cm3(6.8 US oz, 7.0 Imp oz) minimum/lO seconds

00LING SYSTEM SPECIFICATIONS

GENERAL INFORMATION

CYLINDER HEADNALVE SPECIFICATIONS ITEM Cylinder compression at 400 min.' (rpm)

STANDARD 1,373 f 98 kPa

Valve clearance Camshaft

Unit: m m (in) SERVICE LIMIT

Unit: m m (in) SERVICE LIMIT 81.10 (3.193)

IN FX. -. IN EX

Cam lobe height Runout Journal O.D. Oil clearance

rocker arm shaft

Valve, valve clulde

EX Rocker arm I.D. INIEX Rocker arm-to-shaft clearance Valve stem O.D. II IN I FX Valve guide I.D. INIEX Stem-to-guide clearance

I I I

Valve guide projection above cylinder head Valve seat width Valve s ~ r i n a I Free lenath I Cvlinder head warDaae

I I

IN EX INIEX INIEX

CYLINDER/PISTON SPECIFICATIONS ITEM Cylinder

I.D.

piston pin, piston rings

bottom Piston pin bore I.D. Piston pin O.D. Piston-to-piston pin clearance Piston ring end To P gap Second Oil ' (side rail) Piston ring-to-ring Top groove clearance Second Cylinder-to-piston clearance Connecting rod small end I.D. Connectina rod-to- ist ton in clearance W

STANDARD 81.000 - 81.01 5 (3.1890 - 3.1896)

18.002 - 18.008 (0.7087 - 0.7089) 17.994 - 18.000 (0.7084 - 0.7087) 0.002 - 0.014 (0.0001 - 0.0006) 0.20 - 0.35 (0.008 - 0.014) 0.35 - 0.50 (0.014 - 0.020) 0.20 - 0.70 (0.008 - 0.028)

18.05 (0.711) 17.98 (0.708) 0.04 (0.002) 0.50 (0.020) 0.65 (0.026) 0.90 (0.035)

0.010 - 0.045 (0.0004 - 0.0018) 0.010 - 0.045 (0.0004 - 0.0018) 0.010 - 0.045 (0.0004 - 0.0018) 18.016 - 18.037 (0.7093 - 0.7101) 0.016 - 0.043 (0.0006 - 0.0017)

0.065 (0.0026) 0.065 (0.0026) 0.10 (0.004) 18.047 (0.7105) 0.06 (0.002)

GENERAL INFORMATION

CLUTCHIGEARSHIFT LINKAGE SPECIFICATIONS STANDARD 10 - 20 (318 - 3/41 43.2 (1.70) 2.692 - 2.708 (0.1060 - 0.1066) 2.920 - 3.080 (0.1150 - 0.1213) 2.692 - 2.708 (0.1060 - 0.1066)

ITEM Clutch lever free play Clutch Spring free length Disc thickness

Disc A Disc B Disc C

Mainshaft O.D. at clutch outer guide Clutch outer guide-to-mainshaft clearance

21.967 - 21.980 i0.8648 - 0.8654) 0.011 - 0.049 (0.0004 - 0.0019)

Clutch outer-to-outer auide clearance " Oil pump drive sprocket I.D. Oil pump drive sprocket-to-clutch outer guide I clearance

0.025 - 0.066 (0.0010 - 0.0026) 32.025 - 32.145 (1.2608 - 1.2655) 0.066 - 0.170 (0.0026 - 0.0067)

LJnit: m m (ir SERVICE LIMIT

ALTERNATORISTARTER CLUTCH SPECIFICATIONS ITEM Starter driven gear Starter clutch outer I.D.

I.D. O.D.

STANDARD 37.000 - 37.025 (1.4567 - 1.4577) 57.749 - 57.768 (2.2736 - 2.2743) 74.414 - 74.440 (2.9297 - 2.9307)

LJnit: m m (in) SERVICE LIMIT 37.10 (1.461) 57.73 (2.273) 74.46 (2.931)

GENERAL INFORMATION

CRANKSHAFT/TRANSMISSION SPECIFICATIONS ITEM Connecting rod big end side clearance Crankpin bearing oil clearance Main journal oil clearance Crankshaft runout Main journal O.D.

STANDARD 0.05 - 0.20 (0.002 - 0.008)

1'3-

Claw thickness Fork shaft O.D.

Crankshaft

0.028 - 0.052 (0.0011 - 0.0020) 0.020 - 0.038 (0.0008 - 0.0015)

Shift drum O.D. Shift drum journal I.D. Shift drum-to-shift drum journal clearance Transmission Gear I.D. M3 M5

C l , C4 C2 M3 M5

C l , C4 Gear-to-bushing clearance Gear bushing I.D. Mainshaft O.D. Countershaft

0.07 (0.003) 0.07 (0.003) 0.03 (0.001) 52.976 (2.0857) 58.070 (2.2862)

52.976 - 52.994 (2.0857 - 2.0864) 58.010 - 58.022 (2.2839 - 2.2843)

Main journal I.D.

Gear busing O.D.

pnit: m m (in) SERVICE LIMIT 0.30 (0.012)

M3, M5

C l , C4 M3 at M3 at C2

iclni

5.93 - 6.00 (0.233 - 0.236) 12.966 - 12.984 (0.5105 --0.5112) 11.966 - 11.984 (0.4711 - 0.4718) 12.000 - 12.018 (0.4724 - 0.4731 ) 0.016 - 0.042 (0.0006 - 0.0017) 28.020 - 28.041 (1.1031 - 1.1040) 28.000 - 28.021 (1.1024 - 1.1032) 31.000 - 31.025 (1.2204 - 1.2215) 27.991 - 28.012 (1.1020 - 1.1070) 27.979 - 28.000 (1.1015 - 1.1024) 27.959 - 27.980 (1.1007 - 1.1016) 30.950 - 30.975 (1.2185 - 1.2195) 0.020 - 0.062 (0.0008 - 0.0024) 0.025 - 0.075 (0.0010 - 0.0030) 25.000 - 25.021 (0.9843 - 0.9851) 24.959 - 24.980 (0.9826 - 0.9835) 23.971 - 23.984 (0.9437 - 0.9443)

5.6 (0.22) 12.90 (0.508) 11.94 (0.470) 12.05 (0.474) 0.09 (0.035) 28.06 (1.105) 28.04 (1.104) 31.05 (1.222) 28.030 (1.1035) 27.960 (1.1008) 27.940 (1.1000) 30.93 (1.218) 0.08 (0.003) 0.11 (0.004) 25.04 (0.985) 24.94 (0.982) 23.950 (0.9429)

v.-.

Output drive train

I I

Bushing-to-shaft M3 clearance O u t. ~ uaear t I.D. " output gear O.D. bushing I I.D. Output drive gear shaft O.D. Gear-to-bushing clearance Gear bushing-to-shaft clearance Output gear damper spring free length Output drive gear backlash Backlash difference between measurements

0.020

- 0.062 (0.0008 - 0.0024)

0.08 (0.003)

24.000 - 24.021 (0.9449 - 0.9457) 23.959 - 23.980 (0.9433 - 0.9441 ) 20.020 - 20.041 (0.7882 - 0.7890) 19.979 - 20.000 (0.7866 - 0.7874) 0.020 - 0.062 (0.0008 - 0.0024) 0.020 - 0.042 (0.0008 - 0.0016) 66.9 (2.63)

24.04 (0.946)

0.08 - 0.23 (0.003 - 0.009)

0.40 (0.016) 0.10 (0.004)

19.97 (0.786) 0.082 (0.0032) 0.08 (0.003) 63 (2.48)

FINAL DRIVE SPECIFICATIONS ITEM Recommended final drive oil After draining Final drive oil capacity After disassembly Final drive gear backlash Backlash difference between measurements Ring gear-to-stop pin clearance Final drive gear assembly preload

STANDARD Hypoid gear oil, SAE #80 130 cm3 (4.3 US oz, 4.5 Imp oz) 150 cm3 (5.1 US oz, 5.3 Imp oz) 0.05 - 0.15 (0.002 - 0.006)

0.30 - 0.60 (0.012 - 0.0241 0.2 - 0.4 N.m (2 - 4 kgfcm, 1.7 - 3.5 Ibf.ft)

IJnit: m m (in) SERVICE LIMIT

0.30 (0.012) 0.10 (0.004)

FRONT WHEELISUSPENSIONISTEERING SPECIFICATIONS Unit: mm (in]

Fork

426.1 (16.78)

Spring free length Tube runout Recommended fork fluid Fluid level Fluid capacity

Steerincl head bearina ~ r e l o a d

max. 417.6 (16.44) 0.20 (0.008)

Honda ULTRA CUSHION OIL IOW or

124(4.9) 464 & 2.5 cm3 (15.7 0.08 U S oz, 16.3 f 0.09 Imp oz) 8.3 - 13.5 N (0.8 - 1.4 kaf)

REAR WH ttLlSUSPENSlON SPECIFICATIONS pnit: mm (in)

HAULIC BRAKE SPECIFICATIONS Unit: mm (in]

GENERAL INFORMATION

BATTERYICHARGING SYSTEM SPECIFICATIONS ITEM Battery K Current leakage Voltage (20°C/68"F)

Fully charged Needs charging Normal Quick

1.1 AI5 - 10 h 5.5 Al1.0 h 452 kW/5,000 min.' (rpm) 0.1 - 1.0 R

Charging current Capacity Charging coil resistance (20°C/68"F)

Alternator

SPECIFICATIONS 12V - 14 Ah 1 mA max. 13.0 - 13.2 V Below 12.3 V

IGNITION SYSTEM SPECIFICATIONS ITEM Spark plug Standard Spark plug gap Ignition coil primary peak voltage CKP sensor peak voltage Ignition timing ("Furnark)

SPECIFICATIONS CPR8EA-9 (NGK) 0.8 - 0.9 m m (0.031 - 0.035 in) 100 V minimum 0.7 V minimum 10" BTDC at idle

ELECTRIC STARTER SPECIFICATIONS , - . .. -. . . . . . .

ITEM Starter motor brush length

STANDARD 12.0 (0.47)

LIGHTSIMETERSISWITCHES SPECIFICATIONS

1..

( SERVICE LIMIT

6.5 (0.26)

GENERAL INFORMATION

STANDARD TORQUE VALUES

FASTENER TYPE 5 m m hex bolt and nut 6 m m hex bolt and nut

I N m (ktafm. lbf-ft) 11 FASTENER TYPE I 5.2 i6.5.3.81 i/ 5 mm screw 4

v ( k n f - m , lbf-ft) 4.2 (0.4.3.2)

10 m m hex bolt and nut 12 m m hex bolt and nut

ENGINE & FRAME TORQUE VALUES a Torque specifications listed below are for important fasteners. a Others should be tightened to standard torque values listed above.

FRAMEIBODY PANELSIEXHAUST SYSTtM Q'TY

ITEM

Left crankcase rear cover bolt

THREAD DIA. (mm) 6

TORQUE N-m (kgf-m, Ibf-ft) 13 (1.3, 9)

THREAD DIA. (mm) 10 14

TORQUE N-m (kgf-m, Ibf-ft) l 6 (1.6, 12) 10 (1.0,7)

MAlNTENANCt

Timing hole cap

Crankshaft hole cap

REMARKS CT bolt

REMARKS

Apply engine oil to the threads and flange surface Apply engine oil to the

Apply engine oil t o the threads and flange surface

Valve adjusting screw lock nut Engine oil filter cartridge Engine oil drain bolt

1 1

LUBRICATION SYSTEM

Oil pressure switch

THREAD DIA. (mm) PT 118

Oil pressure switch terminal screw Oil cooler bolt

1 1

4 20

1.9 (0.2, 1.4) 64 (6.5,47)

Oil pump assembly bolt

13 (1.3,9)

THREAD DIA. (mm) . . 12

TORQUE N-m (kqfm. Ibf-ftl

Q'TY

ITEM

TORQUE ~ . (kgfm, m ~bf-ft) 12 (1.2,9)

REMARKS Apply sealant to the

Apply engine oil to the threads CT bolt

FUEL SYSTEM ITEM

ECT sensor T h W IACV screw Set plate torx screw Throttle cable guide screw Fuel injector mounting bolt

1 I

1 1 3 2 2 4

REMARKS

5 5 5

5 5

COOLING SYSTEM

1 REMARKS ITEM Q'TY Water pump cover bolt

DIA. (mm) 6

N m (kgf-m, Ibf-ft) 13 (1.3, 9)

CT bolt

GENERAL INFORMATION CYLINDER HEADIVALVE ITEM

Q'TY

Cylinder head cover bolt Cylinder head bolt

8 4

Cylinder head nut

Cam sprocket bolt Cam chain tensioner bolt Camshaft holder bolt

4 4 12

Reed valve cover bolt Cylinder head sealing bolt

4 2

ITEM Cylinder stud bolt Cylinder stud bolt

TORQUE N.m (kgfam, Ibfaft) 10 (1.0,7) 23 (2.3, 17)

REMARKS Apply engine oil to the threads and,flange surface Apply engine oil to the threads and flange surface Apply a locking agent Apply engine oil to the threads and flange surface CT bolt Apply a locking agent

' 2 6

THREAD DIA. (mm) 6 8

THREAD DIA. (mm) 12 10

TORQUE N m (kgf-m, 1bf.R)

THREAD DIA. (mm) 6

TORQUE N-m (kgfsm, Ibf4t) 12 (1.2,9)

REMARKS page 10-8 page 10-8

CLUTCHIGEARSHIFT LINKAGE

Clutch center lock nut

Apply engine oil to the threads and flange surface Stake Apply a locking agent Apply engine oil to the threads and flange surface

Oil pump driven sprocket bolt Primary drive gear bolt Gearshift spindle return spring pin

REMARKS

ALTERNATOR/STARTER CLUTCH ITEM Flywheel bolt

Stator socket bolt Starter one-way clutch outer torx bolt Stator wire holder socket bolt

4 6

THREAD DIA. (mm) 12

TORQUE N-m (kgfam, 1bf.R) 157 (16.0, 116)

6 8 6

12 (1.2,9) 30 (3.1,22) 12 (1.2, 9)

REMARKS Left hand threads Replace with a new one Apply a locking agent Apply a locking agent Apply a locking agent

A 0 - 1 mm (0 - 0.04 in)

GENERAL INFORMATION CRANKSHAFT/TRANSMISSION -

THREAD

ITEM Crankcase bolt, 8 m m

Crank pin bearing cap nut

Output drive gear bearing holder bolt Output driven gear bearing holder socket bolt Output drive gear bearing (inner) lock nut (outer) Output driven gear bearing lock nut

I'=

11 23 11 I

(inner)

(outer)

I.L,

REMARKS

42 (4.3, 31)

l 1 1 1 1 (U

Output gear case mounting bolt

TORQUE N - m (kgf-m, Ibf-ft) 23 (2.3, 17)

Apply engine oil to the threads and flange surface Stake Apply engine oil to the

Apply engine oil to the threads and flange surface Apply sealant to the threads Apply engine oil to the threads and flange surface Apply engine oil to the threads and flange surface Apply engine oil t o the threads and flange surface Stake Apply engine oil to the threads and flange surface

P Stake Apply engine oil to the threads CT bolt

Output drive gear shaft bolt

Oil seal stopper plate bolt

Q'TY

THREAD D., (mm)

1 2

6 5

TORQUE N-m (kgf-m, Ibf-ft) 10 (1.0,7) 4.9 (0.5, 3.6)

THREAD DIA. (mm) 10

TORQUE N-m (kgf-m, Ibf-ft) 12 (1.2.9)

THREAD DIA. (mm) 30

TORQUE N - m (kgf-m, Ibf-ft) 12 (1.2,9)

THREAD DIA. (mm) 6 4

TORQUE N - m (kgf-m, Ibf-ftl 12 (1.2, 9) 1.8 (0.2, 1.3)

tLECTRlC STARTERISTARTER CLUTCH ITEM Starter motor cable terminal nut Starter motor cover bolt

REMARKS

LIGHTS/METERS/SWITCHES

ITEM Neutral switch

Q'TY 1

REMARKS

FRAME FRAMEIBODY PANRSIEXHAUST SYSTEM

MAINTENANCE ITEM Final drive oil filler cap

Q'TY 1

REMARKS

I-UtL SYSTEM ITEM

Fuel pump mounting- nut Fuel fillercap

'lTY

6 1

REMARKS

COOLING SYSTEM

ITEM Thermostat h01ising cover b o k

Q'TY 2

THREAD DIA. (mm) 6

TORQUE N.m (kgf.m, Ibf-ft) 9.8 (1.0,7)

REMARKS

ENGWF MOUNTING

Engine hanger bolt (Front low; A) Engine hanger cross plate bolt Engine hanger cross plate nut Engine hanger bolt (Rear up; C)

2 2 2 1

THREAD D .m m 10 8 8 10

Engine hanger bolt (Rear low; D)

ITEM

TORQUE N m (kgf-m, Ibf-ft) 39 (4.0, 29) 27 (2.8, 20) 27 (2.8, 20) 39 (4.0 29) 39 (4.0 29)

REMARKS

Apply engine oil t o the threads and flange surface Apply engine oil t o the threads and flange surface

Cl UTCWGEARSHIFT UNKAGE .---m

Il t M

Gearshift pedal pivot bolt

ITEM Pinion retainer Pinion retainer lock plate bolt Pinion joint nut Dust guard plate bolt Gear case cover bolt Gear case cover bolt Final gear case assembly mounting nut Final gear case stud bolt

,.,.

U'l Y

Q'TY 1 1 1 1 2 6 4

THREAD DIA. (mm) 8

THREAD DIA. (mm) 64 6 16 6 10 8 10

TORQUE N.m (kgf.m, I b f W 27 (2.8, 20)

TORQUE N - m (kgf-m, Ibfaft) 108 (11.0, 80) 10 (1.0, 7) 108 (11.0,80) 10 (1.0,7) 47 (4.8, 35) 25 (2.6, 19) 64 (6.5,47)

-.-.. -.,KtMAKK3 m

REMARKS

Apply a locking agent Apply a locking agent UBS nut page 14-22

FRONT WHEELISUSPENSIONISTEERING ITEM

THREAD

TORQUE N.m (kgf-m, Ibf-ft) 0 1 - m1 ~ 7 )

10 36 8 10 26 26 24

20 (2.0, 15) 22 (2.2, 16) 23 (2.3, 17) 39 (4.0, 29) page 15-30 page 15-30 103 (10.5,76)

REMARKS

Clutch lever pivot nut Handlebar holder bolt Front axle Front axle pinch bolt Front brake disc bolt Fork center socket bolt Fork cap Fork top bridge pinch bolt Fork bottom bridge pinch bolt Steering top thread Steering top thread lock nut Steering stem nut

2 2 2 2 1 1 1

Apply a locking agent

GENERAL INFORMATION REAR WHEELIBRAKEISUSPENSION

ITEM

Q'TY

Rear axle nut Rear axle pinch bolt Rear shock absorber upper mounting bolt Rear shock absorber lower mounting bolt Swingarm pivot nut Rear brake disc bolt

1 1 1

1 8

Stopper plate bolt

THREAD

TORQUE

REMARKS

89 (9.1, 66) 44 (4.5,32)

1 U-nut ALOC bolt; replace with a new one ALOC bolt; replace with a new one

HYDRAULIC BRAKE THREAD DIA. (mm) 8 4

ITEM Brake caliper bleed valve Front master cylinder reservoir cap screw Brake pad pin Brake hose oil bolt Brake pipe nut

TORQUE

10 10 10

Apply brake fluid to the threads

6 6 6 4 6

Front brake hose clamper bolt Brake lever pivot bolt Brake lever pivot nut Front brake light switch screw Front master cylinder holder bolt ,L I ~ r a c k epm t Rear master cylinder holder bolt

Rear brake reservoir joint screw

4 8

Front brake caliper pin Front brake caliper mounting bolt

8 8

12 (1.2,9) 1.0 (0.1.0.7) 6.0 (0.6,4.4) 1.2 (0.1,O.g) 12 (1.2,9) 4 "

I.,

9 -.

1.4

12 (1.2,9)

ALOC bolt; replace with a new one Apply a locking agent

Apply a locking agent ALOC bolt; replace with a new one

12 18 6

Rear brake caliper stopper bolt Proportional control valve mounting

ITEM

Q'Ty

m =)

Modulator stay bolt

N-mEibf-ft) 12 (1.2,9)

Pulser ring bolt

7.0 (0.7, 5.2)

THREAD DIA. (mm) 6 8

TORQUE N-m (kgf.m, Ibf-ft) 10 (1.0,7) 24 (2.4, 18)

REMARKS ALOC bolt; replace with a new one

LIGHTSIMETERSISWITCHES ITEM Side stand switch bolt Ignition switch mounting bolt

Q'TY 1 2

REMARKS

OTHERS ITEM Side stand pivot bolt Side stand pivot lock nut Step holder bolt

Q'Ty 1 1 4

n L L Z m ) 10 10 8

N.m : k z b f . f t ) 10 (1.0,7) 29 (3.0, 22) 27 (2.8,20)

REMARKS

GENERAL INFORMATION

LUBRICATION & SEAL POINTS ENGINE MATERIAL Molybdenum disulfide oil

REMARKS

LOCATION Camshaft lobes/journals Valve stem (valve guide sliding surface) Rocker arm slipper surface Rocker arm shaft outer surface Crankpin bearing surface Crankshaft journals Clutch outer guide outer surface Transmission gear shift fork groove n

Transmission spline bushing outer surface Connecting rod small end inner surface Piston outer surface Piston ring outer surface Piston pin outer surface Primary drive gear bolt threads and seating surface Flywheel bolt threads and seating surface Starter one-way clutch sprag Starter idle and reduction gear shaft outer surface Clutch center lock nut threads Clutch lifer arm-to-right crankcase cover sliding surface Clutch lifer piece-to-right crankcase cover sliding surface Clutch disc outer surface Cylinder stud bolt threads Cylinder head 8 m m bolt threads and seating surface Valve adjusting screw lock nut threads and seating surface Connecting rod boltlnut threads and seating surface

grease

Transmission gear tooth Oil cooler bolt threads Oil filter cartridge threads and 0-ring Each bearings rotating area Each 0-rings Crankshaft hole cap threads Timing hole cap threads Eachl; seal lips Oil pressure switch threads

Bond 1207Bor equivalent) Right and left crankcase mating surface Right crankcase cover mating surface Left crankcase cover mating surface Output gear case mounting bolt threads Left crankcase cover bolt threads

r Locking agent

Cam sprocket bolt threads Starter one-way clutch outer bolt threads Oil pump driven sprocket bolt threads Final gear case stud bolt threads (gear case side) Stator wire holder socket bolt threads Gearshift stopper arm bolt threads Gearshift cam plate bolt threads Transmission bearing setting plate bolt threads Cam chain tensioner setting plate bolt threads Stator mounting bolt threads Cylinder head sealing bolt threads Left crankcase cover bolt threads (marked ",A,")

Do not apply to the sealant to the head 3 - 4 mm (0.1 - 0.2 in). page 5-5 page 13-47 page 11-20 page 12-11 page 12-11

Coating width: 6.5 f 1 m m (0.26 f 0.04 m m

page 12-11

GENERAL INFORMATION

r--Multi-purpose grease

Urea based multi-purpose grease with extreme pressure (Kyodo Yushi EXCELITE EP2, She1 stamina EP2 or equivalent) Molybdenum disulfide grease

paste

LOCATION Final gear case cover mating surface ECT sensor threads Side stand pivot Throttle pipe flange and sliding surface Clutch lever pivot Gearshift pedal pivot thrust surface Brake pedal pivot sliding surface Frontlrear wheel dust seal lips Swingarm pivot dust seal lips Swingarm pivot bearings Final gear case 0-ring Final gear case oil seal lips Steering head bearings Steering head bearing dust seal lips

Universal joint bearings Drive shaft oil seal lip Drive shaft splines (universal joint side) Final drive pinion joint splines Final driven flange-to-rear wheel h u b mating surface Output shaft splines (universal joint side) Final driven flange 0-ring Rear wheel hub 0-ring groove Ring gear 0-ring groove and spline Final driven flange sliding portion Throttle cable outer inside Clutch cable outer inside Choke cable outer inside Handlebar grip rubber inside

REMARKS Do not apply t o the thread head. Apply 1 9 Spreading 0.2 - 0.3 g

Apply 1.0 - 1.5 g for each bearing

Apply 3 - 5 g for each bearing

I----Cable lubricant

Honda bond A or equivangme 01

steering bearing top mreaas Rear brake cam felt seal Brake lever pivot Brake lever-to-master piston contacting area . P. . R r * Brake caliper bracket pin sliding surface Brake caliper and bracket pin boot inside Brake master piston and cups Brake caliper piston and piston seals Fork dust seal and oil seal lips Fork cap 0-ring Pinion joint nut threads Final gear case cover 10 m m bolt threads Fork center socket bolt threads Brake caliper bracket pin threads Brake caliper slide pin threads Final gear case stud bolt threads Steerina stem cover bolt threads

r Silicone grease

DOT 4 brake fluid

(

Honda ULTRA CUSHION OIL IOW or equivalent Locking agent

GENERAL INFORMATION

CABLE & HARNESS ROUTING (NT700VA) THROTTLE CABLES

LEFT HANDLEBAR SWITCH WIRE

SPEED

GENERAL INFORMATION

SPEEDOMt I t R 20P CONNECTOR BANK ANGLE SENSOR

CLUTCH CABLE

HORN WIRE

SUB-HARNESS 10P (GRAY) CONNECTOR

GENERAL INFORMATION

;

FRO

HEADLIGHT 4~ CONNECTOR FRONT'BRAKE SUB HOSE

BANK ANGLE SENSOR 3P (BLACK) CONNECTOR

GENERAL INFORMATION

FRONT WHEEL SPEED SENSOR WIRE

GENERAL INFORMATION

RIGHT HANDLEBAR SWITCH 9P (RED) CONNECTOR

IAT SENSOR 2P (NATURAL) CONNECTOR

RIGHT HANDLEBAR SWITCH

, , \,

2P (RED) CONNECTOR

,.-

BRAKE P ~ P E

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