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.
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m
You CAN be HURT if you don't follow instructions.
Instructions - how to service this vehicle correctly and safely.
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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.
1
CODE
I
EUROPEAN DIRECT SALES
ED
(Netherlands, Spain, Germany, Belgium, Portugal, Italy, Switzerland, Austria)
E F
U
AREATYPE
U.K. (Ireland)
I
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
YW
d
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)
p
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
1
ELECTRICAL Starting system Charging system Regulatorlrectifier Lighting system
.
Electric starter motor Triple phase output alternator SCR shortedltriple phase full-wave rectification Battery
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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
"U
,
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)
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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
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Unit: m m (in) SERVICE LIMIT
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Unit: m m (in) SERVICE LIMIT 81.10 (3.193)
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IN FX. -. IN EX
Cam lobe height Runout Journal O.D. Oil clearance
D.
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rocker arm shaft
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Valve, valve clulde
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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
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Valve guide projection above cylinder head Valve seat width Valve s ~ r i n a I Free lenath I Cvlinder head warDaae
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IN EX INIEX INIEX
CYLINDER/PISTON SPECIFICATIONS ITEM Cylinder
1
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
.
1
STANDARD 81.000 - 81.01 5 (3.1890 - 3.1896)
I
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
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ALTERNATORISTARTER CLUTCH SPECIFICATIONS ITEM Starter driven gear Starter clutch outer I.D.
I.D. O.D.
1
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)
I
~n
1'3-
I
Claw thickness Fork shaft O.D.
Crankshaft
0.028 - 0.052 (0.0011 - 0.0020) 0.020 - 0.038 (0.0008 - 0.0015)
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'
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
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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
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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
I
0.020
j
1
- 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)
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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
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0.30 (0.012) 0.10 (0.004)
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