HOW TO USE THIS MANUAL,

How To Use This Manual
This manual describes the service procedures for the CTX700/A/D/N/NA/ND-E.
Sections 1, 2 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may
be required to perform service described in the following sections.
Section 4 through 22 describe parts of the motorcycle, grouped according to location.
Follow the Maintenance Schedule (Section 3) recommendations to ensure that the motorcycle is in peak operating condition and
the emission levels are within the standards set by the U.S. Environmental Protection Agency (EPA) and California Air Resources
Board (GARB) and Transport Canada.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Find the section you want on 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 give detailed procedure.
Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI
section troubleshooting first.

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course, it is not practical or 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 1!\ and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:

fij•fMM§;I You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.

fijwJ;WINI You CAN be KILLED or SERIOUSLy HURT if you don't follow instructions.
fijffi\iiiMU You CAN be HURT if you don't follow instructions.
• Instructions - how to service this vehicle correctly and safely.

HOW TO USE THIS MANUAL

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.

lliiijilJ

78

-~

Use the 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 NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example:
Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
'
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example:
Molykote® G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan

..

~

...

~

.

Use silicone grease.

~

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

~

.;imm

I

a

Apply sealant.

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

Use fork or suspension fluid.

CONTENTS
GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
PGM-FI SYSTEM
IGNITION SYSTEM
!=========================================
ELECTRIC STARTER
u I=========================================
ii::
FUEL SYSTEM
I=========================================
w
COOLING SYSTEM
~ I=========================================
~
LUBRICATION SYSTEM
~

<(

0

<(t=============================
et:
CYLINDER HEADNALVES

!===========================================
CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
ii:: I=========================================
c
DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
~ l==A==LT=E=R=N=A=T=O=R=/S=T=A=R=T=E=R=C=L=U=T=C=H=================
~

~

~

I=========================================

z
CRANKCASE/TRANSMISSION/BALANCER
w !=========================================
CRANKSHAFT/PISTON/CYLINDER

ENGINE REMOVAL/INSTALLATION
FRONT WHEEL/SUSPENSION/STEERING
!==========================================
u,
REAR WHEEL/SUSPENSION
~ !==========================================
:c
HYDRAULIC BRAKE
u !=========================================
ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
~

~
BATTERY/CHARGING SYSTEM
WU~=======================================
~-i~ ~
LIGHTS/METERS/SWITCHES
LL W

u:l

WIRING DIAGRAM
INDEX

MEMO

•
SERVICE RULES .......................................... 1-2

LUBRICATION & SEAL POINTS ............... 1-19

MODEL IDENTIFICATION ............................ 1.3

CABLE & HARNESS ROUTING ................. 1.21

SPECIFICATIONS ......................................... 1.5

EMISSION CONTROL SYSTEMS .............. 1-47

TORQUE VALUES ...................................... 1-12

1-1

GENERAL INFORMATION

SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design
specifications may cause damage to the motorcycle.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, 0-rings, cotter pins, and lock plates when reassembling.
5. 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.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as show in the Cable and Harness Routing (page 1-21 ).
9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.

ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term
ABS
CKP sensor
OCT
DLC
OTC
ECM
ECT sensor
EE PROM
EOP sensor
EOP switch
EOT sensor
EVAP
IACV
IAT sensor
MAP sensor
MCS
MIL
02 sensor
PCM
PGM-FI
SCS service connector
TP sensor
TR sensor
VS sensor

1-?

Full term
Anti-lock Brake System
Crankshaft Position sensor
Dual Clutch Transmission
Data Link Connector
Diagnostic Trouble Code
Engine Control Module
Engine Coolant Temperature sensor
Electrically Erasable Programmable Read Only Memory
Engine Oil Pressure sensor
Engine Oil Pressure switch
Engine Oil Temperature sensor
Evaporative Emission
Idle Air Control Valve
Intake Air Temperature sensor
Manifold Absolute Pressure sensor
Motorcycle Communication System
Malfunction Indicator Lamp
Oxygen sensor
Power Control Module
Programmed Fuel Injection
Service Check Short service connector
Throttle Position sensor
Transmission Range Sensor
Vehicle Speed sensor

'

GENERAL INFORMATION

MODEL IDENTIFICATION
CTX700 shown:

CTX700NA shown:

This manual covers following types of CTX?OO:

TYPE
CTX700
CTX700A
CTX?OOD
CTX700N
CTX?OONA
CTX700ND

REGION
U.S.A.
U.S.A. (50 state
Canada
U.S.A.
U.S.A. (50 state
U.S.A.
U.S.A. (50 state
Canada
U.S.A.
U.S.A. (50 state

model)

EVAP

ABS

DCT

-

FRONT SIDE
COWL

REAR
GRIP

-

-

0

0

0

-

0

0

0

0

0

0

0

-

-

-

0

-

-

-

0

0

-

-

0

model)

0
-

model)

-

model)

0

Be sure to refer to the procedure for the appropriate version of the CTX?OO.

1-3

GENERAL INFORMATION
SERIAL NUMBERS/LABELS
The Vehicle Identification Number (V.1.N) [1] is stamped on
the right side of the steering head.

The engine serial number [1] is stamped on the lower right
side of the crankcase.

[1 J
The throttle body identification number [1] is stamped on the
lower left side of the throttle body as shown.

The color label [1] is attached on the left side of the rear
frame. When ordering color-coded parts, always specify the
designated color code.

[1 J
The safety certification label [1] is located on the left side of
the frame.

The Emission Control Information Label [1] is located on the
left side of the swingarm.
[1] (CTX700A/NA only)

[1 J

1 ...4

[1]

GENERAL INFORMATION

SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM

DIMENSIONS

Overall length
Overall width

CTX700/NN/NA
CTX700D/ND
CTX700/ND
CTX700N/NNND

Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Curb weight

CTX700

CTX700A
CTX700D

CTX700N

CTX700NA
CTX700ND

FRAME

Maximum weight capacity
Frame type
Front suspension
Front axle travel
Rear suspension
Rear axle travel
Front tire size
Rear tire size
Front tire brand
Rear tire brand

ENGINE

I

50 state
model

I

50 state
model

I

50 state
model

I

50 state
model

BRIDGESTONE
METZELER
BRIDGESTONE
METZELER

Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train
opens
Intake valve

at 1 mm (0.04 in) lift

closes
opens
closes

at 1 mm (0.04 in) lift
at 1 mm (0.04 in) lift
at 1 mm (0.04 in) lift

Exhaust
valve

Lubrication system
Oil pump type
Cooling system
Air filtration
Engine dry weight
Firing order

CTX700/NN/NA
CTX700D/ND

SPECIFICATIONS
2,265 mm (89.2 in)
855 mm (33.7 in)
840 mm (33.1 in)
1,165 mm (45.9 in)
1,155 mm (45.5 in)
1,530 mm (60.2 in)
720 mm (28.4 in)
308 mm (12.1 in)
130 mm (5.1 in)
224 kg (494 lbs)
225 kg (496 lbs)

226 kg (498 lbs)
234 kg (516 lbs)
235 kg (518 lbs)

..

217 kg (478 lbs)
218 kg (481 lbs)
219 kg (483 lbs)
227 kg (500 lbs)
228 kg (503 lbs)
176 kg (388 lbs)
Diamond
Telescopic fork
107 mm (4.2 in)
Swingarm
110 mm (4.3 in)
120/70ZR 17M/C (58W)
160/60ZR17M/C (69W)
BT023F G
ROADTEC Z8 INTERACT E
BT023R G
ROADTEC ZS INTERACT
Hydraulic single disc
Hydraulic single disc
27° 40'
114 mm (4.5 in)
12.4 liters (3.28 US gal, 2.7 Imp gal)
2 cylinders in-line, slant angle 55°
73.0 x 80.0 mm (2.87 x 3.15 in)
670.0 cm3 (40.9 cu-in)
10.7:1
Chain driven, OHC with rocker arm
No.1: - 20° BTDC
No.2: - 25° BTDC
27° ABDC
30° BBDC
No.1: -15° ATDC
No.2: 20° ATDC
Forced pressure and wet sump
Trochoid
Liquid cooled
Paper element
60.5 kg (133.4 lbs)
67.3 kg (148.4 lbs)
1- 2

1-5

GENERAL INFORMATION
ITEM

FUEL DELIVERY
SYSTEM
DRIVE TRAIN

Type
Throttle bore
Clutch system
Clutch operation system

CTX700/A/NINA
CTX700D/ND
CTX700/A/NINA
CTX700D/ND

Transmission
Primary reduction

CTX700/A/NINA
CTX700D/ND
Final reduction
CTX700/A/NINA
CTX700D/ND
Gear ratio
CTX700/A/N/NA
1st
2nd
3rd
4th
5th
6th
CTX700D/ND
1st
2nd
3rd
4th
5th
6th
Gearshift pattern
CTX700/A/NINA
CTX700D/ND

ELECTRICAL

Ignition system
Starting system
Charging system
Regulator/rectifier
Lighting system

SPECIFICATIONS
PGM-FI (Programmed Fuel Injection)
36 mm (1.4 in)
Multi-plate, wet
2 Multi-plate wet clutches
Cable operating
Automatic
Constant mesh, 6-speeds
1.731 (71/41)
1.921 (73/38)
2.687 (43/16)
2.437 (39/16)
2.812 (45/16)
1.894 (36/19)
1.454 (32/22)
1.200 (30/25)
1.033 (31/30)
0.837 (31/37)
2.666 (40/15)
1.904 (40/21)
1.454 (32/22)
1.200 (30/25)
1.033 (31/30)
0.837 (31/37)
Left foot operated return system,
1-N-2-3-4-5-6
Automatic and electric shift {left hand
operated) return system,
N-1-2-3-4-5-6
Computer-controlled digital
transistorized with electric advance
Electric starter motor
Triple phase output alternator
FET shorted/triple phase full wave
rectification
Battery

PGM-FI SPECIFICATIONS
ITEM
IAT sensor resistance (at 20°C/68°F)
ECT sensor resistance (at 40°C/104 °F)
Fuel injector resistance (at 20°C/68°F)

SPECIFICATIONS
2.2-2.7 kQ
1.0-1.3 kQ
11.6-12.4 Q

IGNITION SYSTEM SPECIFICATIONS
ITEM
Spark plug {Iridium)
Spark plug gap
Ignition coil peak voltage
CKP sensor peak voltage (at 20°C/68°F)
Ignition timing ("F" mark)

SPECIFICATIONS
IFR6G-11 K (NGK)
1.0 - 1.1 mm (0.039 - 0.043 in)
100 V minimum
0.7 V minimum
12° BTDC at idle

ELECTRIC STARTER SPECIFICATION
ITEM

Starter motor brush length

STANDARD
12.0 - 13.0 (0.47 - 0.51)

Unit: mm (in)
SERVICE LIMIT
6.5 (0.26)

GENERAL INFORMATION
FUEL SYSTEM SPECIFICATIONS
ITEM
Throttle body identification number
Idle speed
Throttle grip freeplay
Fuel pressure at idle
Fuel pump flow (at 12 V)
EVAP purge control solenoid valve resistance
(at 20°C/68°F)

SPECIFICATIONS
GQ3UA
1,200 ± 100 rpm
2 - 6 mm (0.1 - 0.2 in)
343 kPa (3.5 kgf/cm 2 , 50 psi)
230 cm 3 (7.8 US oz, 8.1 Imp oz) minimum/10 seconds
30

340

COOLING SYSTEM SPECIFICATIONS
ITEM
Radiator and engine
At draining
Reserve tank
Radiator cap relief pressure
Begin to open
Thermostat
Fully open
Valve lift
Recommended antifreeze
Coolant capacity

Standard coolant concentration

SPECIFICATIONS
1.69 liters (1.79 US qt, 1.49 Imp qt)
1.41 liters (1.49 US qt, 1.24 Imp qt)
0.131iter(0.14USqt,0.11 lmpqt)
108 - 137 kPa (1.1 - 1.4 kgf/cm 2 , 16 - 20 psi)
80- 84°C (176 183°F)
95°C (203°F) ,
8 mm (0.3 in) minimum
Pro Honda HP Coolant or an equivalent high quality ethylene
glycol antifreeze containing silicate-free corrosion inhibitors
1: 1 (mixture with distilled water)

LUBRICATION SYSTEM SPECIFICATIONS
Engine oil
capacity

ITEM
CTX700/NN/NA

CTX700D/ND

After draining
After draining/
filter change
After
disassembly
After draining
After draining/
filter change
After
disassembly

Recommended engine oil

Oil pressure at engine oil filter
Oil pump rotor (CTX700/NN/NA)

Engine oil pump rotor (CTX700D/ND)

Clutch oil pump rotor (CTX700D/ND)

Tip clearance
Body clearance
Side clearance
Tip clearance
Body clearance
Side clearance
Tip clearance
Body clearance
Side clearance

STANDARD
3.1 liters (3.3 US qt, 2. 7 Imp qt)

Unit mm (in)
SERVICE LIMIT
-

3.4 liters (3.6 US qt, 3.0 Imp qt)

-

3.7 liters (3.9 US qt, 3.3 Imp qt)

-

3.2 liters (3.4 US qt, 2.8 Imp qt)
3.4 liters (3.6 US qt, 3.0 Imp qt)

-

4.1 liters (4.3 US qt, 3.6 Imp qt)

-

Pro Honda GN4 4-stroke oil (U.S.A. and
Canada) or equivalent motorcycle oil
API service classification: SG or Higher
JASO T 903 standard: MA
Viscosity: SAE 1OW-30
470 kPa (4.8 kgf/cm 2 , 68 psi)
at 5,000 rpm/(80°C/176°F)
0.15 (0.006)
0.15 - 0.21 (0.006 - 0.008)
0.04 - 0.09 (0.002 - 0.004)
0.15 (0.006)
0.15 - 0.21 (0.006 - 0.008)
0.04 - 0.09 (0.002 - 0.004)
0.15 (0.006)
0.15 - 0.21 (0.006 - 0.008)
0.04 - 0.09 (0.002 - 0.004)

0.20
0.35
0.12
0.20
0.35
0.12

(0.008)
(0.014)
(0.005)
(0.008)
(0.014)
(0.005)

-

1-7

GENERAL INFORMATION
CYLINDER HEADNALVES SPECIFICATIONS
ITEM
Cylinder compression at 470 rpm
Valve clearance

IN
EX

Rocker arm,
rocker arm
shaft

Rocker arm I.D.
Rocker arm shaft O.D.
Rocker arm-to-shaft clearance
Cam chain tensioner wedge B length
Camshaft
Cam lobe height
IN
EX
Runout
Camshaft journal O.D.
Valve, valve
Valve stem O.D.
IN
guide
EX
Valve guide I.D.
IN/EX
Stem-to-guide
IN
clearance
EX
IN
Valve guide
projection above
EX
cylinder head
IN
Valve seat width
EX
Valve spring free length
Cylinder head warpage
Cylinder head camshaft journal 1.0.
Cylinder head-to-camshaft clearance

STANDARD
1,775 kPa (18.1 kgf/cm 2, 257 psi)
0.17 ± 0.02 (0.007 ± 0.001)
0.28 ± 0.02 (0.011 ± 0.001)
20.012 - 20.030 (0.7879- 0.7886)
19.972 - 19.993 (0.7863 - 0.7871)
0.019- 0.058 (0.0007 - 0.0023)
-

34.7897 - 35.0297 (1.36967 -1.37912)
34.9227 - 35.1627 (1.37491 - 1.38436)

-

41.935-41.950 (1.6510-1.6516)
4.975 - 4.990 (0.1959 - 0.1965)
4.965 - 4.980 (0.1955 - 0.1961)
5.000- 5.012 (0.1969 - 0.1973)
0.010- 0.037 (0.0004 - 0.0015)
0.020- 0.047 (0.0008-0.0019)
17.7-18.0 (0.70- 0.71)
19.6 -19.9 (0.77 - 0.78)
0.90 - 1.10 (0.035 - 0.043)
1.30 - 1.50 (0.051 - 0.059)
49.07 (1.932)
-

41.995 - 42.019 (1.6533 - 1.6543)
0.045- 0.084 (0.0018- 0.0033)

Unit" mm (in)
SERVICE LIMIT
-

20.041 (0.7890)
19.961 (0.7859)
0.08 (0.003)
6.0 (0.24)
34.7697
(1.36888)
34.9027
(1.37412)
0.04 (0.002)
41.927 (1.6507)
4.965 (0.1955)
4.955 (0.1951)
5.04 (0.198)
0.07,5 (0.0030)
0.085 (0.0033)
-

1.5 (0.06)
1.9 (0.07)
48.1 (1.89)
0.10 (0.004)
42.027 (1.6546)
0.10 (0.004)

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (CTX700/A/N/NA)
ITEM
Clutch lever freeplay
Clutch

Spring free length
Disc thickness
Plate warpage
I.D.

Clutch outer guide

0.0.
Mainshaft 0.0. at clutch outer guide
Clutch outer guide-to-mainshaft clearance
Primary driven gear 1.0.
Primary driven gear-to-clutch outer guide clearance

STANDARD
10- 20 (0.4 - 0.8)
43.2 (1.70)
2.62- 2.78 (0.103- 0.109)

21.991 22.016 (0.8658 - 0.8668)
31.959 - 31.975 (1.2582 -1.2589)
21.967 - 21.980 (0.8648- 0.8654)
0.011 - 0.049 (0.0004 - 0.0019)
32.000 - 32.025 (1.2598 - 1.2608)
0.025- 0.066 (0.0010 - 0.0026)

Unit· mm (in)
SERVICE LIMIT
-

41.7 (1.64)
2.3 (0.09)
0.30 (0.012)
22.03 (0.867)
31.92 (1.257)
21.95 (0.864)
0.08 (0.003)
32.09 (1.263)
0.10 (0.004)

DUAL CLUTCH TRANSMISSION SPECIFICATIONS (CTX700D/ND)
ITEM
Clutch clearance
EOT sensor resistance (20°C/68°F)

STANDARD
0.9 - 1.1 (0.035 - 0.043)
2.5-2.8 kQ

Unit· mm (in)
SERVICE LIMIT
2.0 (0.08)
-

AL TERNATOR/STARTER CLUTCH SPECIFICATIONS
ITEM
Starter driven gear boss 0.0.
Starter clutch outer 1.0.

...

0

STANDARD
57.749- 57.768 (2.2736 - 2.2743)
74.412- 74.442 (2.9296- 2.9308)

Unit' mm (in)
SERVICE LIMIT
57. 73 (2.273)
74.46 (2.931)

GENERAL INFORMATION
CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS
CTX700/A/N/NA
STANDARD
28.000 - 28.021 (1.1024 - 1.1032)
31.000 - 31.025 (1.2205 - 1.2215)
27.959 - 27.980 (1.1007 - 1.1016)
30.955 - 30.980 (1.2187 - 1.2197)
30.950- 30.975 (1.2185 - 1.2195)
0.020- 0.062 (0.0008- 0.0024)
0.020 - 0.070 (0.0008 - 0.0028)
0.025 - 0.075 (0.0010 - 0.0030)
25.000 - 25.021 (0.9843 - 0.9851)
27.985 - 28.006 (1.1018 1.1026)
24.972 - 24.993 (0.9831 - 0.9840)
27.967 - 27.980 (1.1011 - 1.1016)
0.007 - 0.049 (0.0003 - 0.0020)
0.005- 0.039 (0.0002- 0.0015)
12.000-12.018 (0.4724- 0.4731)
5.93 - 6.00 (0.233 - 0.236)
11.957 - 11.968 (0.4707 - 0.4712)

Unit: mm (in)
SERVICE LIMIT
28.04 (1.104)
31.04 (1.222)
27.94 (1.100)
30.93 (1.218)
30.93 (1.218)
0.08 (0.003)
0.10 (0.004)
0.11 (0.004)
25.04 (0.986)
28.02 (1.103)
24.95 (0.982)
27.95 (1.100)
0.09 (0.004)
0.06 (0.002)
12.03 (0.474)
5.9 (0.23)
11.95 (0.470)

M5
M6
C1
C2
C3,C4
M5
M6
C1
C2
C3, C4
M5
M6
C1
C2
C3, C4
M5
M6
C1
C2

STANDARD
33.000 - 33.025 (1.2992 - 1.3002)
43.000 - 43.025 (1.6929 - 1.6939)
31.010- 31.035 (1.2209-1.2218)
25.000 - 25.021 (0.9843 - 0.9851)
31.000 - 31.025 (1.2205 - 1.2215)
32.955 - 32.980 (1.2974 - 1.2984)
42.950-42.975 (1.6909-1.6919)
30.970 - 30.995 (1.2193 - 1.2203)
24.959 - 24.980 (0.9826 - 0.9835)
30.950 - 30.975 (1.2185 - 1.2195)
0.020 - 0.070 (0.0008 - 0.0028)
0.025 - 0.075 (0.0010- 0.0030)
0.015- 0.065 (0.0006- 0.0026)
0.020 - 0.062 (0.0008 - 0.0024)
0.025 - 0.075 (0.0010- 0.0030)
29.985 - 30.006 (1.1805 - 1.1813)
40.007 - 40.028 (1.5751 - 1.5759)
28.000 - 28.021 (1.1024 - 1.1032)
21.985 - 22.006 (0.8655 - 0.8664)

Unit: mm (in)
SERVICE LIMIT
33.04 (1.301)
43.04 (1.694)
31.06 (1.223)
25.03 (0.985)
31.04 (1.222)
32.93 (1.296)
42.93 (1.690)
30.94 (1.218)
24.94 (0.982)
30.93 (1.218)
0.10 (0.004)
0.11 (0.004)
0.10 (0.004)
0.09 (0.004)
0.11 (0.004)
30.03 (1.182)
40.038 (1.5763)
28.04 (1.104)
22.02 (0.867)

At M5 bushing

29.957 - 29.970 (1.1794 - 1.1799)

29.93 (1.178)

At M6 bushing

39.975 - 39.991 (1.5738 - 1.5744)

39.965 (1.5734)

At C1 bushing
At C2 bushing
M5
M6
C1
C2

27.967-27.980 (1.1011-1.1016)
21.952 - 21.965 (0.8643 - 0.8648)
0.015- 0.049 (0.0006- 0.0019)
0.016 - 0.053 (0.0006 - 0.0021)
0.020 - 0.054 (0.0008 - 0.0021)
0.020 0.054 (0.0008 - 0.0021)
12.000-12.018 (0.4724- 0.4731)
5.93 - 6.00 (0.233 - 0.236)
11.957 - 11.968 (0.4707 - 0.4712)

27.95 (1.100)
21.94 (0.864)
0.09 (0.004)
0.10 (0.004)
0.08 (0.003)
0.08 (0.003)
12.03 (0.474)
5.9 (0.23)
11.95 (0.470)

ITEM

Transmission

Gear 1.0.
Gear bushing

0.0.
Gear-to-bushing
clearance
Gear bushing 1.0.

Shift fork,
fork shaft

Mainshaft 0.0.
Countershaft 0.0.
Bushing-to-shaft
clearance
Fork 1.0.
Claw thickness
Shift fork shaft 0.0.

M5, M6, C1
C2,C3,C4
M5, M6
C2
C3, C4
M5, M6
C2
C3, C4
M5
C2
At M5 bushing
At C2 bushing
M5
C2

CTX700D/ND
ITEM

Transmission

Gear 1.0.

Gear bushing

0.0.

Gear-to-bushing
clearance

Gear bushing 1.0.

Inner mainshaft

0.0.
Outer mainshaft

0.0.
Countershaft 0.0.
Bushing-to-shaft
clearance

Shift fork,
fork shaft

Fork 1.0.
Claw thickness
Shift fork shaft 0.0.

1-9

GENERAL INFORMATION
CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS
ITEM
Crankshaft
Connecting rod side clearance
Runout
Right side
Left side
Main journal bearing oil clearance
Cylinder
1.0.
Out-of-round
Taper
Warpage
Piston, piston
Piston 0.0. at 13 mm (0.5 in) from
rings
bottom
Piston pin bore 1.0.
Piston pin 0.0.
Piston-to-piston pin clearance
Piston ring end
Top
gap
Second
Oil (side rail)
Piston ring-to-ring
Top
groove clearance
Second
Cylinder-to-piston clearance
Connecting rod small end 1.0.
Crankpin bearing oil clearance

STANDARD
0.15 - 0.35 (0.006 - 0.014)

0.019- 0.037 (0.0007 - 0.0015)
73.000- 73.015 (2.8740- 2.8746)

-

Unit· mm (in)
SERVICE LIMIT
0.45 (0.018)
0.03 (0.001)
0.03 (0.001)
0.05 (0.002)
73.07 (2.877)
0.10 (0.004)
0.10 (0.004)
0.10 (0.004)

72.976 - 72.990 (2.8731 - 2.8736)

72.970 (2.8728)

18.010-18.013 (0.7091- 0.7092)
17.996 -18.000 (0.7085 - 0.7087)
0.010 - 0.017 (0.0004 - 0.0007)
0.15- 0.30 (0.006 - 0.012)
0.30- 0.42 (0.012- 0.017)
0.20 0.70 (0.008 - 0.028)
0.035 - 0.080 (0.0014 - 0.0032)
0.030 - 0.055 (0.0012 - 0.0022)
0.010 - 0.039 (0.0004 - 0.0015)
17.964-17.977 (0.7072- 0.7078)
0.026 - 0.044 (0.0010 - 0.0017)

18.023 (0. 7096)
17.988 (0.7082)
0.035 (0.0014)
0.6 (0.02)
0.6 (0.02)
0.8 (0.03)
0.15 (0.006)
0.13 (0.005)
0.05 (0.002)
17.985 (0. 7081)
0.05 (0.002)

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
ITEM

STANDARD

-

Minimum tire tread depth
Up to 90 kg (200 lbs) load
Cold tire
pressure
Up to maximum weight capacity
Axle runout
Wheel rim runout
I Radial
I Axial
Wheel balance weight
Fork

250 kPa (2.50 kgf/cm', 36 psi)
250 kPa (2.50 kgf/cm', 36 psi)

-

Spring free length
Tube runout
Recommended fork fluid

357.0 (14.06)
-

Pro Honda Suspension Fluid SS-4 7
(10W)
103 (4.1)
518 ± 2.5 cm 3 (17.5 ± 0.08 US oz,
18.2 ± 0.09 Imp oz)

Fluid level
Fluid capacity

Unit: mm (in)
SERVICE LIMIT
1.5 (0.06)

0.2 (0.01)
1.0 (0.04)
1.0(0.04)
60 g (2.1 oz)
max.
349.9 (13.78)
0.2 (0.01)
-

-

REAR WHEEL/SUSPENSION SPECIFICATIONS
ITEM

STANDARD

-

Minimum tire tread depth
Up to 90 kg (200 lbs) load
Cold tire
pressure
Up to maximum weight capacity
Axle runout
Radial
Wheel rim runout
Axial
Wheel balance weight
Drive chain

Size/link

CTX700/A/NINA
CTX700D/ND

Slack

250 kPa (2.50 kgf/cm2 , 36 psi)
290 kPa (2.90 kgf/cm 2 , 42 psi)

DID
RK
DID
RK

DID520V0-114LE
RK520KH0-114LE
DID520V0-112LE
RK520KH0-112LE
25-35 (1.0-1.4)

Unit: mm (in)
SERVICE LIMIT
2.0 (0.08)

0.2 (0.01)
1.0 (0.04)
1.0 (0.04)
60 g (2.1 oz)
max.

-

-

GENERAL INFORMATION
HYDRAULIC BRAKE SPECIFICATIONS
Front

Rear

ITEM
Specified brake fluid
Brake disc thickness
Brake disc warpage
Master cylinder 1.0.
Master piston 0.0.
Caliper cylinder 1.0.
Caliper piston 0.0.
Specified brake fluid
Brake disc thickness
Brake disc warpage
Master cylinder 1.0.
Master piston 0.0.
Caliper cylinder 1.0.
Caliper piston 0.0.

Unit· mm (in)
SERVICE LIMIT

STANDARD
DOT4
4.8 - 5.2 (0.19 - 0.20)

-

0.4348)
0.4324)
1.0650)
1.0617)

4.0 (0.16)
0.30 (0.012)
11.055 (0.4352)
10.945 (0.4309)
27.06 (1.065)
26.91 (1.059)

12.700- 12.743 (0.5000 - 0.5017)
12.657 - 12.684 (0.4983 - 0.4994)
38.18 - 38.23 (1.503 - 1.505)
38.098-38.148 (1.4999-1.5019)

4.0 (0.16)
0.30 (0.012)
12.755 (0.5022)
12.645 (0.4978)
38.24 (1.506)
38.09 (1.500)

11.000 10.957 27.000 26.918 DOT4
4.8 - 5.2

11.043 (0.4331 10.984 (0.4314 27.050 (1.0630 26.968 (1.0598 -

-

(0.19 - 0.20)

-

BATTERY/CHARGING SYSTEM SPECIFICATIONS
Battery

ITEM
Type
Capacity
Current leakage
Voltage
(20°C/68°F)
Charging current

Alternator

Fully charged
Needs
charging
Normal
Quick

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

SPECIFICATIONS
YTZ12S
12V-11.0Ah (10HR)
0.2 mA maximum
13.0 -13.2 V
Below 12.4 V
1.1 A/5-10 h
5.5 A/1 h
0.45 kW/5,000 rpm
0.1-0.50

LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM
Headlight
Brake/tail light
License light
Front turn signal/position light
Rear turn signal light
Instrument light
Turn signal indicator
High beam indicator
Neutral indicator
Engine oil pressure indicator
High coolant temperature indicator
MIL
ABS indicator (CTX700A/D/NA/ND)
Parking brake indicator (CTX7000/ND)
Main fuse
Fuse
PGM-FI fuse
Sub fuse
ABS fuse (CTX700A/D/NA/ND)
OCT fuse (CTX7000/ND)
40°C (104°F)
ECT sensor resistance
100°C (212°F)
Full
Fuel level sensor resistance
Empty
Bulbs

SPECIFICATIONS
12 V-60/55 W
LED
12 V-5 W
12V-21/5Wx2
12V-21Wx2
LED
LED
LED
LED
LED
LED
LED
LED
LED
30 A
15 A
15Ax2, 7.5Ax4
30 A, 7.5 A
30 A, 7.5 A
1.0 1.3 kO
0.1-0.2 kO
4-60
80-83 0

1-11

GENERAL INFORMATION

TORQUE VALUES
STANDARD TORQUE VALUES
FASTENER TYPE
5 mm bolt and nut
6 mm bolt (Include SH flange bolt)
and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut

TORQUE
N·m (kgf·m, lbHt)
5.2 (0.5, 3.8)
10(1.0, 7)
22 (2.2, 16)
34 (3.5, 25)
54 (5.5, 40)

TORQUE
N·m (kgf·m, lbHt)
4.2 (0.4, 3.1)
9.0 {0.9, 6.6)
12(1.2,9)

FASTENER TYPE
5 mm screw
6 mm screw
6 mm flange bolt {Include NSHF) and
nut
8 mm flange bolt and nut
10 mm flange bolt and nut

27 (2.8, 20)
39 (4.0, 29)

ENGINE & FRAME TORQUE VALUES
FRAME BODY PANELS/EXHAUST SYSTEM
ITEM
Combination meter mounting
screw
Main step mounting bolt
Gearshift arm pinch bolt
(CTX700/A/N/NA)
Reflector mounting nut
Muffler band bolt
Muffler cover socket bolt
Exhaust pipe joint nut
Exhaust pipe stud bolt

3

THREAD
DIA. (mm)
5

TORQUE
N·m (kgf·m, lbf·ft)
1.0 (0.1, 0.7)

6
1

8
6

27 (2.8, 20)
12(1.2,9)

5
2

5
8

1.7 (0.2, 1.3)
20 (2.0, 15)

1
3
3

6
8
8

10(1.0,7)
28 (2.9, 21)

TORQUE
N·m (kgf·m, lbf·ft)
1.1 (0.1, 0.8)
22 (2.2, 16)
14 (1.4, 10)

Q'TY

-

REMARKS

'

ALOC bolt; replace with a new one.

Apply engine oil to the threads and
seating surface
See page 2-19
See page 2-19

MAINTENANCE

Air cleaner housing cover screw
Spark plug
Valve adjusting screw lock nut

6
2
8

THREAD
DIA. (mm)
5
14
7

Camshaft maintenance cap
Timing hole cap
Crankshaft hole cap
Engine oil drain bolt
Engine oil filter cartridge
Rear axle nut
Drive chain adjuster lock nut
Drive sprocket bolt
Driven sprocket nut
Front master cylinder reservoir
cover screw
Rear master cylinder reservoir
mounting bolt
Rear master cylinder push rod lock
nut
Parking brake adjuster bolt lock
nut (CTX700D/ND)
Sidestand pivot bolt

1
1
1
1
1
1
2
1
5
2

36
14
30
12
20
18
8
10
12
4

4.0 (0.4, 3.0)
10 (1.0, 7)
15 (1.5, 11)
30 (3.1, 22)
26 (2.7, 19)
98 (10.0, 72)
21 (2.1, 15)
54 (5.5, 40)
108 (11.0, 80)
1.5 (0.2, 1.1)

1

6

10(1.0,7)

1

8

17 (1.7, 13)

1

8

17 (1.7, 13)

1

10

-

Sidestand pivot nut

1

10

39 (4.0, 29)

THREAD
DIA. (mm)
10
12

TORQUE
N·m (kgf·m, lbf·ft)
12 (1.2, 9)
24.5 (2.5, 18)

ITEM

Q'TY

REMARKS

Apply engine oil to the threads and
seating surface.
See page 3-9
Apply grease to the threads.
Apply grease to the threads.
Apply engine oil to the threads.
U-nut

U-nut

See page 3-21
Apply grease to the sliding surface.
U-nut

PGM-FI SYSTEM
ITEM
ECT sensor
02 sensor

Q'TY
1
1

REMARKS

GENERAL INFORMATION
IGNITION SYSTEM
ITEM

Q'TY

Timing hole cap
Right crankcase cover wire clamp
bolt (CTX700D/ND)

1
2

THREAD
DIA. (mm)
14
6

TORQUE
N·m (kgf·m, lbHt)
10 (1.0, 7)
12(1.2,9)

THREAD
DIA. (mm)
6

TORQUE
N·m (kgf·m, lbMt)
10 (1.0, 7)

TORQUE
N·m (kgf·m, lbf·ft)
12 (1.2, 9)
3.4 (0.3, 2.5)
2.1 (0.2, 1.5)
1.5 (0.2, 1.1)

REMARKS

Apply grease to the threads.
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip

ELECTRIC STARTER
ITEM

Starter motor terminal nut

Q'TY

1

REMARKS

FUEL SYSTEM
ITEM

Q'TY

Fuel pump mounting nut
Sensor unit torx screw
IACV torx screw
Air cleaner connecting hose band
screw
Insulator band screw

6
3
2
1

THREAD
DIA. (mm)
6
5
4
4

2

5

-

THREAD
DIA. (mm)
6
4
3

TORQUE
N·m (kgf·m, lbHt)
8.4 (0.9, 6.2)
2.7 (0.3, 2.0)
1.0 (0.1, 0.7)

TORQUE
N·m (kgf·m, lbf·ft)

REMARKS

For tightening sequence (page 7-13)

'
See page 7-16

COOLING SYSTEM
ITEM

Fan motor shroud mounting bolt
Fan motor mounting screw
Cooling fan mounting nut

Q'TY

3
3
1

REMARKS

Apply locking agent to the threads.

LUBRICATION SYSTEM

Oil filter boss

1

THREAD
DIA. (mm)
20

Engine oil filter cartridge

1

20

26 (2.7, 19)

TORQUE
N·m (kgf·m, lbf·ft)
10 (1.0, 7)
10 (1.0, 7)

ITEM

Q'TY

-

REMARKS

Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip
Apply engine oil to the threads.

CYLINDER HEADNALVES

Cylinder head cover socket bolt
Rear master cylinder reservoir
mounting bolt
Breather plate mounting bolt

3
1

THREAD
DIA. (mm)
6
6

8

6

12 (1.2. 9)

Rocker arm shaft bolt

3

8

29 (3.0, 21)

Camshaft maintenance cap

1

36

4.0 (0.4, 3.0)

Cam chain tensioner bolt
Cam sprocket bolt

2
1

6
10

12(1.2,9)
56(5.7,41)

Insulator band screw
Cylinder head special bolt

1
6

5
9

44 (4.5, 32)

ITEM

Q'TY

-

REMARKS

Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply engine oil to the threads and
seating surface.
See page 10-10
See page 10-24
Apply engine oil to the threads and
seating surface.
See page 10-22
Apply molybdenum oil solution to the
threads and seating surface.

1-13

GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)

Right engine side cover socket
bolt
Clutch center lock nut

2

THREAD
DIA. (mm)
6

1

18

128 (13.1, 94)

Clutch lifter plate bolt
Primary drive gear mounting bolt

4
1

6
10

12 (1.2, 9)
93 (9.5, 69)

Shift drum stopper arm pivot bolt

1

6

12(1.2,9)

Shift drum center socket bolt

1

8

23 (2.3, 17)

Gearshift pedal pivot bolt
Gearshift arm pinch bolt
Gearshift pedal adjuster lock nut

1
1
2

10
6
6

39 (4.0, 29)
12 (1.2, 9)
10 (1.0, 7)

ITEM

Q'TY

TORQUE
N·m (kgf·m, lbMt)
10(1.0,7)

REMARKS

Apply engine oil to the threads and
seating surface.
Lock nut; replace with a new one and
stake.
Apply engine oil to the threads and
seating surface.
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
ALOC bolt; replace with'a new one.

DUAL CLUTCH TRANSMISSION (DCT) {CTX700D/ND)

Solenoid valve stopper plate bolt

1

THREAD
DIA. {mm)
6

Right crankcase cover wire clamp
bolt

2

6

12 (1.2, 9)

Linear solenoid valve body
mounting bolt
Shift spindle angle sensor bolt
Primary drive gear mounting bolt

6

6

-

1
1

6
10

12(1.2,9)
93 (9.5, 69)

Reduction gear cover bolt
TR sensor bolt
Shift control motor bolt
Shift drum center bolt

3
1
3
1

6
6
6
8

14 (1.4, 10)
12 (1.2, 9)
14 (1.4, 10)
23 (2.3, 17)

Drum shifter guide plate bolt

2

6

12 (1.2, 9)

Clutch line EOP sensor
EOT sensor

3
1

10
10

19.6 (2.0, 14)
14 (1.4, 10)

ITEM

1 .. 1.ct

Q'TY

TORQUE
N·m (kgf·m, lbMt)
12 (1.2, 9)

REMARKS
Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
For tightening sequence
(page 12-62)
Apply engine oil to the threads and
seating surface.

Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply engine oil to the threads and
seating surface.

GENERAL INFORMATION
AL TERNATOR/STARTER CLUTCH

Flywheel mounting bolt

1

THREAD
DIA. (mm)
12

Starter clutch socket bolt

6

8

30 (3.1, 22)

Alternator stator mounting bolt

4

6

10 (1.0, 7)

Alternator wire clamp bolt

1

6

10 (1.0, 7)

TORQUE
N·m (kgf·m, lbf·ft)
12 (1.2, 9)

ITEM

Q'TY

TORQUE
N·m (kgf·m, lbHt)
157 (16.0, 116)

REMARKS

Left hand thread
Apply engine oil to the threads and
seating surface.
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip

CRANKCASE/TRANSMISSION/BALANCER

Mainshaft bearing set plate bolt

3

THREAD
DIA. (mm)
6

Shift drum bearing set plate bolt

2

6

12(1.2,9)

Balancer shaft bearing set plate
bolt

3

6

12 (1.2, 9)

Crankcase main journal bolt (new)

6

9

20 (2.0, 15) + 150°

Crankcase 10 mm bolt
Crankcase 8 mm bolt
Crankcase 8 x 45 mm bolt

1
3
1

10
8
8

39 (4.0, 29)
24 (2.4, 18)
24 (2.4, 18)

Crankcase 6 mm bolt

8

6

12(1.2,9)

QTY

THREAD
DIA. (mm)

Crankpin bearing cap bolt

4

6

TORQUE
N·m (kgf·m, lbf·ft)
10 (1.0, 7) + 90°

Crankcase main journal bolt
(retightening)

6

9

20 (2.0, 15) + 120°

ITEM

Q'TY

-REMARKS

Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in)excepf2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
See page 14-24
Replace with a new one.

Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip

CRANKSHAFT/PISTON/CYLINDER
ITEM

REMARKS

See page 15-7
See page 15-12
Replace with a new one.
Apply engine oil to the threads and
seating surface.
See page 15-9
Apply engine oil to the threads and
seating surface.

1-15

GENERAL INFORMATION
ENGINE REMOVAL/INSTALLATION

1
2
2
1
1
6

THREAD
DIA. (mm)
12
12
12
12
10
8

TORQUE
N·m (kgf·m, lbMt)
59 (6.0, 44)
54 (5.5, 40)
54 (5.5, 40)
54 (5.5, 40)
54 (5.5, 40)
27 (2.8, 20)

2
1

8
6

27 (2.8, 20)
10 (1.0, 7)

1
2

6
6

10 (1.0, 7)
10(1.0,7)

1

6

10 (1.0, 7)

TORQUE
N·m (kgf·m, lbMt)
2.5 (0.3, 1.8)
12 (1.2, 9)
10 (1.0, 7)

ITEM

Q'TY

Rear lower engine hanger nut
Front lower engine hanger bolt
Upper engine hanger bolt
Rear upper engine hanger nut
Drive sprocket bolt
Main step base plate mounting
bolt
Rear brake bracket mounting bolt
Rear master cylinder reservoir
mounting bolt
Starter motor terminal nut
Right engine side cover socket
bolt
Rear master cylinder reservoir
mounting bolt

REMARKS

FRONT WHEEL/SUSPENSION/STEERING
ITEM

Q'TY

Handlebar switch housing screw
Front master cylinder holder bolt
Handlebar weight mounting screw

4
2
2

THREAD
DIA. (mm)
5
6
6

Front brake disc mounting bolt
Front axle
Front axle pinch bolt
Fork socket bolt
Bottom bridge pinch bolt
Fork cap
Top bridge pinch bolt
Front brake caliper mounting bolt
Steering stem adjusting nut

5
1
1
2
2
2
2
2
1

8
18
8
8
10
37
8
8
26

Steering stem adjusting lock nut
Steering stem nut

1
1

26
24

103 (10.5, 76)

THREAD
DIA. (mm)
12
8
18
6
10
10
10
5
18

TORQUE
N·m (kgf·m, lbMt)
108 (11.0, 80)
42 (4.3, 31)
98 (10.0, 72)
10(1.0,7)
44 (4.5, 32)
44 (4.5, 32)
44 (4.5, 32)
5.9 (0.6, 4.4)
98 (10.0, 72)

42 (4.3,
74 (7.5,
22 (2.2,
20 (2.0,
39 (4.0,
22 (2.2,
22 (2.2,
30 (3.1,
23 (2.3,

31)
55)
16)
15)
29)
16)
16)
22)
17)

-

REMARKS '

ALOC screw; replace with a new
one.
ALOC bolt; replace with a new one.
Apply grease to the sliding surface.
Apply locking agent to the threads.

ALOC bolt; replace with a new one.
See page 17-28
Apply engine oil to the threads.
See page 17 -28
See page 17-28

REAR WHEEL/SUSPENSION
ITEM

Q'TY

Driven sprocket nut
Rear brake disc mounting bolt
Rear axle nut
Muffler end cover socket bolt
Shock absorber mounting nut
Shock arm nut
Shock link nut
Drive chain slider mounting screw
Swingarm pivot nut

5
5
1
2
2
1
2
2
1

REMARKS
U-nut
ALOC bolt; replace with a new one.
U-nut
U-nut
U-nut
U-nut
U-nut

GENERAL INFORMATION
HYDRAULIC BRAKE
ITEM
Brake caliper bleed valve
Front master cylinder reservoir
cover screw
Rear master cylinder reservoir
mounting bolt
Brake pad pin
Rear brake caliper mounting bolt
Parking brake caliper mounting
bolt (CTX700D/ND)
Parking brake pad pin
(CTX700D/ND)
Front master cylinder holder bolt
Brake hose oil bolt
Front brake light switch screw
Front brake lever pivot bolt

2
2

THREAD
DIA. (mm)
8
4

TORQUE
N·m (kgf·m, lbHt)
5.4 (0.6, 4.0)
1.5 (0.2, 1.1)

1

6

10 (1.0, 7)

2
1
2

10
8
8

17 (1.7, 13)
22 (2.2, 16)
31 (3.2, 23)

ALOC bolt; replace with a new one.
ALOC bolt; replace with a new one.

2

8

17 (1.7, 13)

ALOC bolt; replace with a new one.

2
4
1
1

6
10
4
6

12(1.2,9)
34 (3.5, 25)
1.2 (0.1, 0.9)
1.0 (0.1, 0.7)

1
2

6
6

5.9 (0.6, 4.4)
12(1.2,9)

2
1

8
4

27 (2.8, 20)
1.5 (0.2, 1.1)

Q'TY

Front brake lever pivot nut
Rear master cylinder mounting
bolt
Rear brake bracket mounting bolt
Rear master cylinder hose joint
screw
Rear master cylinder push rod lock
nut
Front brake caliper mounting bolt
Front brake caliper pin

1

8

17 (1.7, 13)

2
1

8
8

30 (3.1, 22)
22 (2.2, 16)

Front brake caliper bracket pin

1

8

12(1.2,9)

Rear brake caliper pin

1

12

27 (2.8, 20)

Parking brake caliper pin bolt
(CTX700D/ND)
Parking brake adjuster bolt lock
nut (CTX7000/ND)
Parking brake cable mounting nut
(CTX7000/ND)
Parking brake guide (CTX700D/
ND)

1

8

22 (2.2, 16)

1

8

17 (1.7, 13)

1

10

10 (1.0, 7)

2

5

1.3 (0.1, 1)

REMARKS

Apply 0.10 g (0.004 oz) silicone
grease to the sliding surface.

Apply locking agent to the threads.

ALOC bolt; replace with a new one.
Apply locking agent to the threads.
Apply 0.4 g (0.01 oz) silicone grease
to the sliding surface.
Apply locking agent to the threads.
Apply 0.4 g (0.01 oz) silicone grease
to the sliding surface.
Apply 0.4 g (0.01 oz) silicone grease
to the sliding surface.
Apply locking agent to the threads.

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
ITEM
Brake pipe joint nut

THREAD
DIA. (mm)
10

TORQUE
N·m (kgf·m, lbHt)
14 (1.4, 10)

4
3

THREAD
DIA. (mm)
4
5

TORQUE
N·m (kgf·m, lbHt)
1.5 (0.2, 1.1)
1.0(0.1,0.7)

1
2

PT 1/8
8

18(1.8,13)
25 (2.5, 18)

1
1

10
4

12(1.2,9)
1.2 (0.1, 0.9)

1

6

10(1.0,7)

Q'TY
12

REMARKS
Apply brake fluid to the threads.

LIGHTS/METERS/SWITCHES
ITEM
Turn signal light special screw
Combination meter mounting
screw
EOP switch
Ignition switch mounting bolt
Neutral switch
Parking brake switch screw
(CTX700D/ND)
Sidestand switch bolt

Q'TY

REMARKS

Apply sealant to the threads.
One way bolt; replace with a new
one.

ALOC bolt; replace with a new one.

1-17

GENERAL INFORMATION
OTHERS
ITEM

Q'TY

THREAD
DIA. (mm)

TORQUE
N·m (kgf·m, lbMt)

Cam chain tensioner set plate bolt

1

6

12 (1.2, 9)

Camshaft cap
Gearshift spindle return spring pin
Clutch lever pivot bolt
(CTX700/A/N/NA)
Clutch lever pivot nut
(CTX700/A/N/NA)

1
1
1

20
8
6

30(3.1,22)
23 (2.3, 17)
1.0 (0.1, 0.7)

1

6

6.0 (0.6, 4.4)

1 .. 1R

REMARKS
Apply locking agent to the threads.
Coating width; 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip

Apply grease to the sliding surface.

GENERAL INFORMATION

LUBRICATION & SEAL POINTS
ENGINE
MATERIAL
Liquid sealant
(TB1207B manufactured by
Three Bond or equivalent)

Molybdenum oil solution
(a mixture of 1/2 engine oil
and 1/2 molybdenum
disulfide grease)

Engine oil

Multi-purpose grease
Locking agent

Unirex N3 grease
(Exxon Mobil)

LOCATION
Oil pan mating surface
Right crankcase cover mating surface

CKP sensor wire grommet
Linear solenoid valve wire grommet (CTX700D/ND)
Alternator wire grommet
Alternator cover mating surface
Crankcase mating surface
Rocker arm sliding surface
Rocker arm shaft outer surface
Camshaft lobes, journals and thrust surface
Valve stem (valve guide sliding surface) and stem end
Clutch outer guide sliding surface (CTX700/A/N/NA)
Starter reduction and idle gear shaft outer surface
M3/4, C5, C6 gear (shift fork grooves) (CTX700/A/N/NA)
M3, M4, C5, C6 gear (shift fork grooves) (CTX700/A/N/NA)
Each transmission spline collar outer surface
Each transmission collar inner and outer surface
Shift fork guide area and guide pin
Shift fork shaft outer surface
Main journal bearing sliding surface
Crankpin bearing sliding surface
Crankshaft thrust surface
Oil filter cartridge 0-ring
Oil filler cap 0-ring
Timing hole cap 0-ring
Crankshaft hole cap 0-ring
Clutch oil filter cover 0-ring (CTX700D/ND)
Oil joint pipe 0-ring (CTX700D/ND)
Clutch oil guide collar 0-rings (CTX700D/ND)
Oil strainer seal ring
Starter motor 0-ring
Fuel injector seal ring
Water pump large 0-ring
Valve stem seal
Clutch disc entire surface (CTX700/A/N/NA)
Clutch lifter rod A sliding surface (CTX700/A/N/NA)
Clutch lifter rod B sliding surface (CTX700/A/N/NA)
Mainshaft seal rings (CTX700D/ND)
Starter one-way clutch
Piston sliding surface
Piston ring sliding surface
Piston pin outer surface
Each bearing
Each gear teeth and rotating surface
Each 0-ring (except water sealing)
Other rotating area and sliding surface
Each oil seal lips
CKP sensor mounting bolt threads

Electric shift reduction gear teeth and journal (CTX700D/ND)

REMARKS
See page 9-11
CTX700/A/NINA:
See page 11-5
CTX700D/ND:
See page 12-64

See page 13-5
See page 14-23

Coating width;
6.5 ± 1.0 mm
(0.26 ± 0.04 in)
except 2.0 ± 1.0 mm
(0.08 ± 0.04 in) from tip
2-4 g (0.07 -0.14 oz)

1-19

GENERAL INFORMATION
FRAME
MATERIAL
Urea based multi-purpose
grease with extreme
pressure
(example: EXCELITE EP2
manufactured by Kyodo
Yushi, Stamina EP2
manufactured by Shell or
equivalent)
Molybdenum disulfide grease

Multi-purpose grease

Cable lubricant

Honda bond A or Pro Honda
Handgrip Cement (U.S.A.
only) or equivalent
Honda bond A or equivalent
Silicone grease

DOT 4 brake fluid

Fork fluid
Drive chain lubricant
(Pro Honda HP Chain Lube
or equivalent)

1-20

LOCATION
Steering head bearing sliding surface
Steering head dust seal lips

Shock arm needle bearings
Rear shock absorber needle bearing
Rear shock absorber dust seal lips
Swingarm pivot needle bearings
Swingarm pivot ball bearing
Swingarm pivot dust seal lips
Seat catch hook sliding area
Gearshift pedal pivot collar and dust seal lips
(CTX?OO/A/N/NA)
Gearshift pedal tie-rod ball joint area (CTX700/A/N/NA)
Throttle cable end and throttle grip pipe flange groove
Front axle sliding surface
Front wheel dust seal lips
Rear wheel hub 0-ring
Rear wheel dust seal lips
Rear axle sliding surface
Swingarm pivot sliding surface
Rear brake pedal pivot sliding area
Parking brake ratchet A, B teeth and sliding surface
(CTX?OOD/ND)
Parking brake lever, washer sliding surface (CTX?OOD/ND)
Parking brake switch spring sliding surface (CTX?OOD/ND)
Main step sliding area
Pillion step sliding area
Seat lock cable inside
Clutch cable inside (CTX?OO/A/N/NA)
Parking brake cable inside (CTX?OOD/ND)
Handlebar grip rubber inside

Brake pad retainer mating surface
Front brake lever sliding surface and lever-to-master piston
contacting area
Rear brake master cylinder push rod sliding surface and boot
fitting area
Brake caliper dust seals
Rear brake caliper boot inside
Brake pad pin stopper ring
Parking brake shaft outer surface (CTX?OOD/ND)
Parking brake adjuster bolt threads and caliper piston sliding
surface (CTX?OOD/ND)
Parking brake shaft boot lips (CTX?OOD/ND)
Parking brake caliper bracket pin sliding surface
(CTX?OOD/ND)
Parking brake caliper sleeve sliding surface (CTX?OOD/ND)
Brake caliper piston and piston seals
Brake master piston and cups
Brake master cylinder inside
Rear master cylinder reservoir hose joint 0-ring
Fork cap 0-ring
Fork dust seal and oil seal lips
Drive chain whole surface

REMARKS
3 - 5 g (0.1 - 0.2 oz)

'

0.10 g (0.004 oz)

0.4 g (0.01 oz)
0.4 g (0.01 oz) minimum
0.4 g (0.01 oz) minimum
0.4 g (0.01 oz) minimum
0.4 g (0.01 oz) minimum
0.4 g (0.01 oz) minimum

GENERAL INFORMATION

CABLE & HARNESS ROUTING
CTX700/A/N/NA:
CLUTCH CABLE

THROTTLE
CABLE A

THROTTLE
CABLE B

FRONT
BRAKE HOSE

LEFT HANDLEBAR
SWITCH WIRE

LEFT HANDLEBAR
SWITCH WIRE

RIGHT HANDLEBAR
SWITCH WIRE

FRONT
BRAKE HOSE

CTX700D/ND:
PARKING BRAKE
CABLE

THROTTLE
CABLE B

THROTTLE
CABLE A

FRONT
BRAKE HOSE

LEFT HANDLEBAR
SWITCH WIRE

PARKING BRAKE
------..-,
CABLE

LEFT HANDLEBAR
SWITCH WIRE

RIGHT HANDLEBAR
SWITCH WIRE

1-21

GENERAL INFORMATION
CTX700:
COMBINATION METER
16P (Gray) CONNECTOR

CLUTCH CABLE

LEFT HANDLEBAR
SWITCH WIRE

RIGHT HANDLEBAR
SWITCH WIRE

FRONT RIGHT TURN SIGNAL/
POSITION LIGHT 3P (Light blue)
CONNECTOR

MAIN WIRE
HARNESS

CTX700A:
COMBINATION METER
16P (Gray) CONNECTOR

THROTTLE CABLE B

CLUTCH CABLE

LEFT HANDLEBAR
SWITCH WIRE
RIGHT HANDLEBAR
SWITCH WIRE

IGNITION
SWITCH WIRE

MAIN WIRE
HARNESS

GENERAL INFORMATION
CTX7000:
THROTTLE CABLE A

THROTTLE CABLE B

COMBINATION METER
16P (Gray) CONNECTOR
I

I

I

LEFT HANDLEBAR
SWITCH WIRE

FRONT BRAKE
HOSE
RIGHT HANDLEBAR
SWITCH WIRE

IGNITION
SWITCH WIRE

HEADLIGHT 3P (Black)
CONNECTOR

MAIN WIRE
HARNESS

CTX700N:
COMBINATION METER
16P (Gray) CONNECTOR

THROTTLE CABLE B

CLUTCH CABLE

I

I

FRONT RIGHT TURN
SIGNAL/POSITION
LIGHT WIRE

FRONT LEFT TURN
SIGNAL/POSITION
LIGHT WIRE

FRONT TURN SIGNAL/POSITION
LIGHT CONNECTORS:
- Right: 3P (Light blue)
- Left: 3P (Orange)

LEFT HANDLEBAR
SWITCH WIRE

HEADLIGHT STAY

IGNITION
SWITCH WIRE

MAIN WIRE
HARNESS

1-23

GENERAL INFORMATION
CTX700NA:
THROTTLE CABLE B

THROTTLE CABLE A

COMBINATION METER
16P (Gray) CONNECTOR

CLUTCH CABLE

I
I

I

FRONT RIGHT TURN
SIGNAL/POSITION
LIGHT WIRE

FRONT LEFT TURN
SIGNAL/POSITION
LIGHT WIRE

FRONT TURN SIGNAL/POSITION
LIGHT CONNECTORS:
- Right: 3P (Light blue)
- Left: 3P (Orange)

LEFT HANDLEBAR
SWITCH WIRE

MAIN WIRE
HARNESS
HEADLIGHT STAY

IGNITION SWITCH WIRE

CTX700ND:
FRONT BRAKE
HOSE

COMBINATION METER
16P (Gray) CONNECTOR

PARKING
BRAKE CABLE

I
I
/
/

I

FRONT RIGHT TURN
SIGNAL/POSITION
LIGHT WIRE

RIGHT HANDLEBAR
SWITCH WIRE

---1..-

-------f--r-4""1

FRONT LEFT TURN
SIGNAL/POSITION
LIGHT WIRE

FRONT TURN SIGNAL/POSITION
LIGHT CONNECTORS:
- Right: 3P (Light blue)
- Left: 3P (Orange)

LEFT HANDLEBAR
SWITCH WIRE

MAIN WIRE
HARNESS
IGNITION SWITCH WIRE

GENERAL INFORMATION
CTX700/A:
MAIN WIRE HARNESS

CTX700 shown:

LEFT HANDLEBAR

Alf------ SWITCH WIRE

CLUTCH CABLE
2P (Black) CONNECTOR
(Optional)

No.1 IGNITION
COIL WIRE
FRONT
BRAKE HOSE
FRONT LEFT TURN SIGNAL/POSITION
3P (Orange) CONNECTORS

LEFT HANDLEBAR SWITCH
14P (Gray) CONNECTOR

CTX700D:
COMBINATION METER
16P (Gray) CONNECTOR

MAIN WIRE HARNESS

PARKING
BRAKE CABLE
2P (Black) CONNECTOR
(Optional)

No.1 IGNITION
COIL WIRE

FRONT LEFT TURN SIGNAL/POSITION
3P (Orange) CONNECTOR

LEFT HANDLEBAR SWITCH
6P (Black) CONNECTOR

LEFT HANDLEBAR SWITCH
14P (Gray) CONNECTOR

1-25

GENERAL INFORMATION
CTX700N/NA:
CTX700NA shown:
LEFT HANDLEBAR
SWITCH WIRE

CLUTCH CABLE
No.1 IGNITION
COIL WIRE
MAIN WIRE HARNESS
LEFT HANDLEBAR SWITCH
14P (Gray) CONNECTOR

CTX700ND:
COMBINATION METER
16P (Gray) CONNECTOR

No.1 IGNITION
COIL WIRE

LEFT HANDLEBAR SWITCH
14P (Gray) CONNECTOR

GENERAL INFORMATION
CTX700:
THROTTLE CABLE A

FRONT BRAKE HOSE

THROTTLE CABLE B

MAIN WIRE HARNESS
RIGHT HANDLEBAR
SWITCH WIRE

No.2 IGNITION
COIL WIRE
THROTTLE
CABLE B
RIGHT HANDLEBAR SWITCH
8P (Blue) CONNECTOR

IGNITION SWITCH 2P (Brown)
CONNECTOR

CLUTCH CABLE

CTX700A:
THROTTLE CABLE A

CLUTCH CABLE

RIGHT HANDLEBAR
SWITCH WIRE

IGNITION SWITCH
2P (Brown) CONNECTOR

THROTTLE
CABLE A
No.2 IGNITION
COIL WIRE

THROTTLE
CABLE B
RIGHT HANDLEBAR SWITCH
8P (Blue) CONNECTOR

FRONT WHEEL SPEED
SENSOR WIRE

FRONT
BRAKE HOSE

CLUTCH CABLE

1-27

GENERAL INFORMATION
CTX700D:
THROTTLE CABLE A

THROTTLE CABLE B

PARKING BRAKE CABLE

0

THROTTLE
CABLE A

~ ,

~
FRONT
BRAKE HOSE
IGNITION SWITCH
2P (Brown) CONNECTOR

RIGHT HANDLEBAR SWITCH
6P (Black) CONNECTOR

FRONT WHEEL SPEED
SENSOR WIRE

I THROTTLE

:_j CABLE B
PARKING
BRAKE
CABLE

CTX700N/NA:
CTX700NA shown:
THROTTLE CABLE A

MAIN WIRE HARNESS

THROTTLE
CABLE A
THROTTLE
CABLE B

No.2 IGNITION
COIL WIRE
FRONT BRAKE HOSE

RIGHT HANDLEBAR SWITCH
8P (Blue) CONNECTOR

IGNITION SWITCH 2P (Brown)
CONNECTOR

FRONT WHEEL SPEED
SENSOR WIRE
(CTX700NA only)

GENERAL INFORMATION
CTX700ND:
THROTTLE CABLE B

MAIN WIRE HARNESS

THROTTLE
CABLE A
RIGHT HANDLEBAR
SWITCH 8P (Blue)
CONNECTOR

THROTTLE
CABLE B

No.2 IGNITION
COIL WIRE

IGNITION SWITCH 2P (Brown)
CONNECTOR

RIGHT HANDLEBAR SWITCH
6P (Black) CONNECTOR

FRONT WHEEL SPEED
SENSOR WIRE

All type:
CTX700/N:

CTX700A/D/NA/ND:

FRONT WHEEL
SPEED SENSOR
WIRE
FRONT
BRAKE HOSE

1-29

GENERAL INFORMATION
All type:
CRANKCASE
BREATHER HOSE

FAN MOTOR 3P (Gray)
CONNECTOR

RADIATOR
SIPHON HOSE

AIR CLEANER HOSING
DRAIN HOSE

No.2 IGNITION
COIL WIRE

------~.J
No.1 IGNITION
COIL
, WIRE

HORN WIRE
CONNECTORS

02 SENSOR 1 P (Black)
CONNECTOR
EOP SWITCH 1P (Gray) CONNECTOR

02 SENSOR CAP

All type:
CTX700N (50 state model) shown:

MAIN WIRE
HARNESS

LEFT HANDLEBAR SWITCH
6P (Black) CONNECTOR

LEFT HANDLEBAR
SWITCH WIRE

HAZARD DIODE

INDEX

~ARK

Left

FUEL FEED
HOSE

\-{+}

',if

30° ± 22.5°l Left

'1 - ':ln

GENERAL INFORMATION
CTX700/A/N/NA:
CTX700NA (50 state model) shown:

IGNITION SWITCH 2P (Brown) CONNECTOR
RIGHT HANDLEBAR SWITCH
8P (Blue) CONNECTOR
INDEX
MARK

BRAKE
PIPE

No.2 IGNITION
COIL WIRE
ECT SENSOR 2P (Black)
CONNECTOR

RADIATOR
SIPHON HOSE

REAR BRAKE LIGHT SWITCH
2P (Black) CONNECTOR

RADIATOR RESERVE TANK
OVERFLOW HOSE

CTX7000/ND:
50 state model shown:

IGNITION SWITCH 2P (Brown) CONNECTOR
RIGHT HANDLEBAR SWITCH
6P (Black) CONNECTOR

RIGHT HANDLEBAR SWITCH - - - - - - - - , - - - ' f - - f + + ~ ~ - A - ~
8P (Blue) CONNECTOR

INDEX
MARK

No.2 IGNITION
COIL WIRE
ECT SENSOR 2P (Black)
CONNECTOR
RADIATOR
SIPHON HOSE
REAR BRAKE LIGHT SWITCH
2P (Black) CONNECTOR

RADIATOR RESERVE TANK
OVERFLOW HOSE

1-31

GENERAL INFORMATION
All type:
RADIATOR
SIPHON HOSE

REAR BRAKE LIGHT SWITCH
2P (Black) CONNECTOR

\

REAR BRAKE LIGHT
SWITCH SPRING

RADIATOR RESERVE TANK
OVERFLOW HOSE

CTX700/N:
THROTTLE
CABLE A

THROTTLE
CABLE B
IACV 4P (Black)
CONNECTOR

CLUTCH CABLE

HAZARD DIODE
ECT SENSOR 2P (Black)
CONNECTOR

SENSOR UNIT 5P (Black)
CONNECTOR

1.:1?

FUEL INJECTOR 2P (Gray)
CONNECTOR

GENERAL INFORMATION
CTX700A/NA:
THROTTLE
CABLE A

THROTTLE
CABLE B
IACV 4P (Black)
CONNECTOR

No.2 IGNITION COIL
WIRE CONNECTORS

CLUTCH CABLE

ECT SENSOR 2P (Black)
CONNECTOR

SENSOR UNIT 5P (Black)
CONNECTOR

FRONT WHEEL SPEED SENSOR
2P (Blue) CONNECTOR

FUEL INJECTOR 2P (Gray)
CONNECTOR

CTX700D/ND:
THROTTLE
CABLE A

THROTTLE
CABLE B
IACV 4P (Black)
CONNECTOR

No.2 IGNITION COIL
WIRE CONNECTORS

PARKING
BRAKE CABLE

HAZARD DIODE
ECT SENSOR 2P (Black)
CONNECTOR

SENSOR UNIT 5P (Black)
CONNECTOR

FRONT WHEEL SPEED SENSOR
2P (Blue) CONNECTOR

FUEL INJECTOR 2P (Gray)
CONNECTOR

1-33

GENERAL INFORMATION
CTX700/A/N/NA:
IAT SENSOR 2P (Black) CONNECTOR

MAIN WIRE HARNESS

FAN MOTOR 3P (Gray)
CONNECTOR

HAZARD DIODE
FRONT WHEEL SPEED SENSOR
2P (Blue) CONNECTOR
(CTX700A/NA only)
INDEX
MARK

~~"±225"

~.·L
~

I

Front

INDEX MARK

CTX700D/ND:
IAT SENSOR 2P (Black) CONNECTOR

MAIN WIRE HARNESS

FAN MOTOR 3P (Gray)
CONNECTOR

HAZARD DIODE

PARKING BRAKE CABLE

180° ± 22.5°

~mot
INDEX MARK

GENERAL INFORMATION
All type:
FAN MOTOR 3P (Gray)
CONNECTOR

No.1 IGNITION
COIL WIRE

AIR CLEANER HOSING
DRAIN HOSE
MAIN WIRE HARNESS
(To HORN)

CTX700/N/D/ND type:
50 state model shown:

EVAP CANISTER-toFUEL TANK HOSE - - -

VACUUM HOSE

~__,,__.

EVAP CANISTER-to-EVAP PURGE
CONTROL SOLENOID VALVE HOSE

1-35

GENERAL INFORMATION
CTX700/N:
50 state model shown:

EVAP PURGE CONTROL SOLENOID
VALVE 2P (Black) CONNECTOR

FUEL TRAY
DRAIN HOSE

EVAP CANISTER-to-FUEL TANK HOSE

L - - - - VACUUM HOSE

EVAP CANISTER-to-

FUEL PUMP 3P (Black)
CONNECTOR

CTX700D/ND:
50 state model shown:

FUEL TRAY
DRAIN HOSE

FUEL FEED HOSE

FUEL PUMP 3P (Black)
CONNECTOR

EVAP PURGE CONTROL SOLENOID
VALVE 2P (Black) CONNECTOR

EVAP CANISTER-to-FUEL TANK HOSE

L----VACUUM HOSE

GENERAL INFORMATION
CTX700/A/N/NA (Except 50 state model):
FUEL PUMP 3P {Black)
CONNECTOR

BATTERY NEGATIVE(-)
CABLE

MAIN WIRE
HARNESS

ALTERNATOR

:2m!Q~~~t-----w1RE

FUEL TANK
BREATHER

FUEL TRAY
DRAIN HOSE

~ , HOSE

"-""n""'-.,,,,.,___? FUEL TRAY

FUEL TANK
BREATHER HOSE

~-----___.,!

DRAIN HOSE

CTX700/A/N/NA (50 state model):
FUEL PUMP 3P (Black)
CONNECTOR

BATTERY NEGATIVE(-)
CABLE
MAIN WIRE HARNESS
(To ECM)

FUEL FEED HOSE

MAIN WIRE
HARNESS

ALTERNATOR
FUEL TRAY
DRAIN HOSE

~~~~w~,.---WIRE

EVAP CANISTER
BREATHER HOSE

EVAP
CANISTER
DRAIN HOSE
SIDESTAND SWITCH WIRE

FUEL TRAY DRAIN HOSE

1-37

GENERAL INFORMATION
CTX700D/ND (Except 50 state model):
FUEL PUMP 3P (Black)
CONNECTOR

BATTERY NEGATIVE(-)
CABLE
MAIN WIRE HARNESS
(To PCM)

MAIN WIRE
HARNESS

ALTERNATOR
WIRE

SHIFT CONTROL
MOTOR 2P (Black)
CONNECTOR

FUEL TANK
BREATHER HOSE
EOT SENSOR 2P (Black)
CONNECTOR

SHIFT PEDAL ANGLE SENSOR
3P (Blue) CONNECTOR (Optional)

CTX700D/ND (50 state model):
FUEL PUMP 3P (Black)
CONNECTOR

BATTERY NEGATIVE(-)
CABLE
MAIN WIRE HARNESS
(To PCM)

FUEL FEED HOSE

MAIN WIRE
HARNESS

SHIFT CONTROL
MOTOR 2P (Black)
CONNECTOR

EVAP CANISTER
DRAIN HOSE
EOT SENSOR 2P (Black)
CONNECTOR

SHIFT PEDAL ANGLE SENSOR
3P (Blue) CONNECTOR (Optional)

TR SENSOR
WIRE

EVAP CANISTER DRAIN HOSE

GENERAL INFORMATION
CTX700/A/N/NA:
CTX700NA (50 state model) shown:

ALARM 6P CONNECTOR
(Optional)

REAR WHEEL SPEED SENSOR 2P (Gray)
CONNECTOR (CTX700NNA only)

CLUTCH CABLE

REAR WHEEL SPEED
SENSOR WIRE

BRAKE
PIPE

EVAP CANISTER-toFUEL TANK HOSE

GROUND TERMINAL:

EVAP CANISTER-toEVAP PURGE
CONTROL SOLENOID
VALVE HOSE
CKPSENSOR
WIRE

STARTER
MOTOR CABLE

ALARM 6P CONNECTOR
(Optional)

REAR WHEEL SPEED SENSOR
2P (Gray) CONNECTOR

Set the ground terminal
tab against the stay.

CTX700D/ND:
50 state model shown:

PARKING
BRAKE CABLE

/
EVAP CANISTER-toFUEL TANK HOSE

REAR WHEEL SPEED
SENSOR WIRE

EVAP CANISTER-toEVAP PURGE
CONTROL SOLENOID
VALVE HOSE

BRAKE
PIPE

STARTER
MOTOR CABLE

GROUND TERMINAL:

No.2 CLUTCH EOP SENSOR
3P (Gray) CONNECTOR

CLUTCH LINE EOP SENSOR
3P (Black) CONNECTOR
Attach the ground terminal
tab against the stay.

SHIFT SPINDLE ANGLE
SENSOR WIRE

CKP SENSOR
WIRE

No.1 CLUTCH EOP SENSOR
3P (Gray) CONNECTOR

1-39

GENERAL INFORMATION
CTX700/N:
BATTERY NEGATIVE(-) CABLE

MAIN WIRE HARNESS

FUEL PUMP 3P (Black)
CONNECTOR

J._j,µ,__--t---

SIDESTAND SWITCH
2P (Gray) CONNECTOR

STARTER
MOTOR CABLE

ALARM 6P CONNECTOR
(Optional)

GROUND TERMINAL
BANK ANGLE SENSOR
2P (Black) CONNECTOR

VS SENSOR 3P (Black)
CONNECTOR

CTX700A/NA:
VS SENSOR 3P (Black)
CONNECTOR

BATTERY NEGATIVE(-) CABLE

MAIN WIRE HARNESS

FUEL PUMP 3P (Black)
CONNECTOR
STARTER

L,_.,~4---j---- MOTOR CABLE

SIDESTAND SWITCH
2P (Gray) CONNECTOR

BANK ANGLE SENSOR
2P (Black) CONNECTOR

1_An

~
ABS MODULATOR 18P
(Black) CONNECTOR

I
'~"' ,

REAR WHEEL SPEED
SENSOR 2P (Gray)
CONNECTOR

ALARM 6P CONNECTOR
(Optional)

GENERAL INFORMATION
CTX700D/ND:
VS SENSOR 3P (Black)
CONNECTOR

BATTERY NEGATIVE(-)
CABLE

INNER MAINSHAFT SENSOR
3P (Black) CONNECTOR
PARKING
BRAKE CABLE

MAIN WIRE HARNESS

1Jr'f;::c;11"t"-+--

REAR WHEEL SPEED
SENSOR 2P (Gray)
,CONNECTOR

ALARM 6P CONNECTOR
(Optional)
GROUND TERMINAL
BANK ANGLE SENSOR
2P(~ac~CONNECTOR

ABS MODULATOR 18P
(Black) CONNECTOR

CTX700D/ND:
PCM 33P (Black)
CONNECTOR

BANK ANGLE SENSOR
2P (Black) CONNECTOR

SIDESTAND SWITCH
2P (Gray) CONNECTOR

PCM 33P (Gray)
CONNECTOR

FUEL PUMP 3P (Black)
CONNECTOR

REAR WHEEL SPEED
SENSOR 2P (Gray)
CONNECTOR

CKP SENSOR 2P (Red)
CONNECTOR

SHIFT SPINDLE ANGLE SENSOR
3P (Gray) CONNECTOR

PARKING
BRAKE CABLE

OUTER MAINSHAFT SENSOR
3P (Black) CONNECTOR

ABS MODULATOR 18P
(Black) CONNECTOR

1-41

GENERAL INFORMATION
CTX700/N:
ALARM 6P CONNECTOR
(Optional)

BANK ANGLE SENSOR
2P (Black) CONNECTOR

MAIN WIRE HARNESS

Insert into the battery box.

CTX700AID/NAIND:
BANK ANGLE SENSOR
2P (Black) CONNECTOR

REAR WHEEL SPEED SENSOR
2P (Gray) CONNECTOR

ALARM 6P CONNECTOR
(Optional)

MAIN WIRE HARNESS

1-A?

Insert into the battery box.

MAIN WIRE HARNESS
(To REGULATOR/RECTIFIER)

GENERAL INFORMATION
CTX700/A/N/NA:
BATTERY POSITIVE(+)
CABLE TERMINAL

BATTERY NEGATIVE(-)
CABLE TERMINAL

DLC

STARTER RELAY SWITCH
4P (Red) CONNECTOR

·,

STARTER
MOTOR CABLE

To GROUND TERMINAL --!----;i-Jl!"i.
(CTX700A/NA only)

REAR WHEEL SPEED SENSOR WIRE
(CTX700A/NA only)

To ABS MODULATOR
(CTX700A/NA only)

MAIN WIRE
HARNESS

CTX700D/ND:
BATTERY POSITIVE (+)
CABLE TERMINAL

BATTERY NEGATIVE(-)
CABLE TERMINAL

DLC

STARTER RELAY SWITCH
4P (Red) CONNECTOR

STARTER
MOTOR CABLE

(

REAR WHEEL SPEED
SENSOR WIRE

PCM 33P (Black)
CONNECTOR

To ABS
MODULATOR

PCM 33P (Gray)
CONNECTOR

MAIN WIRE
HARNESS

1-43

GENERAL INFORMATION
CTX700/N

REAR BRAKE HOSE

CTX700A/D/NA/ND:
REAR BRAKE HOSE

GROUND CABLE

PARKING BRAKE CABLE (CTX700D/ND only)

GENERAL INFORMATION
All type:
ALTERNA TOR WIRE

Attach the ground terminal
tab against the boss.

REGULATOR/RECTIFIER
3P (Black) CONNECTOR

REAR WHEEL SPEED
SENSOR WIRE
(CTX?OOA/D/NA/ND only)

PARKING BRAKE CABLE
(CTX?OOD/ND only)

GROUND
TERMINAL

ALTERNATOR 3P (Gray)
CONNECTOR

REAR BRAKE HOSE

All type:
MAIN WIRE HARNESS

BRAKE/TAIL LIGHT 6P (Black) CONNECTOR

TURN SIGNAL/HAZARD RELAY 4P CONNECTOR

1-45

GENERAL INFORMATION
All type:
LICENSE LIGHT 3P CONNECTOR

REAR RIGHT TURN SIGNAL LIGHT
2P (Light blue) CONNECTOR

SEAT LOCK CABLE

REAR LEFT TURN S~GNAL LIGHT
2P (Orange) CONNECTOR

BRAKE/TAIL LIGHT 6P (Black)
CONNECTOR

All type:
Insert into the rear fender A.

BRAKE/TAIL LIGHT 6P (Black)
CONNECTOR

REAR RIGHT TURN SIGNAL LIGHT WIRE

REAR LEFT TURN SIGNAL LIGHT WIRE

GENERAL INFORMATION

EMISSION CONTROL SYSTEMS
EXHAUST EMISSION REQUIREMENT
The U.S. Environmental Protection Agency (EPA), California Air Resources Board (CARB) and Transport Canada require
manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when
operated and maintained according to the instructions provided.

NOISE EMISSION REQUIREMENT
The EPA also requires that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or
3,730 miles (6,000 km) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions
provided.

WARRANTY COMPLIANCE
Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in
order to keep the emissions system warranty in effect.

SOURCE OF EMISSIONS
The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). The control of
hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog
when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Uncontrolled fuel evaporation also
releases hydrocarbons to the atmosphere.
Honda Motor Co., Ltd. utilizes various systems (page 1-48) to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.

CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body.

~FRESH AIR
....,.__ BLOW-BY GAS

1-47

GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a three-way catalytic converter and PGM-FI system.
The exhaust emission control system is separate from the crankcase emission control system.

THREE-WAY CATALYTIC CONVERTER
This motorcycle is equipped with a three-way catalytic converter.
The three-way catalytic converter is in the exhaust system. Through chemical reactions, it converts HC, CO, and NOx in the
engine's exhaust to carbon dioxide (C02), nitrogen (N2), and water vapor.
No adjustment to these systems should be made although periodic inspection of the components is recommended.

EVAPORATIVE EMISSION CONTROL SYSTEM (50 STATE MODEL ONLY)
Fuel vapor from the fuel tank is routed into the EVAP canister where it is absorbed and stored while the engine is stopped. When
the engine is running and the EVAP purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine.
FUEL TANK
FRESH AIR
FUEL VAPOR

EVAP CANISTER

EVAP PURGE CONTROL

...n~::=1...s---+r-- SOLENOID VALVE

NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. Federal law prohibits, or Canadian provincial law may
prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of
maintenance, repair or replacement, of any device or element of design incorporated into any vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate customer or while it is in use; (2) the use of the vehicle after such device or element
of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.

2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Removing or disabling any emissions compliance component, or replacing any compliance component with a non-compliant
component.

FUEL PERMEATION EMISSION CONTROL SYSTEM
This motorcycle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency
(EPA), the California Air Resources Board (CARB), and Environment Canada (EC). The fuel tank, fuel hoses, and fuel vapor
charge hoses used on this motorcycle incorporate fuel permeation control technologies. Tampering with the fuel tank, fuel hoses, or
fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal
regulations.

1 ...4R

2. FRAME/B DY PANELS/EXHAUST SYSTEM

•
SERVICE INFORMATION ............................. 2-2

UNDER COWL LID ..................................... 2-12

TROUBLESHOOTING ................................... 2-2

UNDER CENTER COWL ............................ 2-13

BODY PANEL LOCATIONS ......................... 2.3

UNDER SIDE COWL ...............~ ................... 2-13

FRONT INNER COVER (CTX700/A/D) ........ ,2.5

MAIN STEP ................................................. 2-14

FRONT CENTER COWL (CTX700/A/D) ....... 2.5

SEAT ........................................................... 2-14

WIND SCREEN (CTX700/A/D) ...................... 2.5

REAR GRIP (CTX700/A/D) ......................... 2-15

METER COVER (CTX700/A/D) ..................... 2-6

REAR SIDE COWL ..................................... 2-15

FRONT SIDE COWL (CTX700/A/D) .............. 2-6

REAR CENTER COWL ............................... 2-16

RADIATOR SIDE INNER COVER
(CTX700/A/D) ................................................ 2.7

LEFT CRANKCASE REAR COVER ........... 2-16
LEFT REAR UNDER COVER ..................... 2-17

FRONT SPOILER (CTX700/A/D) .................. 2.7
SWIGARM PIVOT COVER ......................... 2-17
HEADLIGHT (CTX700/A/D) .......................... 2-8
REAR FENDER A ....................................... 2-17
HEADLIGHT (CTX700N/NA/ND) ................... 2-8
REAR FENDER B ....................................... 2-18
RADIATOR SIDE COVER
(CTX700N/NA/ND)·········· ............................. 2-10

CHAIN COVER ............................................ 2-18

FRONT FENDER ......................................... 2-10

EXHAUST PIPE/MUFFLER ........................ 2-19

SIDE SHELTER ........................................... 2-11

CENTER CROSS PLATE ........................... 2-20

CENTER SHELTER ..................................... 2-12

2-1

FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION
GENERAL
This section covers removal and installation of the body panels and exhaust system.
Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
Always replace the exhaust pipe gasket with new ones after removing the exhaust pipe from the engine.
When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust pipe joint nuts
first, then tighten the mounting bolts.
• Always inspect the exhaust system for leaks after installation.
•
•
•
•

TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler

,_,

FRAME/BODY PANELS/EXHAUST SYSTEM

BODY PANEL LOCATIONS
CTX700/A/D
[17]

[5]

[12]

[18]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]

Front inner cover (page 2-5)
Front center cowl (page 2-5)
Wind screen (page 2-5)
Meter cover (page 2-6)
Front side cowl (page 2-6)
Radiator side inner cover (page 2-7)
Front spoiler (page 2-7)
Headlight (page 2-8)
Front fender (page 2-10)

[1 OJ
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]

Side shelter (page 2-11)
Center shelter (page 2-12)
Under cowl lid (page 2-12)
Under center cowl (page 2-13)
Under side cowl (page 2-13)
Main step (page 2-14)
Seat (page 2-14)
Rear grip (page 2-15)
Rear side cowl (page 2-15)

[19]
[20]
[21]
[22]
[23]
[24]
[25]

[22]

Rear center cowl (page 2-16)
Left crankcase rear cover (page 2-16)
Left rear under cover (page 2-17)
Swingarm pivot cover (page 2-17)
Rear fender A (page 2-17)
Rear fender B (page 2-18)
Chain cover (page 2-18)

BODY PANEL REMOVAL CHART
This chart shows removal order of frame covers by means of arrow.
[1] Front inner cover

[2] Front center cowl

[3] Wind screen

[16) Seat

[4] Meter cover

1-----....-

.----1

[17] Rear grip

[18] Rear side cowl

[21) Left rear under cover

[5) Front side cowl

[1 OJ Side shelter

[7) Front spoiler

[11] Center shelter

[8] Headlight

[6] Radiator side inner cover

[22) Swingarm pivot cover

[19) Rear center cowl

[23) Rear fender A

[24] Rear fender B

[9] Front fender

[12) Under cowl lid

[20] Left crankcase rear cover

[13] Under center cowl

[14) Under side cowl

[15) Main step

[25] Chain cover

2-3

FRAME/BODY PANELS/EXHAUST SYSTEM
CTX700N/NA/ND

[1 J

[4]

[2]

[6]

[3]

[17]
[1]
[2]
[3]
[4]
[5]
[6]

Headlight (page 2-8)
Radiator side cover (page 2-10)
Front fender (page 2-10)
Side shelter (page 2-11)
Center shelter (page 2-12)
Under cowl lid (page 2-12)

[7] Under center cowl (page 2-13)
[8] Under side cowl (page 2-13)
[9] Main step (page 2-14)
[10] Seat (page 2-14)
[11] Rear side cowl (page 2-15)
[12] Rear center cowl (page 2-16)

[15]
[13]
[14]
[15]
[16]
[17]
[18]

Left crankcase rear cover (page 2-16)
Left rear under cover (page 2-17)
Swingarm pivot cover (page 2-17)
Rear fender A (page 2-17)
Rear fender B (page 2-18)
Chain cover (page 2-18)

BODY PANEL REMOVAL CHART
This chart shows removal order of frame covers by means of arrow.

[1] Headlight

[2] Radiator side cover

[3] Front fender

[10] Seat

[4] Side shelter

[5] Center shelter

[6] Under cowl lid

[7] Under center cowl

2-4

[8] Under side cowl

[11] Rear side cowl

[14] Left rear under cover

[12] Rear center cowl

(15] Swingarm pivot cover

[18] Chain cover

[9] Main step

[16] Rear fender A

[17] Rear fender B

I [13] Left crankcase rear cover

FRAME/BODY PANELS/EXHAUST SYSTEM

FRONT INNER COVER (CTX700/A/D)
REMOVAL/INSTALLATION
Remove the trim clip [1] and two socket bolts [2].

[1 J

Remove the front inner cover [3] by releasing the tabs
[4] and slot [5].
Installation is in the reverse order of removal.

[4]

FRONT CENTER COWL (CTX700/A/D)
REMOVAL/INSTALLATION
Remove the front inner cover (page 2-5).
Remove the two trim clips [1].
Release the four snap fit clips [2] and remove the front
center cowl [3] by releasing the lower side tab [4].
Installation is in the reverse order of removal.

WIND SCREEN (CTX700/A/D)
REMOVAL/INSTALLATION
Remove the front center cowl (page 2-5).

[1 J

[3]

[4]

Remove the following:
-

Socket bolts [1]
Plastic washers [2]
Rubber washers [3]
Wind screen [4]
Cushion rubbers [5]
Washers [6]

Installation is in the reverse order of removal.

[1]

[2]

[3)

[5]

[6]

2-5

FRAME/BODY PANELS/EXHAUST SYSTEM

METER COVER (CTX700/A/D)
REMOVAL/INSTALLATION
Remove the wind screen (page 2-5).
Disconnect the
connector [1].

combination

meter

16P

(Gray)

Remove the three socket bolts [2] and meter cover [3].
Installation is in the reverse order of removal.

DISASSEMBLY/ASSEMBLY
Remove the screws [1], washers [2] and combination
meter [3].

[3]

Assembly is in the reverse order of disassembly.
TORQUE:
Combination meter mounting screw:
1.0 N·m (0.1 kgf·m, 0.7 lbMt)

[1]/[2]

FRONT SIDE COWL (CTX700/A/D)
REMOVAL/INSTALLATION
Remove the front center cowl (page 2-5).
Remove the following:
-

Trim clip A [1]
Two trim clips B [2]
Socket bolt [3]/collar [4]
Two socket bolts [5]/washers [6]

Disconnect the front turn signal/position light 3P
connector [7].
Release the bosses [8] from the grommets.
Pull the right front side cowl [9] forward and release the
tabs [1 O] from the slots of the front spoiler as shown.
Remove the right front side cowl.
Remove the left front side cowl in the same manner of
the right side.
Installation is in the reverse order of removal.

[3]/[4]

[7]

[5]/[6]

[1]

FRAME/BODY PANELS/EXHAUST SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the four screws [1] and inner panel [2).
Remove the two screws [3) and radiator side cover [4)
from the front side cowl [5).
Assembly is in the reverse order of disassembly.

[1)

[2]

[4]

[5]

RADIATOR SIDE INNER COVER (CTX700/A/D)
REMOVAL/INSTALLATION
Remove the two trim clips [1], socket bolts [2] a n d , - - - - - - - - - - - - - - radiator side inner cover [3].
Installation is in the reverse order of removal.

FRONT SPOILER (CTX700/A/D)
REMOVAL/INSTALLATION
Remove the front side cowls (page 2-6).
Remove the four socket bolts [1] and front spoiler [2].
Installation is in the reverse order of removal.

[1)

\

2-7

FRAME/BODY PANELS/EXHAUST SYSTEM

HEADLIGHT (CTX700/A/D)
REMOVAL/INSTALLATION
Remove the front spoiler (page 2-7).
Disconnect the headlight 3P (Black) connector [1].
Remove the following:
-

Two nuts [2]/collars [3]
Two socket bolts [4]/collars [5]

Remove the headlight unit [6] by releasing the bosses
[7] from the grommets.
Installation is in the reverse order of removal.

[4]/[5]

HEADLIGHT (CTX700N/NA/ND)
REMOVAL/INSTALLATION
Remove the two socket bolts [1] and collars [2].
Remove the headlight assembly [3] by releasing it from
the holes [4] of the bottom bridge.
Disconnect the following:
-

Headlight 3P (Black) connector [5]
Right turn signal/position light 3P (Light blue)
connector [6]
Left turn signal/position light 3P (Orange) connector
[7]

Release the wire band boss [8].
Remove the rubber caps [9].
Installation is in the reverse order of removal.

DISASSEMBLY/ASSEMBLY
· Remove the two socket bolts [1], trim clip [2] and
headlight side cover assembly [3].

[3]

[6)/[7]

FRAME/BODY PANELS/EXHAUST SYSTEM
Remove the four socket bolts [1] and headlight cover [2]
from the headlight [3].

Remove the four special bolts [1] and headlight stay [2]
from the headlight unit [3].

Remove the three socket bolts [1] and meter upper
cover[2].

[1]

[2]

_/

[2]

Assembly is in the reverse order of disassembly.

[1]

2-9

FRAME/BODY PANELS/EXHAUST SYSTEM

RADIATOR SIDE COVER (CTX700N/NA/ND)
REMOVAL/INSTALLATION
Remove the two socket bolts [1].
Release the two bosses [2] from the grommets and
remove the radiator side cover [3] by releasing the slot
[4] from the frame.
Installation is in the reverse order of removal.

FRONT FENDER
REMOVAL/INSTALLATION
Remove the following
-

[1]

[3]

[4]

Two bolts [1]/hose guide [2]
Four socket bolts [3]
Front fender [4]
Stay [5]
Front side reflectors [6]

Installation is in the reverse order of removal.

[2]

[5]

FRAMBBODYPANEL~EXHAUSTSYSTEM

SIDE SHELTER
REMOVAL/INSTALLATION
Remove the following:
-

Front side cowl (page 2-6) (CTX700/A/D)
Radiator side cover (page 2-10) (CTX700N/NA/ND)
Seat (page 2-14)
Two trim clips [1] (Large head)
Trim clip [2]
Two socket bolts (3]

Release the three bosses [4] from the grommets.
Remove the side shelter (5] by releasing the upper side tabs [6] and two snap fit clips (7].
Installation is in the reverse order of removal.

DISASSEMBLY/ASSEMBLY
Remove the three screws [1] and side cover [2].
Assembly is in the reverse order of disassembly.

[2]

2-11

FRAME/BODY PANELS/EXHAUST SYSTEM

CENTER SHELTER
REMOVAL/INSTALLATION
Remove the side shelters (page 2-11 ).
Remove the four socket bolts [1].
Remove the center shelter [2] by releasing the fuel tray
drain hose [3] from the hose guides [4].
Installation is in the reverse order of removal.

[3]

DISASSEMBLY/ASSEMBLY
Remove the four screws [1] and inner center cover [2].
Remove the eight screws [3], luggage box [4] and
packing [5].
Assembly is in the reverse order of disassembly.

[1]

\

\

[2]
[5]

UNDER COWL LID
REMOVAL/INSTALLATION
Remove the trim clip [1].
Remove the under cowl lid [2] by releasing the tabs [3]
from the grooves.
Installation is in the reverse order of removal.

? ... 1?

[3]

FRAME/BODY PANELS/EXHAUST SYSTEM

UNDER CENTER COWL
REMOVAL/INSTALLATION
Remove the four socket bolts [1], two trim clips [2] and
under center cowl [3].
Installation is in the reverse order of removal.

[3]

[2]2J

UNDER SIDE COWL
REMOVAL/INSTALLATION
RIGHT SIDE
Remove the following:
-

CTX700NA shown:

Under center cowl (page 2-13)
Under cowl lid (page 2-12)
Socket bolts [1]/washers [2]

CTX700/A/N/NA only

Remove the right under side cowl [3] by releasing the
hose [4] from the hose guides as shown.
Remove the collars [5] from the under side cover.
Installation is in the reverse order of removal.
[3]

c

A
'

7

CTX700/A/N/NA only

[1]

[2]

LEFT SIDE
Remove the under center cowl (page 2-13).
Remove the three socket bolts [1], washers [2] and left
under side cover [3].
Remove the three collars [4] from the under side cover.
Installation is in the reverse order of removal.

2-13

FRAME/BODY PANELS/EXHAUST SYSTEM

MAIN STEP
REMOVAL/INSTALLATION
Remove the under side cowls (page 2-13).
Remove the bolts [1], collars [2] and main step [3].
Installation is in the reverse order of removal.
TORQUE:
Main step mounting bolt:
27 N·m (2.8 kgf·m, 20 lbMt)

SEAT
REMOVAL/INSTALLATION
Unlock the seat [1] using the ignition key [2].
Pull the seat backward and remove it.
Install the seat by aligning the hooks [3] with grooves of
the frame.
Push the rear end of the seat and lock the seat catch.

2-14

[3]

FRAME/BODY PANELS/EXHAUST SYSTEM
KEY CYLINDER REMOVAL/INSTALLATION
Remove the seat (page 2-14).
Release the seat lock cable [1] from cable guide [2],
then disconnect it from the key cylinder [3]
Remove the following:
-

Spring [4]
Cable guide
Key cylinder

Installation is in the reverse order of removal.
• When installing the key cylinder, align each part
direction as shown.

[1]

REAR GRIP {CTX700/A/D)
REMOVAL/INSTALLATION
Remove the following:
-

Caps [1]
Socket bolts [2]
Washers [3]
Rear grips [4]
Collars [5]

Installation is in the reverse order of removal.

REAR SIDE COWL
REMOVAL/INSTALLATION
Remove the following:
-

Seat (page 2-14)
Reargr"ip (page 2-15) (CTX700/A/D)
Three trim clips [1]
Socket bolt [2]
Rubber washer [3]

Release the two bosses [4] and snap fit clip [5].
Slightly pull the rear cowl [6] backward and release the
hooks [7], then remove the rear cowl.
Installation is in the reverse order of removal.

[5]
[6]
[4]

2-15

FRAME/BODY PANELS/EXHAUST SYSTEM

REAR CENTER COWL
REMOVAL/INSTALLATION
Remove the rear side cowls (page 2-15).
Remove the two socket bolts [1].
Remove the rear center cowl [2] by releasing the tabs
(3] from the slots of frame.
Installation is in the reverse order of removal.

[3]

~[1]

I
[2]

LEFT CRANKCASE REAR COVER
REMOVAL/INSTALLATION
CTX700/A/N/NA

Remove the gearshift arm pinch bolt [1] and gearshift
arm [2].
Remove the three bolts [3] and left crankcase rear
cover [4].
Installation is in the reverse order of removal.
• Align the gearshift arm slit with the punch mark.
• Replace the gearshift arm pinch bolt with a new one.
TORQUE:
Gearshift arm pinch bolt:
12 N·m (1.2 kgf·rn, 9 lbf·ft)

CTX700D/ND

Remove the two bolts [1] and left crankcase rear cover
[2].
Installation is in the reverse order of removal.

? .. 1~

FRAME/BODY PANELS/EXHAUST SYSTEM

LEFT REAR UNDER COVER
REMOVAL/INSTALLATION
Remove the two socket bolts [1] and left rear under
cover [2].
Installation is in the reverse order of removal.

SWIGARM PIVOT COVER
REMOVAL/INSTALLATION
Remove the rear side cowl (page 2-15).
Right side:
Left side:

Remove the muffler cover (page 2-19).
Remove the left rear under cover (page 2-17).
Slightly pull the side cover [1] and release its boss [2]
from the grommet [3] of the swingarm pivot cover [4].
Remove the two socket bolts [5] and swingarm pivot
cover.
Installation is in the reverse order of removal.

REAR FENDER A
REMOVAL/INSTALLATION
Remove the following:
-

Rear center cowl (page 2-16)
Seat lock key cylinder (page 2-15)
Four bolts [1] and luggage hooks [2]
Two socket bolts [3] (large head)
Two socket bolts [4]

Disconnect the brake/tail light 6P (Black) connector [5].
Pull the rear fender A [6] backward and remove it.
Installation is in the reverse order of removal.

2-17

FRAME/BODY PANELS/EXHAUST SYSTEM
REAR REFLECTORS REMOVAL/INSTALLATION
Remove the nut [1], washer [2] and rear reflector [3].

[1]/[2]

Remove the two nuts [4], collars [5[, bolts [6] and
number plate stay [7].
Remove the nuts [8] and rear side reflectors [9].
Installation is in the reverse order of removal.

[9]

TORQUE:
Reflector mounting nut:
1.7 N·m (0.2 kgf·m, 1.3 lbMt)

[6]

[4]/[5]

[7]

REAR FENDER B
REMOVAL/INSTALLATION
Remove the following:
-

Rear fender A (page. 2-17)
Turn signal/hazard relay (page 22-22)
Battery (page 21-5)
Two socket bolts [1]
Screw [2]
Rear fender B [3]

Installation is in the reverse order of removal.

CHAIN COVER
REMOVAL/INSTALLATION
Remove the two socket bolts [1].
Remove the chain cover [2] by releasing it from the tab
[3] of the swingarm.
Installation is in the reverse order of removal.

[1]

?-1R

[2]

FRAME/BODY PANELS/EXHAUST SYSTEM

EXHAUST PIPE/MUFFLER
MUFFLER REMOVAUINSTALLATION
Remove the socket bolt [1].

[8]

[9)

[10]

Remove the muffler cover [2] by releasing the bosses
[3] from the slots [4] of the muffler [5].
Loosen the muffler band bolts [6].
Remove the following:
-

Muffler mounting nut [?]/bolt [BJ/washer [9]
Muffler
Collar [10]
Gasket[11]

Installation is in the reverse order of removal.
• Replace the gasket with a new one.
• Apply engine oil to the muffler band bolt threads and
seating surface.
TORQUE:
Muffler band bolt:
20 N·m (2.0 kgf·m, 15 lbHt)
Muffler cover socket bolt:
10 N·m (1.0 kgf·m, 7 lbHt)

[5]

•

s

[11)

[2)
[3]
[1]
[6)71
~---------------'

EXHAUST PIPE REMOVAL/INSTALLATION
Remove the muffler (page 2-19).
Disconnect the 02 sensor 1P (Black) connector
(page 4-36).
Remove the bolt [1] and release the ground terminal [2].
Remove the following:
-

Exhaust pipe mounting bolt [3]/washer [4]
Three joint nuts [5]
Exhaust pipe [6]
Collar [7]
Gasket [8]

Installation is in the reverse order of removal.
• Replace the gasket with a new one.
TORQUE:
Exhaust pipe joint nut:
28 N·m (2.9 kgf·m, 21 lbHt)

[5]

STUD BOLT REPLACEMENT
Remove the exhaust pipe (page 2-19).
Thread two nuts onto the stud and tighten them
together, and use a wrench on them to turn the stud bolt
out.

30.0 - 31.0 mm
(1.18-1.22in)

Install new stud bolts into the cylinder head as shown.
After installing the stud bolts, check that the length from
the bolt head to the cylinder head surface is within
specification.
Install the exhaust pipe (page 2-19).

\

2-19

FRAME/BODY PANELS/EXHAUST SYSTEM

CENTER CROSS PLATE
REMOVAL/INSTALLATION
Remove the fuel tank (page 7-7).
Disconnect the ABS modulator 18P (Black) connector (CTX700A/D/NA/ND) (page 20-7).
Release the following from the center cross plate [1 J:
-

Alarm 6P connector (Optional) [2]
CKP sensor 2P (Red) connector [3]
Sidestand switch 2P (Gray) connector [4]
Wire band bosses [5]

Release and disconnect the following:
-

Rear wheel speed sensor 2P (Gray) connector [6] (CTX700A/D/NA/ND)
Bank angle sensor 2P (Black) connector [7]

Remove the following:
-

Two socket bolts [8]
Two bolts [9]
Three bolts [10]/collars [11] (CTX700A/D/NA/ND)
Four bolts [12]/ground terminals [13]
Center cross plate

Installation is in the reverse order of removal.
[12)
[5) (CTX700A/D/NA/ND)

[4]

[3]

[13)

[10)/[11) (CTX700A/D/NA/ND)

2-20

3.

SERVICE INFORMATION ·····························3-2
MAINTENANCE SCHEDULE························3·2

CE

EVAPORATIVE EMISSION CONTROL
SYSTEM (50 STATE MODEL ONLY) ......... 3.13
DRIVE CHAIN ............................................. 3-13

FUEL LINE···· ................................................. 3.4
BRAKE FLUID ............................................ 3.16
THROTTLE OPERATION····· ......................... 3.4
BRAKE PADS WEAR ................................. 3.17
AIR CLEANER··············· ................................ 3.5
BRAKE SYSTEM ........................................ 3-18
CRANKCASE BREATHER ........................... 3.6
BRAKE LIGHT SWITCH ............................. 3-18
SPARK PLUG,, .............................................. 3.6
VALVE CLEARANCE .................................... 3.7
ENGINE OIL ··················································3-9
ENGINE OIL FILTER ................................... 3.10
CLUTCH OIL FILTER (CTX700D/ND) ········3-11

BRAKE LOCK OPERATION
(CTX700D/ND) ............................................ 3.13
HEADLIGHT AIM ........................................ 3-19
CLUTCH SYSTEM (CTX700/A/N/NA) ........ 3-20
SIDESTAND ................................................ 3-20

ENGINE IDLE SPEED ................................. 3.11

SUSPENSION ............................................. 3-21

RADIATOR COOLANT ............................... 3.12

NUTS, BOLTS, FASTENERS ..................... 3.21

COOLING SYSTEM, .................................... 3.12

WHEELS/TIRES····· ..................................... 3-22
STEERING HEAD BEARINGS ................... 3-22

3-1

MAINTENANCE

SERVICE INFORMATION
GENERAL
• Place the motorcycle on level surface before starting any work.
• Gasoline is extremely flammable and is explosive under certain conditions.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause
a fire or explosion.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the
engine in an open area or with an exhaust evacuation system in an enclosed area.

MAINTENANCE SCHEDULE
CTX700/A/N/NA
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult a dealer.

ITEMS
* FUEL LINE
* THROTTLE OPERATION
AIR CLEANER
CRANKCASE BREATHER
SPARK PLUG
* VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FILTER
* ENGINE IDLE SPEED
RADIATOR COOLANT
* COOLING SYSTEM
* EVAPORATIVE EMISSION CONTROL
SYSTEM
DRIVE CHAIN
BRAKE FLUID
BRAKE PADS WEAR
BRAKE SYSTEM
BRAKE LIGHT SWITCH
HEADLIGHT AIM
CLUTCH SYSTEM
SI DESTAND
* SUSPENSION
* NUTS,BOLTS,FASTENERS
** WHEELS/TIRES
** STEERING HEAD BEARINGS

FREQUENCY ODOMETER READING (NOTE 1)
REFER
x 1,000 mi
0.6
4
8
12
16
20
24
TO
NOTE
x 1,000 km
6.4 12.8 19.2 25.6 32.0 38.4 PAGE
1.0
I
I
I
3-4
I
I
I
3-4
NOTE2
R
R
3-5
NOTE3
3-6
EVERY 16,000 mi (25,600 Km) I,
3-6
EVERY 32,000 mi (51,200 Km) R
I
I
I
3-7
INITIAL= 600 mi (1,000 km) or 1 month: R
3-9
REGULAR= EVERY 8,000 mi (12,800 km) or 12 months: R
R
R
R
R
3-10
I
I
I
I
I
I
I
3-11
NOTE5
I
I
R
3-12
I
I
I
3-12

c

c

NOTE4
NOTE5

c

c

c

I
EVERY 500 mi (800
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I

Km) I, L
R
I
I
I
I
I
I
I
I
I
I
I
I
I

I
I

I

c

I

3-13

R
I
I
I
I
I
I
I
I
I
I

3-13
3-16
3-17
3-18
3-18
3-19
3-20
3-20
3-21
3-21
3-22
3-22

* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
NOTES:
1.
2.
3.
4.
5.

At higher odometer readings, repeat at the frequency interval established here.
Service more frequently when riding in unusually wet or dusty areas.
Service more frequently when riding in rain or at full throttle.
50 state model only.
Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.

MAINTENANCE
CTX700D/ND
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult a dealer.

ITEMS
* FUEL LINE
* THROTTLE OPERATION
AIR CLEANER
CRANKCASE BREATHER
SPARK PLUG
* VALVE CLEARANCE
ENGINE OIL

*
*
*

*

*
*
**
**

ENGINE OIL FILTER
CLUTCH OIL FILTER
ENGINE IDLE SPEED
RADIATOR COOLANT
COOLING SYSTEM
EVAPORATIVE EMISSION CONTROL
SYSTEM
DRIVE CHAIN
BRAKE FLUID
BRAKE PADS WEAR
BRAKE SYSTEM
BRAKE LIGHT SWITCH
BRAKE LOCK OPERATION
HEADLIGHT AIM
SIDESTAND
SUSPENSION
NUTS,BOLTS,FASTENERS
WHEELS/TIRES
STEERING HEAD BEARINGS

FREQUENCY ODOMETER READING (NOTE 1)
REFER
x 1,000 mi
0.6
4
8
12
16
20
24
TO
1.0
NOTE
x 1,000 km
6.4 12.8 19.2 25.6 32.0 38.4 PAGE
I
I
3-4
I
I
I
3-4
I
NOTE2
R
3-5
R
NOTE3
3-6
EVERY 16,000 mi (25,600 Km) I,
3-6
EVERY 32,000 mi (51,200 Km) R
I
I
3-7
I
INITIAL= 600 mi (1,000 km) or 1 month: R
3-9
REGULAR= EVERY 8,000 mi (12,800 km) or 12 months: R
R
R
R
R
3-10
R
R
3-11
I
I
I
I
I
I
I
3-11
NOTE 5
I
I
R
3-12
I
I
3-12
I
NOTE4
I
3-13
I

c

NOTES

c

EVERY 500 mi (800
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I

c

c

Km) I, L
R
I
I
I
I
I
I
I
I
I
I
I
I
I

c

c

I
I

R
I
I
I
I
I
I
I
I
I
I

I

3-13
3-16
3-17
3-18
3-18
3-18
3-19
3-20
3-21
3-21
3-22
3-22

* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
NOTES:
1.
2.
3.
4.
5.

At higher odometer readings, repeat at the frequency interval established here.
Service more frequently when riding in unusually wet or dusty areas.
Service more frequently when riding in rain or at full throttle.
50 state model only.
Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.

3 .. 3

MAINTENANCE

FUEL LINE
INSPECTION
Remove the left side shelter (page 2-11 ).
Check the quick connect fitting [1] for looseness.
Check the fuel feed hose [2] for deterioration, damage
or leakage.
Check the quick connect fittings for dirt, and clean if
necessary.
Replace the fuel pump packing if necessary (page 710)

THROTTLE OPERATION
Check for any deterioration or damage to the throttle
cable.
Check the throttle grip for smooth operation.
Check that the throttle opens and automatically closes
in all steering positions.
If the throttle grip does not return properly, lubricate the
throttle grip housing.
If the throttle grip still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure that the idle speed does not
change.
If idle speed increases, check the throttle grip freeplay
and throttle cable connection.
Measure the throttle grip freeplay at the throttle grip
flange.

FREEPLAY: 2- 6 mm (0.1 - 0.2 in)

MAINTENANCE
Throttle grip freeplay can be adjusted at either end of
the throttle cable.

CTX?OO/A/N/NA:

Minor adjustment is made with the upper adjuster at
throttle housing adjuster.
CTX700DIND only:

Release the dust cover [1].
Loosen the lock nut [2] and turning the adjuster [3].
Tighten the lock nut while holding the adjuster

CTX700DIND only:

Reposition the dust cover properly on the adjuster.
Recheck the throttle operation.

[2]

[3]

[1]

Major adjustment is made with the lower adjuster nut at
the throttle body.
Loosen the lock nut [1] and turn the adjuster nut [2].
Tighten the lock nut while holding the adjuster nut.
Recheck the throttle operation.

AIR CLEANER
REMOVAL/INSTALLATION
Remove the center shelter (page 2-12).
Disconnect the IAT sensor 2P (Black) connector [1].
Remove the air cleaner housing cover screws [2] and
air cleaner housing cover [3].

3-5

MAINTENANCE
Remove the air cleaner element [1] from the housing
cover.
Inspect the air cleaner element in accordance with the
maintenance schedule (page 3-2) or any time the
motorcycle has been ridden in unusually wet or dusty
areas.
Install the air cleaner element in the reverse order of
removal.
• Check that the condition of the packings, replace
them if necessary.
TORQUE:
Air cleaner housing cover screw:
1.1 N·m (0.1 kgf·m, 0.8 lbMt)

CRANKCASE BREATHER
Service more
frequently when
ridden in rain, at full
throttle, or after the
motorcycle is
washed or
overturned.

Service if the

Check the crankcase breather hose [1] for deterioration,
damage or loose connection. Make sure that the hoses
are not kinked, pinched or cracked.
Replace the crankcase breather hose if necessary.

Check the air cleaner housing drain hose [1].

If necessary, remove the drain plug [2] from the air
cleaner housing drain hose and drain the deposits into
transparent section a suitable container.
deposits level can
be seen in the

of the air cleaner
housing drain hose.

Reinstall the drain plug securely.

SPARK PLUG
REMOVAL/INSTALLATION
Disconnect the spark plug caps [1].
Remove the spark plug using the equipped spark plug
wrench.
with compressed air Inspect or replace the spark plug as described in the
before removing the maintenance schedule (page 3-2).
Clean around the
spark plug base

spark plug, and be
sure that no debris
is allowed to enter
the combustion
chamber.

Install and hand tighten the spark plug to the cylinder
head, then tighten the spark plug to the specified torque
using the equipped spark plug wrench.
TORQUE:22 N·m (2.2 kgf·m, 16 lbMt)

Connect the spark plug caps securely.

[1]

MAINTENANCE
INSPECTION
To prevent
damaging the
iridium center
electrode, use a
wire type feeler
gauge to check the
spark plug gap.

Check the spark plug gap between the center and side
electrodes with a wire type feeler gauge (1].

[1]

0

Make sure that the Cl> 1.2 mm (0.05 in) plug gauge does
not insert between the gap.

x

Do not adjust the If the gauge can be inserted into the gap, replace the
spark plug gap. If plug with a new one.
the gap is out of
specification,
replace with a new
one.

VALVE CLEARANCE
INSPECTION
NOTE:
• Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°Ff
• After the valve clearance inspection, check the engine idle speed (page 3-11 ).
• Inspection and adjustment of the valve clearance can be serviced with the engine installed in the frame.

Remove the cylinder head cover (page 10-5).
Remove the timing hole cap and crankshaft hole cap.
Remove the camshaft maintenance cap (1] and 0-ring
[2].

No.1 Cylinder:

Rotate the crankshaft counterclockwise and align the
"1T" mark [1] on the flywheel with the index notch [2] on
the alternator cover.

No.1 CYLINDER:

[5]

Make sure that the "1" mark (3] on the cam sprocket is
aligned with the lower cylinder head index line [4].
If the "1" mark is facing upper cylinder head index line
[5], turn the crankshaft counterclockwise one full turn
(360°) and realign the "1T" mark with the index notch.

[1]

[2]

[3]

[4]

3-7

MAINTENANCE
Check the valve clearance by inserting a feeler gauge
[1] between the valve adjusting screw and valve stem.
VALVE CLEARANCE:
IN: 0.17 ± 0.02 mm (0.007 ± 0.001 in)
EX: 0.28 ± 0.02 mm (0.011 ± 0.001 in)

No.2 Cylinder:

Rotate the crankshaft counterclockwise 3/4 turn (270°)
and align the "2T" mark [1] on the flywheel with the
index notch [2] on the alternator cover.

No.2 CYLINDER:

Make sure that the "2" mark [3] on the cam sprocket is
aligned with the lower cylinder head index line [4].
Check the valve clearance in the same manner as No.1
cylinder.

[1]

ADJUSTMENT
Loosen the lock nut [1] and apply engine oil to the
adjusting screw threads and seating surface.
Adjust by turning the adjusting screw [2] until there is a
slight drag on the feeler gauge [3].
Hold the adjusting screw and tighten the lock nut to the
specified torque.
TORQUE:14 N·m (1.4 kgf·m, 10 lbHt)

After tightening the lock nut, recheck the valve
clearance.

Apply engine oil to a new 0-ring [1] and install it to the
camshaft maintenance cap [2].
Temporarily Install the camshaft maintenance cap to
the cylinder head.
If the engine is removed from the frame, tighten the
camshaft maintenance cap to the specified torque.
TORQUE:4.0 N·m (0.4 kgf·rn, 3.0 lbHt)

[2]

[3]

[4]

MAINTENANCE
If the engine is installed on the frame, insert a feeler
gauge (0.1 mm) [1] between the camshaft maintenance
cap and cylinder head.
Tighten the camshaft maintenance cap securely.
Remove the feeler gauge.
Further tighten the camshaft maintenance cap at 30°.
NOTE:

• The length of one concave area [2] on the camshaft
maintenance cap is equivalent with 30°.
Install the cylinder head cover (page 10-5).
Apply engine oil to new 0-rings and install them to the
timing hole cap and crankshaft hole cap.
Apply grease to the timing hole cap and crankshaft hole cap threads, then install and tighten them.
TORQUE:
Timing hole cap:
10 N·rn (1.0 kgf·rn, 7 lbHt)
Crankshaft hole cap:
15 N·rn (1.5 kgf·m, 11 lbHt)

ENGINE OIL
OIL LEVEL INSPECTION
Hold the motorcycle in an upright position.
Start the engine and let it idle for 3 - 5 minutes.
Stop the engine and wait 2 - 3 minutes.
Remove the oil filler cap/dipstick [1] and wipe it clean.
Reinstall the oil filler cap/dipstick, but do not screw it.
Remove the oil filler cap/dipstick and check the oil level.
If the level is below or near the lower level [2] on the
dipstick, fill the recommended engine oil to the upper
level [3].
RECOMMENDED ENGINE OIL:
Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or
equivalent motorcycle oil
API service classification: SG or Higher
JASO T 903 standard: MA
.
Viscosity: SAE 10W-30

r---_[3)
[2]

Check that the 0-ring [4] is in good condition, replace it if necessary.
Apply engine oil to the 0-ring.
Install the oil filler cap/dipstick.

3-9

MAINTENANCE
ENGINE OIL CHANGE
Warm up the engine.
Stop the engine and remove the oil filler cap/dipstick.
Place an oil pan under the engine to catch the engine
oil, then remove the engine oil drain bolt [1]/sealing
washer [2].
Drain the engine oil completely.
Install a new sealing washer onto the drain bolt.
Install and tighten the drain bolUsealing washer to the
specified torque.
TORQUE:30 N·m (3.1 kgf·m, 22 lbHt)

Fill the engine with the recommended engine oil
(page 3-9).
ENGINE OIL CAPACITY:
CTX700/A/N/NA:
3.1 liters (3.3 US qt, 2.7 Imp qt) at draining
3.4 liters (3.6 US qt, 3.0 Imp qt) at oil filter change
3.7 liters (3.9 US qt, 3.3 Imp qt) at disassembly
CTX700D/ND:
3.2 liters (3.4 US qt, 2.8 Imp qt) at draining
3.4 liters (3.6 US qt, 3.0 Imp qt) at oil filter change
4.1 liters (4.3 US qt, 3.6 Imp qt) at disassembly

Install the oil filler cap/dipstick [1].
Check the engine oil level (page 3-9).
Make sure there are no oil leaks.

ENGINE OIL FILTER
Drain the engine oil (page 3-10).
Remove the oil filter cartridge [1] using the special tool.
TOOL:
[2] Oil Filter Wrench

07HAA-PJ70101 or
07 AAA-PL CA 100
(U.S.A. only)

Apply engine oil to a new oil filter cartridge threads and
0-ring.
Install and tighten the oil filter cartridge [1] to the
specified torque.
TORQUE:26 N·m (2.7 kgf·m, 19 lbHt)

Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-9).

MAINTENANCE

CLUTCH OIL FILTER (CTX700D/ND)
NOTE:
Replace the engine oil filter when the clutch oil filter is replaced.

I

NOTICE

I

Ensure the model-specific engine oil filter is used. Filters with a similar physical appearance may have different
flow characteristics. The use of such filters could cause severe engine damage.
Drain the engine oil (page 3-10).
Remove the right under side cowl (page 2-13).
Remove the following:
-

Bolts [1]
Clutch oil filter cover [2]
Spring [3]
Clutch oil filter [4]
0-ring [5]

Install a new clutch oil fitter with the "OUTSIDE" mark
[6] facing out.

[6)

Installation is in the reverse order of removal.
• Replace the 0-ring with a new one.
• Apply engine oil to a new 0-ring.
Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-9).

ENGINE IDLE SPEED
NOTE:
• Inspect the idle speed after all other engine maintenance items have been performed and are within
specifications.
• Before checking the idle speed, inspect the following items.
- No OTC and MIL blinking
- Spark plug condition (page 3-6)
- Air cleaner element condition (page 3-5)
• The engine must be warm for accurate idle speed inspection.
• This system eliminates the need for manual idle speed adjustment compared to previous designs.
Turn the ignition switch ON and engine stop switch

"o".

Start the engine and let it idle.
Check the idle speed.

IDLE SPEED: 1,200 ± 100 rpm
If the idle speed is out of the specification, check the following:
-

Intake air leak or engine top-end problem (page 10-4)
Throttle operation and freeplay (page 3-4)
IACV operation (page 7-20)

3-11

MAINTENANCE

RADIATOR COOLANT
Check the coolant level of the reserve tank with the
engine running at normal operating temperature.
The level should be between the "UPPER" level line [1J
and "LOWER" level line [2] with the motorcycle in an
upright position.
If necessary, add recommended coolant.
RECOMMENDED ANTIFREEZE:
Pro Honda HP Coolant or an equivalent high
quality ethylene glycol antifreeze containing
silicate-free corrosion inhibitors

Remove the reserve tank cap [1J and add the coolant to
the "UPPER" level line with a 1:1 mixture of distilled
water and antifreeze.
Reinstall the reserve tank cap.
Check to see if there are any coolant leaks when the
coolant level decreases very rapidly.
If the reserve tank becomes completely empty, there is
a possibility of air getting into the cooling system.
Be sure to remove any air from the cooling system
(page 8-4).

COOLING SYSTEM
Check the radiator air passages for clogging or
damage.
Straighten bent fins, and remove insects, mud or other
obstructions with compressed air or low water pressure.
Replace the radiator if the air flow is restricted over
more than 20 % of the radiating surface.
Inspect the water hoses for cracks or deterioration, and
replace them if necessary.
Check the tightness of all water hose band screws
(page 8-8).

MAINTENANCE

EVAPORATIVE EMISSION CONTROL SYSTEM
(50 STATE MODEL ONLY)
Remove the center shelter (page 2-12).
Check the hoses between the fuel tank, EVAP canister
[1], EVAP purge control solenoid valve [2] for
deterioration, damage or loose connection.
Check the EVAP canister for cracks or other damage.

DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
Turn the ignition switch OFF, support the motorcycle on
its sidestand and shift the transmission into neutral.
Check the slack in the drive chain lower run midway
between the sprockets.

DRIVE CHAIN SLACK: 25 - 35 mm (1.0 - 1.4 in)

I

NOTICE

I

Excessive chain slack, 50 mm (2.0 in) or more, may
damage the frame.

Amputation hazard. Never inspect or adjust the
drive chain while the engine is running.

25 - 35 mm (1.0 - 1.4 in)

ADJUSTMENT
Loosen the rear axle nut [1].
Loosen the lock nuts [2] and turn the adjusting nuts [3]
until the correct drive chain slack is obtained.
Make sure the index lines [4] on both adjusting plates
are aligned with the rear end of the axle slots [5] in the
swing arm.
Tighten the axle nut to the specified torque.

TORQUE: 98 N·m (10.0 kgf·m, 72 lbHt)
Hold the adjusting nuts and tighten the k)ck nuts to the
specified torque.

TORQUE:21 N·m (2.1 kgf·m, 15 lbHt)
Recheck the drive chain slack and free wheel rotation.

3-13

MAINTENANCE
Check the drive chain wear indicator label attached on
the left swingarm.
If the drive chain adjuster arrow mark [1] reaches red
zone [2] of the indicator label, replace the drive chain
with a new one (page 3-15).

CLEANING AND LUBRICATION
Clean the drive chain [1] with a chain cleaner designed
specifically for 0-ring chains or a neutral detergent. Use
a soft brush if the drive chain is dirty.

[1]

I NOTICE I
Do not use a steam cleaner, high pressure cleaner, wire
brush, volatile solvent such as gasoline and benzene,
abrasive cleaner or a chain cleaner NOT designed
specifically for 0-ring chains to clean the drive chain.

Inspect the drive chain for possible damage or wear.
Replace any drive chain that has damaged rollers,
loose fitting links, or otherwise appears unserviceable.
Be sure the drive chain has dried completely before
lubricating.

[2]

Lubricate the drive chain with drive chain lubricant [2].
RECOMMENDED LUBRICANT:
Pro Honda HP Chain Lube or equivalent

I NOTICE I
Do not use a chain lubricant NOT designed specifically for use with 0-ring chains to lubricate the drive chain.

Wipe off the excess oil or drive chain lubricant.

SPROCKET INSPECTION
Remove the left crankcase rear cover (page 2-16).
Inspect the drive and driven sprocket teeth for wear or damage, replace if necessary.
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good condition, or new replacement chain will wear rapidly.

Check the attaching bolts and nuts on the drive and driven sprockets.
If any are loose, torque them.
TORQUE:
Drive sprocket bolt:
54 N·m (5.5 kgf·m, 40 lbf.ft)
Driven sprocket nut:
108 N·m (11.0 kgf·m, 80 lbf·ft)

Install the left crankcase rear cover (page 2-16).

3-14

MAINTENANCE
REPLACEMENT
This motorcycle uses a drive chain with a staked master
link.
Fully slacken the drive chain (page 3-13).
Remove the drive chain using the special tool.
• When using the special
manufacturer's instruction.
TOOL:
Drive chain tool set

tool,

follow

J. •·

1:i:(
1 LINK

the

07HMH-MR10103 or
07HMH-MR101 OC
(U.S.A. only)

Remove the excess drive chain links from a new drive
chain with the drive chain tool set.

CTX700/NN/NA: 114 LINKS
CTX700D/ND: 112 LINKS

STANDARD LINKS:
CTX700/A/N/NA/: 114 LINKS
CTX700D/ND:
112 LINKS
REPLACEMENT CHAIN
DID: DID520VO
RK: RK520KHO
Never reuse the old
drive chain, master
link, master link
plate and 0-rings.

Insert a new master link [1] with new 0-rings [2] from
the inside of the drive chain, and install a new plate [3]
and 0-rings with the identification mark facing the
outside.
Assemble the master link, 0-rings and plate.
TOOL:
Drive chain tool set

07HMH-MR10103 or
07HMH-MR1010C
(U.S.A. only)

Make sure that the master link pins [1] are installed
properly.
Measure the master link pin length projected from the
plate.
STANDARD LENGTH:
Approx. 1.3 mm (0.05 in)

Stake the master link pins.

3-15

MAINTENANCE
Make sure that the pins are staked properly by
measuring the diameter of the staked area using a slide
caliper [1).

[1 J

DIAMETER OF THE STAKED AREA:
DID: 5.40- 5.60 mm (0.213- 0.220 in)
RK: 5.30- 5.70 mm (0.209- 0.224 in)
After staking, check the staked area of the· master link
for cracks.
If there is any cracking, replace the master link, 0-rings
and plate.

BRAKE FLUID

I

NOTICE

Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is
serviced.
NOTE:

•
•
•
•

Do not mix different types of fluid, as they are not compatible with each other.
Do not allow foreign material to enter the system when filling the-reservoir.
When the fluid level is low, check the brake pads for wear (page 3-17).
A low fluid level may be due to wear of the brake pads. If the brake pads are worn and caliper pistons are
pushed out, this accounts for a low fluid level. If the brake pads are not worn and fluid level is low, check the
entire system for leaks (page 3-18).

FRONT BRAKE
Turn the handlebar to the left so that the reservoir is ,---[-- - - - - - - , - - - - - - - - - - - - .
21
level and check the front brake fluid level through the
[41
sight glass.
If the level is near the "LOWER" level line [1), fill the
recommended brake fluid.
Remove the following:
-

Screws [2]
Reservoir cover [3)
Set plate [4]
Diaphragm [5)

Fill the reservoir with DOT 4 brake fluid from a sealed
container to the casting ledge [1].
Install the diaphragm, set plate and reservoir cover.
Install and tighten the cover screws to the specified
torque.

TORQUE: 1.5 N·m (0.2 kgf·m, 1. 1 lbHt)

3-16

MAINTENANCE
REAR BRAKE
Support the motorcycle on a level surface, and check
the rear brake fluid level.
Check the brake fluid level.
If the level is near the "LOWER" level line [1], fill the
recommended brake fluid.

[1]

Remove the bolt [1], reservoir cover [2] and rear master , - - - - - - - - - - - - - - - - - - ~
cylinder reservoir [3].
[2]
Temporarily install the reservoir and mounting bolt to
the stay.
Remove the cover cap [4], set plate [5] and diaphragm

[6J.
Fill the reservoir with DOT 4 brake fluid from a sealed
container to the "UPPER" level line.
Install the removed parts in the reverse order of
removal.
[1]

TORQUE:
Rear master cylinder reservoir mounting bolt:
10 N·m (1.0 kgf·m, 7 lbMt)

[3]

[4]

BRAKE PADS WEAR
BRAKE PADS
Check the brake pads for wear.
Always replace the
brake pads as a set
to assure even disc
pressure.

Front:

Rear:

[1 J

[1]

Replace the brake pads if either pad is worn to the
bottom of wear limit grooves [1 ].
For brake pad replacement.
-

Front brake pad (page 19-9)
Rear brake pad (page 19-10)

3-17

MAINTENANCE

BRAKE SYSTEM
INSPECTION
Firmly apply the brake lever or pedal, and check that no
air has entered the system.
If the lever or pedal feels soft or spongy when operated,
bleed the air from the system.
For brake air bleeding (page 19-7).
lnspE1ct the brake hose [1] and fittings for deterioration,
cracks and signs of leakage.
Tighten any loose fittings.
Replace hoses and fittings as required.

I

\

BRAKE LIGHT SWITCH
Remove the under cowl lid (page 2-12).
The front brake light
switch does not
require adjustment.

[1]

Adjust the brake light switch [1] so that the brake light
comes on just prior to the brake actually being
engaged.
If the light fails to come on, adjust the switch so that the
light comes on at the proper time.
• Hold the switch body and turn the adjuster [2]. Do
not turn the switch body.
Install the under cowl lid (page 2-12).

[2]

BRAKE LOCK OPERATION (CTX700D/ND)
INSPECTION
Support the motorcycle using a safety stand or hoist,
raise the rear wheel off the ground.
Turn the rear wheel with your hands and pull the
parking brake lever [1] slowly.
Check the parking brake lever"!:::,.'' mark [2] within the
index lines [3] at the rear wheel stopped.
If the parking brake lever "!:::,.'' mark not within the index
lines, adjust the parking brake (page 3-19).

[1]

MAINTENANCE
ADJUSTMENT
Parking brake lever position can be adjusted at the
upper end of the parking brake cable and at the parking
brake caliper adjuster bolt.
Minor adjustment is made with the upper adjuster.
Release the dust cover [1].
Adjust the lever position by loosening the lock nut [2],
and turning the adjuster [3].
After adjustment, tighten the lock nut securely.
If the correct freeplay cannot be gained from the upper
adjuster, turn the adjuster all the way in.
Make major adjustments with the parking brake caliper
adjuster bolt.
Major adjustment is made with the parking brake caliper
adjuster bolt [1 ].
Loosen the lock nut [2].
Turn the adjuster bolt clockwise until bolt resistance is
felt (brake pads contact with the brake disc).
Then turn the adjuster bolt 1/4 turn counterclockwise
and tighten the lock nut to the specified torque while
holding the adjuster bolt.

TORQUE:17 N·m (1.7 kgf·m, 13 lbHt)
Recheck the parking brake operation.

HEADLIGHT AIM
Support the motorcycle in an upright position.
Adjust the headlight
aim as specified by
local laws and
regulations.

CTX700/A/D:

Adjust the headlight aim vertically by turning the vertical
beam adjusting screw [1].
A clockwise rotation moves the beam up and
counterclockwise rotation moves the beam down.

CTX?OON/NA/ND:

[1]

[1 J

3-19

MAINTENANCE

CLUTCH SYSTEM (CTX700/A/N/NA}
Measure the clutch lever freeplay at the end of the
clutch lever.

10-20 mm (0.4-0.8 in)

FREEPLAY:10 - 20 mm (0.4- 0.8 in)

The adjuster may
be damaged if it is
positioned too far
out, leaving minimal
thread
engagement.

Minor adjustment is made with the upper adjuster at the
clutch lever.

[1]

Loosen the lock nut [1] and turn the adjuster [2].
If the adjuster is threaded out near its limit and the
correct freeplay cannot be obtained, turn the adjuster all
the way in and back out one turn.
Tighten the lock nut while holding the adjuster.
Recheck the clutch lever freeplay.

Major adjustment is made with the lower adjusting nut
[1] at the clutch lifter arm.
Loosen the lock nut [2] and turn the adjusting nut to
adjust the freeplay.
Tighten the lock nut while holding the adjusting nut.
If proper freeplay cannot be obtained, or the clutch slips
during test ride, disassemble and inspect the clutch
(page 11-8).

SIDESTAND
INSPECTION
Support the motorcycle using a safety stand or hoist.

[1]

Check the sidestand spring [1] for damage or loss of
tension.
Check the sidestand [2] assembly for freedom of
movement and lubricate the sidestand pivot if
necessary.
Check the sidestand ignition cut-off system:
-

Sit astride the motorcycle and raise the sidestand.
Start the engine with the transmission in neutral,
then, with the clutch lever fully squeezed, shift the
transmission into gear.
Move the sidestand full down.
The engine should stop as the sidestand is lowered.

If there is a problem with the system, check the
sidestand switch (page 22-21 ).

[2]

[2]

MAINTENANCE
REMOVAL/INSTALLATION
Support the motorcycle upright on a level surface.
Remove the sidestand switch bolt and sidestand switch
(page 22-21 ).
Remove the sidestand springs [1].
Remove the sidestand pivot nut [2], bolt [3] and
sidestand [4].
Apply grease to the sidestand pivot bolt sliding surface.

-~
[3]

Install the sidestand and sidestand pivot bolt.
Tighten the sidestand pivot bolt to the specified torque.
TORQUE:10 N·m (1.0 kgf·m, 7 lbHt)
Loosen the sidestand pivot bolt 45 - 90°.

[1]

Install and tighten the sidestand pivot nut to the
specified torque while holding the pivot bolt.
TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft)
Install the sidestand springs.
Install the sidestand switch (page 22-21 ).

SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the forks by operating the front brake and compressing the front suspension several times.
Check the entire assembly for signs of leaks, damage or loose fasteners.
Replace damaged components which cannot be repaired.
• Loose, worn or damaged suspension parts impair motorcycle stability and control.
Tighten all nuts and bolts.
For fork service (page 17-18).

REAR SUSPENSION INSPECTION
Check the action of the rear shock absorber by compressing the rear end several times.
Check the entire shock absorber assembly for leaks, damage or loose fasteners.
Replace damaged components which cannot be repaired.
• Loose, worn or damaged suspension parts impair motorcycle stability and control.
Tighten all nuts and bolts.
For shock absorber service (page 18-11 ).
Support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground.
Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel side to side.
Replace the bearings if any looseness to noted.
Forswingarm service (page 18-13).

NUTS,BOLTS,FASTENERS
Check that all chassis nuts, screws and bolts are tightened to their correct torque values (page 1-12).
Check that all cotter pins, safety clips, hose clamps and cable stays are in place and properly secured.

3-21

MAINTENANCE

WHEELS/TIRES
Support the motorcycle using a safety stand or hoist, raise the front wheel off the ground.
Hold the front fork leg and move the front wheel sideways with force to see if the wheel bearings are worn.
Forfront wheel service (page 17-14).
Support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground.
Hold the swingarm and move the rear wheel sideways with force to see if the wheel and driven flange bearings
are worn.
For rear wheel service (page 18-5).
Check the tire pressure with a tire pressure gauge when the tires are cold.
-

Front tire (page 1-10)
Rear tire (page 1-10)

Check the tires for cuts, embedded nails, or other damage.
Check the front and rear wheels for trueness.
Measure the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the following limits.
-

Front tire (page 1-10)
Rear tire (page 1-10)

STEERING HEAD BEARINGS
Support the motorcycle using a safety stand or hoist, raise the front wheel off the ground.
Check that the handlebar moves freely from side to side. Make sure the control cables do not interfere with the
handlebar rotation.
Check for steering stem bearings by grabbing the fork legs and attempting to move the front fork forward to
backward.
If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings
(page 17-4 ).

4. PGM-FI SYSTE

PGM-FI SYSTEM LOCATION ....................... 4.2

OTC TROUBLESHOOTING ........................ 4-12

PGM-FI SYSTEM OIAGRAM ......................... 4.3

Mil CIRCUIT TROUBLESHOOTING ......... 4.32

SERVICE INFORMATION ............................. 4.5

IAT SENSOR ............................ :·.................. 4-32

PGM-FI SYMPTOM
TROUBLESHOOTING···················· ............... 4.7

ECT SENSOR ............................................. 4-33
BANK ANGLE SENSQR ............................. 4.33

PGM-FI TROUBLESHOOTING
INFORMATION .............................................. 4.7

ECM/PCM .................................................... 4-34

OTC INOEX .................................................. 4.10

02 SENSOR ................................................ 4-36

SENSOR UNIT POWER LINE
INSPECTION ............................................... 4.11

4-1

PGM-FI SYSTEM

PGM-FI SYSTEM LOCATION
CTX700IAININA:
SENSOR UNIT:
-MAP SENSOR
-TP SENSOR

FUEL
INJECTOR

EVAP PURGE CONTROL
SOLENOID VALVE

FUEL PUMP

ECT SENSOR

COMBINATION
METER

IAT SENSOR
DLC

IACV

02SENSOR
CKP SENSOR

EOP SWITCH

CTX700DIND:
SENSOR UNIT:
-MAP SENSOR
-TP SENSOR

FUEL
INJECTOR

EVAP PURGE CONTROL
SOLENOID VALVE

FUEL PUMP

ECT SENSOR

IGNITION SWITCH

COMBINATION
METER

DLC

FUSE BOX
- FUEL CUT RELAY
- FAN CONTROL RELAY

02SENSOR
EOPSWITCH

SIDESTAND SWITCH

VS SENSOR

CKP SENSOR

PGM-FI SYSTEM

PGM-FI SYSTEM DIAGRAM
CTX700/A/N/NA:
MAIN FUSE
30A

Bl

IGNITION SWITCH

ENG STOP
RIBI
7.5A WIY

R/8!

R

W/Y

Bl

Fl
15A

FUEL
PUMP
UNIT

ENGINE STOP SWITCH

81/R

BIIW

COMBINATION METER
ILLUMI/STOP/HORN
7.5A

RIB! 81/W YIR

®

P/Bu

P!Bu

MIL

FAN
15A

@(86)
RN/

Be
81/G

TXD/RXD

GIR

I P/G
Bl

©(54)
BANK ANGLE SENSOR

BIIW

@(11)~

w

VS SENSOR~

DLC

d}

---,

Be
G

EVAP PURGE CONTROL
SOLENOID VALVE
SENSOR UNIT
-------

I-

-~--~-~:__---==~--~--~-'

@(1);

50 state model only

MAP SENSOR I

FUEL CUT
RELAY

I

Bl

Br/Bl

BIIW

Be

@(8):
I

TPSENSOR

I

1----------- I

©
©
©

G/Y

(9)

IAT SENSOR

Bu

Bl/Bu

Bl

(7)

FAN CONTROL
RELAY

G

FAN MOTOR
ECT SENSOR
Bl

No.1 FUEL INJECTOR

Lg

(87)

EDP SWITCH
Bl

No.2FUELINJECTOR

@(21)

Bl

WIG

e
e
~

~

...

(12)

)Xt

(13)

~ ,,

.

02SENSOR

. ,.
)Xt

CKPSENSOR

0

y

y

W/Y

G/0

~
~

G/0

IGNITION COIL /SPARK PLUG
GIR

NEUTRAL
DIODE
Bl

IACV

Bl

CLUTCH
SWITCH
GIW

(9)(29)

© ()=

Bl : Black
Br: Brown
Bu: Blue
G : Green
Gr: Gray
Lg : Light green
0 : Orange

DTC/MIL number

l?s( =Engine does not start
when detecting DTC/MIL

cJ} =

Short terminals for
reading DTC/MIL

12
23

P
R
V
W
Y

: PINK
: Red
:Violet
:White
:Yellow

ECM 33P CONNECTOR
ECM side of male terminals

4-3

PGM-FI SYSTEM
CTX700D/ND:

MAIN FUSE
30A

Bl

IGNITION SWITCH
R

ENG STOP
7 .SA W/Y

W/Y

Bl

Fl

15A

FUEL
PUMP
UNIT

ENGINE STOP SWITCH

RISI

RISI

81/R

BIIW
COMBINATION METER

ILLUMI/STOP/HORN
7.5A P/Bu

FAN
15A

P/Bu

9

R/81 81/W

MIL

Br

@(86)
RIW

Y/R

81/G

TXD/RXD

G/R

..

I P/G

w

@(54)
BANK ANGLE SENSOR

I

Bl

-....,__,.- RJW

DLC

d}

@(11)~

81/W

VS SENSOR~

w
Br

G

EVAP PURGE CONTR0:-----1
SOLENOID VALVE
,
81/W

SENSOR UNIT
I

I

---------------------'
50 state model only

:

@(1):
FUEL CUT
RELAY

MAP SENSOR:
I

Bl

Br/8!

81/W

Br

G/Y

81/W

Bl/Bu

RJW

@(8):
I

TP SENSOR

: ___________

(9)

@

I

Bu

IAT SENSOR

Bl

FAN MOTOR
@

(7)

G

FAN CONTROL
RELAY

ECT SENSOR
Bl

No.1 FUEL INJECTOR
@

(87) EOP SWITCH

e

':::::::,I

(12)

Bl

No.2FUELINJECTOR@(13)
81

@(21)

~ .......

g

02SENSOR

~0
'"

W/Y

CKPSENSOR

IACV

@(29)

@ ( )=

Bl : Black
Br: Brown
Bu: Blue
G : Green
Gr: Gray
Lg : Light green
0 : Orange

DTC/MIL number

)8 = Engine does not start
when detecting DTC/MIL

d} =

12

23

Short terminals for
reading DTC/MIL
PCM 33P (BLACK) CONNECTOR
PCM side of male terminals

PCM 33P (GRAY) CONNECTOR
PCM side of male terminals

P : PINK
R : Red
V :Violet

W :White
Y : Yellow

PGM-FI SYSTEM

SERVICE INFORMATION
GENERAL
• Use an electric heating element to heat the water for the ECT sensor inspection, keep flammable materials away from the
electric heating element. Wear protective clothing, insulated gloves and eye protection.
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
• The PGM-FI system is equipped with the Self-Diagnostic System (page 4-7). If the MIL blinks, follow the Self-Diagnostic
Procedures to remedy the problem.
• When checking the PGM-FI, always follow the steps in the troubleshooting flow chart.
• The PGM-FI system is provided with fail-safe function to secure a minimum running capability even when there is any trouble in
the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by making use of the
numerical values of a situation preset in the simulated program map.
It must be remembered, however, that when any abnormality is detected in injector, the fail-safe function stops the engine to
protect it from damage.
• For PGM-FI system location (page 4-2).
• Use a digital tester for PGM-FI system inspection.
• The following color codes are used throughout this section.
Bl= Black
Br= Brown

Bu= Blue
G = Green

Gr= Gray
Lg = Light green

0 = Orange
P = Pink

R= Red
V = Violet

W = White
Y = Yellow

TOOLS
SCS service connector
070PZ-ZY30100

Test probe, 2 packs
07ZAJ-RDJA 110

4-5

PGM-FI SYSTEM
ECM/PCM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION
This motorcycle is equipped with a ECM/PCM-to-combination meter two-way serial communication system.
The ECM/PCM sends the following information to combination meter:
-

High coolant temperature indicator signal
Engine oil pressure indicator signal
Engine speed signal
MIL signal
Gear position indicator signal (CTX7000/NO)

The combination meter sends the VS sensor signal and ignition switch OFF time information (elapsed time after the ignition switch
is turned OFF) to the ECM/PCM. The ECM/PCM uses this information and the VS sensor signal to detect an open circuit in the
EOP line.
These signals are communicated between the combination meter and ECM/PCM via one wire. This wire is called the serial
communication line.

ECT SENSOR
SERIAL COMMUNICATION LINE

COMBINATION
METER
VS SENSOR

EOPSWITCH

ECM or PCM
CKP SENSOR

To COMBINATION METER:
- High coolant temperature indicator signal
- Engine oil pressure indicator signal
- Engine speed signal
- MIL signal
- Gear position indicator signal (CTX700D/ND only)
To PCM:
- VS sensor signal
- Ignition switch OFF time information

CTX700D/ND only
I

: TR SENSOR
L--------..1

WHEN THERE IS A PROBLEM IN THE SERIAL COMMUNICATION LINE
When an open or short circuit occurs in the serial communication line, the
combination meter will indicate the problem in the following ways:
-

The MIL [1] will come on.
The engine oil pressure indicator [2] will come on.
The tachometer will go off.
The high coolant temperature indicator will go off.
Shift indicator"-" [3] is blinking. (CTX7000/NO only)

When the ECM does not receive combination meter information, the ECM
will store OTC 86-1. Check OTC 86-1 with the MCS (page 4-8).
Check the ECM in the ECM communication diagnostic mode (page 4-30).
Check the combination meter with the combination meter communication
diagnostic mode (page 22-8).
[3]

PGM-FI SYSTEM

PGM-FI SYMPTOM TROUBLESHOOTING
When the motorcycle has one of these symptoms, check the OTC or MIL blinking, refer to the OTC index (page 4-1 O) and begin the
appropriate troubleshooting procedure. If there are no OTC/MIL blinking stored in the ECM/PCM memory, do the diagnostic
procedure for the symptom, in sequence listed below, until you find cause.

Symptom
Engine cranks but won't start
(No OTC and MIL blinking)

Engine cranks but won't start
(No fuel pump operation sound
when the turning the ignition
ON)

Engine stalls, hard to start,
rough idling

Afterburn when engine braking
is used
Backfiring or misfiring during
acceleration
Poor performance (driveability)
and poor fuel economy

Idle speed is below
specifications or fast idle too low
(No OTC and MIL blinking)
Idle speed is above
specifications or fast idle too
high (No OTC and MIL blinking)

MIL stays ON but no DTCs set,
or MIL never comes ON at all

Diagnosis procedure
1. Inspect the spark plug condition
(page 3-6).
2. Inspect the ignition system (page 5-6).
3. Inspect the cylinder compression
(page 10-5).
4. Inspect the IACV (page 7-20).
5. Inspect the fuel supply system (page 7-10).

1. ECM/PCM power/ground circuits
malfunction (page 4-35).
2. Inspect the fuel supply system (page 7-10).

1.
2.
3.
4.

Inspect the engine idle speed (page 3-11 ).
Inspect the IACV (page 7-20).
Inspect the fuel supply system (page 7-4).
Inspect the battery charging system
(page 21-6).
5. Inspect the ignition system (page 5-6).
Inspect the ignition system (page 5-6).

for
. No fuel toAlsofuelcheck
injector

..
.
.

..
.
...
..

- Clogged fuel filter
- Pinched or clogged fuel feed
hose
- Faulty fuel pump
- Faulty fuel pump circuits
Intake air leak
Contaminated/deteriorated fuel
Faulty fuel injector
Open circuit in the power input
and/or ground wire of the ECM/
PCM
Blown main fuse (30 A)
Blown sub fuse 15 A (Fl)
Blown sub fuse 7.5 A (ENG STOP)
Restricted fuel feed hose
Contaminated/deteriorated fuel
Intake air leak
Faulty MAP sensor
Restricted fuel tank breather hose

Inspect the ignition system (page 5-6).
1. Inspect the fuel supply system (page 7-4).
2. Inspect the air cleaner element (page 3-5).
3. Inspect the ignition system (page 5-6).
Inspect the engine idle speed (page 3-11 ).
Inspect the IACV (page 7-20).
Inspect the ignition system (page 5-6).
Inspect the engine idle speed (page 3-11 ).
Inspect the throttle operation and freeplay
(page 3-4).
3. Inspect the IACV (page 7-20).
4. Inspect the ignition system (page 5-6).
Inspect the MIL circuit (page 4-32).

1.
2.
3.
1.
2.

. Faulty pressure regulator (fuel
pump)
.. Faulty
fuel injector
Faulty MAP sensor

..

Intake air leak
Engine top-end problem
• Air cleaner element condition

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

Opens and Shorts
"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With ECM/
PCMs this can something mean something work, but not the way it's supposed to.

If the MIL has come on
Refer to OTC READOUT (page 4-9).

If the MIL did not stay on
If the MIL did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 4-7).

4-7

PGM-FI SYSTEM
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The PGM-FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system, the ECM/PCM turns
on the MIL and stores a OTC in its erasable memory.

FAIL-SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system. When any abnormality is detected by the self-diagnosis function, running capability is maintained by pre-programed value
in the simulated program map. When any abnormality is detected in the fuel injector, the fail-safe function stops the engine to
protect it from damage.

DTC
• The OTC is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the
ECM/PCM with the MCS.
The digits in front of the hyphen are the main code, they indicate the component of function failure.
The digits behind the hyphen are the sub code, they detail the specific symptom of the component or function failure.
For example, in the case of the TP sensor:
- OTC 08 - 1 = (TP sensor voltage) - (lower than the specified value)
- OTC 08 - 2 = (TP sensor voltage) (higher than the specified value)
• The MAP, ECT, TP and IAT sensor diagnosis will be made according to the voltage output of the affected sensor.
If a failure occurs, the ECM/PCM determines the Function Failure, compares the sensor voltage output to the standard value,
and then outputs the corresponding OTC to the MCS.

MIL Blink Pattern
• If the MCS is not available, OTC can be read from the ECM/PCM memory by the MIL [1] blink pattern.
• The number of MIL blinks is the equivalent the main code of the OTC (the sub code cannot be displayed by the MIL).
• The MIL will blink the current OTC, in case the ECM/PCM detects the problem at present, when the ignition switch ON and
engine stop switch "O" or idling with the sidestand down. The MIL will stay ON when the engine speed is over 1,850 rpm or with
the sidestand up.
• The MIL has two types of blinks, a long blink and short blink. The long blinking lasts for 1.3 seconds, the short blinking lasts for
0.3 seconds. One long blink is the equivalent of ten short blinks. For example, when two long blinks are followed by five short
blinks, the MIL is 25 (two long blinks= 20 blinks, plus five short blinks).
• When the ECM/PCM stores more than one OTC, the MIL will indicate them by blinking in the order from the lowest number to
highest number.

MIL Check
When the ignition switch is turned ON and engine stop switch
not come on, troubleshoot the MIL circuit (page 4-32).

"o" the MIL will stay on for a few seconds, then go off.

If the MIL does

CURRENT OTC/FREEZE DTC
The OTC is indicated in two ways according to the failure status.
• In case the ECM/PCM detects the problem at present, the MIL will come on and the MIL will start to blink as its OTC when the
sidestand is lowered. It is possible to readout the MIL blink pattern as the current OTC.
• In case the ECM/PCM does not detect any problem at present but has a problem stored in its memory, the MIL will not light and
blink. If it is necessary to retrieve the past problem, readout the freeze OTC by following the OTC readout procedure
(page 4-9).

MCS INFORMATION
• The MCS can readout the OTC, freeze data, current data and other ECM/PCM condition.

How to connect the MCS
Turn the ignition switch OFF.
Remove the dummy connector from the OLC (page 4-9).
Connect the MCS to the OLC.
Turn the ignition switch ON and engine stop switch "O" check the OTC and freeze data.
NOTE:
Freeze data indicates the engine conditions when the first malfunction was detected.

ECM/PCM reset
The MCS can reset the ECM/PCM data including the OTC, freeze data and some learning memory.

4-8

PGM-FI SYSTEM
DTC READOUT
Start the engine and check the MIL.
NOTE:
When the ignition switch is turned ON and engine stop switch "0", the MIL will stay on for a few seconds, then go off.
If the MIL stays on or blinks, connect the MCS to the DLC (page 4-8).
Read the OTC, freeze data and follow the troubleshooting index
(page 4-10).
To read the OTC with the MIL blinking, refer to the following procedure.

Reading DTC with the MIL
Turn the ignition switch OFF.
Remove the seat (page 2-14).
Remove the DLC [1] from the battery box.
Remove the dummy connector from the DLC.
Short the DLC terminals using a special tool.

CONNECTION: Brown - Green
TOOL:
[2] SCS service connector

070PZ-ZY30100

Turn the ignition switch ON and engine stop switch
blinks and refer to the OTC index (page 4-10).

"o".

read, note the MIL

NOTE:
If the ECM/PCM has any OTC in its memory, the MIL will start blinking.

How to clear the DTC with SCS connector
1. Connect the SCS connector to the DLC (page 4-9).
2. Turn the ignition switch ON and engine stop switch "O".
3. Disconnect the SCS connector [1] from the DLC [2].
Connect the SCS connector to the DLC again while the MIL stays ON
about 5 seconds (reset receiving pattern).
4. The stored OTC is erased if the MIL goes off and starts blinking
(successful pattern).
• The DLC must be jumped while the MIL lights. If not, the MIL will not
start blinking. In that case, turn the ignition switch OFF and try again
from step 3.
• Note that the self-diagnostic memory cannot be erased if the ignition
switch is turned "OFF" before the MIL starts blinking.

CIRCUIT INSPECTION
INSPECTION AT ECM/PCM CONNECTOR
• Always clean around and keep any foreign material away from the ECM/
PCM 33P connector(s) before disconnecting it.
A faulty PGM-FI system is often related to poorly connected or corroded
terminals. Check those connections before proceeding.
• In testing at ECM/PCM 33P connector(s) (wire harness side) terminal,
always use the test probe [1]. Insert the test probe into the connector
terminal, then attach the digital multimeter probe to the test probe.

TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

4-9

PGM-FI SYSTEM

DTCINDEX
DTC
(MIL
blinks)

1-1 (1)

1-2 (1)

7-1 (7)

7-2 (7)

8-1 (8)

8-2 (8)
9-1 (9)

9-2 (9)

11-1
(11)

12-1
(12)

13-1
(13)
21-1
(21)
29-1
(29)
33-2(-)
54-1
(54)

54-2
(54)
84-1
(84)
86-1
(86)

87-1
(87)

4-10

Function Failure

.
.
.
.

MAP sensor circuit low voltage (less than 0.029 V)
MAP sensor or its circuit malfunction
MAP sensor circuit high voltage (more than 3.809 V)
Loose or poor contact of the sensor unit
connector
MAP sensor or its circuit malfunction
ECT sensor circuit low voltage (less than 0.049 V)
ECT sensor or its circuit malfunction

.

ECT sensor circuit high voltage (more than 4.946 V)
Loose or poor contact of the ECT sensor
connector
ECT sensor or its circuit malfunction
TP sensor circuit low voltage (less than 0.122 V)
Loose or poor contact of the sensor unit
connector
• TP sensor or its circuit malfunction
TP sensor circuit high voltage (more than 4.966 V)
• · TP sensor or its circuit malfunction
IAT sensor circuit low voltage (less than 0.049 V)
IAT sensor or its circuit malfunction
IAT sensor circuit high voltage (more than 4.946 V)
Loose or poor contact of the IAT sensor
connector
IAT sensor or its circuit malfunction
VS sensor no signal
Loose or poor contact of the VS sensor connector
Open or short circuit in the VS sensor wire
Faulty VS sensor
No.1 Fuel injector circuit malfunction
Loose or poor contact of the fuel injector
connector
Fuel injector or its circuit malfunction
No.2 Fuel injector circuit malfunction
Loose or poor contact of the fuel injector
connector
Fuel injector or its circuit malfunction
02 sensor malfunction
Loose or poor contact of the 02 sensor connector
02 sensor or its circuit malfunction
IACV circuit malfunction
Loose or poor contact of the IACV connector
IACV or its circuit malfunction
ECM/PCM EEPROM malfunction
Bank angle sensor circuit low voltage (less than
0.020 V)
Bank angle sensor or its circuit malfunction
Bank angle sensor circuit high voltage (more than
4.986 V)
Loose or poor contact of the bank angle sensor
connector
Bank angle sensor or its circuit malfunction
CPC in the PCM malfunction
Faulty PCM
Meter communication malfunction
Open or short circuit in the TXD/RXD wire
Faulty combination meter
EOP switch high voltage (more than 1.001 V)
Loose or poor contact of the EOP switch
connector
Open circuit in the EOP switch wire
EOP switch or its circuit malfunction

.
.

.

.

.
...
.
.

.
.
..

..

.

.

.
.
..

.
..

Refer
to
page

Symptom/Fail-safe function

.. Engine operates normally
Pre-program value: 225 mmHg/30 kPa

..

4-12

Engine operates normally
Pre-program value: 225 mmHg/30 kPa

4-14

Hard start at a low temperature
... Pre-program
value: 110°C/230°F
Cooling fan turns on
.. Hard start at a low temperature

.

4-15

Pre-program value: 110°C/230°F
Cooling fan turns on

4-16

Poor engine acceleration
.. Pre-program
value: 0°
Poor engine acceleration
.. Pre-program
value: 0°
.. Engine operates
normally
Pre-program value: 35°C/95°F
.. Engine operates normally
Pre-program value: 35°C/95°F

4-17
,

4-18
4-19

4-20

. Engine operates normally
4-21
Engine does not start
.. Fuel
injector, fuel pump and ignition coil

..
.

shut down

4-22

Engine does not start
Fuel injector, fuel pump and ignition coil
shut down

4-23

Engine operates normally

. Engine stalls, hard to start, rough idling

4-24

4-25

...
..

Engine operates normally
Engine operates normally
Engine stop function does not operate

4-26
4-27

Engine operates normally
Engine stop function does not operate
4-28

. Gearshift system stops
. Engine operates normally

..

4-29
4-29

Engine operates normally
Oil pressure indicator stays on
4-31

PGM-FI SYSTEM

SENSOR UNIT POWER LINE INSPECTION
BEFORE OTC TROUBLESHOOTING
NOTE:
• When the DTC displays 1-1, 1-2, 8-1 and 8-2, check the following before DTC troubleshooting.
• Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and
ECM/PCM 33P connector{s).
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) {CTX700D/ND).

1. Sensor Unit Power Input Voltage Inspection
Turn the ignition switch OFF.

[1 J

Disconnect the sensor unit 5P (Black) connector
(page 7-14).
Turn the ignition switch ON and engine stop switch

"o".

Measure the voltage at the sensor unit 5P (Black)
connector [1] of the wire harness side.
Connection:
CTX700/A/N/NA:
Yellow/red(+)- Green/yellow(-)
CTX700D/ND:
Yellow/violet(+)- Green/yellow(-)

Standard: 4.75 - 5.25 V
If the voltage within 4. 75 - 5.25 V?
YES

- Turn the ignition switch OFF. Connect the sensor unit 5P (Black) connector and start the OTC
troubleshooting (page 4-12).

NO

- GO TO STEP 2.

2. Sensor Unit Input Voltage Line Short Circuit Inspection
Turn the ignition switch OFF.
Check for continuity between the sensor unit 5P
(Black) connector [1] of the wire harness side and
ground.
Connection:
CTX700/A/N/NA:
Yellow/red - Ground
CTX700D/ND:
Yellow/violet - Ground

[1]

Y/RorYN

Is there continuity?
YES

- • Short circuit in the Yellow/red wire
• Short circuit in the Yellow/violet wire

NO

- GO TO STEP 3.

4-11

PGM-FI SYSTEM
3. Sensor Unit Power Line Open Circuit Inspection
Disconnect the following:
-

CTX700/A/NINA:

[1]

ECM 33P (Black) connector [1] (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Black) [2]/33P (Gray) [3] connectors
(page 4-34) (CTX?OOD/ND)

Check for continuities between the sensor unit 5P
(Black) connector [4] and ECM/PCM 33P connector.
Connection:
CTX700/A/N/NA:
Yellow/red -Yellow/red
Green/yellow - Green/yellow
CTX700D/ND:
Yellow/violet- Yellow/violet
Green/yellow - Green/yellow

Y/R

G/Y

[4]
CTX?OOD/ND:

TOOL:
Test probe, 2 packs

[2]

07ZAJ-RDJA110

Is there continuity?
YES
NO

- Replace the ECM/PCM with a known good
one, and recheck.
-

Y/V

• Open circuit in the Yellow/red wire
• Open circuit in the Yellow/violet wire
• Open circuit in the Green/yellow wire

[3]

DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW VOLTAGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).

1. MAP Sensor System Inspection
Turn the ignition switch ON and engine stop switch

"o".

Check the MAP sensor with the MCS.
Is about O Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Sensor Unit Power Line Inspection
Check the sensor unit power line inspection (page 4-11 ).
Is the sensor unit power line normal?
YES

- GO TO STEP 3.

NO

- Replace or repair the abnormal circuit.

PGM-FI SYSTEM
3. MAP Sensor Output Voltage Inspection
Turn the ignition switch OFF.

[1 J

Disconnect the sensor unit 5P (Black) connector
(page 7-14).
Turn the ignition switch ON.

V/R

Measure the voltage at the sensor unit 5P (Black)
connector [1] of the wire harness side.
Connection: Violet/red (+) - ground (-)
4.75-5.25 V
Standard:

ffi

Is the voltage within 4.75- 5.25 V?
YES

- GO TO STEP 5.

NO

- GO TO STEP 4.

4. MAP Sensor Output Line Short Circuit Inspection
Turn the ignition switch OFF.

[1]

Check for continuity between the sensor unit 5P
(Black) connector [1] of the wire harness side and
ground.
Connection: Violet/red - ground

V/R

Is there continuity?
YES

- Short circuit in the VioleVred wire

NO

- GO TO STEP 5.

5. MAP Sensor Inspection

Replace the sensor unit with a known good one (page 7-14).
Turn the ignition switch OFF.
Connect the sensor unit 5P (Black) connector.
Erase the DTCs (page 4-9).
Turn the ignition switch ON.
Check the MAP sensor with the MCS.
Is DTC 1-1 indicated?
YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- Faulty original sensor unit (MAP sensor)

4-13

PGM-FI SYSTEM
DTC 1-2 (MAP SENSOR HIGH VOLTAGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
1. MAP Sensor System Inspection 1

Turn the ignition switch ON and engine stop switch "O".
Check the MAP sensor with the MCS.
Is about 5 Vindicated?
YES

- GO TO STEP 2.

NO

-

• Intermittent failure
• Loose or poor contact on the sensor unit 5P (Black) connector

2. Sensor Unit Power Line Inspection

Check the sensor unit power line inspection (page 4-11 ).
Is the sensor unit power line normal?
YES

- GO TO STEP 3.

NO

- Replace or repair the abnormal circuit.

3. MAP Sensor System Inspection 2

Turn the ignition switch OFF.

[2]

Disconnect the sensor unit 5P (Black) connector
(page 7-14 ).
Connect the sensor unit 5P (Black) connector [1]
terminals at the wire harness side with a jumper wire
[2].
Connection:

GIY

Violet/red - Green/yellow

V/R

Turn the ignition switch ON.
Check the MAP sensor with the MCS.
Is about O Vindicated?
YES

- Faulty sensor unit (MAP sensor)

NO

- GO TO STEP 4.

[1]

4. MAP Sensor Output Line Open Circuit Inspection

Turn the ignition switch OFF.
Remove the jumper wire.
Disconnect the following:
-

V/R

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Check for continuity between the ECM/PCM 33P
connector [1] and sensor unit 5P (Black) connector
[2] of the wire harness side.
Connection: Violet/red - Violet/red
TOOL:
Test probe, 2 packs

[2]
07ZAJ-RDJA 110

Is there continuity?

4-14

YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- Open circuit in the Violet/red wire

(1]

PGM-FI SYSTEM
DTC 7-1 (ECT SENSOR LOW VOLTAGE)
NOTE:

If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX?OOD/ND).

1. ECT Sensor System Inspection
Turn the ignition switch ON and engine stop switch"()".
Check the ECT sensor with the MCS.

Is about O Vindicated?

YES

- GO TO STEP 2.

NO

- Intermittent failure

2. ECT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the ECT sensor 2P (Black) connector (page 4-33).
Turn the ignition switch ON.
Check the ECT sensor with the MCS.

Is about O Vindicated?

YES

- GO TO STEP 4.

NO

- GO TO STEP 3.

3. ECT Sensor Resistance Inspection
Turn the ignition switch OFF.

[1)

Measure the resistance at the ECT sensor 2P
(Black) connector [1] terminals of the sensor side.

Standard: 1.0-1.3 kO (40°C/104°F)
Is the resistance within 1.0-1.3 k!l
(40°C/104°F)?

YES

- Replace the ECM/PCM with a known good
one, and recheck.

NO

- Faulty ECT sensor

4. ECT Sensor Output Line Short Circuit Inspection
Turn the ignition switch OFF.

[1)

Check for continuity between the ECT sensor 2P
(Black) connector [1] of the wire harness side and
ground.
Connection: Pink/white - Ground

Is there continuity?

YES

- Short circuit in the Pink/white wire

NO

- Replace the ECM/PCM with a known good
one, and recheck.

P/W

4-15

PGM-FI SYSTEM
DTC 7-2 (ECT SENSOR HIGH VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or poor contact on the ECT sensor 2P (Black) connector and
ECM/PCM 33P connector(s), then recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
1. ECT Sensor System Inspection

Turn the ignition switch ON and engine stop switch "O".
Check the ECT sensor with the MCS.
Is about 5 Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. ECT Sensor Inspection
Turn the ignition switch OFF.

[1]

Disconnect the ECT sensor 2P (Black) connector
(page 4-33).
Connect the ECT sensor 2P (Black) connector [1]
terminals at the wire harness side with a jumper wire
[2].
Connection: Pink/white - Green/yellow
Turn the ignition switch ON.
Check the ECT sensor with the MCS.
Is about O Vindicated?
YES

NO

- Inspect the ECT sensor (page 22-13).
- GO TO STEP 3.

[2]
~----------------'

3. ECT Sensor Line Open Circuit Inspection
Turn the ignition switch OFF.
Remove the jumper wire.
Disconnect the following:
-

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Check for continuities between the ECM/PCM 33P
connector [1] and ECT sensor 2P (Black) connector
[2] of the wire harness side.
Connection: Pink/white - Pink/white
Green/yellow - Green/yellow
TOOL:
Test probe, 2 packs

G/Y

GIY

P/W

[2]

07ZAJ-RDJA 110

Is there continuity?
YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- • Open circuit in the Pink/white wire
• Open circuit in the Green/yellow wire

[1]

PGM-FI SYSTEM
OTC 8-1 (TP SENSOR LOW VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and
ECM/PCM 33P connector(s), then recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
1. TP Sensor System Inspection

Turn the ignition switch ON and engine stop switch

"o".

Check the TP sensor with the MCS with the throttle fully closed.
Is about O Vindicated?
YES

- Intermittent failure

NO

- GO TO STEP 2.

2. Sensor Unit Power Line Inspection
Check the sensor unit power line inspection (page 4-11 ).
Is the sensor unit power line normal?
YES

- GO TO STEP 3.

NO

- Replace or repair the abnormal circuit.

3. TP Sensor Output Line Short Circuit Inspection
Turn the ignition switch OFF.

[1 J

Disconnect the sensor unit 5P (Black) connector
(page 7-14).
Check for continuity between the sensor unit 5P
(Black) connector [1] of the wire harness side and
ground.
Connection: Red/yellow - Ground

R/Y

Is there continuity?
YES

- Short circuit in the Red/yellow wire

NO

- GO TO STEP 4.

4. TP Sensor Output Line Open Circuit Inspection

Disconnect the following:
-

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Check for continuity between the ECM/PCM 33P
connector [1] and sensor unit 5P (Black) connector
[2] of the wire harness side.
Connection: Red/yellow - Red/yellow
TOOL:
Test probe, 2 packs

R/Y

07ZAJ-RDJA 110

Is there continuity?
YES

- GO TO STEP 5.

NO

- Open circuit in the Red/yellow wire

[2]

[1 J

4-17

PGM-FI SYSTEM
5. TP Sensor Inspection

Replace the sensor unit with a known good one (page 7-14).
Connect the following:
-

Sensor unit SP (Black) connector
ECM/PCM 33P connector

Erase the DTCs (page 4-9).
Turn the ignition switch ON.
Check the TP sensor with the MCS.
Is DTC 8-1 indicated?
YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- Faulty original sensor unit (TP sensor)

DTC 8-2 (TP SENSOR HIGH VOLT AGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).

1. TP Sensor System Inspection
Turn the ignition switch ON and engine stop switch

"o".

Check the TP sensor with the MCS.
Is about 5 Vindicated?
YES

- GO TO STEP 3.

NO

- GO TO STEP 2.

2. TP Sensor Inspection

Check that the TP sensor voltage increases continuously when moving the throttle from fully closed to fully
opened using the data list menu of the MCS.
Is the voltage increase continuously?
YES

- Intermittent failure

NO

- Replace the TP sensor (sensor unit) with a known good one, and recheck.

3. TP Sensor Resistance Inspection
Turn the ignition switch OFF.
Disconnect the following:
-

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

~-~GIY

Measure the resistance at the ECM/PCM 33P
connector [1) of the wire harness side.
Connection: Red/yellow - Green/yellow
Standard:
0.29 - 0.71 0 (20°C/68°F)
TOOL:
Test probe, 2 packs

07ZAJ-RDJA110

Is the resistance within 0.29 - 0. 71
(20°C/68°F)?

n

YES

- GO TO STEP 4.

NO

- Faulty sensor unit (TP sensor)

[1]

PGM-FI SYSTEM
4. TP Sensor Power Input Voltage Inspection

Connect the ECM/PCM 33P connector.
Disconnect the sensor unit 5P (Black) connector
(page 7-14).

[

1

1

Turn the ignition switch ON.
Measure the voltage at the sensor unit 5P (Black)
connector [1] of the wire harness side.
Connection:
CTX700/A/N/NA:
Yellow/red(+)- Green/yellow(-)
CTX700D/ND:
Yellow/violet(+)- Green/yellow(-)
Standard: 4.75 - 5.25 V

Is the voltage within 4.75- 5.25 V?
YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- • Open circuit in the Green/yellow wire
• Open circuit in the Yellow/red or Yellow/violet wire

DTC 9-1 (IAT SENSOR LOW VOLTAGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
1. IAT Sensor System Inspection

Turn the ignition switch ON and engine stop switch

"o".

Check the IAT sensor with the MCS.
Is about O Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. IAT Sensor Inspection

Turn the ignition switch OFF.
Disconnect the IAT sensor 2P (Black) connector (page 4-32).
Turn the ignition switch ON.
Check the IAT sensor with the MCS.
Is about O Vindicated?
YES

- GO TO STEP 3.

NO

- Faulty IAT sensor

3. IAT Sensor Voltage Output Line Short Circuit Inspection

Turn the ignition switch OFF.
Check for continuity between the IAT sensor 2P
(Black) connector [1] of the wire harness side and
ground.
Connection: Gray/blue - Ground

[1 J

Gr/Bu

Is there continuity?
YES

- Short circuit in the Gray/blue wire

NO

- Replace the ECM/PCM with a known good
one, and recheck.

4-19

PGM-FI SYSTEM
OTC 9-2 (IAT SENSOR HIGH VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or poor contact on the IAT sensor 2P (Black) connector and
ECM/PCM 33P connector, then recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).

1. IAT Sensor System Inspection
Turn the ignition switch ON and engine stop switch

"o".

Check the IAT sensor with the MCS.
Is about 5 Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. IAT Sensor Inspection
Turn the ignition switch OFF.

[1]

Disconnect the IAT sensor 2P (Black) connector
(page 4-32).
Connect the IAT sensor 2P (Black) connector [1]
terminals at the wire harness side with a jumper wire
[2].
Connection: Gray/blue - Green/yellow
Turn the ignition switch ON.
Check the IAT sensor with the MCS.
Is about O Vindicated?
YES

- Faulty IAT sensor

NO

- GO TO STEP 3.

[2]

3. IAT Sensor Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconneqt the following:
-

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX?OOD/ND)

Gr/Bu
Gr/Bu

Check for continuity between the ECM/PCM 33P
connector [1] and IAT sensor 2P (Black) connector
[2] of the wire harness side.
Connection: Gray/blue - Gray/blue
Green/yellow - Green/yellow
TOOL:
Test probe, 2 packs

[2]
07ZAJ-RDJA 110

Is there continuity?

.4 ..?n

YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

-

• Open circuit in the Gray/blue wire
• Open circuit in the Green/yellow wire

[1]

PGM-FI SYSTEM
OTC 11-1 (VS SENSOR)
NOTE:
• Before starting the inspection, check for loose or poor contact on the VS sensor 3P (Black) and combination
meter 16P (Gray) connector, then recheck the DTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX?OOD/ND).
1. VS Sensor System Inspection

Erase the DTCs (page 4-9).
Test-ride the motorcycle above 2,000 rpm.
Stop the engine.
Turn the ignition switch ON and engine stop switch

"o".

Check the VS sensor with the MCS.
Is the DTC 11-1 indicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Speedometer Inspection

Check for operation of speedometer.
Does the speedometer operate normally?
YES

- GO TO STEP 3.

NO

- GO TO STEP 4.

3. DTC Recheck

Check the DTC with the MCS.
Is the DTC 86-1 indicated?
YES

- Check the meter communication malfunction (page 4-29).

NO

- Replace the combination meter with a known good one, and recheck.

4. VS Sensor Input Voltage Inspection

Turn the ignition switch OFF.

[1 J

Disconnect the VS sensor 3P (Black) connector
(page 22-12).
Turn the ignition switch ON.
Measure the
connector [1]
Connection:
Standard:

voltage at the VS sensor 3P {Black)
of the wire harness side.
Pink/blue(+) - Green/red (-)
Battery voltage

Is there battery voltage?
YES

- GO TO STEP 5.

NO

-

• Open circuit in the Pink/blue wire
• Open circuit in the Green/red wire

5. VS Sensor Signal Line Short Circuit Inspection

Turn the ignition switch OFF.

[1]

Check for continuity between the VS sensor 3P
(Black) connector [1] of the wire harness side and
ground.
Connection: Pink/green - Ground
Is there continuity?
YES

- Short circuit in the Pink/green wire

NO

- GO TO STEP 6.

P/G

4-21

PGM-FI SYSTEM
6. VS Sensor Signal Line Open Circuit Inspection

Disconnect the combination meter 16P (Gray)
connector.
-

[1]

[2]

CTX700/A/D (page 2-6)
CTX700N/NA/ND (page 22-7)

Check for continuity between the VS sensor 3P
(Black) connector [1] and combination meter 16P
(Gray) connector [2] of the wire harness side.
Connection: Pink/green - Pink/green

P/G

P/G

Is there continuity?
YES

- GO TO STEP 7.

NO

- Open circuit in the Pink/green wire

7. VS Sensor Inspection

Replace the VS Sensor with a known good one (page 22-12).
Connect the combination meter 16P (Gray) connector.
Erase the DTCs (page 4-9).
Test-ride the motorcycle above 2,000 rpm.
Stop the engine.
Turn the ignition switch ON and engine stop switch

"o".

Check the VS sensor with the MCS.
Is the DTC 11-1 indicated?
YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- Faulty original VS sensor

DTC 12-1 (No.1 FUEL INJECTOR)
NOTE:
• Before starting the inspection, check for loose or poor contact on the fuel injector 2P (Gray) connector and
ECM/PCM 33P connector(s), then recheck the OTC.
• If the PCM is replaced, perform the clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
1. Fuel Injector System Inspection

Erase the DTCs (page 4-9).
Turn the ignition switch ON and engine stop switch
Check the fuel injector with the MCS.

"o".

Is the DTC 12-1 indicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Fuel Injector Input Voltage Inspection

Turn the ignition switch OFF.
Disconnect the fuel injector 2P (Gray) connector
(page 7-18).
Turn the ignition switch ON.
Measure the voltage between the fuel injector 2P
(Gray) connector [1] of the wire harness side and
ground.
Connection: Black(+) - Ground (-)
Standard:
Battery voltage
Does the standard voltage exist?

.4 ...??

YES

- GO TO STEP 3.

NO

- Open or short circuit in the Black wire

[1]

PGM-FI SYSTEM
3. Fuel Injector Signal Line Short Circuit Inspection
Turn the ignition switch OFF.

[1]

Check for continuity between the fuel injector 2P
(Gray) connector [1] of wire harness side and
ground.
Connection: No.1: Pink/yellow - Ground
No.2: Violet/yellow - Ground
Is there continuity?
YES

- • Short circuit in the Pink/yellow wire
• Short circuit in the Violet/yellow wire

NO

- GO TO STEP 4.

4. Fuel Injector Resistance Inspection
Measure the resistance between the fuel injector 2P
(Gray) connector [1] terminals.
Standard: 11.6 -12.4 n (20°C/68°F)

[1]

Is the resistance within 11.6 - 12.4 D (20°C/
68°F)?
YES

- GO TO STEP 5.

NO

- Faulty fuel injector

5. Fuel Injector Signal Line Open Circuit Inspection
Disconnect the following:

-

[2]

[1]

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX?OOD/ND)

Check for continuity between the ECM/PCM 33P
connector [1] and fuel injector 2P (Gray) connector
(2] of the wire harness side.
Connection: No.1: Pink/yellow - Pink/yellow
No.2: Violet/yellow - Violet/yellow
TOOL:
Test probe, 2 packs

07ZAJ·RDJA110

V/Y

[2]

Is there continuity?
YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- • Open circuit in the Pink/yellow wire
• Open circuit in the Violet/yellow wire

DTC 13-1 (No.2 FUEL INJECTOR)
See page 4-22

4-23

PGM-FI SYSTEM
OTC 21-1 (02 SENSOR}
NOTE:
• Before starting the inspection, check for loose or poor contact on the 02 sensor 1P (Black) connector or 0 2
sensor cap and ECM/PCM 33P connector(s), then recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/NO).
1. 02 Sensor System Inspection

Turn the ignition switch ON and engine stop switch

"o".

Start the engine and warm up the engine up to coolant temperature is 80°C (176°F).
Test-ride the motorcycle and check the 02 sensor with the MCS.
Is the DTC 21-1 indicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. 02 Sensor Short Circuit Inspection

Turn the ignition switch OFF.
Disconnect the 02 sensor 1P {Black) connector
(page 4-36).

[1 J

Check for continuity between the 02 sensor 1P
(Black) connector [1] of the wire harness side and
ground.
Connection: White/green - Ground

WIG

Is there continuity?
YES

- Short circuit in the White/green wire

NO

- GO TO STEP 3.

3. 02 Sensor Line Open Circuit Inspection 1

Disconnect the following:
-

[2]

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Check for continuity between the ECM/PCM 33P
connector [1] and 02 sensor 1P (Black) connector
[2] of the wire harness side.
Connection: White/green - White/green
TOOL:
Test probe, 2 packs

07ZAJ-RDJA110

Is there continuity?

.4-2.4

YES

- GO TO STEP 4.

NO

- Open circuit in the White/green wire

WIG

WIG

PGM-FI SYSTEM
4. 02 Sensor Line Open Circuit Inspection 2
Disconnect the 02 sensor cap (page 4-36).

[1 J

[2]

Check for continuity between the 02 sensor cap [1]
and 02 sensor 1P (Black) connector [2] of the
sensor side.
Connection: Black - Black
Is there continuity?

YES

- GO TO STEP 5.

NO

- Open circuit in the Black wire

Bl

Bl

5. 02 Sensor Inspection
Replace the 02 sensor with a known good one (page 4-36).
Connect the following:

-

02 sensor 1P (Black) connector

-

ECM/PCM 33P connector

Erase the DTCs (page 4-9).
Start the engine and warm up the engine up to coolant temperature is 80°C (176°C).
Test-ride the motorcycle and recheck the 02 sensor with the MCS.
Is the OTC 21-1 indicated?

YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- Faulty original 02 sensor and/or 02 sensor cord

DTC 29-1 (IACV)
NOTE:
• Before starting the inspection, check for loose or poor contact on the IACV 4P (Black) connector and ECM/
PCM 33P connector(s), then recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX?OOD/ND).
1. Recheck DTC
Erase the DTCs (page 4-9).
Turn the ignition switch ON and engine stop switch

"o".

Check the IACV with the MCS.
Is the OTC 29-1 indicated?

YES

- GO TO STEP 2.

NO

- • Intermittent failure
• Loose or poor contact on the IACV 4P (Black) connector

2. IACV Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the IACV 4P (Black) connector
(page 7-20).
Check for continuities between the IACV 4P (Black)
connector [1] of the wire harness side and ground.
Connection: Yellow/green - Ground
Gray/red - Ground
Violet/white - Ground
Pink/black - Ground

Y/G

V/W

Is there continuity?

YES

- • Short circuit in the Yellow/green or
Gray/red or Violet/white or Pink/black
'-------------------_J
wire

NO

- GO TO STEP 3.

4-25

PGM-FI SYSTEM
3. IACV Open Circuit Inspection
Disconnect the following:
-

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Y/G

Gr/R

Check for continuities between the ECM/PCM 33P
connector [1] and IACV 4P (Black) connector [2] of
the wire harness side.

Connection: Yellow/green -Yellow/green
Gray/red - Gray/red
Violet/white - Violet/white
Pink/black - Pink/black
TOOL:
Test probe, 2 packs

P/BI

V/W

07ZAJ-RDJA 110

[1 J

Is there continuity?
YES

- GO TO STEP 4.

NO

- • Open circuit in the Yellow/green or Gray/red wire
• Open circuit in the Violet/white or Pink/black wire

4. IACV Resistance Inspection
Measure the resistance at the IACV 4P (Black)
connector [1] at the motor side.

Connection: A - D

B-C
Standard:

11 O- 150 0 (25°C/77°F)

D

Is the resistance within 110 - 150 D (25°C/77°F)?
YES

- Replace the ECM/PCM with a known good
one, and recheck.

NO

- Faulty IACV

c

[1)

DTC 33-2 (EEPROM)
NOTE:
If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX?OOD/ND).

1. Recheck DTC
Erase the DTCs (page 4-9).
Turn the ignition switch ON and engine stop switch

"o".

Recheck the ECM EEPROM.

Is the DTC 33-2 indicated?

4-26

YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- Intermittent failure

PGM-FI SYSTEM
DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)
NOTE:

If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
1. Recheck DTC

Erase the DTCs (page 4-9).
Turn the ignition switch ON and engine stop switch

"o".

Check the bank angle sensor with the MCS.
Is about O Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Bank Angle Sensor Power Input Line Short Circuit Inspection

Turn the ignition switch OFF.

[1 J

Disconnect the bank angle sensor 2P (Black)
connector (page 4-33).
Check for continuity between the bank angle sensor
2P (Black) connector [1] of the wire harness side
and ground.
Connection: Black - Ground

Bl

Is there continuity?
YES

- GO TO STEP 3.

NO

- Short circuit in the Black wire

3. Bank Angle Sensor Output Line Short Circuit Inspection

Disconnect the following:
-

[1 J

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Check for continuity between the bank angle sensor
2P (Black) connector [1] of the wire harness side
and ground.
Connection: Black/blue - Ground

Bl/Bu

Is there continuity?
YES

- Short circuit in the Black/blue wire

NO

- GO TO STEP 4.

4. Bank Angle Sensor Inspection

Replace the bank angle sensor with a known good one (page 4-33).
Connect the following:
-

Bank angle sensor 2P (Black) connector
ECM/PCM 33P connector

Erase the DTCs (page 4-9).
Turn the ignition switch ON.
Check the bank angle sensor with the MCS.
Is DTC 54-1 indicated?
YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- Faulty original bank angle sensor

4-27

PGM-FI SYSTEM
DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or poor contact on the bank angle sensor 2P (Black)
connector and ECM/PCM 33P connector(s), then recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
1. Recheck DTC

Erase the DTCs (page 4-9).
Turn the ignition switch ON and engine stop switch "O".
Check the bank angle sensor with the MCS.
Is about 5 Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Bank Angle Sensor Power Input Voltage Inspection

Turn the ignition switch OFF.
Disconnect the bank angle sensor 2P (Black)
connector (page 4-33).

[1 J

Turn the ignition switch ON.
Measure the voltage at the bank angle sensor
connector [1] of the wire harness side and ground.
Connection: Black(+) - Ground (-)
Standard:
Battery voltage

Bl

Does the standard voltage exist?
YES

- GO TO STEP 3.

NO

- Open circuit in the Black wire

3. Bank Angle Sensor Output Line Short Circuit Inspection

Turn the ignition switch OFF.

[1]

Disconnect the following:
-

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Bl/Bu

Check for continuity between the bank angle sensor
2P (Black) connector [1] of the wire harness side
and ground.
Connection: Blacklblue - Ground
Is there continuity?
YES

- Short circuit in the Black/blue wire

NO

- GO TO STEP 4.

4. Bank Angle Sensor Output Line Open Circuit Inspection

Check for continuity between the ECM/PCM 33P
connector [1] and bank angle sensor 2P (Black)
connector [2] of the wire harness side.
Connection: Blackfblue - Blacklblue
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

Is there continuity?

A .. ?R

• Inspect the bank angle sensor
(page 4-34).
• Replace the ECM/PCM with a known
good one, and recheck.

YES

-

NO

- Open circuit in the Black/blue wire

[1 J

Bl/Bu
Bl/Bu

PGM-FI SYSTEM
DTC 84-1 (CPU IN THE PCM MALFUNCTION) (CTX700D/ND)
NOTE:
If the PCM is replaced, perform the Clutch Initialize Learning Procedure (CTX700D/ND) (page 12-81 ).

1. DTC Recheck
Erase the DTCs (page 4-9).
Check the OTC with the MCS.

Is DTC 84-1 indicated?
YES

- Replace the PCM with a known good one, and recheck.

NO

- Intermittent failure

DTC 86-1 (METER COMMUNICATION MALFUNCTION)
NOTE:
• Before starting the inspection, check for loose or poor contact on the combination meter 16P (Gray)
connector and ECM/PCM 33P connector(s), then recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).

1. Recheck DTC
Erase the DTCs (page 4-9).
Turn the ignition switch ON and engine stop switch "O".
Check the meter communication with the MCS.

Is the DTC 86-1 indicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Combination Meter Serial Line Short Circuit Inspection
Turn the ignition switch OFF.

[1)

Disconnect the following:
-

-

Combination meter 16P (Gray) connector
- CTX700/A/D (page 2-6)
- CTX700N/NA/ND (page 22-7)
ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

R/Bu

Check for continuity between the combination meter
16P (Gray) connector [1] of the wire harness side
and ground.

Connection: Red/blue - Ground
Is there continuity?
YES

- Short circuit in the Red/blue wire

NO

- GO TO STEP 3.

3. Combination Meter Serial Line Open Circuit Inspection
Turn the ignition switch OFF.

[1]

[2]

Check for continuity between the combination meter
16P (Gray) connector [1] and ECM/PCM 33P
connector [2] of the wire harness side.

Connection: Red/blue - Red/blue
TOOL:
Test probe, 2 packs

R/Bu

07ZAJ-RDJA 110

Is there continuity?
YES

- GO TO STEP 4.

NO

- Open circuit in the Red/blue wire

R/Bu

-------- Q - 4-29

PGM-FI SYSTEM
4. Combination Meter Serial Line Output Voltage Inspection
Turn the ignition switch OFF.
Connect the
connector.

combination

meter

16P

(Gray)

Turn the ignition switch ON while pushing and
holding combination meter A button.[1] and B button
[2] over 10 seconds.
The combination meter enters the communication
diagnostic mode.

[1 J
Measure the voltage at the ECM/PCM 33P
connector [1] of the wire harness side and ground.
Connection: Red/blue(+) - Ground (-)
Standard:
8 V or more (Every 5 seconds)

TOOL:
Test probe, 2 packs

[1 J

07ZAJ·RDJA 110

Does the standard voltage exist?

YES

- GO TO STEP 5.

NO

- Inspect the combination meter
(page 22-7).

5. ECM Serial Line Output Voltage Inspection
Turn the ignition switch OFF.
Disconnect the combination meter 16P (Gray)
connector.
Connect the ECM/PCM 33P connector.
Remove the DLC [1] from the battery box.
Remove the dummy connector from the DLC.
Short the DLC terminals using a special tool.
Connection: Brown - Green

TOOL:
[2] SCS service connector

[2]

070PZ·ZY30100

Rotate and hold the throttle grip [1] to the fully open
position.
Turn the ignition switch ON while holding the throttle
grip at the fully open position over 10 seconds.
The ECM enters the communication diagnostic
mode.

R/Bu

PGM-FI SYSTEM
Measure the voltage at the combination meter 16P
(Gray) connector [1] of the wire harness side and
ground.
Connection: Red/blue(+) - Ground (-)
Standard:
8 V or more (Every 5 seconds)

[1]

Does the standard voltage exist?

R/Bu

YES

- Inspect the combination meter
(page 22-7).

NO

- Replace the ECM/PCM with a known good
one, and recheck.

DTC 87-1 (EOP SWITCH MALFUNCTION)
NOTE:
• Before starting the inspection, check for loose or poor contact on the combination meter 16P (Gray)
connector, EOP switch 1P (Gray) connector and ECM/PCM 33P connector(s), then recheck the DTC.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
1. EOP Switch System Inspection

Erase the DTCs (page 4-9).
Turn the ignition switch ON and engine stop switch

"o".

Check the EOP switch with the MCS.
Is the DTC 87-1 indicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. EOP Switch Output Line Open Circuit Inspection

Turn the ignition switch OFF.

[1]

[2]

Disconnect the following:
-

EOP switch 1P (Gray) connector (page 22-14)
ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Lg

Check for continuity between the EOP switch 1P
(Gray) connector [1] and ECM/PCM 33P connector
[2) of the wire harness side.
Connection: Light green - Light green
TOOL:
Test probe, 2 packs

Lg

07ZAJ-RDJA110

Is there continuity?
YES

- GO TO STEP 3.

NO

- Open circuit in the Light green wire

3. EOP Switch Inspection

Replace the EOP switch with a known good one.
Connect the following:
-

EOP switch 1P (Gray) connector
ECM/PCM 33P connector

Erase the DTCs (page 4-9).
Turn the ignition switch ON and check the EOP switch with the MCS ..
Is the DTC 87-1 indicated?
YES

- Replace the ECM/PCM with a known good one, and recheck.

NO

- Faulty original EOP switch

4-31

PGM-FI SYSTEM

MIL CIRCUIT TROUBLESHOOTING
NOTE:
If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).

Check that the MIL comes on for 2 seconds and goes
off when the ignition switch is turned ON and engine
stop switch "o".
If the MIL does not come on at all, inspect the
combination meter (page 22-7).
CTX700/AININA:

If the MIL [1] and engine oil pressure indicator [2] are
stay on, and the tachometer, high coolant temperature
indicator do not come on, inspect the serial
communication line (page 22-8).

CTX700DIND:

If the MIL [1] and engine oil pressure indicator [2] stay
on, the shift indicator "-" [3] is blinking, and the
tachometer, high coolant temperature indicator do not
come on, inspect the serial communication line
(page 22-8).
If the MIL stays on, check as follows:
Turn the ignition switch OFF.
Disconnect the following:
ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
- PCM 33P (Gray) connector (page 4-34)
· (CTX700D/ND)

-

Check for continuity between the ECM/PCM 33P
connector [1] of the wire harness side and ground.
CONNECTION: Brown - Ground
No continuity
STANDARD:
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

If there is continuity, check for short circuit in the Brown wire between the DLC and ECM/PCM.
If there is no continuity, replace the ECM/PCM with a known good one, and recheck.

IAT SENSOR
REMOVAL/INSTALLATION
Remove the center shelter (page 2-12).
Disconnect the IAT sensor 2P (Black) connector [1] and
remove the IAT sensor [2].
Installation is in the reverse order of removal.

[3]

[1]

PGM-FI SYSTEM

ECT SENSOR
REMOVAL/INSTALLATION
Drain the coolant (page 8-4 ).
Remove the ECT
sensor while the
engine is cold.

Disconnect the ECT sensor 2P (Black) connector [1].
Remove the ECT sensor [2] and 0-ring [3].
Install a new 0-ring onto the ECT sensor and install
them.
Tighten the ECT sensor to the specified torque.
TORQUE:12 N·m (1.2 kgf·m, 9 lbHt)

Connect the ECT sensor 2P (Black) connector.
Fill the cooling system with recommended coolant
(page 8-4).

BANK ANGLE SENSOR
REMOVAL/INSTALLA Tl ON
Remove the left side shelter (page 2-11 ).
Disconnect the bank angle sensor 2P (Black) connector
[1] and release it from the center cross plate.

Release the wire band boss [1].
Remove the two bolts [2] and bank angle sensor
assembly [3].

Remove the two socket bolts [1], collars [2] and bank r - - - - - - - - - - - - - - - - [5]
angle sensor [3] from the stay [4].
[3]
Installation is in the reverse order of removal.
• Install the bank angle sensor with its "UP" mark [5]
facing up.

[2]

v

[1]

\

[4]

4-33

PGM-FI SYSTEM
SYSTEM INSPECTION
Connect the MCS (page 4-8).
Remove the bank angle sensor (page 4-33).

42.5° BANK ANGLE POSITION

~

Connect the bank angle sensor 2P (Black) connector.
Place the bank angle sensor is horizontal as shown.
Turn the ignition switch ON and engine stop switch "O".
Read the voltage with the MCS.

STANDARD: 3.5 - 3.8 V
Incline the bank angle sensor approximately 42.5° to
the left or right with keeping the ignition switch ON.
Read the voltage with MCS.
1

STANDARD: 6.7-7.2V

~

~

-----Li':'-'.
approximately 42.5°

HORIZONTAL

ii!J

approximately 42.5°

ECM/PCM
ECM REMOVAL/INSTALLATION
(CTX700/A/N/NA)
Remove the seat (page 2-14).
Turn the ignition switch OFF.
Release the band [1] and remove the ECM [2] from the
battery box.
Disconnect the ECM 33P (Black) connector [3].
Installation is in the reverse order of removal.

PCM REMOVAL/INSTALLATION
(CTX700D/ND)
Remove the seat (page 2-14).
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector [1] and
PCM 33P (Gray) connector [2].
Release the band [3] and remove the PCM [4] from the
battery box.
Installation is in the reverse order of removal.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

A.:~A

PGM-FI SYSTEM
ECM/PCM POWER/GROUND LINE INSPECTION
NOTE:
• Before starting the inspection, check for loose or poor contact on the ECM/PCM 33P connector and recheck
the MIL blinking.
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX7000/ND).
ENGINE DOES NOT START (MIL does not blink)
1. ECM/PCM Power Input Voltage Inspection
Disconnect the following:
-

[1]

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX700D/ND)

Turn the ignition switch ON and engine stop switch

"o".

Bl

Measure the voltage at the ECM/PCM 33P
connector [1] of the wire harness side and ground.
Connection: Black(+)- Ground (-)
Standard:
Battery voltage
TOOL:
Test probe, 2 packs

07ZAJ·RDJA110

Does the standard voltage exist?

YES

- GO TO STEP 2.

NO

- •
•
•
•
•

Open or short circuit in the Black wire
Faulty ignition switch
Blown main fuse 30 A
Blown sub fuse 7.5 A (ENG STOP)
Faulty engine stop switch

2. ECM/PCM Ground Line Inspection

Turn the ignition switch OFF.

[1 J

Check for continuities between the ECM/PCM 33P
connector [1] of the wire harness side and ground.
Connection: Green/orange - Ground
Green - Ground
TOOL:
Test probe, 2 packs

07ZAJ-RDJA110

Is there continuity?

YES

- Replace the ECM/PCM with a known good
one, and recheck.

NO

- • Open circuit in the Green/orange wire
• Open circuit in the Green wire

4-35

PGM-FI SYSTEM

02 SENSOR

I

NOTICE

• Do not get grease, oil or other materials in the 02 sensor air hole.
• The 02 sensor may be damaged if dropped. Replace it with a new one, if dropped.
NOTE:

• Handle the 02 sensor with care.
• Do not service the 02 sensor while it is hot.

REMOVAL/INSTALLATION
Remove the radiator reserve tank (page 8-11 ).
Disconnect the 02 sensor 1P (Black) connector [1].
Disconnect the cap [2] from the sensor while slightly
turning it, less than 1/2 of a turn.

Remove the 02 sensor [1].

I NOTICE I
Do not use an impact wrench while removing or
installing the 02 sensor, or it may be damaged.
Install and hand tighten the 02 sensor [1].
Tighten the 02 sensor to the specified torque.
TORQUE: 24.5 N·m (2.5 kgf·m, 18 lbHt)

Connect the 02 sensor cap [1] to the 02 sensor by
pushing it straight.
Connect the 02 sensor 1P (Black) connector [2].

I

NOTICE

I

• Take care not to tilt the 02 sensor cap when
connecting the cap to the 02 sensor.
• Do not tum the 02 sensor cap, after connecting it.
Install the radiator reserve tank (page 8-11 ).

4-36

5. IGNITION SYSTEM

SYSTEM LOCATION·· ................................... 5.2

IGNITION SYSTEM INSPECTION ................ 5-6

SYSTEM DIAGRAM ...................................... 5.3

IGNITION TIMING ......................................... 5-8

SERVICE INFORMATION ............................. 5.4

IGNITION COIL ........................ :.................... 5-8

TROUBLESHOOTING···· ............................... 5.5

CKP SENSOR ............................................... 5-9

5-1

IGNITION SYSTEM

SYSTEM LOCATION
CTX700/A/N/NA:
IGNITION COILS

ENGINE STOP SWITCH

BANK ANGLE SENSOR

IGNITION SWITCH
MAIN FUSE 30 A

CLUTCH SWITCH

FUSE BOX
- FUEL CUT RELAY
- NEUTRAL DIODE
NEUTRAL SWITCH

SIDESTAND SWITCH

CKP SENSOR

CTX700D/ND:
IGNITION COILS

ENGINE STOP SWITCH

BANK ANGLE SENSOR

MAIN FUSE 30 A
IGNITION SWITCH

FUSE BOX
- FUEL CUT RELAY
NEUTRAL SWITCH

SIDESTAND SWITCH

CKP SENSOR

IGNITION SYSTEM

SYSTEM DIAGRAM
CTX700/A/N/NA:

nl
l_ _i
-

8

ECM
~ERi~~
30 A

SWITCH

I
Br/Bl

Bl/Bu

BI/W

~

SP
(BLUE)

00--w!Y

Bl

Y/Bu
Bu/Y

y

G!W

I

G/R

G

W/Y

'-----BIIR

y

W/Y

)___j, CKP
~SENSOR

1----81

0

Bl

~-----<o-----Br
FUEL CUT RELAY
Br

G(O

~2P(RED)

ENG STOP
7.5A

ENGINE STOP
SWITCH

Bl: Black
Br: Brown
Bu: Blue
G: Green
Lg: Light green
0: Orange
R: Red
W: White
Y: Yellow

15 A

R/81

(B

BATTERY

I

INDICATOR

Br
Bu/Y

Y/Bu

A

~

NEUTRAL
DIODE

SI DESTAND SWITCH

DG

W

No 2.
IGNITION
COIL

No 1.
IGNITION
COIL
SPARK A
PLUG ~

To NEUTRAL

R/W

14P
(GRAY)....____,
Bl
Bl

Q

NEUTRAL
SWITCH

vJ

BANKANGLEl
SENSOR
-::-

SPARK
PLUG

Lg

CLUTCH
SWITCH

CTX700D/ND:

[J

I

PCM

~R~i--.-a...,o-~
Bl MAIN FUSE IGNITION
Fl
30 A
SWITCH
15 A
R/BI

-'----'-L.,

8

0o-w!Y

BI/W

I

f:LUE)

Br/Bl

Bl/Bu
Bl

Y/Bu
Bu/Y

y

G!W
G

ENGINE STOP
SWITCH

~

SENSOR

Br
Y/Bu

SPARK_!_
PLUG -:c-

W/Y

0

Bl
FUEL CUT RELAY

No 1.
IGNITION
COIL

-

QcKP

~----Br

Br

Gro

2P(RED)

y

1 - - - - Bl

'-----81/R

I

Lg

W/Y~
ENG STOP
7.5A

No 2.
IGNITION
COIL
_!_ SPARK
-:c- PLUG

w

DG1
R!W

BANK
ANGLE
SENSOR

_

SI DESTAND
SWITCH

OLg
NEUTRAL
SWITCH

Bl: Black
Br: Brown
Bu: Blue
G: Green
Lg: Light green
0: Orange
R: Red
W: White
Y: Yellow

5-3

IGNITION SYSTEM

SERVICE INFORMATION
GENERAL

NOTICE
• The ECMIPCM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive
voltage may damage the module. Always turn off the ignition switch before servicing.
• Use spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
• When servicing the ignition system, always follow the steps in the troubleshooting table (page 5-5).
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is turned to ON position and current is present.
• A faulty ignition system is often related to poorly connected or corroded connections. Check those connections before
proceeding.
• Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking
speed as well as no spark at the spark plug.
• For ECM/PCM service (page 4-34).
• Refer to following components informations:
- Ignition switch (page 22-17)
- Engine stop switch (page 22-18)
- Bank angle sensor (page 4-33)
- Sidestand switch (page 22-21)
- Neutral switch (page 22-20)
- Fuel cut relay (page 7-21)
• The following color codes are used throughout this section.
Bl= Black
Br= Brown

Bu= Blue
G = Green

Lg = Light green

0 = Orange

R= Red
W = White

Y = Yellow

TOOLS
lgnitionMate peak voltage tester
MTP07-0286 (U.S.A. only)

Peak voltage adaptor
07HGJ-0020100

(Not available in U.S.A.) with
commercially available digital
multimeter (impedance 1O MQ/DCV
minimum)

5-4

Test probe, 2 packs
07ZAJ-RDJA 110

IGNITION SYSTEM

TROUBLESHOOTING
• Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Water got into the spark plug cap (Leaking the ignition coil secondary voltage)
• If there is no spark at cylinder, temporarily exchange the ignition coil with a known-good one and perform the spark test. If there
is spark, the original ignition coil is faulty.
• "Initial voltage" of the ignition primary coil is the battery voltage with the ignition switch turned ON and engine stop switch "O"
(The engine is not cranked by the starter motor).
No spark at spark plug
Ignition coil
primary voltage

Unusual condition
No initial voltage with the ignition
switch turned ON and engine
stop switch "O" (Other electrical
components are normal).

1.
2.
3.
4.

5.
6.
Initial voltage is normal, but it
drops by 2 - 4 V while cranking
the engine.

1.

2.
3.
4.

5.
6.
7.

8.

9.
Initial voltage is normal but there
is no peak voltage while cranking
the engine.

1.
2.
3.
4.

Initial voltage is normal but peak
voltage is lower than the
standard value.

1.
2.
3.
4.

Initial and peak voltages are
normal but no spark jumps.
CKP sensor

Peak voltage is lower than
standard value.

1.
2.
1.
2.
3.

4.
No peak voltage

1.
2.

Probable cause (Check in numerical order)
Faulty ignition switch
Faulty engine stop switch
Faulty fuel cut relay or its related circuits
An open circuit in Brown wire between the ignition coil and fuel
cut relay
Loose or poor connection of the primary terminal, or an open
circuit in the primary coil
Faulty ECM/PCM (in case when the initial voltage is normal with
the ECM/PCM connector disconnected).
Incorrect peak voltage adaptor connections (System is normal if
measured voltage is over the specifications with reverse
connections).
Battery is undercharged (Voltage drops largely when the engine
is started).
No voltage between the Black (+)wire and body ground (-) at the
ECM/PCM connector or loosen ECM/PCM connection
An open circuit or loose connection in Green and Green/orange
wire at the ECM/PCM
An open circuit or loose connection in Blue/yellow or Yellow/blue
wire between the ignition coil and ECM/PCM
Faulty sidestand switch, neutral diode (CTX700/A/N/NA) or
neutral switch
Loose or poor connection or an open circuit in No. 6 related wires
- Sidestand switch line: Green/white and Green
- Neutral switch line (CTX700/A/N/NA): Green/red and Light
green
- Neutral switch line (CTX700D/ND): Light green
Faulty CKP sensor (Measure peak voltage)
Faulty ECM/PCM (in case when above No. 1 through 8 are
normal).
Incorrect peak voltage adaptor connections
Faulty peak voltage adaptor
Faulty CKP sensor
Faulty ECM/PCM (in case when above No. 1 through 3 are
normal).
The multimeter impedance is too low; below 10 MO/DCV.
Cranking speed is too slow (Battery is undercharged).
The sampling timing of the tester and measured pulse were not
synchronized (System is normal if measured voltage is over the
standard voltage at least once).
Faulty ECM/PCM (in case when above No. 1 through 3 are
normal).
Faulty spark plug or leaking ignition coil secondary current
ampere
Faulty ignition coil
The multimeter impedance is too low; below 10 MO/DCV.
Cranking speed is too low. (Battery is undercharged.)
The sampling timing of the tester and measured pulse were not
synchronized (System is normal if measured voltage is over the
standard voltage at least once).
Faulty CKP sensor (in case when above No.1 through 3 are
normal).
Faulty peak voltage adapter
Faulty CKP sensor

5-5

IGNITION SYSTEM

IGNITION SYSTEM INSPECTION
NOTE:
• If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak
voltage.
• Use a commercially available digital multimeter with an impedance of 10 MO/DCV minimum.
• The display value differs depending upon the internal impedance of the multimeter.
• If the peak voltage tester (U.S.A. only) is used, follow the manufacturer's instructions.
Connect the peak voltage adaptor [1] to the digital
multimeter [2], or use the peak voltage tester.

.....····.,.

[2)

TOOLS:
lgnitionMate peak voltage tester MTP07-0286
(U.S.A. only) or
Peak voltage adaptor
07HGJ-0020100
(Not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 M!l/DCV minimum)

[1 J

IGNITION COIL PRIMARY PEAK VOLTAGE
NOTE:
• Check all system connections before performing this inspection. Loose connectors can cause incorrect
readings.
• If the system is disconnected, incorrect peak voltage might be measured.
• Check the cylinder compression and check that the spark plug is installed correctly in the cylinder head.
Disconnect the spark plug caps (page 3-6).
Connect a known good spark plug [1] to the spark plug
cap and ground it to the cylinder head as done in a
spark test.

5-6

IGNITION SYSTEM
Remove the side shelters (page 2-11 ).
Do not disconnect
the ignition coil
primary wire.

With the ignition coil primary wire connected, connect
the peak voltage tester (U.S.A. only) or peak voltage
adaptor probes to the ignition coil primary terminal [1]
and ground.

TOOLS:
lgnitionMate peak voltage tester MTP07-0286
(U.S.A. only) or
Peak voltage adaptor
07HGJ-0020100
(Not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 MO/DCV minimum)
CONNECTION:
No.1: Blue/yellow(+) - Ground (-)
No.2: Yellow/blue(+)- Ground(-)
Turn the ignition switch ON and engine stop switch

"o".

Check the initial voltage at this time.
The battery voltage should be measured.
If the initial voltage cannot be measured, follow the checks described in the troubleshooting table
(page 5-5).
Shift the transmission into neutral.
A void touching the
spark plug and
tester probes to
prevent electric
shock.

Crank the engine with the starter motor and measure the ignition coil primary peak voltage.

PEAK VOLTAGE: 100 V minimum
If the peak voltage is abnormal, follow the checks described in the troubleshooting table (page 5-5).
Install the side shelters (page 2-11 ).

CKP SENSOR PEAK VOLTAGE
NOTE:
Check the cylinder compression and check that the spark plugs are installed correctly in the cylinder head.

Disconnect the following:
-

[2]

ECM 33P (Black) connector (page 4-34)
(CTX700/A/N/NA)
PCM 33P (Gray) connector (page 4-34)
(CTX?OOD/ND)

Connect the peak voltage tester (U.S.A. only) or peak
voltage adaptor probes to the ECM/PCM 33P connector
[1] terminals of the wire harness side.

TOOLS:
lgnitionMate peak voltage tester MTP07-0286
(U.S.A. only) or
[2] Peak voltage adaptor
O?HGJ-0020100
(Not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 MO/DCV minimum)
Test probe, 2 packs
07ZAJ-RDJA110

[1]

~------------------'

CONNECTION: Yellow(+) - Green/orange (-)
Shift the transmission into neutral.
Turn the ignition switch ON and engine stop switch

"o".

Crank the engine with the starter motor and measure the CKP sensor peak voltage.

PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at the ECM/PCM 33P connector is abnormal, measure the peak voltage at the
CKP sensor connector.

5-7

IGNITION SYSTEM
Turn the ignition switch OFF.
Disconnect the CKP sensor 2P (Red) connector [1] and
connect the tester probes to the connector terminals of
the CKP sensor side.
CONNECTION: Yellow (+)-White/yellow(-)
In the same manner as at the ECM/PCM 33P
connector, measure the peak voltage and compare it to
the voltage measured at the ECM/PCM 33P connector.
-

-

If the peak voltage measured at the ECM is
abnormal and the one measured at the CKP sensor
is normal, the wire harness has an open or short
circuit or loose connection.
If the peak voltage of the CKP sensor side is lower
than standard value, follow the checks described in
the troubleshooting table (page 5-5).

For CKP sensor replacement (page 5-9).
Install the removed parts in the reverse order of removal.

IGNITION TIMING
Warm up the engine.
Stop the engine and remove the timing hole cap.
Connect the timing light [1] to the spark plug wire.
• Read the instructions for timing light operation.
Start the engine and let it idle.
IDLE SPEED: 1,200 ± 100 rpm
The ignition timing is correct if the "F" mark [2] on the
flywheel aligns with the index notch [3] on the alternator
cover.
Apply engine oil to a new 0-ring and install it to the
timing hole cap.
Apply grease to the timing hole cap threads.
Install and tighten the timing hole cap to the specified
torque.
TORQUE:10 N·m (1.0 kgf·m, 7 lbHt)

IGNITION COIL
REMOVAL/INSTALLATION
No.1 IGNITION COIL
Remove the left side shelter (page 2-11 ).
Disconnect the spark plug cap [1].
Release the wire band [2] from the frame pipe.
Release the spark plug wire [3] from the two clamps [4].
Release the clamp [5] from the frame tab.

[2]

[3]

IGNITION SYSTEM
Release the wire band boss [1].
Disconnect the primary wire (Brown) connector [2] and
wire (Blue/yellow) connector [3].
Remove the bolts [4], spacers (5] and ignition coil [6]
from the ignition coil stay.
Installation is in the reverse order of removal.

No.2 IGNITION COIL

Remove the right side shelter (page 2-11 ).
Disconnect the spark plug cap [1].
Release the two clamps [2] from the frame tab.

Release the wire band boss [1].
Disconnect the primary wire (Brown) connector [2] and
wire (Yellow/blue) connector (3].
Remove the bolts (4], spacers [5] and ignition coil [6]
from the ignition coil stay.
Installation is in the reverse order of removal.

CKP SENSOR
REMOVAL/INSTALLATION
(CTX700/A/N/NA)
Remove the right crankcase cover (page 11-4).
Remove the wire grommet [1] from the right crankcase
cover.
Remove the CKP sensor mounting bolts [2] and CKP
sensor [3].
Installation is in the reverse order of removal.
• Apply locking agent to the CKP sensor mounting
bolts threads (page 1-19).
• Apply liquid sealant (Three bond 12078 or
equivalent) to the CKP sensor wire grommet sealing
surface.

5-9

IGNITION SYSTEM
REMOVAL/INSTALLATION
(CTX700D/ND)
Remove the right crankcase cover (page 12-57).
Remove the right crankcase cover wire clamp bolts [1]
and wire clamp [2].

Remove the wire grommet [1] from the right crankcase
cover.
Remove the CKP sensor mounting bolts [2] and CKP
sensor [3].
Installation is in the reverse order of removal.
• Apply locking agent to the CKP sensor mounting bolt
threads (page 1-19).
• Apply locking agent to the right crankcase cover wire
clamp bolt threads (page 1-13).
• Apply sealant to the wire grommet seating surface
and grommet mating surface.
TORQUE:
Right crankcase cover wire clamp bolt:
12 N·m (1.2 kgf·m, 9 lbHt)

6. ELECTRIC STARTER

SYSTEM LOCATION·········· ........................... 6-2

STARTER MOTOR ....................................... 6-8

SYSTEM DIAGRAM ...................................... 6-3

STARTER RELAY SWITCH ....................... 6-10

SERVICE INFORMATION ............................. 6-4

NEUTRAL DIODE (CTX700/A/N/NA) ......... 6-11

TROUBLESHOOTING········· .......................... 6-5

STARTER RELAY (CTX700D/ND) ............. 6-12

•

6-1

ELECTRIC STARTER

SYSTEM LOCATION
CTX700/A/N/NA:
ENGINE STOP SWITCH

STARTER SWITCH

STARTER RELAY SWITCH/
MAIN FUSE 30 A

IGNITION SWITCH

ECM

CLUTCH SWITCH

BATTERY
STARTER MOTOR

NEUTRAL SWITCH

SI DESTAND SWITCH

FUSE BOX
- NEUTRAL DIODE

CTX700D/ND:
ENGINE STOP SWITCH

ST ARTER SWITCH

STARTER RELAY SWITCH/
MAIN FUSE 30 A

IGNITION SWITCH

PCM

BATTERY
STARTER MOTOR

NEUTRAL SWITCH

FUSE BOX
- STARTER RELAY

ELECTRIC STARTER

SYSTEM DIAGRAM
CTX700/A/N/NA:

Bl

Bl

Bl

Bl

STARTER
MOTOR

STARTER RELAY SWITCH

BATTERY

MAIN FUSE
30A

R

G/R

IGNITION
SWITCH

~>--~

CLUTCH
SWITCH

14P
(GRAY)

Y/R

L::=rrrG/R

~

~

ENG STOP
7.5 A

NEUTRAL
DIODE

G/W

I

O-BI/R-o~ W / Y
STARTER
ENGINE STOP ,
SWITCH
SWITCH

R/BI

T

From NEUTRAL
INDICATOR

~

~

Bl: Black
G: Green
Lg: Light green
R: Red
Y: Yellow
W:White

NEUTRAL
SWITCH

CTX700D/ND:

Bl

Bl

Bl

Bl

STARTER RELAY SWITCH

Bl: Black
G: Green
R: Red
V: Violet
W: White
Y: Yellow

BATTERY

Y/R

G/R

R

L
~

STARTER
SWITCH

~

BI/R - 0
ENGINE STOP
SWITCH

~

0 - - - R/BI

IGNITION
SWITCH

W/Y ---a.....,""o-----_.
ENG STOP
7.5A

------G
To PCM

' ! - - - - - - - - - - BI/W - - - - - - - - - C i . / ' 0 - - - - - _ J

STARTER
RELAY

Fl
15A

6-3

ELECTRIC STARTER

SERVICE INFORMATION
GENERAL

I NOTICE
If the current is kept flowing through the starter motor causing it to tum while the engine is not cranking over, the starter motor may
be damaged.
•
•
•
•
•

The starter motor can be serviced with the engine installed in the frame.
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
When servicing the starter system, always follow the steps in the troubleshooting flow chart (page 6-5).
Refer to the following components information:
- Ignition switch (page 22-17)
- Starter switch (page 22-18)
- Engine stop switch (page 22-18)
- Neutral switch (CTX700/A/N/NA) (page 22-20)
- Sidestand switch (CTX700/A/N/NA) (page 22-21)
- Clutch switch (CTX700/A/N/NA) (page 22-19)

ELECTRIC STARTER

TROUBLESHOOTING
Starter motor does not turn (CTX700/A/N/NA)
1. Fuse Inspection
Check for blown main fuse 30 A or sub fuse 7.5 A (ENG STOP).
Is the fuse blown?
YES

- Replace the fuse.

NO

- GO TO STEP 2.

2. Battery Inspection
Make sure the battery is fully charged and in good condition (page 21-5).
Is the battery in good condition?
YES

- GO TO STEP 3.

NO

- Charge or replace the battery.

3. Starter Relay Switch Operation
Check the starter relay switch operation.
You should hear the relay "CLICK" when the starter switch button is depressed.
Is there a "CLICK"?
YES

- GO TO STEP 4.

NO

- GO TO STEP 5.

4. Starter Motor Inspection
Apply battery voltage directly to the starter motor and check the operation.
Does the starter motor turn?
YES

- • Poorly contacted starter motor cable
• Faulty starter relay switch (page 6-10)

NO

- Faulty starter motor (page 6-8)

5. Relay Coil Ground Lines Inspection
Disconnect the starter relay switch connector, and check the relay coil ground wire line as below for
continuity:
1. Green/red terminal - neutral diode - neutral switch line (with the transmission in neutral and clutch lever
released).
2. Green/red terminal - clutch switch - sidestand switch (in any gear except neutral, and with the clutch
lever pulled in and sidestand up.)
Is there continuity?
YES
NO

- GO TO STEP 6.
•
•
•
•
•
•

Loose or poor contact connector
Open circuit in wire harness
Faulty neutral diode (page 6-11)
Faulty neutral switch (page 22-20)
Faulty sidestand switch (page 22-21)
Faulty clutch switch (page 22-19)

6. Starter Relay Input Voltage Inspection
Connect the starter relay switch connector.
With the ignition switch turned ON and engine stop switch "O" and the starter switch is pushed, measure the
voltage at the starter relay switch connector (between Yellow/red(+) and ground(-)).
Does the battery voltage exist?
YES
NO

- GO TO STEP 7.
•
•
•
•
•

Faulty ignition switch (page 22-17)
Faulty starter switch (page 22-18)
Faulty engine stop switch (page 22-18)
Loose or poor contact connector
Open circuit in wire harness

6-5

ELECTRIC STARTER
7. Starter Relay Switch Continuity Inspection

Remove and check the operation of the starter relay switch (page 6-11 ).
Is there continuity?
YES

- Loose or poor contact starter relay switch connector

NO

- Faulty starter relay switch

Starter motor does not turn (CTX700D/ND)
1. Fuse Inspection

Check for blown main fuse (30 A), ENG STOP fuse (7.5 A) and Fl fuse (15 A).
Are the fuses in good condition?
YES

- GO TO STEP 2.

NO

- Replace the blown fuse.

2. Battery Inspection
Make sure the battery is fully charged and in good condition (page 21-5).
Is the battery in good condition?
YES

- GO TO STEP 3.

NO

- Charge or replace the battery.

3. Starter Relay Switch Operation Inspection
Check the starter relay switch operation (page 6-10).
Does the starter relay switch click?
YES

- GO TO STEP 4.

NO

- GO TO STEP 5.

4. Starter Motor Inspection
Turn the ignition switch OFF.
Apply battery voltage directly to the starter motor and check the operation.
Does the starter motor turn?
• Poorly contacted battery positive cable or starter motor cable
• Faulty starter relay switch

YES

-

NO

- Faulty starter motor (page 6-8)

5. Relay Coil Input Line Inspection

Check the relay coil input line of the starter relay switch (page 6-10).
Is the input line normal?
YES

- GO TO STEP 6.

NO

-

•
•
•
•
•

Faulty ignition switch (page 22-17)
Faulty starter switch (page 22-18)
Faulty engine stop switch (page 22-18)
Loose or poor connected connector
Open circuit in the wire harness

6. Relay Coil Ground Line Inspection

Check the relay coil ground line of the starter relay switch (page 6-10).
Is the ground line normal?
YES

- GO TO STEP 7.

NO

- GO TO STEP 8.

7. Starter Relay Switch Continuity Inspection
Check the starter relay switch (page 6-11 ).
Is there continuity?
YES

- Loose or poor contact starter relay switch connector

NO

- Faulty starter relay switch

ELECTRIC STARTER
8. Starter Relay Inspection

Check the starter relay (page 6-12).
Is the starter relay normal?
Loose or poor connected connector
Open circuit in the wire harness
Faulty neutral switch or its circuit
Faulty PCM

YES

- •
•
•
•

NO

- Faulty starter relay

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. (CTX700/A/N/NA)
1. Clutch Switch Inspection

Check the clutch switch operation (page 22-19).
Is the clutch switch operation normal?
YES

- GO TO STEP 2.

NO

- Faulty clutch switch

2. Sidestand Switch Inspection

Check the sidestand switch operation (page 22-21 ).
Is the sidestand switch operation normal?
• Loose or poor contact connector
• Open circuit in wire harness

YES

-

NO

- Faulty sidestand switch

Starter motor turns slowly
• Low battery voltage
• Poorly connected battery terminal cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected battery ground cable
Starter motor turns, but engine does not turn
• Starter motor is running backwards
- Case assembled improperly
- Terminals connected improperly
• Faulty starter clutch
• Damaged or faulty starter reduction gear/shaft
• Damaged or faulty starter idle gear/shaft
Starter relay switch "Clicks", but engine does not turn over
• Crankshaft does not turn due to engine problems

6-7

ELECTRIC STARTER

STARTER MOTOR
REMOVAL/INSTALLATION
Disconnect the battery negative cable (page 21-5).
Release the rubber cap [1].
Remove the starter motor terminal nut [2] and starter
motor cable [3].
Remove the stater motor mounting bolts [4] and ground
cable [5].
Remove the starter motor [6].

Remove the 0-ring [1].
Installation is in the reverse order of removal.
• Apply engine oil to a new 0-ring.

TORQUE:
Starter motor terminal nut:
10 N·m (1.0 kgf·m, 7 lbf·ft)

r11

lii1S~

711

DISASSEMBLY/ASSEMBLY
MOTOR CASE

1lt

1lt

SEAL RING

SEAL RING

FRONT COVER

~711

S

BOLTS

. !iilO-RING

~

~oo
INSULATOR
TERMINAL STOPPER

ARMATURE

POSITIVE BRUSHES
TERMINAL BOLT

ELECTRIC STARTER
INSPECTION
FRONT COVER

Check the oil seal [1) in the front cover for deterioration,
wear or damage.

[1]

Turn the inner race of bearing [2) in the front cover with
your finger.
The bearings should turn smoothly and quietly.
Also check that the outer race fits tightly in the front
cover.
Replace the starter motor as an assembly if necessary.

[2]

REAR COVER

Inspect the brushes for damage and measure the brush
length.

[3]

[2]

[1]

SERVICE LIMIT: 6.5 mm (0.26 in)

Check for continuity or no continuity for each part of
rear cover [1] as below:
-

Between the positive brush [2] and cable terminal
[3]: should be continuity.
Between the cable terminal and the rear cover:
should be No continuity.
Between the positive brush and rear cover: should
be No continuity.
Between positive brush and negative brush [4]:
should be No continuity.

ARMATURE
Clean the metallic debris off between commutator bars r - - - - - - - - - - - - - - - - - - - ,
[1 ].
[1]

Check the commutator bars of the armature for
discoloration.
Check for continuity or no continuity for each part of
armature as below:
-

Between pair of commutator bars: should be
continuity.
Between each commutator bar and the armature
shaft [2]: should be No continuity.

Replace the starter motor as an assembly if necessary.
[2]

6-9

ELECTRIC STARTER

STARTER RELAY SWITCH
INSPECTION
Remove the seat (page 2-14).
Shift the transmission into neutral.
Turn the ignition switch ON and engine stop switch "O".
Push the starter switch.
The coil is normal if the starter relay switch clicks.
If you don't hear the starter relay switch "CLICK",
inspect the starter relay switch using a procedure
below.

STARTER RELAY INPUT VOLTAGE
Turn the ignition switch ON and engine stop switch

"o".

Measure the voltage between the Yellow/red (+) wire
terminal at the starter relay switch 4P (Red) connector
[1] and ground(-).
If the battery voltage appears only when the starter
switch is pushed with the ignition switch turned ON and
engine stop switch "O", the starter relay input voltage is
normal.

GROUND LINE (CTX700/A/N/NA)
Disconnect the starter relay switch 4P (Red) connector
[1].
Check for continuity between the Green/red wire of the
wire harness side (ground line) and ground.
If there is continuity when the transmission is in neutral
or when the clutch is disengaged and the sidestand is
retracted, the ground circuit of the relay coil is normal.
(In neutral, there is a slight resistance due to the diode.)

GROUND LINE (CTX700D/ND)
Turn the ignition switch ON and engine stop switch "O".
Measure the voltage between the Yellow/red (+) and
Green/red (-) wire terminals at the starter relay switch
4P (Red) connector [1].
If the battery voltage appears only when the starter
switch is pushed with the ignition switch turned ON and
engine stop switch "O", the starter relay ground line is
normal.

ELECTRIC STARTER
OPERATION CHECK
Remove the starter relay switch (page 6-11 ).
Connect a 12 V battery to the starter relay switch as
shown.
There should be continuity between the cable terminals
when the battery is connected, and not continuity when
the battery is disconnected.

EB
8
BATIE RY
REMOVAL/INSTALLATION
Remove the seat (page 2-14).
Disconnect the battery negative(-) cable (page 21-5).
Release the starter relay switch [1] from the battery box
tabs [2].
Release the rubber cover [3].
Disconnect the starter relay switch 4P (Red) connector
[4].
Remove the bolts [5] and cables [6].
Installation is in the reverse order of removal.

NEUTRAL DIODE (CTX700/A/N/NA)
INSPECTION
Remove the seat (page 2-14).

[1 J

Open the fuse box cover and remove the neutral diode

[1 ].
Check for
terminals.

continuity

between

the

neutral

diode

When there is continuity, a small resistance value will
register.
If there is continuity, in direction shown by the arrow,
the neutral diode is normal.

B

~[..,,I,,.. h
B

c

6-11

ELECTRIC STARTER

STARTER RELAY (CTX700D/ND)
INSPECTION
Remove the seat (page 2-14).
Open the fuse box cover and remove the starter relay

[1 ].

Connect an ohmmeter to the starter relay [1] connector
terminals.
Connect a 12 V battery to the starter relay connector
terminals as shown.
There should be continuity only when 12 V battery is
connected.
If there is no continuity only when the 12 V battery is
connected, replace the starter relay.

6-12

[1 J

[ ]
1

7. FUEL SYSTE

COMPONENT LOCATION ............................ 7.2

THROTTLE BODY ...................................... 7.14

SERVICE INFORMATION ·····························7-3

FUEL INJECTOR ........................................ 7.18

FUEL LINE REPLACEMENT ........................ 7.4

IACV ........................................ :................... 7-20

FUEL TANK···················································7-7

FUEL CUT RELAY ...................................... 7-21

FUEL PUMP UNIT ....................................... 7.10

EVAP PURGE CONTROL SOLENOID
VALVE (50 STATE MODEL)·················· .. ···7-22

AIR CLEANER HOUSING ........................... 7.13
EVAP CANISTER (50 STATE MODEL) ·····7-22

7-1

FUEL SYSTEM

COMPONENT LOCATION

(l

I

I

I

FUEL SYSTEM

SERVICE INFORMATION
GENERAL
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
• Before disconnecting the fuel feed hose, relieve fuel pressure from the system (page 7-4).
• Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss
of vehicle control.
• Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle
operation.
• Seal the intake ports with tape or a clean cloth to keep dirt and debris from entering the engine after the throttle body or fuel rail
has been removed.
• Do not damage the throttle body. It may cause incorrect throttle valve operation.
• Prevent dirt and debris from entering the throttle bore and air passages after the throttle body has been removed. Clean them
using a compressed air if necessary.
• Do not loosen or tighten the white painted nut and screw of the throttle body. Loosening or tightening them can cause throttle
valve and idle control failure.
• The parts of the throttle body not shown in this manual should not be disassembled.
• For fuel level sensor inspection (page 22-15).

TOOLS
Fuel pressure gauge, 0 - 100 psi
07 406-0040004

Pressure gauge manifold
07ZAJ-S5A0111

Hose attachment, 9 mm/9 mm
07ZAJ-S5A0120

or 07406-0040008 or 07406-004000C
(U.S.A. only)
Hose attachment, 6 mm/9 mm
07ZAJ-S5A0130

(Not available in U.S.A.)

(Not available in U.S.A.)

Attachment joint, 8 mm/9 mm
07ZAJ-S7C0200

Pressure manifold hose
07 AMJ-HW3A 100 (U.S.A. only)

tJ
(Not available in U.S.A.)
Adaptor C, male
07MJ-S6MA200 (U.S.A. only)

(Not available in U.S.A.)
Adaptor C, female
07AAJ-S6MA500 (U.S.A. only)

SCS service connector
070PZ-ZY30100

7..3

FUEL SYSTEM

FUEL LINE REPLACEMENT
FUEL PRESSURE RELIEVING
NOTE:

Before disconnecting fuel feed hose, relieve pressure from the system as follows.
1. Turn the ignition switch OFF.
2. Remove the left side shelter (page 2-11 ).
3. Disconnect the fuel pump 3P (Black) connector [1].
Turn the ignition switch ON and engine stop switch

"o".
4. Start the engine, and let it idle until the engine stalls.
5. Turn the ignition switch OFF.
6. Disconnect the battery negative (-) cable
(page 21-5).

QUICK CONNECT FITTING REMOVAL
FUEL PUMP SIDE

Refer to page 7-7.
FUEL INJECTOR SIDE

1. Relieve the fuel pressure (page 7-4 ).
Check the fuel quick connect fitting [1] for dirt, and
clean if necessary.
Place a shop towel

over the quick connect fitting.

2. Pull and release the joint rubber [1] tabs from the
retainer.

[1]

3. Squeeze the retainer tabs [2] with the hand or
special tool to release them from the locking pawls
[3].
U.S.A. TOOL:
Fuel retainer compressor

07AMF-001A100

Pull the fuel feed hose off and remove the retainer.
• Absorb the remaining fuel in the fuel feed hose from
flowing out with a shop towel.
• Be careful not to damage the hose or other parts.
• Do not use tools.
• If the connector does not move, keep the retainer '----[2_l_____________-----'
tabs pressed down, and alternately pull and push
the connector until it comes off easily.

FUEL SYSTEM
4. To prevent damage and keep foreign matter out,
cover the disconnected connector and pipe end with
the plastic bags [1].

[1]

QUICK CONNECT FITTING INSTALLATION
FUEL PUMP SIDE
Refer to page 7-7.
FUEL INJECTOR SIDE
1. Insert a new retainer [1] into the connector [2].
• Align new retainer locking pawls with the connector
grooves.
• Replace the retainer and joint rubber with the same
manufacturer's item that was removed.

[2]

Align

2. Set a new joint rubber [1] as shown.
Then press the fuel feed hose into the quick connect
fitting until both retainer pawls [2] lock with a
"CLICK".
• Align retainer tabs with joint rubber grooves.
If it is hard to connect, put a small amount of engine
oil on the fuel injector joint.

[2]
3. Make sure the connection is secure and that the
pawls are firmly locked into place; check visually and
by pulling the fuel feed hose [1].
4. Make sure the joint rubber [2] is in place (between
the retainer tabs).
5. Increase the fuel pressure and check that there is no
leakage in fuel supply system (page 7-6).

[2]

[1]

7-5

FUEL SYSTEM
FUEL PRESSURE NORMALIZATION
1. Connect the fuel pump 3P (Black) connector [1 ].
Connect the battery negative(-) cable (page 21-5).
2. Turn the ignition switch ON and engine stop switch

"o".

• Do not start the engine.
The fuel pump will run for about 2 seconds, and fuel
pressure will rise.
3. Repeat 2 or 3 times, and check that there is no
leakage in the fuel supply system.
4. Turn the ignition switch OFF.
Install the seat (page 2-14).

FUEL PRESSURE TEST
Relieve the fuel pressure (page 7-4 ).
Disconnect the quick connect fitting from the fuel pump
(page 7-8).
Attach the fuel pressure gauge, attachments and
manifold.

TOOLS:
[1] Fuel pressure gauge, 0 -100 psi07406-0040004
[2] Pressure gauge manifold
07ZAJ-S5A0111
[3] Hose attachment, 9 mm/9 mm 07ZAJ-S5A0120
[4] Hose attachment, 8 mm/9 mm 07ZAJ-S7C0100
[5] Attachment joint, 8 mm/9 mm 07ZAJ-S7C0200
U.S.A. TOOLS:
Fuel pressure gauge, 0 -100 psi 07 406-0040008 or
07 406-004000C
07 AMJ-HW3A 100
Pressure manifold hose
07 AAJ-S6MA300
Adaptor C, male
Adaptor C, female
07AAJ-S6MA500
Temporarily connect the battery negative(-) cable and fuel pump 3P (Black) connector.
Turn the ignition switch ON and engine stop switch "O".
Start the engine and let it idle.
Read the fuel pressure.

STANDARD: 343 kPa (3.5 kgf/cm 2 , 50 psi)
If the fuel pressure is higher than specified, replace the fuel pump assembly.
If the fuel pressure is lower than specified, inspect the following:
-

Pinched or clogged fuel tank breather hose
Fuel pump unit (page 7-10)
Clogged fuel filter (page 7-10)

After inspection, relieve the fuel pressure (page 7-4 ).
Remove the fuel pressure gauge, attachment and manifold from the fuel injector.
Connect the quick connect fitting to the fuel pump and normalize the fuel pressure (page 7-9).

FUEL SYSTEM
FUEL FLOW INSPECTION
Relieve the fuel pressure and disconnect the quick
connect fitting from the fuel injector (page 7-4 ).
Clean up any spilled
fuel.

[1]

Place the end of the hose [1 J into an approved fuel
container.
Temporarily connect the battery negative
fuel pump 3P (Black) connector.

H

cable and

Turn the ignition switch ON and engine stop switch "O".
Measure the amount of fuel flow.
• The fuel pump operates for 2 seconds. Repeat 5
times so that the total measuring time.
• Return fuel to the fuel tank when the first fuel is
flowed.
Amount of fuel flow:
230 cm 3 (7.8 US oz, 8.1 Imp oz) minimum/
10 seconds at 12 V

If fuel flow is less than specified, inspect the following:
-

Fuel line leaking
Pinched or clogged fuel feed hose
Fuel pump unit (page 7-10)
Clogged fuel filter (page 7-10)

Connect the quick connect fitting and normalize the fuel pressure (page 7-5).

FUEL TANK
REMOVAL/INSTALLATION
Remove the center shelter (page 2-12).
Relieve the fuel pressure and disconnect the quick
connect fitting from the fuel injector (page 7-4 ).
Except 50 state
model:

Release the fuel tank breather hoses [1] from the wire
guides [2].

50 state model:

Disconnect the EVAP canister drain hose [1] from the
EVAP canister.

7-7

FUEL SYSTEM
Disconnect the following:
-

Except 50 state model shown:

Fuel tray drain hose [1]
Fuel tank breather hose [2] (Except 50 model only)

[13]

[14]

Remove the following:
50 state model only:

Two bolts [3]/washers [4]/collars [5]
Bolts [6]/washer [?]/collar [8]

[11 J

Move the fuel tank and disconnect the vacu1,1m hose [9]
and EVAP purge control solenoid valve 2P (Black)
connector [1 OJ.
Remove the fuel tank [11] by releasing the fuel feed
hose from the hose clamp [12].
Remove the tank cap [13] and fuel tray [14] as
necessary.
Installation is in the reverse order of removal.
• After installing quick connect fittings, normalize the
fuel pressure (page 7-6).

50 state model only:
[10]

[9]

[12]

FUEL PUMP SIDE QUICK CONNECT FITTING REMOVAL
1. Remove the center shelter (page 2-12).
2. Relieve the fuel pressure (page 7-4).
3. Remove the fuel tank mounting bolts, then lift up and
support the fuel tank (page 7-13).
4. Check the fuel quick connect fitting [1] for dirt, and
clean if necessary.
·
Place a shop towel over the quick connect fitting.

5. Pull and release the joint rubber [1] from the
retainer.

[1 J

[2]

6. Hold the connector with one hand and squeeze the
retainer tabs [2] with the other hand or special tool to
release them from the locking pawls [3].

U.S.A. TOOL:
Fuel retainer compressor

07AMF-001A100

Pull the connector off and remove the retainer.
• Absorb the remaining fuel in the fuel feed hose from
flowing out with a shop towel.
• Be careful not to damage the hose or other parts.
• Do not use tools.
3
• If the connector does not move, keep the retainer ' - - - - - - - - - - - - [ _J_ _ _ _ _ _ _ __J
tabs pressed down, and alternately pull and push
the connector until it comes off easily.

7-R

FUEL SYSTEM
7. To prevent damage and keep foreign matter out,
cover the disconnected connector and pipe end with
the plastic bags [1].

FUEL PUMP SIDE QUICK CONNECT FITTING INSTALLATION

1. Insert a new retainer [1] into the connector [2].
• Align new retainer locking pawls with the connector
grooves.
• Replace the retainer and joint rubber with the same
manufacturer's item that was removed.

[2)

Align

2. Set a new joint rubber [1] as shown.
Then press the quick connect fitting onto the pipe
until both retainer pawls [2] lock with a "CLICK".
• Align the quick connect fitting with the pipe.
• If it is hard to connect, put a small amount of engine
oil on the pipe end.

3. Make sure the connection is secure and that the , - - - - - - - - - - - - - - - - - - - ~
pawls are firmly locked into place; check visually and
by pulling the connector [1].
4. Make sure the joint rubber [2] is in place (between
the retainer tabs [3]).
5. Normalize the fuel pressure and check that there is
no leakage in fuel supply system (page 7-6).
Set the fuel tank in position, install and tighten the
three mounting bolts (page 7-13).
Install the center shelter (page 2-12).
[2]

[3]

7-9

FUEL SYSTEM

FUEL PUMP UNIT
REMOVAL
Remove the fuel tank (page 7-7).
Disconnect the quick connect fitting from the fuel pump
(page 7-4).
Clean around the fuel pump.
Loosen the fuel pump mounting nuts [1] in a crisscross
pattern in 2 or 3 steps and remove the nuts.
Remove the fuel pump unit [2] and packing [3].
• Be careful not to damage the fuel level sensor float
arm.

DISASSEMBLY/INSPECTION
Remove the screws [1], Black wire terminals [2] and
stoppers [3].
Disconnect the Pink wire connector [4] and Blue wire
connector [5].

Remove the fuel pump unit assembly [1] and 0-ring [2]
from the fuel pump stay [3].

Remove the chamber [1].
Release the tabs [2] and remove the fuel level sensor
assembly [3] from the fuel filter [4].

[1 J

~

[1]

[4]

[2]

7-10

FUEL SYSTEM
Remove the fuel pump [1) and 0-ring [2).
Visually inspect the fuel pump filter [3) for dirt, debris or
any clogging.
Replace fuel pump unit as an assembly if necessary.

[2]

Remove the pressure regulator [1) and 0-ring [2] from
the fuel filter [3).

[2]

ASSEMBLY
Replace the fuel filter [1) with a new one.
Install a new 0-ring [2) to the pressure regulator [3).
Install the pressure regulator.

Install a new 0-ring [1] to the fuel pump [2].

[2]

Install the fuel pump.
• Align the Blue wire with the fuel filter groove.

~
[118

7-11

FUEL SYSTEM
Insert the fuel pump filter edge [1] between the fuel
pump and pressure regulator.
Install the chamber [2].
Install the fuel level sensor assembly [3] until tabs [4]
lock with a "CLICK".

Install a new 0-ring (1] to the fuel pump stay [2].
Install the fuel pump unit assembly [3] by aligning the
groove with the fuel pump stay tab.

Install the stoppers [1], Black wire terminals [2] and
screws [3].
Tighten the screws securely.
Connect the Pink wire connector [4] and Blue wire
connector [5].

INSTALLATION
Install a new packing [1] onto the fuel pump unit [2].
• Always replace the packing with a new one.
• Be careful not to pinch any dirt or debris between the
fuel pump unit and packing.
• Align the packing tab with the fuel pipe.

e
~

7-12

[1]

Align

FUEL SYSTEM
Install the fuel pump unit [1] into the fuel tank.
Install and tighten the fuel pump mounting nuts [2] to
the specified torque in the sequence as shown.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)
Install the fuel tank (page 7-7).

AIR CLEANER HOUSING
REMOVAL/INSTALLATION
Pull down the radiator (page 8-7).
Disconnect the crankcase breather hose [1] from the
cylinder head.

Disconnect the IAT sensor 2P (Black) connector [1 ].
Loosen the air cleaner connecting hose band screw [2].
Remove the bolts [3], washer [4] and collar [5].

[9]

Remove the fuel tank mounting bolts [6] and washer [7],
then slightly pull the fuel tank [8] backward.
Disconnect connecting hose and remove the air cleaner
housing [9].
Installation is in the reverse order of removal.
TORQUE:
Air cleaner connecting hose band screw:
1.5 N·m (0.2 kgf·m, 1.1 lbHt)

[2]

[6]/[7]

~

I
!

[8]

7-13

FUEL SYSTEM

THROTTLE BODY
REMOVAL
Remove the air cleaner housing (page 7-13).
Disconnect the sensor unit 5P (Black) connector [1] and
IACV 4P (Black) connector [2].

Loosen the throttle cable A adjuster lock nut [1] and
adjusting nut [2] then disconnect the throttle cable A [3]
from the throttle drum and cable stay.
Loosen the throttle cable B lock nut [4] then disconnect
the throttle cable B [5] from the throttle drum and cable
stay.
Loosen the insulator band screw [6] and remove the
throttle body assembly.

DISASSEMBLY

I

NOTICE

I

• Do not remove the sensor unit unless it is replaced.
• The throttle body/sensor unit is factory pre-set. Do
not disassemble in a way other than shown in this
manual.
• Do not snap the throttle valve from full open to full
close after the throttle cable has been removed. It
may cause incorrect idle operation.
• Do not damage the throttle body. It may cause
incorrect throttle valve operation.
• Do not loosen or tighten the white painted nut and
screw [1} of the throttle body. Loosening or
tightening it can cause throttle valve and idle control
failure.
• Always clean around the throttle body before each
[1]
sensor removal to prevent dirt and debris from
entering the air passage.
'--------------------.J
NOTE:
For IACV removal (page 7-20).

7-1.d.

FUEL SYSTEM
Remove the sensor unit torx screws [1], sensor unit [2]
and 0-ring [3].

[1]

/

[3]
Cleaning the air
passages and
sensor hole with a
piece of wire will
damage the throttle
body.

[2]

Clean the air passage of the throttle body using
compressed air.
Check the air passage for clogs.

ASSEMBLY
NOTE:
For IACV installation (page 7-21).
TORXSCREWS
THROTTLE BODY

:ft

0-RING

SENSOR UNIT
SETTING PLATE

TORX SCREWS

i::::__ _ _ _ _,-:;·

3.4 N·m (0.3 kgf-m, 2.5 lbMt)

7-15

FUEL SYSTEM
ff the 0-ring is not

Install a new 0-ring [1] to the throttle body properly.

[2]

installed properly,
the idle air will leak
and engine idle

When installing the sensor unit [2] to the throttle body,
align the following:
speed wi/1 be - The TP sensor clip with the throttle valve boss
unstable. - The sensor unit tab with the throttle body hole

S~
Install and tighten the sensor unit torx screws [1] to the
specified torque.

[1]

[1]

TORQUE: 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)

INSTALLATION
Install the throttle body assembly [1] to the cylinder
head by aligning the tab with the insulator groove.
Tighten the insulator band screw [2] to the specified
range.
Connect the throttle cables [3] to the throttle drum and
throttle cable stay.
Tighten the throttle cable B lock nut [4] securely.
Temporarily tighten the throttle cable A adjuster lock nut
[5].
Adjust the throttle grip freeplay (page 3-4).

11 - 13 mm (0.4 - 0.5 in)

7-16

FUEL SYSTEM
Connect the sensor unit 5P (Black) connector [1] and
IACV 4P (Black) connector [2].
Install the air cleaner housing (page 7-13 ).

THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE
NOTE:
If the sensor unit is removed, reset the throttle valve fully closed position as following.
1. Erase the DTC's (page 4-9).
2. Turn the ignition switch OFF.
3. Short the DLC [1] terminals using a special tool.

Connection: Brown - Green

TOOL:
(2] SCS service connector

070PZ-ZY30100

4. Disconnect the ECT sensor 2P (Black) connector

[1 ].
Short the ECT sensor 2P (Black) connector
terminals of the wire harness side with a jumper wire
[2].
5. Turn the ignition switch ON and engine stop switch
"O", then MIL will start blinking.
Disconnect the jumper wire while the MIL blinking
(within 10 seconds).
After disconnection of the jumper wire, the MIL start
to short blinking.
[2]

7-17

FUEL SYSTEM
6. Check if the MIL blinks.
If the MIL begins short blink (0.3 seconds), the throttle valve fully closed position is reset.

~~~nd:'"in 1oseronds

'
MILON
~

MIL OFF

- -,-' - -- -I'
I
I
I

Mjt}'o':::::d,

f

,fl
-.,..,..,
'
''

.

1.2
seconds

RESET RECEIVING PATTERN

SUCCESSFUL PATTERN

If the MIL stays lit, the throttle valve fully closed position is not reset, repeat the reset procedure from step 1.
7. Turn the ignition switch OFF.
8. Install the removed parts in the reverse order of removal.

FUEL INJECTOR
REMOVAL·
Relieve the fuel pressure and disconnect the quick .,.........
connect fitting from the fuel injector side (page 7-4 ).
Remove the fuel tank (page 7-7).
Disconnect the fuel injector 2P (Gray) connectors [1].
Remove the clip [2] from the fuel rail.
Remove the bolts [3], collars [4] and fuel injector
assembly [5].

Remove the retainers [1] from the fuel injector/fuel rail.

7-18

[1]

FUEL SYSTEM
Remove the fuel injectors [1] from the fuel rail.

[1 J
Remove the 0-ring [1], cushion rubber [2] and seal ring

[3] from the fuel injector [4].
Check the removed parts for wear or damage and
replace them if necessary.

[2]

\
/'

[3]

[4]

INSTALLATION
Apply engine oil to a new 0-ring [1] and a new seal ring
[2].
Install the cushion rubber [3] until it is fully seated.
• Align the cushion rubber cut out with the fuel injector
connector.
Install the seal ring to the fuel injector [4], being careful
not to damage them.
Install the 0-ring to the fuel injector.

[3]

\
71,
s~

Install the fuel injectors [1] to the fuel rail [2], being
careful not to damage the 0-ring,

[4]

[2]

Align
[2]

[1 J

• Align the fuel injector body with the fuel rail tab [3] as
shown.

(3)

7-19

FUEL SYSTEM
Install the retainers [1] to the fuel injector/fuel rail.

Install the fuel injector assembly [1], bolts [2] and collars ,,__....
[3].
Tighten the fuel rail mounting bolts securely.
Connect the fuel injector 2P (Gray) connectors [4] while
aligning their grooves with the fuel rail tabs.
Install the clip [5] to the fuel rail.
Install the fuel tank (page 7-7).
Connect the quick connect fitting to the fuel injector side
and normalize the fuel pressure (page 7-5).

IACV
REMOVAL
Remove the air cleaner housing (page 7-13).
The !ACV is installed on the throttle body and is
operated by the step motor. When the ignition switch is
turned ON and engine stop switch "O", the IACV
operates for a few seconds.
Check the step motor operating (beep) sound with the
ignition switch turned ON and engine stop switch "O".
Disconnect the IACV 4P (Black) connector [1].
Remove the IACV setting plate torx screws [2] and
setting plate [3].
Remove the !ACV [4] and 0-ring [5].

INSPECTION
Remove the IACV (page 7-20).
Check the IACV [1] for wear or damage.
The IACV operation can be checked visually as follows:
1. Connect the IACV 4P (Black) connector [2].
2. Turn ignition switch ON and engine stop switch "0",
the slide valve [3] should move back and forth.
3. After inspection, install the IACV (page 7-21 ).

7 .. ?n

[1]

FUEL SYSTEM
INSTALLATION
Turn the slide valve [1] clockwise until lightly seated on
IACV.

[1]

Install a new 0-ring [1] to the IACV [2].
Install the IACV by aligning its groove with the slide
valve housing pin.
Install the setting plate [3] while aligning its cut-out with
the tab on the IACV.
Install and tighten the IACV setting plate torx screws [4]
to the specified torque.
TORQUE: 2.1 N·m {0.2 kgf·m, 1.5 lbHt)

Connect the IACV 4P (Black) connector [5].
Install the air cleaner housing (page 7-13).

FUEL CUT RELAY
INSPECTION
Remove the seat (page 2-14 ).
Open the fuse box cover and remove the fuel cut relay

[1 ].

Connect a ohmmeter to the fuel cut relay [1] terminals.

[1 J

Connect a 12 V battery to the fuel cut relay terminals as
shown.
There should be continuity only when 12 V battery is
connected.
If there is no continuity only when the 12 V battery is
connected, replace the fuel cut relay.

7-21

FUEL SYSTEM

EVAP PURGE CONTROL SOLENOID VALVE
(50 STATE MODEL}
REMOVAL/INSTALLATION
Remove the fuel tank (page 7-7).
Disconnect the canister-to-EVAP purge control solenoid
valve hose [1].

[3]

Remove the two nuts [2] and EVAP purge control
solenoid valve [3].
Installation is in the reverse order of removal.
[2]

~
INSPECTION
Remove the EVAP purge control solenoid valve [1]
(page 7-22).

[1]

Check that air should not flow (A) to (B), only when a
12 V battery is connected to the EVAP purge control
solenoid valve terminals.
Check the resistance between the terminals of the
EVAP purge control solenoid valve.

STANDARD: 30- 34 n (20°C/68°F)
If the resistance is out of specification, replace the
EVAP purge control solenoid valve.

(A)

---------

.,..___

EVAP CANISTER (50 STATE MODEL)
REMOVAL/INSTALLATION
Remove the fuel tank (page 7-7).
Disconnect the following from the EVAP canister [1]:
-

EVAP canister-to-fuel tank hose [2]
Canister-to-EVAP purge control solenoid valve hose
[3]

Remove the EVAP canister from the tabs [4] of the stay.
Installation is in the reverse order of removal.

7-22

[1 J

8. COOLING SYSTEM

SYSTEM FLOW PATTERN·, ..................... ,.. ,s.2
SERVICE INFORMATION ............................. s-3
TROUBLESHOOTING····· .............................. 8•3

THERMOSTAT/
THERMOSTAT HOUSING ............................ S-S
RADIATOR ............................... :.................... B-?
WATER PUMP .............................................. a.g

SYSTEM TESTING ........................................ 8•4
COOLANT REPLACEMENT ......................... s-4

RADIATOR RESERVE TANK ..................... 8-11
FAN CONTROL RELAY ............................. 8 -11

8-1

COOLING SYSTEM

SYSTEM FLOW PATTERN

RADIATOR CAP

THERMOSTAT

RADIATOR

WATER PUMP

A .. ?

RADIATOR RESERVE TANK

COOLING SYSTEM

SERVICE INFORMATION
GENERAL

Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap.

NOTICE
Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap
water may cause engine damage.
•
•
•
•
•

Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system services can be done with the engine installed in the frame.
Avoid spilling coolant on painted surfaces.
After servicing the system, check for leaks with a cooling system tester.
Refer to the ECT sensor inspection (page 22-13).

TROUBLESHOOTING
Engine temperature too high
• Faulty high coolant temperature indicator or ECT sensor
• Thermostat stuck closed
• Faulty radiator cap
• Insufficient coolant
• Passage blocked in radiator, hoses or water jacket
• Air in system
• Faulty cooling fan motor
• Faulty fan control relay
• Faulty water pump
Engine temperature too low
• Faulty high coolant temperature indicator or ECT sensor
• Thermostat stuck open
• Faulty fan control relay
Coolant leak
Faulty water pump mechanical seal
Deteriorated 0-rings
Faulty radiator cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or clamp
Damaged or deteriorated hose
Damaged radiator

8-3

COOLING SYSTEM

SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE INSPECTION
Remove the radiator cap (page 8-4).
Wet the sealing surfaces of the cap, then install the cap
onto the tester [1].
Pressure test the radiator cap.
Replace the radiator cap if it does not hold pressure, or
if relief pressure is too high or too low.
It must hold specified pressure for at least 6 seconds.

RADIATOR CAP RELIEF PRESSURE:
108 -137 kPa (1.1 -1.4 kgf/cm2, 16- 20 psi)
Install the tester to the radiator.
Pressure the radiator, engine and hoses, and check for
leaks.

I NOTICE

[1]

I

Excessive pressure can damage the cooling system components. Do not exceed 137 kPa (1.4 kgflcm 2,
Wp~.
,
Repair or replace components if the system will not hold specified pressure for at least 6 seconds.

COOLANT REPLACEMENT
REPLACEMENT/AIR BLEEDING
NOTE:
When filling the system or reserve tank with coolant or checking the coolant level, place the motorcycle in an
upright position on a flat, level surface.

Remove the following:
-

Right front side cowl (page 2-6)
(CTX700/A/D)
Right radiator side cover (page 2-10)
(CTX700N/NA/ND)

The engine must be cool before removing the
radiator cap, or severe scalding may result.

Remove the drain bolt [1], sealing washer [2] and drain
the coolant.
Reinstall the drain bolts with a new sealing washer.
Tighten the drain bolt securely.

8-4

COOLING SYSTEM
Fill the system with the recommended coolant through
the filler opening up to filler neck [1].
Remove the radiator reserve tank cap [2] and fill the
reserve tank to the upper level line.
Bleed air from the system as follows:
1. Shift the transmission into neutral.
Start the engine and let it idle for 2 - 3 minutes.
2. Snap the throttle 3 or 4 times to bleed air from the
system.
3. Stop the engine and add coolant up to the filler neck
if necessary.
Install the radiator cap.
4. Check the level of coolant in the reserve tank and fill to the upper level line if it is low (page 3-12).
NOTE:
• When air bleeding is insufficient, level of coolant in the reserve tank will decrease. If so, fill to the upper level
line with coolant.
After installation, check that there are no coolant leaks.
Install the following:
-

Right front side cowl (page 2-6)
(CTX700/A/D)
Right radiator side cover (page 2-10)
(CTX700N/NA/ND)

THERMOSTAT/THERMOSTAT HOUSING
REMOVAL/INSTALLATION
Drain the coolant (page 8-4 ).
Remove the following:
-

Air cleaner housing (page 7 -13)
Fuel tank (page 7-7)

Disconnect the ECT sensor 2P (Black) connector [1].
Loosen the water hose band screw [2] and disconnect
the radiator upper water hose [3].

Loosen the water hose band screw [1] and disconnect
the water bypass hose [2].
Remove the bolts [3], stay [4] and thermostat housing

[5].
• When connecting the hose, align the index mark
with the thermostat housing tab.

8-5

COOLING SYSTEM
Remove the 0-ring [1].
• Replace the 0-ring with a new one.

~
[11S
Remove the bolts [1] and thermostat housing cover [2].

[2]

[1]

Remove the thermostat [1] from the housing.
Installation is in the reverse order of removal.
• Align the thermostat air bleed hole with the rib side
bolt hole.
• Tighten the water hose band screws to the specified
range (page 8-8).
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-4 ).

INSPECTION
Visually inspect the thermostat [1] for damage.
Check for damage of the seal ring [2].
Wear insulated gloves and adequate eye protection.
Keep flammable materials away from the electric
heating element.

8-6

[1 J

[2]

COOLING SYSTEM
Do not let the
thermostat or
thermometer [1]
touch the pan, or
you will get false
reading.

Heat the water with an electric heating element to
operating temperature for 5 minutes.
Suspend the thermostat [2] in heated water to check its
operation.
Replace the thermostat if the valve stays open at room
temperature, or if it responds at temperatures other
than those specified.
THERMOSTAT BEGIN TO OPEN:
80 - 84°C (176 - 183°F)
VALVE LIFT:
8 mm (0.3 in) minimum at 95°C (203°F)

[2]

RADIATOR
PULL DOWN THE RADIATOR
Perform this procedure, before removing
following:
- Air cleaner housing (page 7-13)
- Cylinder head cover (page 10-5)
- Radiator (page 8-7)
Front wheel speed sensor (page 20-21)

the

Remove the following:
-

Front side cowls (page 2-6)
(CTX700/A/D)
Radiator side covers (page 2-10)
(CTX700N/NA/ND)

Remove the bolt [1] and radiator lower stay [2] by
releasing it from the radiator boss [3].
Remove the bolt [4] and release the radiator mounting
rubbers [5] from the boss of the frame.
Disconnect the fan motor 3P (Gray) connector [1].
Release the wire band boss [2] and air cleaner housing
drain hose [3) from the radiator.
Pull down the radiator.
Installation is in the reverse order of removal.

REMOVAL/INSTALLATION
Drain the coolant (page 8-4 ).
CTX700/AID only:

Remove the radiator side inner cover (page 2-7).
Pull down the radiator (page 8-7).
Loosen the water hose band screws [1) and disconnect
the radiator lower water hose [2) and radiator upper
water hose [3].
Disconnect the siphon hose [4].

8-7

COOLING SYSTEM
Installation is in the reverse order of removal.
• Tighten the water hose band screws to the specified
range as shown.
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-4).

I

I

. t ------- -- - - I

I

--:-----+!
I

~

-

I

I

0-1 mm
(0 - 0.04 in)

DISASSEMBLY/ASSEMBLY
Disassemble and assemble the radiator as following the illustration.
• Align the cooling fan and fan motor shaft flat surfaces.
• Apply locking agent to the cooling fan mounting nut threads.
RADIATOR

COOLING FAN
FAN MOTOR

SIDE COVER

-,,
SOCKET BOLTS

~

COOLING FAN MOUNTING NUT

1.0 N·m (0.1 kgf·m, 0.7 lbf-ft)

8-8

&"'

/~

,$_~

8.4 N·m (0.9 kgf·m, 6.2 lbf·ft)

2.7 N·m (0.3 kgf·m, 2.0 lbf·ft)

COOLING SYSTEM

WATER PUMP
MECHANICAL SEAL INSPECTION
Check the bleed hole [1 J of the water pump for signs of
coolant leakage.
• A small amount of coolant weeping from the bleed
hole is normal.
• Make sure that there are no continuous coolant
leakage from the bleed hole while operating the
engine.
Replace the water pump as an assembly if necessary.

[1]

REMOVAL/INSTALLATION
Remove the following:
-

Left front side cowl (page 2-6)

-

Left radiator side cover (page 2-10)

-

Left under side cowl (page 2-13)

(CTX700/A/D)
(CTX?OON/NA/ND)

Drain the coolant (page 8-4 ).
Loosen the water hose band screws [1] and disconnect
the radiator lower water hose [2] and water bypass
hose [3].
• When connecting the water bypass hose, align the
index mark with the water pump tab.
Remove the following:
-

6 x 50 mm bolt [1]
6 x 32 mm bolt [2]

Loosen the 6 x 32 mm bolt [3] and 6 x 35 mm bolts [4].

8-9

COOLING SYSTEM
Pull out and slide the water pump assembly [1].
Remove the 6 x 35 mm bolts [2].
Reinstall the water pump assembly.
Remove the 6 x 32 mm bolt [3] and sealing washer [4].
• Replace the sealing washer with new one.

Remove the following:
-

Water pump cover [1]
Packing [2]
Plate [3]

• Replace the packing with new one.

Remove the packing [1] and dowel pins [2] from the
water pump body.
• Replace the packing with new one.

Remove the water pump body [1) and 0-rings [2] from
the cylinder head.
Installation is in the reverse order of removal.
•
•
•
•

Replace the 0-rings with new ones.
Apply engine oil to the large 0-ring.
Align the water pump slit with camshaft tab.
Tighten the water hose band screws to the specified
range (page 8-8).

Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-4).

8-10

COOLING SYSTEM

RADIATOR RESERVE TANK
REMOVAL/INSTALLATION
Remove the left under side cowl (page 2-13).
Release the 02 sensor 1P (Black) connector [1] from
the stay.
Release the 02 sensor wire [2] from the radiator reserve
tank [3].
Remove the bolt [4].

Release the reserve tank overflow hose [1] from the
tank stay [2].
Release the overflow hose and siphon hose [3] from the
hose guide [4].
Remove the radiator reserve tank [5] from the tank stay
hole.
Disconnect the siphon hose and drain the coolant from
the reserve tank.
Installation is in the reverse order of removal.
Fill the radiator reserve tank with the recommended
coolant (page 3-12).

FAN CONTROL RELAY
INSPECTION
Remove the seat (page 2-14).
Open the fuse box cover and remove the fan control
relay [1].

Connect an ohmmeter to the fan control relay [1]
connector terminals.

[1]

Connect a 12 V battery to the fan control relay
connector terminals as shown.
There should be continuity only when 12 V battery is
connected.
If there is no continuity only when the 12 V battery is
connected, replace the fan control relay.

8-11

MEMO

9. LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM ············9-2

OIL FILTER BOSS ........................................ 9-6

SERVICE INFORMATION ............................. 9.4

OIL PUMP (CTX700/A/N/NA) ....................... 9-7

TROUBLESHOOTING·· ................................. 9.5

OIL PUMP (CTX700D/ND) ...... :..................... 9-8

OIL PRESSURE INSPECTION ..................... 9.5

OIL STRAINER ........................................... 9-11

9-1

LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM
CTX700/A/N/NA:

ROCKER ARM SHAFT

OIL FILTER CARTRIDGE

PRESSURE
RELIEF VALVE
CRANKSHAFT

OIL PUMP

OIL STRAINER

COUNTERSHAFT

Q.. 7

LUBRICATION SYSTEM
CTX700D/ND:

EOP SWITCH

CRANKSHAFT

CLUTCH
OIL PUMP

ENGINE
OIL PUMP
OIL STRAINER

MAINS HAFT
COUNTERS HAFT
LINEAR SOLENOID VALVE

9 ..3

LUBRICATION SYSTEM

SERVICE INFORMATION
GENERAL

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
•
•
•
•
•
•

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

TOOLS
Oil pressure gauge attachment
070MJ-0010101

Oil filter wrench
07HM-PJ70101

Oil pressure gauge set
07506-3000001

or 07AMJ-001A100 (U.S.A. only)
Oil pressure gauge attachment
07 406-0030000

or 07MA-PLCA100 (U.S.A. only)

or equivalent commercially available

or equivalent commercially available

n

A

LUBRICATION SYSTEM

TROUBLESHOOTING
Oil level too low
• Oil consumption
• External oil leak
• Worn piston rings
• Improperly installed piston rings
• Worn cylinders
• Worn valve stem seals
• Worn valve guide
Low oil pressure
• Oil level low
• Clogged oil strainer
• Faulty oil pump
• Internal oil leak
• Incorrect oil being used
No oil pressure
• Oil level too low
• Oil pressure relief valve stuck open
• Damaged oil pump
• Internal oil leak
High oil pressure
• Oil pressure relief valve stuck closed
• Clogged oil filter, oil gallery or metering orifice
• Incorrect oil being used
Oil contamination
• Oil or filter not changed often enough
• Worn piston rings
Oil emulsification
• Blown cylinder head gasket
• Leaky coolant passage
• Entry of water

9-5

LUBRICATION SYSTEM

OIL PRESSURE INSPECTION
Remove the engine oil filter cartridge (page 3-10).
Apply engine oil to the 0-ring and install the oil pressure
attachment [1] onto the oil filter boss.
TOOL:
Oil pressure gauge attachment

070MJ-0010101 or
07 AMJ-001A100
(U.S.A. only)

Apply engine oil to the 0-ring and install the engine oil
filter cartridge [2] onto the oil pressure attachment.
TOOL:
Oil filter wrench

07HAA-PJ70101 or
07AAA-PLC A 100
(U.S.A. only)

TORQUE:26 N·m (2.7 kgf·m, 19 lbMt)

Connect the oil pressure gauge [3] and attachment [4]
to the oil pressure gauge attachment.
TOOLS:
Oil pressure gauge set

Oil pressure gauge attachment

07506-3000001 or
equivalent
commercially
available
07406-0030000 or
equivalent
commercially
available

Fill the engine with the recommended engine oil
(page 3-10).
Warm the engine to normal operating temperature
(approximately 80°C/176°F) and increase the engine
speed to 5,000 rpm and read the oil pressure.
STANDARD:
470 kPa (4.8 kgf/cm 2 , 68 psi)
at 5,000 rpm/(80°C/176°F)

Stop the engine and remove the tools.
Install the engine oil filter cartridge (page 3-10).

OIL FILTER BOSS
INSPECTION
Remove the engine oil filter (page 3-10).

[1]

Check that the oil filter boss [1] protrusion from the
crankcase is specified length as shown.
SPECIFIED LENGTH: 16.5 ± 0.5 mm (0.65 ± 0.02 in)

If the length is out of specification, correct the oil filter
boss length as specified.
When removing the oil filter boss, apply locking agent to
the threads (page 1-13).
Install and tighten the oil filter boss.
Check that the oil filter boss protrusion from the
crankcase is specified length (See above).
Install the engine oil filter (page 3-10).

16.5 ± 0.5 mm
(0.65 ± 0.02 in)

LUBRICATION SYSTEM

OIL PUMP (CTX700/A/N/NA)
REMOVAL/INSTALLATION
Remove the right crankcase cover (page 11-4).
Remove the bolts [1] and oil pump [2].

Remove the 0-rings [1] and dowel pins [2].
Installation is in the reverse order of removal.
• Replace the 0-rings with a new one.
• Align the oil pump shaft tab with the balancer shaft
slit.

DISASSEMBLY/ASSEMBLY
Remove the bolts [1], oil pump cover [2] and dowel pins

[9]

[3].
Remove the thrust washer [4], oil pump shaft [5], drive
pin [6], outer rotor [7] and inner rotor [8] from the oil
pump body [9].
·
Clean all disassembled parts thoroughly.
Assembly is in the reverse order of disassembly.
• Dip all parts in clean engine oil.

[1 J

9-7

LUBRICATION SYSTEM
INSPECTION
NOTE:
• If any portion of the oil pump is worn beyond the
service limit, replace the oil pump as an assembly.
Inspection the following parts for damage, abnormal
wear, deformation or burning:
-

Oil pump shaft
Drive pin
Inner rotor
Outer rotor
Oil pump body

Measure the oil pump clearances according
LUBRICATION SYSTEM SPECIFICATIONS
(page 1-7).

to

If any of the measurement is out of the service limit,
replace the oil pump as an assembly.

OIL PUMP {CTX700D/ND)
REMOVAL/INSTALLATION
Remove the right crankcase cover (page 12-57).
Remove the bolts [1] and oil pump [2].

Remove the 0-rings [1] and dowel pins [2].
Installation is in the reverse order of removal.
• Replace the 0-rings with new ones.
• Align the oil pump shaft end with the balancer shaft
groove.

LUBRICATION SYSTEM
DISASSEMBLY
Remove the bolts [1] and oil pump cover [2].

[1]

[2]

Remove the clutch oil pump inner rotor [1] and o u t e r , - - - - - - - - - - - - - - - - - ~
ro~r~.
~]
~

Remove the drive pin [1], oil pump plate [2] and dowel , - - - - - - - - - - - - - - - - - - - ,
pins [3].
[3]

Remove the oil pump shaft [1], drive pin [2], engine oil , - - - - - - - - - - - - - - - - - - - ,
pump inner rotor [3] and outer rotor [4].
[1]
[2]

9-9

LUBRICATION SYSTEM
INSPECTION
NOTE:

If any portion of the oil pump is worn beyond the service
limit, replace the oil pump as an assembly.
Inspection the following parts for damage, abnormal
wear, deformation or burning:
-

Oil pump shaft
Drive pin
Inner rotor
Outer rotor
Oil pump body

Measure the

oil

pump

clearances

according

to

LUBRICATION SYSTEM SPECIFICATIONS

(page 1-7).
If any of the measurement is out of the service limit,
replace the oil pump as an assembly.

ASSEMBLY
Assembly is in the reverse order of disassembly.
• Dip all parts in clean engine oil.

CLUTCH OIL PUMP
INNER ROTOR

DRIVE PIN

CLUTCH OIL PUMP
OUTER ROTOR

ENGINE OIL PUMP
OUTER ROTOR
ENGINE OIL PUMP
INNER ROTOR
OIL PUMP COVER

OIL PUMP SHAFT

LUBRICATION SYSTEM

OIL STRAINER
REMOVAL
Drain the engine oil (page 3-10).
Remove the exhaust pipe/muffler (page 2-19).
Loosen the bolts [1] in a crisscross pattern in 2 or 3
steps, and remove the bolts and oil pan [2].

Remove the oil strainer [1] and seal ring [2].
Clean the oil strainer screen and check for damage,
replace it if necessary.

INSTALLATION
Apply engine oil to a new seal ring [1] and install it onto
the oil strainer [2].
Install the oil strainer into the crankcase while aligning
the oil strainer boss with the crankcase groove.

Clean the oil pan mating surface thoroughly.
Apply liquid sealant (TB1207B manufactured by Three
Bond or equivalent) to the oil pan mating surface as
shown.
• Do not apply more liquid sealant than necessary.

9-11

LUBRICATION SYSTEM
Install the oil pan [1] and bolts [2].

[1]

Tighten the bolts in a crisscross pattern in 2 or 3 steps.
Install the exhaust pipe/muffler (page 2-19).
Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-9).

[2]

9-12

10. CYLINDERHEADNALVES

COMPONENT LOCATION .......................... 10-2

ROCKER ARM ............................................ 10-7

SERVICE INFORMATION ···························10-3

CAM CHAIN TENSIONER·············· .......... 10-10

TROUBLESHOOTING························· .. ······ 10-4

CAMSHAFT··· ...........................,: ................ 10-12

CYLINDER COMPRESSION TEST········· .. ··10-5

CYLINDER HEAD ..................................... 10-14

CYLINDER HEAD COVER··· .. ·····················10-5

10-1

CYLINDER HEADNALVES

COMPONENT LOCATION
1O N·m (1.0 kgf·m, 7 lbf·ft)

~
12 N·m (1.2 kgf·m, 9 lbf·ft)

56 N·m (5. 7 kgf·m, 41 lbf·ft)
4.0 N·m (0.4 kgf·m, 3.0 lbf·ft)

I
29 N·m (3.0 kgf·m, 21 lbf-ft)

10-2

CYLINDER HEADNALVES

SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves, camshaft and rocker arm.
• The rocker arm services can be done with the engine installed in the frame. The cylinder head, valves and camshaft service
requires engine removal.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder
head.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.

TOOLS
Gear holder, 2.5
07724-0010100

Valve spring compressor
07757-0010000

Valve guide reamer, 5.010 mm
07984-MA60001

Valve guide driver
077 43-0020000

or 07984-MA6000D (U.S.A. only)
Seat cutter, 27.5 mm (45° IN)
07780-0010200

or 07724-001A 100 (U.S.A. only)
Valve guide driver
07942-8920000

(Not available in U.S.A.)

or equivalent commercially available in
U.S.A.

Seat cutter, 24 mm (45° EX)
07780-0010600

Cutter holder, 5.0 mm
07781-0010400

Flat cutter, 28 mm (32° IN)
07780-0012100

or equivalent commercially available in
U.S.A.

or equivalent commercially available in
U.S.A.

or equivalent commercially available in
U.S.A.

10-3

CYLINDER HEADNALVES
Flat cutter, 25 mm (32° EX)
07780-0012000

Interior cutter, 26 mm (60° IN)
07780-0014500

Interior cutter, 22 mm (60° EX)
07780-0014202 ·

or equivalent commercially available in
U.S.A.

or equivalent commercially available in
U.S.A.

or equivalent commercially available in
U.S.A.

TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test or by
tracing engine noises to the top-end with a sounding rod stethoscope.
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for
a seized piston ring (page 15-16).
Compression too low, hard starting or poor performance at low speed
Valves:
- Incorrect valve clearance adjustment
- Burned or bent valve
- Incorrect valve timing
- Broken valve spring
- Uneven valve seating
Cylinder head:
- Leaking or damaged cylinder head gasket
- Warped or cracked cylinder head
- Loose spark plug
Worn cylinder, piston or piston rings (page 15-16)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston crown or on combustion chamber
Excessive smoke
• Cylinder head:
- Worn valve stem or valve guide
- Damaged stem seal
• Worn cylinder, piston or piston rings (page 15-16)
Excessive noise
Cylinder head:
- Incorrect valve clearance adjustment
Sticking valve or broken valve spring
- Damaged or worn camshaft
- Loose or worn cam chain
- Worn or damaged cam chain
- Worn or damaged cam chain tensioner
- Worn cam sprocket teeth
- Worn rocker arm and/or shaft
- Worn rocker arm and valve stem end
Worn cylinder, piston or piston rings (page 15-16)
Rough idle
• Low cylinder compression

CYLINDER HEADNALVES

CYLINDER COMPRESSION TEST
Warm the engine to normal operating temperature.
Stop the engine and remove the all spark plug caps and
spark plugs (page 3-6).
Disconnect the fuel pump 3P (Black) connector
(page 7-4).
Install a compression gauge [1] into the spark plug hole.
Open the throttle all the way and crank the engine with
the starter motor until the gauge reading stops rising.

[1]

The maximum reading is usually reached within 4 - 7
seconds.
STANDARD:
1,775 kPa (18.1 kgf/cm 2 , 257 psi) at 470 rpm

Low compression can be caused by:
-

Blown cylinder head gasket
Improper valve clearance adjustment
Valve leakage
Worn piston ring or cylinder

High compression can be caused by:
-

Carbon deposits in combustion chamber or on
piston head

CYLINDER HEAD COVER
REMOVAL/INSTALLATION
Pull down the radiator (page 8-7).
Disconnect the crankcase breather hose [1].

Remove the bolt [1], reservoir cover [2] and rear master
cylinder reservoir [3] from the frame.

10-5

CYLINDER HEADNALVES
Remove the cylinder head cover socket bolts [1] and
mounting rubbers [2].

[1]/[2]

Remove the cylinder head cover [1] from the cylinder
head.
Remove the cylinder head cover packing [2] from the
cylinder head cover.
• Replace the cylinder head cover packing with a new
one.

Installation is in the reverse order of removal.
Check the mounting rubbers [1] are in good
condition, replace them if necessary.
• Install the mounting rubbers with their "UP" mark [2]
facing up.
TORQUE:
Cylinder head cover socket bolts:
10 N·m (1.0 kgf·m, 7 lbHt)
Rear master cylinder reservoir mounting bolt:
10 N·m (1.0 kgf·m, 7 lbMt)

[1 J

DISASSEMBLY/ASSEMBLY
Remove the breather plate mounting bolts [1].
• When assembly, apply locking agent to the breather
plate mounting bolt threads (page 1-13).

10-6

CYLINDER HEADNALVES
Remove the breather plate [1] and gasket [2].
Assembly is in the reverse order of disassembly.
• Replace the breather plate gasket with a new one.

TORQUE:
Breather plate mounting bolt:
12 N·m (1.2 kgf·m, 9 lbMt)

e
~

[2]

[1]

ROCKER ARM
REMOVAL
Remove the cylinder head cover (page 10-5).
Remove the camshaft maintenance cap [1] and 0-ring
[2].

Remove the crankshaft hole cap.
Turn the crankshaft counterclockwise and align the "!':,."
mark [1] on the cam sprocket with the lower cylinder
head index line [2].

Remove the rocker arm shaft bolts [1].

10-7

CYLINDER HEADNALVES
Remove the rocker arm assembly [1].
• Be careful not to let the dowel pin [2] fall into the
crankcase.
Remove the dowel pin from the rocker arm shaft.

DISASSEMBLY/ASSEMBLY
Remove the washers [1] and rocker arms from the
rocker arm shaft [2].
Apply molybdenum oil solution to the rocker arm sliding
surface and rocker arm shaft outer surface.
Install the washers and rocker arms to the rocker arm
shaft.
NOTE:

Rocker arm identification tips
•
•
•
•

"PWC-A" mark: exhaust rocker arm A [3]
White paint mark: Intake rocker arm S [4]
No mark: Intake rocker arm P [5]
"PWC-B" mark: exhaust rocker arm B [6]

[3],

[4],
[5],

[6],

[6],

CYLINDER HEADNALVES
INSPECTION
inspect the following parts for damage, abnormal wear,
deformation, burning or clogs in oil passages.
-

Rocker arms
Rocker arm shafts

Measure each part and clearance according
CYLINDER HEADNALVES SPECIFICATIONS
(page 1-8).

to

Replace any part if it is out of service limit.

INSTALLATION
Make sure the"!::,'' mark [1] on the cam sprocket facing
the lower cylinder head index line [2].
If it does not align, turn the crankshaft counterclockwise
and align it.

Install the dowel pin [1] to the rocker arm shaft.
Install the rocker arm assembly [2].
• Align boss [3] and dowel pin with the cylinder head
holes [4].
• Make sure the washers [5] are installed in correct
position.
• Be careful not to let the dowel pin fall into the
crankcase.

Apply engine oil to the rocker arm shaft bolts threads
and seating surface.
Install and tighten rocker arm shaft bolts [1] to the
specified torque.
TORQUE: 29 N·m (3.0 kgf·m, 21 lbf·ft)

10-9

CYLINDER HEADNAlVES
Apply engine oil to a new 0-ring [1] and install it to the
camshaft maintenance cap [2].
Temporarily install the camshaft maintenance cap to
the cylinder head.
If the engine is removed from the frame, tighten the
camshaft maintenance cap to the specified torque.

TORQUE:4.0 N·m (0.4 kgf·m, 3.0 lbHt)

If the engine is installed on the frame, insert a feeler
gauge (0.1 mm) [1] between the camshaft maintenance
cap and cylinder head.
Tighten the camshaft maintenance cap securely.
Remove the feeler gauge.
Further tighten the camshaft maintenance cap at 30°.
NOTE:
The length of one concave area [2] on the camshaft
maintenance cap is equivalent with 30°.
Install the following:
-

Cylinder head cover (page 10-5)
Crankshaft hole cap (page 3-9)

CAM CHAIN TENSIONER
CAM CHAIN INSPECTION
Remove the cylinder head cover (page 10-5).

[1]

Measure the cam chain tensioner wedge B [1] length.

SERVICE LIMIT: 6.0 mm (0.24 in)
Replace the cam chain with a new one if the projection
exceeds the service limit.
For the cam chain replacement, remove the following:
-

Cam sprocket (page 10-12)
Primary drive gear
- CTX700/A/N/NA (page 11-11)
- CTX700D/ND (page 12-69)

RELEASING CAM CHAIN TENSION
Remove the cylinder head cover (page 10-5).
Install an O.D. 2 mm pin [1] into the cam chain
tensioner wedge A hole while pulling the wedge A [2]
straight up and pushing down the wedge B [3].
• Be careful not to let the 2 mm pin fall into the
crankcase.

1n.1n

O L -!~ 6.0 mm (0.24 io)

CYLINDER HEADNALVES
REMOVAL/INSTALLATION
Remove the thermostat housing (page 8-5).
Release the cam chain tension (page 10-10).
Remove the cam chain tensioner bolts [1] and sealing
washers [2].
Remove the cam chain tensioner [3].

Install the cam chain tensioner [1] while aligning
tensioner end with the groove in the crankcase.
Install new sealing washers, cam chain tensioner bolts
and tighten the cam chain tensioner bolts to the
specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)

Apply the cam chain tension (page 10-11 ).
Install the thermostat housing (page 8-5).

INSPECTION
Remove the cam chain tensioner (page 10-11 ).
Check the cam chain tensioner [1] for wear or damage.
Replace the cam chain tensioner if necessary.
Remove the cam chain guide (page 10-14).
Check the cam chain guide [21 for wear or damage.
Replace the cam chain guide if necessary.

(2]

~
[1)

APPLYING CAM CHAIN TENSION
Remove the 0.0. 2 mm pin [1] from the cam chain
tensioner wedge A hole while pulling the wedge A [2]
straight up and pushing down the wedge B [3].
• Be careful not to let the 2 mm pin fall into the
crankcase.
Install the cylinder head cover (page 10-5).

10-11

CYLINDER HEADNALVES

CAMSHAFT
REMOVAL
Remove the engine.
-

CTX700/A/N/NA (page 16-5)
CTX700D/ND (page 16-14)

Loosen the water hose band screw [1] and disconnect
the water bypass hose.
Remove the bolts [2], water pump [3] and 0-rings [4].

Remove the rocker arm (page 10-7).
Release the cam chain tension (page 10-10).
Loosen the cam sprocket bolt [1] by holding the
flywheel mounting bolt and remove it.
Remove the cam sprocket bolt and cam sprocket [2] by
removing the cam chain [3] from the cam sprocket.
• Attach a piece of wire to the cam chain to prevent it
from falling into the crankcase.

Remove the camshaft [1].

INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning or clogs in oil passages.
-

Cam sprocket
Camshaft

Measure each part according to CYLINDER HEAD/
VALVES SPECIFICATIONS (page 1-8).
Replace any part if it is out of service limit.

10-12

CYLINDER HEADNALVES
CAMSHAFT RUNOUT

Support both sides of the camshaft (at journals) with Vblocks and check the camshaft runout with a dial
gauge.
SERVICE LIMIT: 0.04 mm (0.002 in)

INSTALLATION
Apply molybdenum oil solution to the camshaft lobes,
journals and thrust surfaces.
Install the camshaft [1].

Align the "1 T" mark on the flywheel with the index notch
on the alternator cover (page 3-7).
Align the "1" mark [1] on the cam sprocket with the
upper index line [2] on the cylinder head and install the
cam chain onto the cam sprocket
Install the cam sprocket onto .the camshaft by aligning
the groove with the pin.

Apply engine oil to the cam sprocket bolt threads and
seating surface.
Install the cam sprocket bolt [1].
Hold the flywheel mounting bolt and tighten the cam
sprocket bolt to the specified torque.
TORQUE:56 N·m (5.7 kgf·m, 41 lbHt)

Apply the cam chain tension (page 10-11 ).
Install the rocker arm (page 10-9).

10-13

CYLINDER HEADNALVES
Apply engine oil to a new large 0-ring [1] and install it to
the water pump [2].
Install a new 0-ring [3] to the water pump.
Install the water pump to the cylinder head.
• Align the water pump shaft groove with camshaft
tab.

Install and tighten the bolts [1].
Connect the water bypass hose [2].
• Align the water bypass hose index mark with the
water pump tab.
Tighten the water hose band screws to the specified
range (page 8-8).
Install the engine.
-

CTX700/A/N/NA (page 16-9)
CTX700D/ND (page 16-18)

CYLINDER HEAD
REMOVAL
Remove the following:
-

Engine
- CTX700/A/N/NA (page 16-5)
- CTX700D/ND (page 16-14)
Cylinder head cover (page 10-5)
Right crankcase cover
- CTX700/A/N/NA (page 11-4)
- CTX700D/ND (page 12-57)

Remove the camshaft maintenance cap [1] and 0-ring

[2].

1 n.. 1.4

CYLINDER HEADNALVES
Turn the crankshaft clockwise and align the index lines
[1] with the crankcase matting surface, while the "TOP"
mark [2] is facing down.

Make sure the "S' mark [1] on the cam sprocket facing
the lower cylinder head index line [2].
If the "S' mark on the cam sprocket is facing the upper
cylinder head index line [3], turn the crankshaft
clockwise one full turn (360°) and realign the "S' mark
with the lower cylinder head index line.

Remove the cam chain tensioner (page 10-11 ).
Insert the gear holder [1] between the primary drive
gear and driven gear.

TOOL:
Gear holder, 2.5

07724-0010100 or
07724·001A100
(U.S.A. only)

Remove the cam sprocket bolt [2].
Remove the cam sprocket [3] by removing the cam
chain [4] from the cam sprocket.
• Attach a piece of wire to the cam chain to prevent it
from falling into the crankcase.

10-15

CYLINDER HEADNALVES
Remove the 6 mm bolts [1].

Remove the cylinder head special bolts [1].
• Loosen the cylinder head special bolts in a
crisscross pattern in 2 or 3 steps.
Remove the cylinder head [2].
• Attach a piece of wire to the cam chain to prevent it
from falling into the crankcase.
• Do not strike the cylinder too hard and do not
damage the mating surface with a screwdriver.

Remove the gasket [1], dowel pins [2] and cam chain
guide [3].

Remove the partition plate [1].
Check the partition plate for deterioration or damage.

10-16

CYLINDER HEADNALVES
DISASSEMBlY
Remove the following:
-

[2]

Cylinder head (page 10-14)
Spark plug (page 3-6)
Injector (page 7-18)
Camshaft (page 10-12)

Loosen the insulator band screws [1] and remove the
insulator [2].

Remove the valve spring cotters using the special tool
as shown.
TOOL:
Valve spring compressor

07757-0010000

• To prevent loss of tension, do not compress the
valve springs more than necessary to remove the
cotters.

Remove the following:
-

Spring retainer [1]
Valve spring [2]
Valve [3]
Stem seal [4]
Valve spring seat [5]

[3]

V
[5]~1/
[2]

• Mark all parts during disassembly so they can be
placed back in their original locations.

/

[4]

[1]

1,'f

INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning or clogs in oil passages.

-

Cylinder head
Inner/outer valve springs
Valve guides

Measure each part and clearance according
CYLINDER HEAD/VALVES SPECIFICATIONS
(page 1-8).

to

Replace any part if it is out of service limit.
• Ream the valve guide using the valve guide reamer
to remove any carbon build up before measuring the
guide (page 10-18).
• Refer to valve seat inspection (page 10-18).

10-17

CYLINDER HEADNALVES
VALVE GUIDE REPLACEMENT
Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.

[1]

Do not use a torch Heat the cylinder head to 100 - 150°C (212 - 302°F)
to heat the cylinder with a hot plate or oven.
head; it may cause To avoid burns, wear heavy gloves when handling the
warping. heated cylinder head.

Support the cylinder head and drive out the valve
guides from combustion chamber side of the cylinder
head.

TOOL:
[1] Valve guide driver

07942-8920000

USA Only:
Mark all of the guides with a sharpie at the specified
height. Place them in a freezer for at least 1 hour. Heat
the cylinder head to the specified temp.
Drive the guides in to the line and check with a pair of
calipers.

L---------=====---_J

Drive in the valve guides to the specified depth from the
top of the cylinder head.
SPECIFIED DEPTH:
IN: 17.7 -18.0 mm (0.70 - 0.71 in)
EX: 19.6 -19.9 mm (0.77 - 0.78 in)

TOOL:
[1] Valve guide driver

077 43-0020000
(Not available in
U.S.A.)

Let the cylinder head cool to room temperature.
[1]
Use cutting oil on
the reamer during
this operation.

Ream new valve guides after installation.
Insert the reamer [1] from the combustion chamber side
of the cylinder head and always rotate the reamer
clockwise.

TOOL:
Valve guide reamer, 5.010 mm

07984-MA60001 or
07984-MAGOOOD
(U.S.A. only)

Clean the cylinder head thoroughly to remove any
metal particles.
Reface the valve seat (page 10-18).

VALVE SEAT INSPECTION/REFACING
Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to the valve
seats.
Tap the valves and seats using a rubber hose or other
hand-lapping tool [1].

10-18

[1]

CYLINDER HEADNALVES
Remove the valve and inspect the valve seat face.
The valve seat contact should be within the specified
width and even all around the circumference.
STANDARD:
IN: 0.90 -1.10 mm (0.035- 0.043 in)
EX: 1.30 -1.50 mm (0.051 - 0.059 in)
SERVICE LIMITS:
IN: 1.5 mm (0.06 in)
EX: 1.9 mm (0.07 in)

t
t

1=====:::!--"

If the seat width is not within specification, reface the
valve seat (page 10-19).

SEAT WIDTH

Inspect the valve seat face for:
• Uneven seat width:
- Replace the valve and reface the valve seat.
• Damaged face:
- Replace the valve and reface the valve seat.
The valves cannot be ground.
If a valve face is burned or badly worn or if it contacts
the seat unevenly, replace the valve.
• Contact area (too high or too low)
- Reface the valve seat.

Follow the refacing
manufacturer's
operating
instructions.

VALVE SEAT REFACING
Valve seat cutters/grinders or equivalent valve seat
refacing equipment are recommended to correct worn
valve seats.

If the contact area is too high on the valve, the seat
must be lowered using a 32° flat cutter.
If the contact area is too low on the valve, the seat must
be raised using a 60° interior cutter.
Refinish the seat to specifications, using a 45° finish
cutter.

Reface the seat with
a 45° cutter
whenever a valve
guide is replaced.

Use a 45° cutter to remove any roughness or
irregularities from the seat.
TOOLS:
Seat cutter, 27.5 mm (45° IN)
Seat cutter, 24 mm (45° EX)
Cutter holder, 5.0 mm

g

c:;:J '\,2'

.. J45°

~\60°

\_/_

..•........................

\

07780-0010200
07780-0010600
07781-0010400

Use a 32° cutter to remove the top 1/4 of the existing
valve seat material.
TOOLS:
Flat cutter, 28 mm (32° IN)
Flat cutter, 25 mm (32° EX)
Cutter holder, 5.0 mm

07780-0012100
07780-0012000
07781-0010400

Use a 60° cutter to remove the bottom 1/4 of the old
seat.
TOOLS:
Interior cutter, 26 mm (60° IN)
Interior cutter, 22 mm (60° EX)
Cutter holder, 5.0 mm

07780-0014500
07780-0014202
07781-0010400

Using a 45° seat cutter, cut the seat to the proper width.
Make sure that all pitting and irregularities are removed.
Refinish if necessary.

10-19

CYLINDER HEADNALVES
After cutting the seat, apply lapping compound to the
valve face, and lap the valve using light pressure.

I NOTICE I
• Excessive lapping pressure may deform or damage
the seat.
• Change the angle of lapping tool [1] frequently to
prevent uneven seat wear.
• Do not allow lapping compound to enter the guides.

After lapping, wash all residual compound off the
cylinder head and valve.
Recheck the seat contact after lapping.
[1]

ASSEMBLY
INSULATOR

~

0

"'~OTTERS

=.!/_,....

~RETAINER

~

VALVE SPRING

,r~TEMSEAL
,

- ~ SPRINGSEAT
VALVE GUIDE

,

INTAKEVALVE
EXHAUST VALVE,

10-70

.,_

'IE!'

CYLINDER HEADNALVES
Install the valve spring seats [1].
Apply engine oil to new stem seals [2] inside and install
them.
Apply molybdenum oil solution to the valve stem sliding
surface and stem end.
Insert the valve [3] into the valve guide while turning it
slowly to avoid damage to the stem seal.
Install the valve springs [4] with the tightly wound coils
facing the combustion chamber.
Install the valve spring retainer [5].

71(3]
[4]

COMBUSTION CHAMBER SIDE

Install the valve cotters using the special tool as shown.

TOOL:
Valve spring compressor

07757-0010000

• To prevent loss of tension, do not compress the
valve spring more than necessary.
• Grease the cotters to ease installation.

Tap the valve stems gently with plastic hammer and
shaft as shown to seat the cotters firmly.
• Support the cylinder head above the work bench
surface to prevent possible valve damage.

10-21

CYLINDER HEADNALVES
Install the insulator [1] while aligning its slit with cylinder
head tab.

[1]

11 -13 mm
(0.4 - 0.5 in)

Tighten the band screw [2] to the specified range.
Install the following:
-

Camshaft (page 10-13)
Injector (page 7-19)
Spark plug (page 3-6)
Cylinder head (page 10-22)

INSTALLATION
Install the partition plate [1] to the No.1 cylinder intake
side.
• Install the partition plate with its tab [2] side facing
inside.

Install the cam chain guide [1].
• Align the cam chain guide end with the groove in the
crankcase.
• Align the cam chain guide tabs with the grooves in
the crankcase.

Install the dowel pins [1] and new gasket [2].

1n .. 22

-~

CYLINDER HEADNALVES
Route the cam chain through the cylinder head and
install the cylinder head [1] onto the cylinder.
Apply molybdenum oil solution to the cylinder head
special bolts [2] threads and seating surface.
Install and tighten the cylinder head special bolts in a
crisscross pattern in 2 or 3 steps to the specified torque.
TORQUE: 44 N·m (4.5 kgf-m, 32 lbHt)

Install and tighten the 6 mm bolts [1].

Turn the crankshaft clockwise and align the index lines
[1] with the crankcase matting surface, while the "TOP"
mark [2] is facing down.

10-23

CYLINDER HEADNALVES
Install the cam sprocket to the camshaft while installing
cam chain [1] onto the cam sprocket.
• Install the cam sprocket with its "MGS" mark [2]
facing out.
• Align the cam sprocket slit with camshaft pin.
• Align the cam sprocket "!).'' mark with cylinder head
lower index line.
Apply engine oil to the cam sprocket bolt threads and
seating surface.
Install the cam sprocket bolt [3].
Insert the gear holder [4] between the primary drive
gear and driven gear, then tighten the cam sprocket bolt
to the specified torque.
TOOL:
Gear holder, 2.5

07724-0010100 or
07724-001A100
(U.S.A. only)

TORQUE: 56 N·m (5.7 kgf·m, 41 lbMt)

Install the cam chain tensioner (page 10-11 ).

Apply engine oil to a new 0-ring [1] and install it to the
camshaft maintenance cap [2].
Temporarily install the camshaft maintenance cap to
the cylinder head.
If the engine is removed from the frame, tighten the
camshaft maintenance cap to the specified torque.
TORQUE:4.0 N·m (0.4 kgf·m, 3.0 lbHt)

If the engine is installed on the frame, insert a feeler
gauge (0.1 mm) [1] between the camshaft maintenance
cap and cylinder head.
Tighten the camshaft maintenance cap securely.
Remove the feeler gauge.
Further tighten the camshaft maintenance cap at 30°.
• One concave area [2] size is equivalent with 30°.
Install the following:
-

Cylinder head cover (page 10-5)
Right crankcase cover
- CTX700/A/N/NA (page 11-4)
- CTX700D/ND (page 12-64)
Engine
- CTX700/A/N/NA (page 16-9)
- CTX?OOD/ND (page 16-18)

11. CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)

COMPONENT LOCATION .......................... 11-2

CLUTCH ...................................................... 11-6

SERVICE INFORMATION ........................... 11-2

PRIMARY DRIVE GEAR/
CKP SENSOR ROTOR ............................. 11-11

TROUBLESHOOTING ................................. 11-3
GEARSHIFT LINKAGE ............................. 11-13
RIGHT CRANKCASE COVER .................... 11-4
GEARSHIFT PEDAL ................................. 11-16

11-1

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)

COMPONENT LOCATION

93 N·m (9.5 kgf·m, 69 lbf-ft)

~

lcf'

~

. __,...

128 N·m (13.1 kgf·m. 94 lbf·ft)

12 N·m (1.2 kgf·m. 9 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

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

11 .. ?

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
TOOLS
Holder Clutch Center
07 JMB-MN50302

Gear holder, 2.5
07724-0010100

Holder plate
07HGB-00101 OB (U.S.A. only)
Holder collar
07HGB-001020B (U.S.A. only)

or 07724-001A100 (U.S.A. only)

TROUBLESHOOTING
Clutch lever is too hard to pull in
• Damaged, kinked or dirty clutch cable
• Improperly routed clutch cable
• Damaged clutch lifter mechanism
• Faulty clutch lifter bearing
• Clutch lifter piece installed improperly
Clutch slips when accelerating
• Clutch lifter sticking
• Worn clutch disc
• Weak clutch springs
• No clutch lever freeplay
• Engine oil mixed with molybdenum or graphite additive
Clutch will not disengage or motorcycle creeps with clutch disengaged
• Excessive clutch lever freeplay
• Clutch plate warped
• Engine oil level too high, improper engine oil viscosity or additive used
• Loose clutch center lock nut
·
• Damaged clutch lifter mechanism
• Clutch lifter rod installed improperly
• Worn clutch outer slot and clutch center grooves
• Improper clutch operation
Hard to shift
• Misadjusted clutch cable
• Improper clutch operation
• Improper engine oil viscosity
• Damaged or bent shift fork
• Bent shift fork shaft
• Bent shift fork claw
• Loose shift drum stopper plate bolt
• Damaged shift drum stopper plate
• Damaged shift drum guide grooves
• Damaged or bent gearshift spindle
Transmission jumps out of gear
Worn shift drum stopper arm
Weak or broken shift drum stopper arm return spring
Loose shift drum stopper plate bolt
Damaged shift drum stopper plate
Bent shift fork shaft
Damaged or bent shift forks
Worn gear engagement dogs or slots
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Damaged or bent gearshift spindle

11-3

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)

RIGHT CRANKCASE COVER
REMOVAL/INSTALLATION
Remove the following:
-

Left side shelter (page 2-11)
Right under side cover (page 2-13)

Drain the engine oil (page 3-10).
Release the CKP sensor 2P (Red) connector [1] from
the stay and disconnect it.
Release the wire band [2] from the frame pipe.

Remove the two socket bolts [1] and right engine side
cover [2].
Remove the two collars [3] from the right engine side
cover.
Remove the bolts [4] and clutch cable guide [5], then
disconnect the clutch cable [6] from the clutch lifter arm
[7].

Loosen the right crankcase cover bolts [1] in a
crisscross pattern in 2 or 3 steps, and remove the bolts
and sealing washer [2].
• Replace the sealing washer with a new one.
Remove the right crankcase cover [3].

Remove the dowel pins [1].
Clean off any sealant from the right crankcase cover
mating surfaces.

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
Installation is in the reverse order of removal.
• Apply liquid sealant (TB1207B manufactured by
Three bond or equivalent) to the right crankcase
cover mating surface as shown.
• Do not apply more liquid sealant than necessary.
• Apply liquid sealant (TB1207B manufactured by
Three bond or equivalent) to the CKP sensor wire
grommet sealing surface.
TORQUE:
Right engine side cover socket bolt:
10 N·m (1.0 kgf·m, 7 lbHt)

Adjust the clutch lever freeplay (page 3-20).
Fill the engine with the recommended engine oil and ~ - - - - - - - - - - - - - - - - - - - - J
check that there are no oil leaks (page 3-9).

CLUTCH LIFTER ARM REMOVAL/
INSTALLATION
Remove the clutch lifter rod A [1].
Remove the snap ring [2], clutch lifter arm [3] and return
spring [4] from the right crankcase cover.

Install the clutch lifter arm [1], return spring [2] and snap
ring (3].
• Align the return spring hook (4] with right crankcase
cover.
• Align the return spring end [5] with clutch lifter arm
groove.
• Make sure the snap ring is firmly seated in the
groove.
Apply engine oil to the clutch lifter rod A sliding surface.
Install the clutch lifter rod A [6].

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Clutch lifter arm bushing
Clutch lifter arm
Return spring
Clutch lifter rod A

Replace if necessary.

11-5

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)

CLUTCH
REMOVAL
Remove the right crankcase cover (page 11-4).
Remove the clutch lifter rod B [1].
Loosen the clutch lifter plate bolts [2] in a crisscross
pattern in 2 or 3 steps, and remove the bolts, lifter plate/
bearing [3] and clutch springs [4].

Unstake the clutch center lock nut [1].
• Be careful not to damage the mainshaft threads.

Hold the clutch pressure plate with the special tool and
loosen the clutch center lock nut [1].
TOOL:
Clutch center holder [2]

07 JMB-MN50302

U.S.A. TOOLS:
Holder plate
Holder collar

07HGB-00101 OB
07HGB-0010208

Remove and discard the lock nut.

Remove the lock washer [1] and thrust washer [2].

11-"

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
Remove the clutch assembly [1].

Remove the following:
-

Clutch center [1]
Spring seat [2]
Judder spring [3]
Clutch disc B [4]
Seven clutch plates [5]
Six clutch discs C [6]
Clutch disc A [7]
Pressure plate [8]

Remove the thrust washer [1].

Remove the clutch outer guide [1].

11-7

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
INSPECTION
Inspect the following parts for scratch,
abnormal wear and deformation.
-

damage,

Clutch lifter rod B
Clutch lifter bearing
Clutch lifter plate
Clutch springs
Clutch center
Spring seat
Judder spring
Clutch discs/plates
Clutch outer/primary driven gear/needle bearing
Clutch outer guide
Mainshaft

Measure each part according to CLUTCH/GEARSHIFT
LINKAGE SPECIFICATIONS (page 1-8).
Replace any if it is out of service limit.
• Replace the clutch springs as a set.
• Replace the clutch discs and plates as a set.

INSTALLATION

CLUTCH DISC A ,

CLUTCH PLATE

,

JUDDER SPRING

SPRING SEAT

CLUTCH DISC B

CLUTCH CENTER

THRUST WASHER
LOCK WASHER
128 N·m (13.1 kgf·m, 94 lbf·ft) ,
CLUTCH LIFTER BEARING

11-8

LIFTER PLATE

CLUTCH SPRING

:,/

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
Apply molybdenum oil solution to the clutch outer guide
sliding surface.
Install the clutch outer guide [1] to the mainshaft.

Install the thrust washer [1] to the clutch outer.

Apply engine oil to the clutch discs entire surface.
Install the spring seat [1], judder spring [2] and clutch
disc B [3] to the clutch center [4].
Install the clutch discs C [5] and clutch plates [6]
alternately, starting with the clutch plate.
Install the clutch disc A [7] and pressure plate [8].

[6)

7° 30'
CLUTCH DISC A ~

[8)

CLUTCH DISC B ~

5.3 - 5.9 mm (0.21 - 0.23 in)
go
CLUTCH DISC C .

[1)

[2)

[4)

11-9

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
Install the clutch center assembly [1] to the clutch outer

[2].
• Align the clutch disc A/C tabs with clutch outer slits

[3].
• Align the clutch disc B tabs with clutch outer shallow
slots [4].

Install the clutch assembly [1] to the clutch outer guide.

Install the thrust washer [1].
Install the lock washer [2] with its "OUTSIDE" mark [3]
facing out.

Apply engine oil to a new clutch center lock nut threads
and seating surface.
Install the clutch center lock nut [1] onto the mainshaft.
Hold the pressure plate with the special tool and tighten
the lock nut to the specified torque.
TOOL:
Clutch center holder [2]

07 JMB-MN50302

U.S.A. TOOLS:
Holder plate
Holder collar

07HGB-00101 OB
07HGB-0010208

TORQUE: 128 N·m (13.1 kgf·m, 94 lbMt)

11-10

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
Stake the clutch center lock nut [1] into the mainshaft
groove.
• Be careful not to damage the mainshaft threads.

Install the clutch springs [1], lifter plate/bearing [2] and
clutch lifter plate bolts [3].
Tighten the clutch lifter plate bolts to the specified
torque in a crisscross pattern in 2 or 3 steps.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)

Apply engine oil to the clutch lifter rod B sliding surface.
Install the clutch lifter rod B [4].
Install the right crankcase cover (page 11-4).

~[4]

PRIMARY DRIVE GEAR/CKP SENSOR ROTOR
REMOVAL
Remove the right crankcase cover (page 11-4 ).
Hold the primary drive gear [1] using a special tool and
remove the primary drive gear mounting bolt [2] and
washer [3].
TOOL:
[41 Gear holder, 2.5

07724-0010100 or
07724-001A100
(U.S.A. only)

Remove the gear holder.
Remove the CKP sensor rotor [5] and primary drive
gear.

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Primary drive gear
CKP sensor rotor

Replace if necessary.

11-11

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
INSTALLATION
Install the primary drive gear [1] on the crankshaft.
• Align the primary drive gear wide groove with the
crankshaft wide tooth.
• Install the primary drive gear with its "OUT" mark [2]
facing out.

Install the CKP sensor rotor [1] on the crankshaft.
• Align the CKP sensor rotor wide groove with the
crankshaft wide tooth.
• Install the CKP sensor rotor with its "MGS" mark [2]
facing out.

Apply engine oil to the primary drive gear mounting bolt
threads and seating surface.
Install the washer [1] and primary drive gear mounting
bolt [2].
Hold. the primary drive gear using a special tool and
tighten the primary drive gear mounting bolt to the
specified torque.
TOOL:
[3] Gear holder, 2.5

07724-0010100 or
07724-001A 100
(U.S.A. only)

TORQUE: 93 N·m (9.5 kgf·m, 69 lbf·ft)

Remove the gear holder.
Install the right crankcase cover (page 11-4).

11_1?

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)

GEARSHIFT LINKAGE
REMOVAL
Remove the following:
-

Left rear cover (page 2-16)
Right crankcase cover (page 11-4)

Clean the gearshift spindle [1].

Remove the gearshift spindle [1] and washer [2].

Remove the following:
-

Shift drum stopper arm pivot bolt [1]
Washers [2]
Stopper arm [3]
Return spring [4]

Remove the shift drum center socket bolt [5], shift drum
stopper plate [6] and dowel pin [7].

Remove the bolt [1] and setting plate [2].
Remove the gearshift spindle oil seal [3].

11-13

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
INSPECTION
Inspect the following parts for scratch,
abnormal wear and deformation.
-

damage,

Shift drum stopper plate
Shift drum stopper arm
Shift drum stopper arm return spring

Replace if necessary.
GEARSHIFT SPINDLE

Check the return springs [1] and spindle arm spring [2]
for fatigue or damage replace them if necessary.

[4]

Check the gearshift spindle [3] for wear or bend.
Check the spindle arm [4] for wear, damage or
deformation.
Replace the gearshift spindle as an assembly if
necessary.

[3]
[1 J

INSTALLATION
Install a new gearshift spindle oil seal [1] as shown.
• Install the oil seal with its marked side facing out.
• Apply grease to the oil seal lips.

Install the setting plate [1] and a new bolt [2].
• Align the setting plate hole with the crankcase boss.

0.4-1.6 mm
(0.02 - 0.06 in)

CLUTCH/GEARSHIFT LINKAGE (CTX700/A/N/NA)
Install the following:
-

Return spring [1]
Stopper arm [2]
Washers [3]
Shift drum stopper arm pivot bolt [4]

• Apply locking agent to the shift drum stopper arm
pivot bolt threads (page 1-14).
• Align the return spring hook [5] with stopper arm cutout.
• Install the stopper arm with its "MGS" mark [6] facing
out.

TORQUE:
Shift drum stopper arm pivot bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Hold the stopper arm [1] with a screwdriver.
Install the dowel pin [2] into the shift drum hole.
Install the shift drum stopper plate [3] while aligning its
slit with the dowel pins.

Apply locking agent to the shift drum center socket bolt
threads (page 1-14 ).
Install and tighten the shift drum center socket bolt [1] to
the specified torque.

TORQUE:23 N·m (2.3 kgf·m, 17 lbHt)

Install the washer [1] and gearshift spindle [2].
• Align the return spring ends with the spring pin.
Install the following:
-

Right crankcase cover (page 11-4)
Left rear cover (page 2-16)

11-15

CLUTCH/GEARSHIFT UNKAGE (CTX700/A/N/NA)

GEARSHIFT PEDAL
REMOVAL/INSTALLATION
Remove the left under side cover (page 2-13).
Remove the bolt [1] and disconnect the gearshift arm
[2] from the spindle.

Remove the gearshift pedal pivot bolt [1] and gearshift
pedal [2].

Remove the pivot collar [1] and dust seals [2].
• When installation, apply grease to the gearshift
pedal pivot collar sliding surface and dust seal lips.

~[1]

~[2]

Installation is in the reverse\order of removal.

[1 J

• Apply grease to the gearshift pedal tie-rod ball joint
area.
TORQUE:
Gearshift pedal pivot bolt:
39 N·m (4.0 kgf·m, 29 lbf·ft)
Gearshift arm pinch bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

Adjust the tie-rod length so that the distance between
the ball joint ends is standard length as shown.
After adjustment tighten the gearshift pedal adjuster
lock nut [1 J to the specified torque.

246.8 mm (9.72 in)

[1]
'-~

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

11 .. 1~

12. DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)

COMPONENT LOCATION ··························12-2

RIGHT CRANKCASE COVER·················· 12-57

SERVICE INFORMATION ···························12-3

DUAL CLUTCH ......................................... 12-66

OCT SYMPTOM TROUBLESHOOTING ·····12·5

PRIMARY DRIVE GEAR/
CKP SENSOR ROTOR .............. ··············· 12-69

OCT ELECTRICAL SYSTEM
LOCATION ···· ···· ··· ····· ···· ·········· ········ ············ 12-5

SHIFT CONTROL MOTOR/
REDUCTION GEARS································ 12-70

OCT SYSTEM DIAGRAM····························12-6
GEARSHIFT LINKAGE·····························12-73
OCT TROUBLESHOOTING
INFORMATION············································12-7

MAINSHAFT SENSOR····························· 12-76

OTC INDEX················································12-11

TR SENSOR··············································12-76

OTC TROUBLESHOOTING ...................... 12-16

SHIFT SPINDLE ANGLE SENSOR·········· 12-77

MODE/SHIFT INDICATOR CIRCUIT
TROUBLESHOOTING······························· 12-56

CLUTCH EOP SENSOR········· .. ················ 12-78
EOT SENSOR··········································· 12-79

AT/MT MODE SWITCH
TROUBLESHOOTING······························· 12-56
RIGHT ENGINE SIDE COVER ··················12-57

OCT SHIFT PEDAL (OPTIONAL) ............. 12-79
CLUTCH INITIALIZE LEARNING
(PCM) ........................................................ 12-81

12-1

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)

COMPONENT LOCATION

23 N·m (2.3 kgf-m, 17 lbf·ft)

12 N·m (1.2 kgf-m, 9 lbf·ft)

12-2

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)

SERVICE INFORMATION
GENERAL
• This section covers service of the electrical and mechanical systems of the Dual Clutch Transmission (OCT).
• A faulty OCT system is often related to poorly connected or corroded connectors. Check those connections before proceeding.
• Read the "OCT Troubleshooting Information" carefully, and inspect and troubleshoot the OCT system according to the OTC.
Observe each step of the procedures one by one. Note the OTC and probable faulty part before starting diagnosis and
troubleshooting.
• The PCM may be damaged if dropped. Also, if a connector is disconnected when current is flowing, the excessive voltage may
damage the PCM. Always turn off the ignition switch before servicing.
• The drive mode AT or MT are changed electrically with the AT/MT mode switch.
• Be sure to use the recommended tires, and the specified drive and driven sprocket to operate the dual clutch transmission
system normally.
• For oil pump service (page 9-8).
• For neutral switch service (page 22-20).
• For VS sensor service (page 22-12).
• The following color codes are used throughout this section.
Bl= Black
Br= Brown

Bu= Blue
G = Green

Gr= Gray
Lg = Light green

0 = Orange
P = Pink

R= Red
V = Violet

W = White
Y=Yellow

For DCT System Troubleshooting
• The OCT system is controlled by the PCM. Therefore some detection items are shared in the PGM-FI and OCT systems, and
they may affect the operation of both systems.
• Before starting any troubleshooting, check the following items and refer to the appropriate troubleshooting.
- MIL blinks or DTC for the PGM-FI system (page 4-9).
- Shift indicator blinks or OTC for the OCT system (page 12-7)
- Symptom of the OCT system operation (page 12-5)
- Serial communication line (page 22-8)
• Refer to the "PGM-FI Troubleshooting Information" for the "CIRCUIT INSPECTION" information (page 4-9).
• The gearshift mechanism included the following items. If the gearshift mechanism is faulty, refer to each component service.
Shift control motor/reduction gears (page 12-70)
- Gearshift linkage (page 12-73)
- Shift drum/shift fork (page 14-14)

Shift Control Motor Function Procedures
NOTE:
• If the PCM has a DTC, the function test does not work.
• The function test is not for the quality check of the shift control motor.
Conduct a test of the shift control motor when the following items have been serviced or replaced.
-

Shift control motor
Reduction gears
TR sensor
Shift spindle angle sensor

1. Connect the MCS (page 4-8).
2. Select the "DRIVE TRAIN MODE MENU".
3. Select the "FUNCTION TEST" and then select the "SHIFT CONTROL MOTOR".
4. Place the motorcycle on its centerstand to raise the rear wheel off the ground.
5. Select the "Shift Up" or "Shift Down" mode while turning the rear wheel above 5 km/h (3 mph) with your hands. Measure the shift
spindle angle sensor voltage at this time. This also tests the mechanical function of the OCT to shift between gears.

12-3

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Linear Solenoid Valve Function Procedures
NOTE:
• If the PCM has a OTC, the function test does not work.
• The function test is not for the quality check of the linear solenoid valve.
• Do not open the throttle while testing the linear solenoid valve function.

Conduct a test of the linear solenoid valves when the linear solenoid valves have been serviced or replaced.
1. Connect the MCS.
2. Select the "DRIVE TRAIN MODE MENU".
3. Select the "FUNCTION TEST" and then select the "Linear Solenoid".
4. Select the "Linear Solenoid 1" or "Linear Solenoid 2".
5. Start the engine and let it idle.
6. Make sure that the transmission is in neutral position.
7. Select the "Drive Linear Solenoid To O kPa", "Drive Linear Solenoid To 400 kPa" or "Drive Linear Solenoid To 800 kPa" mode.
Measure the linear solenoid current at each mode.

TOOLS
SCS service connector
070PZ-ZY30100

Test probe, 2 packs
07ZAJ-RDJA 110

lgnitionMate peak voltage tester
MTP0?-0286 (U.S.A. only)

Peak voltage adaptor
O?HGJ-0020100

Bearing remover, 20 mm
07931-MA?OOOO

Gear holder, 2.5
07724-0010100

(Not available in U.S.A.) with
commercially available digital
multimeter (impedance 10 MQ/DCV
minimum)

(Not available in U.S.A.)

or 07724-001A100 (U.S.A. only)

12-4

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)

DCT SYMPTOM TROUBLESHOOTING
Check the shift indicator"-" blinking of the combination meter (page 12-7).
If the shift indicator"-" is blinking, refer to the OTC index (page 12-11) and begin the appropriate troubleshooting procedure.
If there are no"-" blinking, inspect the engine oil condition and follow the symptom troubleshooting described below.

CLUTCH SLIPS AND MOTORCYCLE DOES NOT ACCELERATE
Check the clutch clearance (page 12-67).

EXCESSIVE NOISE OR VIBRATION AROUND THE DCT SYSTEM
Inspect the following components:
-

Clutch clearance
Dual clutch needle bearings for wear or damage
Primary drive/sub-gear for wear or damage
Primary driven gear for wear or damage
Each fasteners are tightened to their correct torque values

Replace the damaged components if necessary and tighten the loose fasteners to the specified torque.

DCT ELECTRICAL SYSTEM LOCATION

VS SENSOR

CKP SENSOR

PCM

INNER MAINSHAFT
SENSOR
DLC

OUTER MAIN SHAFT
SENSOR

No.2 CLUTCH
EOP SENSOR

--r---1:~~~

SHIFT SPINDLE
ANGLE SENSOR

No.2 LINEAR
SOLENOID VALVE

No.1 CLUTCH
EOP SENSOR
NEUTRAL SWITCH

SHIFT CONTROL
MOTOR

TR SENSOR

No.1 LINEAR
SOLENOID VALVE

12-5

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)

DCT SYSTEM DIAGRAM
FRONT BRAKE LIGHT SWITCH

ILLUMIISTOPIHORN

....
Fu.sr;jE",7i..5·A-. . .Pl~Bu
. ..._8~1-'I"

Bl

GIY

REAR BRAKE LIGHT SWITCH
MAIN FUSE 30A R

ENG STOP
FUSE 7.5A

RIBI

P/Bu
WIY

Bl

GIY
Bl

BIIR

ENGINE STOP-0 s·wjjlii,1T""'c_H_ _ _ _ _...,_ _ __

IGNITION
SWITCH

BIIW
Fl FUSE 15A
SUB PVB
FUSE 7.5A

R

Br/R

From STARTER
RELAY
SWITCH

PVB FUSE30A
830 NEUTRAL

NEUTRAL
SWITCH

-

813 ·T DIRX

(52)

PVB

A12

PVB

A13

SUBVB

A3

YIR
Y/R
Br/R

STARTER
RELAY

-(84)PCM
IGP

823

Bl

Bu/Y
WIY

ABS
L_~~~p-tIA3~3[:::JF~VW1i!i1]
MODULATOR

r

I

•I

VS SENSOR

-

Bu

(66)
FRONT WHEEL
SPEED SENSOR

-

0

W

O

CKPSENSOR -

(19)

~~6

(67)

~0NTROL _

SHIFT SWITCH

-

Lg/R

LglR

A30SFTDOWN

( 24, 31 )

(42)
BuN

A7

SFTUP

N-D SHIFT SWITCH

-(41)
STOP

A26

G/Y

No.1 CLUTCH DOES NOT DISENGAGE

-(58)
No.2 CLUTCH DOES NOT DISENGAGE

-(59)

SFTPANG

MAINSHAFT/COUNTERSHAFT SPEED RATIO

-(71.72)
FAIL SAFE RELAY

-(32)
IGNITION HOLD RELAY

-

-(37)

PC1

(47)

No.1 CLUTCH SLIPS

-(68)
No.2 CLUTCH SLIPS

-(69)
No, 1 CLUTCH OIL PRESSURE

-

- (61,62)

(21,22,23)

No.2 CLUTCH OIL PRESSURE

-(63,64)
FRONT/REAR WHEEL SPEED

TR SENSOR

-

-(65)

(27,51)

GEARSHIFT MECHANISM

-(57)

-:it r:'A"'21,......-,.,:-=,-,

TP SENSOR

A25

-

-(8)

(54)
INNER MAINSHAFT
SENSOR

-

DOWN

(53)

PG1
EOTSENSOR

8u/G

A19

TOIL

B12

PG2

A23

PG2

A24

-(44)

-

( ) :OTC/Number of shift
indicator blinks

d}
12-6

:Short terminals for
reading OTC I shift indicator

PCM 33P (BLACK)
CONNECTOR A

PCM 33P (GRAY)
CONNECTORB

SIDESTAND
SWITCH

Br: Brown
Bl: Black
Y: Yellow
Bu: Blue
G: Green
R: Red
W:White
0: Orange
Lg : Light green
P: Pink
Gr: Gray
V :Violet

DUAL CLUTCH TRANSMISSION (OCT} (CTX7000/ND}

OCT TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the shift indicator"-" does not come
on, check for poor contact or loose pins at all connectors related to the circuit that you are troubleshooting. If the shift indicator"-"
was on, but then went out, the original problem may be intermittent.
Opens and Shorts
"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With
PCMs this can sometimes mean something works, but not the way it's supposed to.
If the shift indicator"-" has come on
Refer to OTC READOUT (page 12-9).
If the shift indicator"-" did not stay on
If the shift indicator"-" did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 12-5).

SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The OCT system is equipped with the self-diagnostic system. When any
abnormality occurs in the OCT system, the PCM have the shift indicator [1]
blinking "-" and stores a OTC in its erasable memory for the relevant
system failure.

\

'

FAIL-SAFE FUNCTION
The OCT system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system.
When the PCM detects a problem in the OCT system, the PCM stops the gearshift function, and hold the gear position. Also, the
·
shift indicator blinks "-" to indicate the OTC.
OTC (Diagnostic Trouble Code)
• The OTC is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the PCM
with the MCS.
The digits in front of the hyphen are the main code, they indicate the component of function failure.
The digits behind the hyphen are the sub code, they detail the specific symptom of the component or function failure.
For example, in the case of the shift spindle angle sensor:
- OTC 21 1 = (Shift spindle angle sensor voltage)- (lower than the specified value)
- OTC 21 - 2 = (Shift spindle angle sensor voltage)- (higher than the specified value)

12-7

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Shift indicator"-" Blink Pattern
• If the MCS is not available, OTC can be read from the PCM memory by the shift indicator "-" blink pattern.
• The number of shift indicator "-" blinks is the equivalent of the main code of the OTC (the sub code cannot be displayed by the
shift indicator"-").
• The shift indicator "-" has two types of blinks, a long blink and short blink. The long blinking lasts for 1.2 seconds, the short
blinking lasts for 0.4 seconds. One long blink is the equivalent of ten short blinks. For example, OTC 14 and OTC 8 are indicated
in the following blink pattern.
• When there isn't a OTC, the shift indicator"-" lights for 2 seconds at intervals of 3 seconds (page 12-10).

t;
::::-:
,,

ON

2 sec.

1.2 sec/

11

11 i1

OFF
2.5 sec.

2.5 sec.

W

0.4 sec.

0.4 sec.

2 sec.

rf
I.

.I W

\0.4 sec. 2.5 sec. \0.4 sec.

I-~---1111
OTC 14

1-~----1111
OTC 8

One long blink = 1O blinks,
plus four short blinks

Eight short blinks

r-1

2.5 sec.

1.2 sec:/

0.4 sec.

r, ri
w

2.5 sec.

\ 0.4 sec.

I

... 1

~

OTC'14

- - - - - - - - - - - - - - - - - - - - _ _ . . , . . . - - - - - • - Pattern repeated
1 cycle

Shift indicator Check
When the ignition switch is turned ON with the engine stop switch to "O", the shift indicator will stay on for a few seconds, then go
off.

CURRENT OTC/STORED DTC
The OTC is indicated in two ways according to the failure status.
• If the PCM detects a current problem, the shift indicator"-" will come on and begin to blink when the sidestand is lowered. The
shift indicator "-" blink pattern will indicate the current OTC.
• If the PCM does not detect any current but has a problem stored in its memory, the shift indicator "-" will not light and blink. If it
is necessary to retrieve the past problem, readout the stored OTC by following the OTC readout procedure (page 12-9).

MCS INFORMATION
Refer to the PGM-FI system (page 4-8).

NOTE:
The front wheel speed sensor signal can be disabled with the MCS for testing. Never ride the motorcycle with the PCM in this
mode.

17 ..R

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC READOUT
NOTE:
• If the shift indicator [1 J blinks, check the PGM-FI OTC (page 4-9). If there
is any problem in the PGM-FI system, troubleshoot it first. Then recheck
the OCT system after erasing the PGM-FI OTC.
• After performing diagnostic troubleshooting, erase the problem code(s)
(page 12-10) and test-ride the motorcycle to be sure that the problem(s)
have been removed.

Read the OTC and stored data with the MCS, and follow the troubleshooting
index (page 12-11).
To read the OTC without the MCS, use the following procedure.

-......_

'~

[1]

Reading DTC with the shift indicator "-"
1. Turn the ignition switch OFF.
Remove the seat (page 2-14).
2. Remove the OLC [1] from the battery box.
Remove the dummy connector from the OLC.
Short the OLC terminals using a special tool.

Connection: Brown - Green

TOOL:
[2] SCS service connector

070PZ-ZY30100

3. Make sure the engine stop switch is turned to "O".
While pushing the shift switch (+) [1], turn the ignition switch ON. Read,
note the shift indicator "-" blinks and refer to the troubleshooting index
(page 12-11 ) .
NOTE:
• If the PCM has no OTC in its memory, the shift indicator "-" will start
blinking (page 12-10).

4. Release the shift switch(+).

[1]

..,

[1]

Jf O

12-9

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
ERASING DTC
Connect the MCS to the OLC (page 4-8).
Erase the OTC with the MCS while the engine is stopped.
To erase the OTC without MCS, refer to the following procedure.

How to erase the DTC without MCS
1. Connect the SCS connector to the DLC (page 12-9).
Make sure the engine stop switch is turned to "O".
While pushing the shift switch (+) [1], turn the ignition switch ON and
engine stop switch "o".

2. Push the shift switch

H

[2].

3. Push the shift switch (+ ).

[2]

4. The self-diagnostic memory is erased if the shift indicator"-" goes off and starts blinking as shown.
2 sec.

2 sec.

II

Ill

I

I

I

I

I

2 sec.

r-1

tt.~~

::....:::
\. I

'\

ON

OFF

l
I

3 sec.

I

I

I

I

- - - - - - 1......
1 cycle

J

3 sec.

3 sec.

I

\

(

I

----11,..__.. Pattern repeated

NOTE:
Note that the self-diagnostic memory cannot be erased if the ignition switch is turned to "OFF" before the shift indicator "-" starts
blinking.

5. Turn the ignition switch OFF.
6. Remove the special tool from the DLC.

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)

DTCINDEX
OTC

Function Failure

("-" blinks)

8-1 (8)

9-1 (9)

9-2 (9)

19-1 (19)

21-1 (21)

21-2(21)

22-1 (22)

23-1 (23)

24-1 (24)

27-1 (27)

31-1 (31)

32-1 (32)

37-1 (37)

41-1 (41)

...

TP sensor abnormal voltage
Loose or poor contact of the TP sensor connector
TP sensor or its circuit malfunction
Faulty PCM
Clutch line EOP sensor low voltage
Clutch line EOP sensor or its circuit malfunction
Faulty PCM
Clutch line EOP sensor high voltage
Loose or poor contact of the clutch line EOP sensor
connector
Clutch line EOP sensor or its circuit malfunction
Faulty PCM
CKP sensor no signal
Loose or poor contact of the CKP sensor connector
Electromagnetic interference at CKP sensor
CKP sensor or its circuit malfunction
Faulty PCM
Shift spindle angle sensor low voltage
Loose or poor contact of the shift spindle angle sensor
connector
Shift spindle angle sensor or its circuit malfunction
Faulty PCM
Shift spindle angle sensor high voltage
Shift spindle angle sensor or its circuit malfunction
Faulty PCM
Shift spindle operation malfunction (after operating gearshift
mechanism)
Gearshift mechanism malfunction
Shift spindle angle sensor malfunction
Shift spindle operation malfunction (while operating gearshift
mechanism)
Gearshift mechanism malfunction
Shift spindle angle sensor malfunction
Shift control motor drive circuit
Shift control motor or its circuit malfunction
Shift control motor drive circuit in the PCM malfunction
Faulty PCM
Shift drum position malfunction
• TR sensor malfunction
Gearshift mechanism malfunction
Faulty PCM
Shift control motor low voltage
Shift control motor circuit malfunction
Ignition hold relay circuit in the PCM malfunction
Blown PVB fuse (30 A)
Loose or poor contact of the PCM 33P (Black) connector
Faulty PCM
Fail safe relay circuit malfunction
PCM (OCT drive circuit) power input line malfunction
Blown PVB fuse (30 A)
Fail safe relay in the PCM malfunction
Faulty PCM
Ignition hold relay malfunction
PCM (OCT drive circuit) sub power input line malfunction
Blown SUB PVB fuse (7.5 A)
Ignition hold relay in the PCM malfunction
Faulty PCM
N-D shift switch malfunction
Loose or poor contact of the N-D shift switch connector
N-0 shift switch or its circuit malfunction
Faulty PCM

..
.
..
...
.

.
..

Symptom/Fail-safe function

. Gearshift function works
normally

.

.
.
.

.
.
.
.

.
...
.
...

12-16

Gearshift function works
normally

. Gearshift function does not

..

..
.

normally

12-17

.

..
..
..
.

12-16

. Gearshift function works

..

..
...

Refer
to
page

work (while driving)
Engine does not operate

12-18

,
Gearshift function does not
work (while driving)
Only shifted into 1st gear

Gearshift function does not
work (while driving)
• Only shifted into 1st gear
Gearshift function does not
work (while driving)
Only shifted into 1st gear

12-19

12-20

.

Gearshift function does not
work (while driving)
Only shifted into 1st gear

.

Gearshift function does not
work (while driving)
Engine does not operate

.

Gearshift function does not
work (while driving)
Engine does not operate

.

12-21

12-22

12-23

12-24

.
.

Gearshift function does not
work (while driving)
Engine does not operate

.
.

Gearshift function does not
work (while driving)
Engine does not operate

12-26

. Gearshift function does not
(while driving)
. work
Engine does not operate

12-26

.

N-D shift switch does not
operate

12-25

12-27

12-11

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC
("-" blinks)

42-1 (42)

44-1 (44)

44-2 (44)

47-1 (47)

47-2 (47)

48-1 (48)

48-2 (48)

49-1 (49)

49-2 (49)

51-1 (51)

51-2 (51)

52-1 (52)

52-2 (52)

53-1 (53)

54-1 (54)

Function Failure

...
..

Shift switch malfunction
Loose or poor contact of the shift switch connector
Shift switch or its circuit malfunction
Faulty PCM
EOT sensor low voltage
EOT sensor or its circuit malfunction
Faulty PCM
EOT sensor high voltage
Loose or poor contact of the EOT sensor connector
EOT sensor or its circuit malfunction
Faulty PCM
No.1 clutch EOP sensor low voltage
No.1 clutch EOP sensor or its circuit malfunction
Faulty PCM
No.1 clutch EOP sensor high voltage
Loose or poor contact of the No.1 clutch EOP sensor
connector
No.1 clutch EOP sensor or its circuit malfunction
Faulty PCM
No.2 clutch EOP sensor low voltage
No.2 clutch EOP sensor or its circuit malfunction
Faulty PCM
No.2 clutch EOP sensor high voltage
Loose or poor contact of the No.2 clutch EOP sensor
connector
No.2 clutch EOP sensor or its circuit malfunction
Faulty PCM
Clutch line low oil pressure (when clutch engage)
Engine oil level low
Faulty oil pump
Faulty clutch oil circuit
Clutch line EOP sensor malfunction
Faulty PCM
Clutch line low oil pressure (when engine running)
Engine oil level low
Faulty oil pump
Faulty clutch oil circuit
Clutch line EOP sensor malfunction
Faulty PCM
TR sensor low voltage
• Loose or poor contact of the TR sensor connector
• TR sensor or its circuit malfunction
Faulty PCM
TR sensor high voltage
TR sensor or its circuit malfunction
Faulty PCM
Neutral switch stuck OFF
Loose or poor contact of the neutral switch connector
Neutral switch or its circuit malfunction
Faulty PCM
Neutral switch stuck ON
Neutral switch or its circuit malfunction
Faulty PCM
Inner mainshaft sensor speed low
Loose or poor contact of the inner mainshaft sensor
connector
Inner mainshaft sensor or its circuit malfunction
Electromagnetic interference
Faulty PCM
Outer rnainshaft sensor speed low
Loose or poor contact of the outer mainshaft sensor
connector
Outer mainshaft sensor or its circuit malfunction
Electromagnetic interference
Faulty PCM

...
..

.
..
..
.

..

..
..

.
...
..

.
..

...

..
.

...
.
..
.

Symptom/Fail-safe function

.

Shift switch does not
operate

Refer
to
page
12-28

. Gearshift function works

.
.

normally

12-29

Gearshift function works
normally

12-30

Gearshift function does not
work

12-31

. Gearshift function does not
work
12-32

. Gearshift function does not
'

.

work

12-31

Gearshift function does not
work
12-32

.

Engine does not operate

.

Engine does not operate

.
.
.
.
.

.

.
..

Gearshift function does not
work (while driving)
Engine does not operate
Gearshift function does not
work (while driving)
Engine does not operate
Operates normally
Shift indicator blinking

Gearshift function does not
work (while driving)
Engine does not operate
Gearshift function does not
work

12-34

12-35

12-36

12-37

12-37

12-38

.

Gearshift function does not
work
12-40

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
OTC

Function Failure

("-" blinks)

55-1 (55)

.
.
.
.

No.1 linear solenoid valve current failure
Loose or poor contact of the No.1 linear solenoid valve
connector
No.1 linear solenoid valve or its circuit malfunction
No.1 linear solenoid valve drive circuit in the PCM
malfunction
Faulty PCM
No.1 linear solenoid valve driver in the PCM failure
Loose or poor contact of the No.1 linear solenoid valve
connector
Loose or poor contact of the PCM 33P connector
No.1 linear solenoid valve or its circuit malfunction
No.1 linear solenoid valve drive circuit in the PCM
malfunction
Faulty PCM
No.2 linear solenoid valve current failure
Loose or poor contact of the No.1 linear solenoid valve
connector
No.2 linear solenoid valve or its circuit malfunction
No.2 linear solenoid valve drive circuit in the PCM
malfunction
Faulty PCM
No.2 linear solenoid valve driver in the PCM failure
Loose or poor contact of the No.2 linear solenoid valve
connector
Loose or poor contact of the PCM 33P connector
No.2 linear solenoid valve or its circuit malfunction
No.2 linear solenoid valve drive circuit in the PCM
malfunction
Faulty PCM
Gearshift mechanism malfunction
Gearshift mechanism malfunction
TR sensor or its circuit malfunction
Faulty PCM
Gear position malfunction Qumps out of gear)
Gearshift mechanism malfunction
TR sensor or its circuit malfunction
Faulty PCM
No.1 clutch does not disengage (when shifting gear)
No.1 clutch sticking
Faulty clutch oil circuit
No.2 clutch does not disengage (when shifting gear)
No.2 clutch sticking
Faulty clutch oil circuit
No.1 clutch oil pressure malfunction (at clutch initial diagnosis)
No.1 clutch EOP sensor malfunction
Faulty clutch oil circuit
Faulty PCM
No.1 clutch no oil pressure
No.1 clutch EOP sensor malfunction
Faulty clutch oil circuit
No.1 linear solenoid valve or its circuit malfunction
Faulty PCM
No.1 clutch oil pressure degradation
No.1 clutch EOP sensor malfunction
Faulty clutch oil circuit
No.1 linear solenoid valve malfunction
Faulty PCM
No.1 clutch oil pressure canceling malfunction
No.1 clutch EOP sensor malfunction
Faulty clutch oil circuit
Loose or poor contact of the linear solenoid valve and No.1
clutch EOP sensor connectors
No.1 linear solenoid valve malfunction
Faulty PCM

Symptom/Fail-safe function

.

Refer
to
page

Gearshift function does not
work

0

.

Gearshift function does not
work

12-43

0

55-2 (55)

.
.
0

.

56-1 (56)

..
.

.

56-2 (56)

57-1 (57)

57-2 (57)

58-1 (58)

59-1 (59)

61-1 (61)

...
.
..

.
..
.
..

..

..

. Gearshift function does not
work

'

. Gearshift function does not

12-44

work

.
.

.
.

Gearshift function does not
work (while driving)
Engine does not operate
Gearshift function does not
work (while driving)
Engine does not operate

12-45

12-45

. Engine does not operate

.

12-45
Engine does not operate
12-46

. Gearshift function does not
work

0

61-2(61)

61-3 (61)

61-4 (61)

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

• Gearshift function does not
work

. Gearshift function does not
work

.

12-46

Engine does not operate

12-13

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
OTC

Function Failure

("-" blinks)

62-1 (62)

62-2 (62)

63-1 (63)

63-2 (63)

63-3 (63)

63-4 (63)

64-1 (64)

..

No.1 clutch oil pressure high
No.1 clutch EOP sensor malfunction
Faulty clutch oil circuit
No.1 linear solenoid valve malfunction
Faulty PCM
No.1 clutch oil pressure high (Prevention of motorcycle
creeps)
No.1 clutch EOP sensor malfunction
Faulty clutch oil circuit
No.1 linear solenoid valve malfunction
Faulty PCM
No.2 clutch oil pressure malfunction (at clutch initial diagnosis)
No.2 clutch EOP sensor malfunction
Faulty clutch oil circuit
Faulty PCM
No.2 clutch no oil pressure
No.2 clutch EOP sensor malfunction
Faulty clutch oil circuit
No.2 linear solenoid valve or its circuit malfunction
Faulty PCM
No.2 clutch oil pressure degradation
No.2 clutch EOP sensor malfunction
Faulty clutch oil circuit
No.2 linear solenoid valve malfunction
Faulty PCM
No.2 clutch oil pressure canceling malfunction
No.2 clutch EOP sensor malfunction
Faulty clutch oil circuit
Loose or poor contact of the linear solenoid valve and No.2
clutch EOP sensor connectors
No.2 linear solenoid valve or its circuit malfunction
Faulty PCM
No.2 clutch oil pressure high
No.2 clutch EOP sensor malfunction
Faulty clutch oil circuit
No.2 linear solenoid valve malfunction
Faulty PCM
No.2 clutch oil pressure high (Prevention of motorcycle
creeps)
No.2 clutch EOP sensor malfunction
Faulty clutch oil circuit
No.2 linear solenoid valve malfunction
Faulty PCM
Front and rear wheel speed signal malfunction
Front wheel speed sensor or its circuit malfunction
VS sensor or its circuit malfunction
Faulty ABS modulator
Faulty PCM
VS sensor no signal
VS sensor or its circuit malfunction
Loose or poor contact of the VS sensor connector
Electromagnetic interference at VS sensor
Faulty PCM
Front wheel speed sensor no signal
Front wheel speed sensor or its circuit malfunction
Loose or poor contact of the front wheel speed sensor
connector
Electromagnetic interference at front wheel speed sensor
Faulty ABS modulator
Faulty pulser ring
Faulty PCM
No.1 clutch operation malfunction (clutch slips)
VS sensor or its circuit malfunction
Faulty No.1 clutch
Faulty PCM

..

..
..
..
.
..
..

..
..
..
.
..

...
.

64-2 (64)

65-1 (65)

66-1 (66)

67-1 (67)

...
.

...
.

..
..

..
..
.
.

68-1 (68)

..
.

Symptom/Fail-safe function

.
.

Gearshift function does not
work (while driving)
Engine does not operate

.
.

Gearshift function does not
work (while driving)
Engine does not operate

.

Refer
to
page

12-46

Gearshift function does not
work

. Gearshift function does not
work

.
.

'

Gearshift function does not
work

12-47

Engine does not operate

. Gearshift function does not
(while driving)
. work
Engine does not operate
. Engine does not operate

.

12-47

Gearshift function does not
work
12-48

.

Gearshift function does not
work
12-49

. Gearshift function does not
work
12-51

.

Gearshift function does not
work

12-52

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC

Function Failure

("-" blinks)

69-1 (69)

71-1 (71)

72-1 (72)

84-1 (84)

1-1 (1)

No.2 clutch operation malfunction (clutch slips)
• VS sensor or its circuit malfunction
Faulty No.2 clutch
Faulty PCM
Inner mainshaft I countershaft speed ratio failure
VS sensor or its circuit malfunction
Inner mainshaft sensor or its circuit malfunction
Faulty PCM
Outer mainshaft I countershaft speed ratio failure
• VS sensor or its circuit malfunction
Outer mainshaft sensor or its circuit malfunction
Faulty PCM
CPU in the PCM malfunction
Faulty PCM
Shift pedal angle sensor (Optional) malfunction
Shift pedal angle sensor or its circuit malfunction
DCT shift pedal (Optional) mechanism malfunction
Loose or poor contact of the shift pedal angle sensor
connector
Faulty PCM

..

...

..

.

..

.
.

Symptom/Fail-safe function

. Gearshift function does not
work

.

Refer
to
page
12-52

Gearshift function does not
work

. Gearshift function does not

12-53

work

.

Gearshift system stops

. DCT shift pedal (Optional)

12-53

function does not work
12-54

,

12-15

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)

DTC TROUBLESHOOTING
OTC 8-1 (TP SENSOR ABNORMAL
VOLTAGE)
1. TP Sensor System Inspection
Check the TP sensor with the MCS when the throttle
is fully closed.

Is Low voltage (about O V) or High voltage (about
5 V) indicated?

YES

- • About O V: See OTC 8-1 (page 4-17)
• About 5 V: See OTC 8-2 (page 4-18)

NO

- Intermittent failure

OTC 9-1 (CLUTCH LINE EOP SENSOR
LOW VOLTAGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. Clutch Line EOP Sensor System Inspection
Connect the MCS and start the engine.
Check the clutch line EOP sensor with the MCS.

Is about O Vindicated?

YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Clutch Line EOP Sensor Inspection
Stop the engine.
Disconnect the clutch line EOP sensor 3P (Black)
connector (page 12-78).
Turn the ignition switch ON and engine stop switch

llo".

Check the clutch line EOP sensor with the MCS.

Is about O Vindicated?

YES

- GO TO STEP 3.

NO

- Replace the clutch line EOP sensor with a
known good one, and recheck.

3. Clutch Line EOP Sensor Input Line Open Circuit
Inspection
Measure the voltage between the wire harness side
clutch line EOP sensor 3P (Black) connector [1]
terminals.

Connection: Yellow/red (+) - Green/yellow(-)
Is the voltage within 4. 75 - 5.25 V?

YES

- GO TO STEP 4.

NO

- Open circuit in the Yellow/red wire
Y/R

G/Y

[1)

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
4. Clutch Line EOP Sensor Output Line Short
Circuit Inspection

Check for continuity between the wire harness side
clutch line EOP sensor 3P (Black) connector [1]
terminal and ground.
Connection: Violet/green - Ground

[1]

Is there continuity?
YES

- Short circuit in the Violet/green wire

NO

- Replace the PCM with a known good one,
and recheck.

V/G

DTC 9-2 (CLUTCH LINE EOP SENSOR
HIGH VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the clutch line EOP sensor 3P
(Black) and PCM 33P connectors, and recheck the
DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. Clutch Line EOP Sensor System Inspection

Check the clutch line EOP sensor with the MCS.
Is about 5 Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Clutch Line EOP Sensor"lnspection

Turn the ignition switch OFF.
Disconnect the clutch line EOP sensor 3P (Black)
connector (page 12-78).
Connect the wire harness side clutch line EOP
sensor 3P (Black) connector [1] terminals with a
jumper wire [2].
Connection: Violet/green - Green/yellow

[1]

Turn the ignition switch ON and engine stop switch

"o".

Check the clutch line EOP sensor with the MCS.
Is the O Vindicated?

YES

- Faulty clutch line EOP sensor

NO

- GO TO STEP 3.

[2]

12-17

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3. Clutch Line EOP Sensor Ground Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector
(page 4-34 ).
Check for continuity between the wire harness side
clutch line EOP sensor 3P (Black) connector [1] and
PCM 33P (Gray) connector [2] terminals.
Connection: Green/yellow - 822
TOOL:
Test probe, 2 packs

B22

[1]

[2]

G/Y

07ZAJ-RDJA 110

Is there continuity?
YES

- GO TO STEP 4.

NO

- Open circuit in the Green/yellow wire

4. Clutch Line EOP Sensor Output Line Open
Circuit Inspection
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
clutch line EOP sensor 3P (Black) connector [1] and
PCM 33P (Black) connector [2] terminals.

[2]

Connection: Violet/green -A17
TOOL: Test probe, 2 packs

VIG

07ZAJ-RDJA110

Is there continuity?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Open circuit in the Violet/green wire

A17

[1 J

DTC 19-1 (CKP SENSOR NO SIGNAL)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the CKP sensor 2P (Red) and PCM
33P (Gray) connectors, then recheck the DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. CKP sensor Peak Voltage Inspection
Disconnect the CKP sensor 2P (Red) connector
(page 12-57).
Turn the ignition switch ON with the engine stop
switch "o".
Crank the engine with the starter motor, and
measure the CKP sensor peak voltage at the CKP
sensor 2P (Red) connector [1] terminals of the CKP
sensor side.
Connection: Yellow (+)-White/yellow(-)
TOOLS:
lgnitionMate peak voltage
tester
Peak voltage adaptor [2]

MTP07-0286
(U.S.A. only) or
07HGJ-0020100
(Not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 MO/DCV minimum)
Is the voltage more than 0. 7 V?

1? .. 1R

YES

- GO TO STEP 2.

NO

- Faulty CKP sensor

[1]
W/Y

y

ffi

8
[2]

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
2. CKP sensor Circuit Inspection

Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector
(page 4-34 ).
Check for continuity between the CKP sensor 2P
(Red) connector [1] and PCM 33P (Gray) connector
[2] terminals.
Connection: Yellow- 811
Green/orange - 86
TOOL:
Test probe, 2 packs

811

86

[1]

07ZAJ-RDJA110

Is there continuity?
YES

- Short circuit in the Yellow wire

NO

-

[2]

• Open circuit in the Yellow wire
• Open circuit in the Green/orange wire

DTC 21-1 (SHIFT SPINDLE ANGLE
SENSOR LOW VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the shift spindle angle sensor 3P
(Gray) and PCM 33P connectors, and recheck the
OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. Shift Spindle Angle Sensor System Inspection

Check the shift spindle angle sensor with the MCS.

Is about O Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Shift Spindle Angle Sensor Input Line Open
Circuit Inspection

Turn the ignition switch OFF.
Disconnect the shift spindle angle sensor 3P (Gray)
connector (page 12-77).
Turn the ignition switch ON and engine stop switch

[1]

"o".

Measure the voltage between the wire harness side
shift spindle angle sensor 3P (Gray) connector [1]
terminals.
Connection: Yellow/red (+) - Green/yellow(-)

Is the voltage within 4.75 - 5.25 V?
YES

- GO TO STEP 3.

NO

- Open circuit in the Yellow/red wire

12-19

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3.' Shift Spindle Angle Sensor Output Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
shift spindle angle sensor 3P (Gray) connector [1]
and PCM 33P (Black) connector [2] terminals.

TOOL:
Test probe, 2 packs

[2]

07ZAJ-RDJA110

V/R

Connection: Violet/red -A16
Is there continuity?

YES

- GO TO STEP 4.

NO

- Open circuit in the Violet/red wire

[ 1]

A16

~-'

4. Shift Spindle Angle Sensor Output Line Short
Circuit Inspection
Check for continuity between the wire harness side
shift spindle angle sensor 3P (Gray) connector [1]
terminal and ground.

Connection: Violet/red - ground
Is there continuity?

YES

- Short circuit in the Violet/red wire

NO

- GO TO STEP 5.

5. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a known
good one (page 12-77).
Connect the shift spindle angle sensor 3P (Gray)
connector and PCM 33P (Black) connector.
Turn the ignition switch ON.
Check the shift spindle angle sensor with the MCS.

Is about O Vindicated?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty original shift spindle angle sensor

DTC 21-2 (SHIFT SPINDLE ANGLE
SENSOR HIGH VOLTAGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. Shift Spindle Angle Sensor System Inspection
Check the shift spindle angle sensor with the MCS.

Is about 5 Vindicated?

12 ..20

YES

- GO TO STEP 2.

NO

- Intermittent failure

[1]

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
2. Shift Spindle Angle Sensor Ground Line Open
Circuit Inspection

Turn the ignition switch OFF.
Disconnect the shift spindle angle sensor 3P (Gray)
connector (page 12-77).
Turn the ignition switch ON and engine stop switch

[1]

"o".
Measure the voltage between the wire harness side
shift spindle angle sensor 3P (Gray) connector [1]
terminals.
Connection: Yellow/red(+)- Green/yellow(-)
Is the voltage within 4.75- 5.25 V?
YES

- GO TO STEP 3.

NO

- Open circuit in the Green/yellow wire

3. Shift Spindle Angle Sensor System Inspection
Replace the shift spindle angle sensor with a known
good one (page 12-77).
Connect the shift spindle angle sensor 3P (Gray)
connector.
Turn the ignition switch ON.
Check the shift spindle angle sensor with the MCS.
Is about 5 Vindicated?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty shift spindle angle sensor

DTC 22-1 (SHIFT SPINDLE
OPERATION MALFUNCTION: AFTER
OPERATING GEARSHIFT
MECHANISM)
1. Shift Spindle Angle Sensor System Inspection

Check the shift spindle angle sensor with the MCS.
Is Low voltage (about O V) or High voltage (about
5 V) indicated?
• About O V: See DTC 21-1 (page 12-19).
• About 5 V: See DTC 21-2 (page 12-20).

YES

-

NO

- GO TO STEP 2.

2. Shift Control Motor/Reduction Gear Condition

Check the shift control motor and reduction gears
are installed properly and are not damaged.
Are the shift control motor and reduction gears
in normal condition?
YES

- GO TO STEP 3.

NO

- Install the shift control motor and reduction
gears properly or replace faulty parts.

12-21

DUAL CLUTCH TRANSMISSION (DCT) {CTX700D/ND)
3. Shift Control Motor Condition Inspection

Remove the shift control motor (page 12-70).
Connect a fully charged 12 V battery [1] to the shift
control motor [2] 2P connector terminals to check
the motor operation.
Change the battery connection to check the reverse
operation.
Does the shift control motor turn in both
directions?
YES

- GO TO STEP 4.

NO

- Faulty shift control motor

12]/
4. Shift Spindle Angle Sensor System Inspection

Remove the shift spindle angle sensor with the
connector connected (page 12-77).
Turn the ignition switch ON.
While turning the shift spindle angle sensor shaft,
check the shift spindle angle sensor voltage with the
MCS.
When turning the sensor shaft clockwise:
Voltage increase
When turning the sensor shaft
counterclockwise:
Voltage decrease
Does the voltage vary properly?
YES

- GO TO STEP 5.

NO

- Faulty shift spindle angle sensor

5. Shift Spindle Angle Sensor Condition Inspection

Check that the shift spindle angle sensor is installed
properly.
Is the shift spindle angle sensor in normal
condition?
YES

- GO TO STEP 6.

NO

- Install the shift spindle angle sensor
properly.

6. DTC Recheck

Recheck the DTC with the MCS.
Is DTC 22-1 indicated?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Intermittent failure

DTC 23-1 (SHIFT SPINDLE
OPERATION MALFUNCTION: WHILE
OPERATING GEARSHIFT
MECHANISM)
Refer to DTC 22-1 (page 12-21)

DUAL CLUTCH TRANSMISSION (OCT) (CTX7000/ND)
OTC 24-1 (SHIFT CONTROL MOTOR
DRIVE CIRCUIT)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. Shift Control Motor Line Open Circuit Inspection
Disconnect the following:
-

A2

A1

PCM 33P (Black) connector (page 4-34)
Shift control motor 2P (Black) connector
(page 12-70)

Check for continuity between the wire harness side
shift control motor 2P (Black) connector [1] and
PCM 33P (Black) connector [2] terminals.

Connection: Pink/blue -A1
Pink/blue - A2
Yellow/blue - A4
Yellow/blue -A15
TOOL:
Test probe, 2 packs

[1]

'[2]

07ZAJ-RDJA110

A4

A15

Is there continuity?
YES

- GO TO STEP 2.

NO

-

• Open circuit in the Pink/blue wire
• Open circuit in the Yellow/blue wire

2. Shift Control Motor Line Short Circuit Inspection
Check for continuity between the wire harness side
shift control motor 2P (Black) connector [1]
terminals and ground.

Connection: Pink/blue - Ground
Yellow/blue - Ground

Y/Bu

Is there continuity?
YES

-

• Short circuit in the Pink/blue wire
• Short circuit in the Yellow/blue wire

NO

- GO TO STEP 3.

[1]

3. Shift Control Motor Inspection
Remove the shift control motor (page 12-70).
Connect a fully charged 12 V battery [1] to the shift
control motor [2] 2P connector terminals to check
the motor operation.
Change the battery connection to check the reverse
operation.

Does the shift control motor turn in both
directions?
YES

- Replace the PCM with a known good one.

NO

- Faulty shift control motor

12)/
12-23

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 27-1 (SHIFT DRUM POSITION
MALFUNCTION)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. TR Sensor System Inspection
Check the TR sensor with the MCS.

Is Low voltage (about O V) or High voltage (about
5 V) indicated?
• About O V: See OTC 51-1 (page 12-35).
• About 5 V: See OTC 51-2 (page 12-36).

YES

-

NO

- GO TO STEP 2.

2. Shift Control Motor/Reduction gear condition
Check the shift control motor and reduction gears
are installed properly and are not damaged.

Are the shift control motor and reduction gears
in normal condition?
YES

- GO TO STEP 3.

NO

- Install the shift control motor and reduction
gears properly or replace faulty parts.

3. Shift Control Motor Condition Inspection
Remove the shift control motor (page 12-70).
Connect a fully charged 12 V battery [1 J to the shift
control motor [2) 2P connector terminals to check
the motor operation.
Change the battery connection to check the reverse
operation.

Does the shift control motor turn in both
directions?
YES

- GO TO STEP 4.

NO

- Faulty shift control motor

12]/
4. TR Sensor System Inspection
Remove the TR sensor with the connector
connected (page 12-76).
Turn the ignition switch ON.
While turning the TR sensor shaft, check the TR
sensor voltage with the MCS.

When turning the sensor shaft clockwise:
Voltage increase
When turning the sensor shaft
counterclockwise:
Voltage decrease
Does the voltage vary properly?
YES

- GO TO STEP 5.

NO

- Faulty TR sensor

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
5. TR Sensor Condition Inspection
Check that the TR sensor is installed properly and is
not damaged.

Is the TR sensor in normal condition?

YES

- GO TO STEP 6.

NO

- Install the TR sensor properly.

6. DTC Recheck
Recheck the OTC with the MCS.

Is DTC 27-1 indicated?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Intermittent failure

DTC 31-1 (SHIFT CONTROL MOTOR
LOW VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the shift control motor 2P (Black)
and PCM 33P (Black) connectors, and recheck the
OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. DTC Recheck
Erase the DTCs (page 12-10).
Check the OTC with the MCS.

Is DTC 32-1 or 37-1 indicated?

YES

- • OTC 32-1 indicated (page 12-26).
• OTC 37-1 indicated (page 12-26).

NO

- GO TO STEP 2.

2. Shift Control Motor Line Open Circuit Inspection
Disconnect the following:
-

A2

A1

PCM 33P (Black) connector (page 4-34)
Shift control motor 2P (Black) connector
(page 12-70)

Check for continuity between the wire harness side
shift control motor 2P (Black) connector [1) and
PCM 33P (Black) connector [2) terminals.

Connection: Pink/blue -A1
Pink/blue - A2
Yellow/blue -A4
Yellow/blue -A15
TOOL:
Test probe, 2 packs

[1)
07ZAJ-RDJA 110

[2)

A4

A15

Is there continuity?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- • Open circuit in the Pink/blue wire
• Open circuit in the Yellow/blue wire

12-25

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 32-1 (FAIL SAFE RELAY CIRCUIT
MALFUNCTION)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the PCM 33P (Black) connector and
recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. Shift Control
Inspection

Motor Power Supply Voltage

Check the shift control motor power supply voltage
with the MCS.

Is there battery voltage?

YES
NO

- GO TO STEP 2.
Open circuit in the Yellow/red wire
between the PCM 33P (Black)
connector and fuse box
• Open circuit in the Red wire between
the fuse box and starter relay switch 4P
(Red) connector
• Blown PVB fuse (30 A)

2. DTC Recheck
Recheck the OTC with the MCS.

Is DTC 32-1 indicated?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Intermittent failure

DTC 37-1 (IGNITION HOLD RELAY
MALFUNCTION)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the PCM 33P (Black) connector and
recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. PCM (DCT Drive Circuit) Sub Power Voltage
Inspection
Check the PCM sub power voltage with the MCS.

Is the battery voltage indicated?

YES
NO

- GO TO STEP 2.
Open circuit in the Brown/red wire
between the PCM 33P (Black)
connector and fuse box
• Open circuit in the Red wire between
the fuse box and starter relay switch 4P
(Red) connector
• Blown SUB PVB fuse (7.5 A)

2. DTC Recheck
Recheck the OTC with the MCS.

Is DTC 37-1 indicated?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Intermittent failure

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 41-1 (N-D SHIFT SWITCH
MALFUNCTION)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the right handlebar switch and PCM
33P connectors, and recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. N-0 Shift Switch Power Input Voltage Inspection
Disconnect the right handlebar switch 6P (Black)
connector (page 22-18).
Turn the ignition switch ON with the engine stop
switch "o".
Measure the voltage between the wire harness side
right handlebar switch 6P (Black) connector [1]
terminal and ground.
Connection: Yellow/red (+) - Ground (-)

[1]

Is the voltage within 4.75- 5.25 V?
YES

- GO TO STEP 2.

NO

- Open circuit in the Yellow/red wire

2. N-D Shift Switch Inspection
Turn the ignition switch OFF.
Check for continuity between the switch side right
handlebar switch 6P (Black) connector [1] terminals
in each switch position.
Connection:
N switch:
Light green/blue - Red
D switch:
Black/yellow - Red

[1)

BI/Y

Is there continuity with the switch pushed and
no continuity with the switch released?
YES

- GO TO STEP 3.

NO

- Faulty N-D shift switch

3. N·D Shift Switch Input Line Open Circuit
Inspection
Disconnect the PCM 33P (Black) connector
(page 4-34).
Check for continuity between the wire harness side
right handlebar switch 6P (Black) connector [1] and
PCM 33P (Black) connector [2] terminals.
Connection: Light green/black -A18
Black/yellow - A29

TOOL:
Test probe, 2 packs

A18

Lg/Bl

07ZAJ-RDJA110

Is there continuity?
YES

- GO TO STEP 4.

NO

- • Open circuit in the Light green/black
wire
• Open circuit in the Black/yellow wire
~-

[1]

A29

[2]

12-27

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
4. N-D Shift Switch
Inspection

Input Line

Short Circuit

Check for continuity between the wire harness side
PCM 33P (Black) connector [1] terminals and
ground.

A18

Connection: A18- Ground
A29-Ground
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

Is there continuity?
YES

- • Short circuit in the Light green/black
wire
• Short circuit in the Black/yellow wire

NO

- Replace the PCM with a known good one,
and recheck.

A29

DTC 42-1 (SHIFT SWITCH
MALFUNCTION)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the left handlebar switch and PCM
33P connectors, then recheck the DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. Shift Switch Power Input Voltage Inspection
Disconnect the left handlebar switch 6P (Black)
connector (page 22-.18).
Turn the ignition switch ON with the engine stop
switch "o".
Measure the voltage between the wire harness side
left handlebar switch 6P (Black) connector [1]
terminal and ground.

Connection: Yellow/red (+) - Ground (-)

Is the voltage within 4.75- 5.25 V?
YES

- GO TO STEP 2.

NO

- Open circuit in the Yellow/red wire

2. Shift Switch Inspection
Turn the ignition switch OFF.
Check for continuity between the switch side left
handlebar switch 6P (Black) connector [1] terminals
in each switch position.
Connection:
"+" switch:
Green/blue - Yellow/red
"-" switch:
Light green/red - Yellow/red

Is there continuity with the switch pushed and
no continuity with the switch released?

1? ...?A

YES

- GO TO STEP 3.

NO

- Faulty shift switch

[1]

. Lg/R
G/Bu

[1]

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3. Shift Switch Input Line Open Circuit Inspection

Disconnect the PCM 33P (Black) connector
(page 4-34).
Check for continuity between the wire harness side
left handlebar switch 6P (Black) connector [1] and
PCM 33P (Black) connector [21 terminals.
Connection: Blue/yellow -A7
Light green/red - A30
TOOL:
Test probe, 2 packs

Bu/Y
.-----1

07ZAJ-RDJA 110

Is there continuity?
YES

- GO TO STEP 4.

NO

-

Lg/R
A30

• Open circuit in the Blue/yellow wire
• Open circuit in the Light green/red wire

[2]

4. Shift Switch Input Line Short Circuit Inspection
Check for continuity between the wire harness side
PCM 33P (Black) connector [1) terminals and
ground.
Connection: A7 - Ground
A30-Ground
TOOL:
Test probe, 2 packs

A7

07ZAJ-RDJA 110

Is there continuity?
• Short circuit in the Blue/yellow wire
• Short circuit in the Light green/red wire

YES

-

NO

- Replace the PCM with a known good one,
and recheck.

A30

[1]

DTC 44-1 (EQT SENSOR LOW
VOLTAGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. EOT Sensor System Inspection

Check the EOT sensor with the MCS.
Is about O Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. EOT Sensor Inspection

Turn the ignition switch OFF.
Disconnect the EOT sensor 2P (Black) connector
(page 12-79).
Turn the ignition switch ON and engine stop switch

"o".

Check the EOT sensor with the MCS.
Is about O Vindicated?

YES

- GO TO STEP 4.

NO

- GO TO STEP 3.

12-29

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3. EOT Sensor Resistance Inspection

Turn the ignition switch OFF.
Measure the resistance at the EOT sensor [1]
terminals.

[1]

Is the resistance within 2.5- 2.8 kO (20°C/68°F)?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty EOT sensor

4. EOT Sensor Input Line Short Circuit Inspection

Check the continuity between the wire harness side
2P (Black) connector [1] terminal and ground.
Connection: Blue/green - Ground

[1]

Is there continuity?
YES

- Short circuit in the Blue/green wire

NO

- Replace the PCM with a known good one,
and recheck.

DTC 44-2 (EQT SENSOR HIGH
VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the EOT sensor 2P (Black) and
PCM 33P connectors, and recheck the DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. EOT Sensor System Inspection

Check the EOT sensor with the MCS.
Is about 5 Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. EOT Sensor Inspection

Turn the ignition switch OFF.
Disconnect the EOT sensor 2P (Black) connector
(page 12-79).
Short the wire harness side EOT sensor 2P (Black)
connector [1] terminals with a jumper wire [2].
Connection: Blue/green - Green/yellow

[1]

Turn the ignition switch ON and engine stop switch

"o".

Check the EOT sensor with the MCS.

Is about O Vindicated?
YES

- Faulty EOT sensor.

NO

- GO TO STEP 3.

[2]

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3. EOT Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
EOT sensor 2P (Black) connector [1] and PCM 33P
(Black) connector [2] terminals.

[2]

Connection: Blue/green -A19
TOOL:
Test probe, 2 packs

Bu/G

07ZAJ-RDJA 110

Is there continuity?
YES

- GO TO STEP 4.

NO

- Open circuit in the Blue/green wire

4. EOT

Sensor
Inspection

Ground

Line

Open

[1 J

A19

Circuit

Disconnect the PCM 33P (Gray) connector
(page 4-34 ).
Check for continuity between the wire harness side
EOT sensor 2P (Black) connector [1] and PCM 33P
(Gray) connector [2] terminals.

[1]

[2]

Connection: Green/yellow - 822
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

Is there continuity?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Open circuit in the Green/yellow wires

822

DTC 47-1 or 48-1 (No.1 or No.2
CLUTCH EOP SENSOR LOW
VOLTAGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. Clutch EOP Sensor System Inspection
Connect the MCS and start the engine.
Check the clutch EOP sensor with the MCS.

Is about O Vindicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Clutch EOP Sensor Inspection
Stop the engine.
Disconnect the clutch EOP sensor 3P (Gray)
connector (page 12-78).
Turn the ignition switch ON and engine stop switch
110".
Check the clutch EOP sensor with the MCS.

Is about O Vindicated?
YES

- GO TO STEP 3.

NO

- Faulty clutch EOP sensor

12-31

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3. Clutch EOP Sensor Input Line Open Circuit
Inspection
Measure the voltage between the wire harness side
clutch EOP sensor 3P (Gray) connector [1]
terminals.
Connection: Yellow/red (+) - Green/yellow(-)
/s the voltage within 4.75- 5.25 V?

YES

- GO TO STEP 4.

NO

- Open circuit in the Yellow/red wire

[1]

4. Clutch EOP Sensor Output Line Short Circuit
Inspection
Turn the ignition switch OFF.
Check for continuity between the wire harness side
clutch EOP sensor 3P (Gray) connector [1] terminal
and ground.
Connection:
No.1 clutch EOP sensor:
Yellow/green - Ground
No.2 clutch EOP sensor:
Black/green - Ground
/s there continuity?

YES

- • Short circuit in the Yellow/green wire
• Short circuit in the Black/green wire

NO

- Replace the PCM with a known good one,
and recheck.

DTC 47-2 or 48-2 (No.1 or No.2
CLUTCH EOP SENSOR HIGH
VOLTAGE)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the clutch EOP sensor 3P (Gray)
and PCM 33P connectors, and recheck the DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. Clutch EOP Sensor System Inspection
Check the clutch EOP sensor with the MCS.
/s about 5 Vindicated?

YES

- GO TO STEP 2.

NO

- Intermittent failure

[1]

Y/G or BI/G

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
2. Clutch EOP Sensor Inspection
Turn the ignition switch OFF.
Disconnect the clutch EOP sensor 3P (Gray)
connector (page 12-78).
Short the wire harness side clutch EOP sensor 3P
(Gray) connector [1] terminals with a jumper wire
[2].

[1]

Connection:
No.1 clutch EOP sensor:
Yellow/green - Green/yellow
No.2 clutch EOP sensor:
Black/green - Green/yellow
Turn the ignition switch ON and engine stop switch

"o".

[2]

Check the clutch EOP sensor with the MCS.

Is about O Vindicated?

YES

- Faulty clutch EOP sensor

NO

- GO TO STEP 3.

3. Clutch EOP Sensor Ground Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector
(page 4-34 ).
Check for continuity between the wire harness side
clutch EOP sensor 3P (Gray) connector [1] and
PCM 33P (Gray) connector [2] terminals.

[

1

[2]

1

Connection: Green/yellow- 822
G/Y

TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

Is there continuity?

YES

- GO TO STEP 4.

NO

- Open circuit in the Green/yellow wire

822

4. Clutch EOP Sensor Output Line Open Circuit

Inspection
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
clutch EOP sensor 3P (Gray) connector [1] and
PCM 33P (Black) connector [2] terminals.

Connection:
No.1 clutch EOP sensor:
Yellow/green -AG
No.2 clutch EOP sensor:
Black/green - AS
TOOL:
Test probe, 2 packs

A6

[2]

BI/G

07ZAJ-RDJA 110

Is there continuity?

YES

[1]

A5

- Replace the PCM with a known good one,
and recheck.

NO

- • Open circuit in the Yellow/green wire
• Open circuit in the Black/green wire

12-33

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
OTC 49-1, 49-2 (CLUTCH LINE LOW
Oil PRESSURE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. Clutch Line EOP Sensor System Inspection
Check the clutch line EOP sensor with the MCS.
Is Low voltage (about O VJ or High voltage (about
5 VJ indicated?
YES

- • About O V (while engine running): See
OTC 9-1 (page 12-16).
• About 5 V: See OTC 9-2 (page 12-17).

NO

- GO TO STEP 2.

2. Engine Oil Level Inspection
Check the engine oil level (page 3-9).
Is the engine oil level correct?
YES

- GO TO STEP 3.

NO

- Add the recommended oil to the upper
level.

3. Clutch Line Oil Filter Condition Inspection
Check the clutch oil filter (page 3-11 ).
Is the oil filter in good condition?
YES

- GO TO STEP 4.

NO

- Replace the clutch oil filter.

4. Clutch Line EOP Sensor Inspection
Replace the clutch line EOP sensor with a known
good one (page 12-78).
Erase the DTCs (page 12-10).
Test-ride the motorcycle above 2,000 rpm and stop
the engine.
Check the clutch line EOP sensor with the MCS.
Is DTC 49-1 or 49-2 indicated?
YES

- GO TO STEP 5.

NO

- Faulty original clutch line EOP sensor

5. PCM Inspection
Replace the PCM with a known good one
(page 4-34 ).
Test-ride the motorcycle above 2,000 rpm and stop
the engine.
Check the clutch line EOP sensor with the MCS.
Is DTC 49-1 or 49-2 indicated?
YES

- • Oil pressure relief valve stuck open
• Damaged oil pump
• Internal oil leak in the clutch oil line

NO

- Faulty original PCM

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
OTC 51-1 (TR SENSOR LOW
VOLTAGE)
NOTE:

• Before starting the inspection, check for loose or
poor contact on the TR sensor 3P (Black) and PCM
33P connectors, and recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81).
1. TR Sensor System Inspection

Check the TR sensor with the MCS.
Is the voltage about O V?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. TR Sensor Input Line Open Circuit Inspection

Turn the ignition switch OFF.
Disconnect the TR sensor 3P (Black) connector
(page 12-76).
Turn the ignition switch ON and engine stop switch

[1]

"o".

Measure the voltage between the wire harness side
TR sensor 3P (Black) connector (1] terminals.
Connection: Yellow/red (+) - Green/yellow(-)
Is the voltage within 4.75- 5.25 V?
YES

- GO TO STEP 3.

NO

- Open circuit in the Yellow/red wire

3. TR Sensor Output Line Open Circuit Inspection

Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector
(page 4-34).
Check for continuity between the wire harness side
TR sensor 3P (Black) connector [1] and PCM 33P
{Black) connector [2] terminals.
Connection: Black/pink -A28
TOOL:
Test probe, 2 packs

[1]

[2]

BI/P

07ZAJ-RDJA110

Is there continuity?
YES

- GO TO STEP 4.

NO

- Open circuit in the Black/pink wire

A28

4. TR Sensor Output Line Short Circuit Inspection

Check for continuity between the wire harness side
TR sensor 3P (Black) connector [1] terminal and
ground.
Connection: Black/pink - Ground

[1]

Is there continuity?
YES

- Short circuit in the Black/pink wire

NO

- GO TO STEP 5.

12-35

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
5. TR Sensor Inspection

Replace the TR sensor with a known good one
(page 12-76).
Connect the TR sensor 3P (Black) connector and
PCM 33P (Black) connector.
Turn the ignition switch ON.
Check the TR sensor with the MCS.
Is the voltage about O V?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty original TR sensor

DTC 51-2 (TR SENSOR HIGH
VOLTAGE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. TR Sensor System Inspection

Check the TR sensor with the MCS.
Is about 5 Vindicated?

YES

- GO TO STEP 2.

NO

- Intermittent failure

2. TR Sensor Ground Line Open Circuit Inspection

Turn the ignition switch OFF.
Disconnect the TR sensor 3P (Black) connector
(page 12-76).
Turn the ignition switch ON and engine stop switch

"o".
Measure the voltage between the wire harness side
TR sensor 3P (Black) connector [1] terminals.
Connection: Yellow/red(+)- Green/yellow(-)
Is the voltage within 4. 75 - 5.25 V?

YES

- GO TO STEP 3.

NO

- Open circuit in the Green/yellow wire

3. TR Sensor Inspection

Replace the TR sensor with a known good one
(page 12-76).
Connect the TR sensor 3P (Black) connector.
Turn the ignition switch ON.
Check the TR sensor with the MCS.
Is about 5 Vindicated?

1?..~R

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty original TR sensor

[1)

DUAL CLUTCH TRANSMISSION (OCT) (CTX7000/ND)
OTC 52-1 (NEUTRAL SWITCH STUCK
OFF)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the neutral switch and PCM 33P
(Gray) connectors, and recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. OTC Recheck
Recheck the OTC with the MCS.

Is DTC 52-1 indicated?

YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Neutral Switch Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the following:
-

[1 J

830

[2]

PCM 33P (Gray) connector (page 4-34)
Neutral switch connector (page 22-20)

Check for continuity between the wire harness side
PCM 33P (Gray) connector [1] and neutral switch
connector [2] terminals.

Connection: 830 - Light green
TOOL:
Test probe, 2 packs

Lg

07ZAJ-RDJA 110

Is there continuity?

YES

- GO TO STEP 3.

NO

- Open circuit in the Light green wire

3. Neutral Switch Inspection
Replace the neutral switch with a known good one
(page 22-20).
Connect the PCM 33P (Gray) connector and neutral
switch connector.
Turn the ignition switch ON and engine stop switch

"o".

Recheck the OTC with the MCS.

Is DTC 52-1 indicated?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty original neutral switch

OTC 52-2 (NEUTRAL SWITCH STUCK
ON)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81).

1. Neutral Switch Line Short Circuit Inspection
Disconnect the neutral switch connector
(page 22-20).
Check for continuity between the neutral switch
connector terminal and ground.

Connection: Light green - Ground
Is there continuity?

YES

- Short circuit in the Light green wire.

NO

- GO TO STEP 2.

12-37

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
2. Neutral Switch Inspection
Replace the neutral switch with a known good one
(page 22-20).
Connect the neutral switch connector.
Check the DTC with the MCS.

Is DTC 52-2 indicated?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty original neutral switch

DTC 53-1 (INNER MAINSHAFT
SENSOR SPEED LOW)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the inner mainshaft sensor 3P
(Black) and PCM 33P connectors, and recheck the
DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. DTC Recheck
Erase the DTCs (page 12-10).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS.

Is DTC 53-1 indicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Inner Mainshaft Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the inner mainshaft sensor 3P (Black)
connector (page 12-76).
Turn the ignition switch ON and engine stop switch
"O".
Measure the voltage between the wire harness side
inner mainshaft sensor 3P (Black) connector [1]
terminals.
Connection: Brown/yellow(+) - Green/yellow(-)

[1]

Is there about battery voltage?
YES

- GO TO STEP 3.

NO

- GO TO STEP 4.

3. Inner Mainshaft Sensor Output Line Inspection
Measure the voltage between the wire harness side
3P (Black) connector [1] terminal and ground.
Connection: Gray/yellow(+) - Ground (-)

Is the voltage within 4.75- 5.25 V?

17-~A

YES

- GO TO STEP 8.

NO

- GO TO STEP 6.

[1]

GrN

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
4. Inner Mainshaft Sensor Input Line Open Circuit
Inspection

Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
inner mainshaft sensor 3P (Black) connector [1] and
PCM 33P (Black) connector [2] terminals.
Connection: Brown/yellow-A14
TOOL:
Test probe, 2 packs

[1]

A14

Br/Y
07ZAJ-RDJA 110

Is there continuity?
YES

- GO TO STEP 5.

NO

- Open circuit in the Brown/yellow wire

[2]

5. Inner Mainshaft Sensor Ground Line Open
Circuit Inspection

Disconnect the PCM 33P (Gray) connector
(page 4-34 ).
Check for continuity between the wire harness side
inner mainshaft sensor 3P (Black) connector [1] and
PCM 33P (Gray) connector [2] terminals.

[2]

Connection: Green/yellow - 822
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

Is there continuity?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Open circuit in the Green/yellow wire

6. Inner Mainshaft Sensor
Circuit Inspection

Output Line

[1]

822

Open

Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
inner mainshaft sensor 3P (Black) connector [1] and
PCM 33P (Black) connector [2] terminals.

[2]

Connection: Gray/yellow - A20

Gr/Y
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

Is there continuity?
YES

- GO TO STEP 7.

NO

- Open circuit in the Gray/yellow wire

A20

[1]

12-39

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
7. Inner Mainshaft Sensor Output Line Short
Circuit Inspection

Check for continuity between the wire harness side
inner mainshaft sensor 3P (Black) connector [1]
terminal and ground.
Connection: Gray/yellow - Ground
Is there continuity?

YES

- Short circuit in the Gray/yellow wire

NO

- GO TO STEP 8.

8. Inner Mainshaft Sensor Inspection

Turn the ignition switch OFF.
Replace the inner mainshaft sensor with a known
good one (page 12-76).
Erase the DTCs (page 12-10).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS.
Is DTC 53-1 indicated?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty original inner mainshaft sensor

DTC 54-1 (OUTER MAINSHAFT
SENSOR SPEED LOW)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the outer mainshaft sensor 3P
(Black) and PCM 33P connectors, and recheck the
DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. DTC Recheck

Erase the DTCs (page 12-10).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS.
Is DTC 54-1 indicated?

1,.A.n

YES

- GO TO STEP 2.

NO

- Intermittent failure

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
2. Outer
Mainshaft
Inspection

Sensor

Input

Voltage

Turn the ignition switch OFF.
Disconnect the outer mainshaft sensor 3P (Black)
connector (page 12-76).
Turn the ignition switch ON and engine stop switch

[1]

"O".
Measure the voltage between the wire harness side
outer mainshaft sensor 3P (Black) connector [1]
terminals.

Connection: White/blue (+) - Green/yellow(-)
Is there about battery voltage?

YES

- GO TO STEP 3.

NO

- GO TO STEP 4.

3. Outer Mainshaft Sensor Output Line Inspection
Measure the voltage between the wire harness side
3P (Black) connector [1] terminal and ground.

[1]

Connection: Pink/yellow(+) - Ground (-)
Is the voltage within 4. 75 - 5.25 V?

YES

- GO TO STEP 8.

NO

- GO TO STEP 6.

4. Outer Mainshaft Sensor Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
outer mainshaft sensor 3P (Black) connector [1] and
PCM 33P (Black) connector [2] terminals.

[1]

[2]

Connection: White/blue - A25
W/Bu

TOOL:
Test probe, 2 packs

07ZAJ-RDJA110

Is there continuity?

YES

- GO TO STEP 5.

NO

- Open circuit in the White/blue wire

A25

12-41

DUAL CLUTCH TRANSMISSION (OCT) {CTX700D/ND)
5. Outer Mainshaft Sensor Ground Line Open
Circuit Inspection

Disconnect the PCM 33P (Gray) connector
(page 4-34 ).
Check for continuity between the wire harness side
outer mainshaft sensor 3P (Black) connector [1] and
PCM 33P (Gray) connector [2] terminals.
Connection: Green/yellow - 822
TOOL:
Test probe, 2 packs

[1 J

[2]

07ZAJ-RDJA 110

Is there continuity?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Open circuit in the Green/yellow wire

822

6. Outer Mainshaft Sensor Output Line Open
Circuit Inspection

Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
outer mainshaft sensor 3P (Black) connector [1] and
PCM 33P (Black) connector [2] terminals.

[2]

Connection: Pink/yellow - A21
P/Y

TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

Is there continuity?
YES

- GO TO STEP 7.

NO

- Open circuit in the Pink/yellow wire

A21

7. Outer Mainshaft Sensor Output Line Short
Circuit Inspection

Check for continuity between the wire harness side
outer mainshaft sensor 3P (Black) connector [1]
terminal and ground
Connection: Pink/yellow - Ground
Is there continuity?
YES

- Short circuit in the Pink/yellow wire

NO

- GO TO STEP 8.

8. Outer Mainshaft Sensor Condition Inspection

Turn the ignition switch OFF.
Replace the outer mainshaft sensor with a known
good one (page 12-76).
Erase the DTCs (page 12-10).
Test-ride the motorcycle and stop the engine.
Check the OTC with the MCS. .
Is DTC 54-1 indicated?

12-42

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty original outer mainshaft sensor

[1 J

[1 J

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 55-1, 55-2 (No.1 LINEAR
SOLENOID VAL VE)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the linear solenoid valve 4P (Green)
and PCM 33P (Black) connectors, and recheck the
DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. DTC Recheck
Recheck the DTC with the MCS.
Is DTC 55-1 or 55-2 indicated?

YES

- GO TO STEP 2.

NO

- Intermittent failure

2. No.1 Linear Solenoid Valve Inspection
Turn the ignition switch OFF.
Disconnect the linear solenoid valve 4P (Green)
connector (page 12-57).
Measure the resistance between the linear solenoid
valve side 4P (Green) connector [1] terminals.

[1]

Connection: Blue - Gray
Standard: 5.0 - 5.6 O (20°C/68°F)
Is the resistance within standard range?

YES

- GO TO STEP 3.

NO

- Faulty linear solenoid valve

Gr

3. No.1 Linear Solenoid Valve Input/ground Line
Open Circuit Inspection
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
linear solenoid valve 4P (Green) connector [1] and
PCM 33P (Black) connector [2] terminals.
Connection: Gray/white - A9
Blue/white -A10

TOOL:
Test probe, 2 packs

(1]

A9

[2]

07ZAJ-RDJA 110

Is the continuity normal?

YES

- GO TO STEP 4.

NO

- • Open circuit in the Gray/white wire
• Open circuit in the Blue/white wire

A10

12-43

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
4. No.1 Linear Solenoid Valve Input/ground Line
Short Circuit Inspection

Check for continuity between the wire harness side r - - - - - - - - - - - - - - - - - - - ,
linear solenoid valve 4P (Green) connector [1]
[ 1]
terminals and ground.
Connection: Gray/white - Ground
Blue/white - Ground
Is there continuity?
• Short circuit in the Gray/white wire
• Short circuit in the Blue/white wire

YES

-

NO

- Replace the PCM with a known good one,
and recheck.

DTC 56-1, 56-2 (No.2 LINEAR
SOLENOID VALVE)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the linear solenoid valve 4P (Green)
and PCM 33P (Black) connectors, and recheck the
OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. DTC Recheck

Recheck the OTC with the MCS.
Is DTC 56-1 or 56-2 indicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. No.2 Linear Solenoid Valve Inspection

Turn the ignition switch OFF.
Disconnect the linear solenoid valve 4P (Green)
connector (page 12-57).
Measure the resistance between the linear solenoid
valve side 4P (Green) connector [1] terminals.
Connection: Yellow-White/red

[1 J

Standard: 5.0 - 5.6 Q (20°C/68°F)
Is the resistance within standard range?
YES

- GO TO STEP 3.

NO

- Faulty linear solenoid valve

.____ __, W/R

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3. No.2 Linear Solenoid Valve Input/ground Line
Open Circuit Inspection

Disconnect the PCM 33P (Black) connector
(page 4-34).
Check for continuity between the wire harness side
linear solenoid valve 4P (Green) connector (1] and
PCM 33P (Black) connector (2] terminals.
Connection: Pink/white - A 11
Brown/white -A22
TOOL:
Test probe, 2 packs

[1 J

A11

[2]

07ZAJ-RDJA 110

Is the continuity normal?
YES

- GO TO STEP 4.

NO

-

A22

• Open circuit in the Pink/white wire
• Open circuit in the Brown/white wire

4. No.2 Linear Solenoid Valve Input/ground Line
Short Circuit Inspection

Check for continuity between the wire harness side
linear solenoid valve 4P (Green) connector [1]
terminals and ground.
Connection: Pink/white - Ground
Brown/white - Ground

[ ]
1

Is there continuity?
• Short circuit in the Pink/white wire
• Short circuit in the Brown/white wire

YES

-

NO

- Replace the PCM with a known good one,
and recheck.

DTC 57-1 (GEARSHIFT MECHANISM
MALFUNCTION)
See page 12-24

DTC 57-2 (GEAR POSITION
MALFUNCTION; JUMPS OUT OF
GEAR)
See page 12-24

DTC 58-1 (No.1 CLUTCH DOES NOT
DISENGAGE; WHEN SHIFTING GEAR)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. Clutch Condition Inspection

Remove the dual clutch assembly and inspect the
clutch for sticking (page 12-66).
Is the No. 1 clutch stuck?
YES

- Faulty clutch

NO

- GO TO STEP 2.

12-45

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
2. Clutch Oil Line Inspection
Check the clutch oil passages in the right crankcase
cover and mainshaft for clogging.
Is the oil passage clogged?

YES

- Clean the oil passage.

NO

- Replace the PCM with a known good one,
and recheck.

DTC 59-1 (No.2 CLUTCH DOES NOT
DISENGAGE; WHEN SHIFTING GEAR)
See page 12-45

DTC 61-1, 61-2, 61-3, 61-4, 62-1, 62-2
(No.1 CLUTCH OIL PRESSURE
MALFUNCTION)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. DTC Recheck
Recheck the OTC with the MCS.
Is DTC 47·1, 47-2, 55-1 or 55-2 indicated?

YES

- •
•
•
•

NO

- GO TO STEP 2.

OTC
OTC
OTC
OTC

47-1
47-2
55-1
55-2

is
is
is
is

indicated
indicated
indicated
indicated

(page
(page
(page
(page

12-31).
12-32).
12-43).
12-43).

2. No.1 Clutch EOP Sensor Inspection

Replace the No.1 clutch EOP sensor with a known
good one (page 12-78).
Erase the OTCs (page 12-10).
Test-ride the motorcycle and stop the engine.
Check the No.1 clutch EOP sensor with the MCS.
Is DTC 61-1, 61-2, 61-3, 61-4, 62-1 or 62-2
indicated?

YES

- GO TO STEP 3.

NO

- Faulty original No.1 clutch EOP sensor

3. PCM Inspection
Replace the PCM with a known good one
(page 4-34).
Test-ride the motorcycle and stop the engine.
Check the No.1 clutch EOP sensor with the MCS.
Is DTC 61-1, 61-2, 61-3, 61-4, 62·1 or 62-2
indicated?

YES

- • Faulty No.1 linear solenoid valve
• Clogged No.1 clutch oil line
• Internal oil leak in the No.1 clutch oil
line

NO

- Faulty original PCM

DUAL CLUTCH TRANSMISSION (OCT) (CTX7000/ND)
OTC 63-1, 63-2, 63-3, 63-4, 64-1, 64-2
(No.2 CLUTCH Oil PRESSURE
MALFUNCTION)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. DTC Recheck
Recheck the OTC with the MCS.

Is DTC 48-1, 48-2, 56-1 or 56-2 indicated?
•
•
•
•

OTC 48-1
OTC 48-2
OTC 56-1
OTC 56-2

is
is
is
is

indicated
indicated
indicated
indicated

YES

-

NO

- GO TO STEP 2.

(page
(page
(page
(page

12-31).
12-32).
12-44).
12-44).

2. No.2 Clutch EOP Sensor Inspection

Replace the No.2 clutch EOP sensor with a known
good one (page 12-78).
Erase the DTCs (page 12-10).
Test-ride the motorcycle and stop the engine.
Check the No.2 clutch EOP sensor with the MCS.

Is DTC 63-1, 63-2, 63-3, 63-4, 64-1 or 64-2
indicated?
YES

- GO TO STEP 3.

NO

- Faulty original No.2 clutch EOP sensor

3. PCM Inspection

Replace the PCM with a known good one
(page 4-34).
Test-ride the motorcycle and stop the engine.
Check the No.2 clutch EOP sensor with the MCS.

Is OTC 63-1, 63-2, 63-3, 63-4, 64-1 or 64-2
indicated?
• Faulty No.2 linear solenoid valve
• Clogged No.2 clutch oil line
• Internal oil leak in the No.2 clutch oil
line

YES

-

NO

- Faulty original PCM

12-47

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 65-1 {FRONT AND REAR WHEEL
SPEED SIGNAL MALFUNCTION)
NOTE:
• Before starting the inspection, check that the tire
sizes are correct, and the drive and driven sprockets
are the specified ones.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).
1. DTC Recheck

Erase the OTCs (page 12-10).
Test-ride the motorcycle above 18 km/h ( 11 mph)
for more than 30 seconds.
Stop the engine.
Check the OTC with the MCS.
Is DTC 66-1 or 67-1 indicated?
• OTC 66-1 is indicated (page 12-49).
• OTC 67-1 is indicated (page 12-51).

YES

-

NO

- GO TO STEP 2.

2. Front Wheel Speed Sensor Air Gap Inspection

Measure the front wheel speed sensor air gap
(page 20-20).
Is the air gap correct?
YES

- GO TO STEP 3.

NO

- Check each part for deformation and
looseness
and
correct accordingly.
Recheck the air gap.

3. Front Wheel Speed Sensor Condition Inspection
Inspect the area around the front wheel speed
sensor.
Check that there is no iron or other magnetic
deposits between the pulser ring and wheel speed
sensor, and check the pulser ring slots for
obstructions.
Check installation condition of the pulser ring or
wheel speed sensor for looseness.
Check the pulser ring and sensor tip for deformation
or damage.
Are the sensor and pulser ring in
condition?

good

YES

- GO TO STEP 4.

NO

- Remove any deposits. Install properly or
replace faulty part.

4. VS Sensor Condition Inspection
Remove the VS sensor (page 22-12).
Check the VS sensor for damage or contaminated.
Is the VS sensor in good condition?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Replace the VS sensor with a known good
one, and recheck.

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 66-1 (VS SENSOR NO SIGNAL)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the VS sensor 3P (Black) and PCM
33P (Black) connector, and recheck the DTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. DTC Recheck
Erase the DTCs (page 12-10).
Test-ride the motorcycle above 18 km/h (11 mph)
for more than 30 seconds.
Stop the engine.
Check the DTC with the MCS.
Is DTC 66-1 indicated?

YES

- GO TO STEP 2.

NO

- Intermittent failure

2. VS Sensor Pulse Inspection
Support the motorcycle securely and raise the rear
wheel off the ground.
Disconnect the PCM 33P (Black) connector
(page 4-34).
Turn the ignition switch ON and engine stop switch

[1 J

"o".

Measure the voltage between the PCM 33P (Black)
connector [1] and ground while slowly turning the
rear wheel by hand.
Connection: A32 (+)-Ground(-)
Standard:
Repeat O to 5 V
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

A32

Is the indicated voltage at the standard value?

YES

- Replace the PCM with a known good one,
and recheck.

NO

- GO TO STEP 3.

3. VS Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the VS sensor 3P (Black) connector
(page 22-12).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
VS sensor 3P (Black) connector [1] terminals.
Connection: Pink/blue (+) - Green/red (-)

[1]

Is there battery voltage?

YES

- GO TO STEP 4.

NO

- • Open circuit in the Pink/blue wire
• Open circuit in the Green/red wire

12-49

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
4. VS Sensor Output Line Inspection
Measure the voltage between the wire harness side
3P (Black) connector [1] terminal and ground.

[1]

Connection: Pink/green (+) - Ground (-)
P/G

Is the voltage within 4. 75 - 5.25 V?
YES

- GO TO STEP 7.

NO

- GO TO STEP 5.

5. VS Sensor Output Line Open Circuit Inspection
Turn the ignition switch OFF.
Check for continuity between the wire harness side
VS sensor 3P (Black) connector [1] and PCM 33P
(Black) connector [2] terminals.

[2]

[1]

Connection: Pink/green - A32
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110

PIG

Is there continuity?
YES

- GO TO STEP 6.

NO

- Open circuit in the Pink/green wire
A32

6. VS Sensor Output Line Short Circuit Inspection
Check for continuity between the wire harness side
VS sensor 3P (Black) connector [1] terminal and
ground.
Connection: Pink/green - Ground
Is there continuity?
YES

- Short circuit in the Pink/green wire

NO

- GO TO STEP 7.

7. VS Sensor Inspection
Turn the ignition switch OFF.
Replace the VS sensor with a known good one
(page 22-12).
Erase the DTCs (page 12-10).
Test-ride the motorcycle above 18 km/h ( 11 mph)
for more than 30 seconds.
Stop the engine.
Check the OTC with the MCS.
Is DTC 66-1 indicated?

12-50

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty original VS sensor

[1]

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 67-1 (FRONT WHEEL SPEED
SENSOR NO SIGNAL)
NOTE:
• Before starting the inspection, check for loose or
poor contact on the front wheel speed sensor 2P
(Blue), ABS modulator 18P and PCM 33P (Black)
connectors, and recheck the OTC.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. DTC Recheck
Erase the DTCs (page 12-10).
Test-ride the motorcycle above 18 km/h (11 mph).
Stop the engine.
Check the OTC with the MCS.

Is OTC 67-1 indicated?
YES

- GO TO STEP 2.

NO

- Intermittent failure

2. ABS Problem Code Inspection
Check the ABS problem code (page 20-8).

Does the ABS modulator have any problem
code?
YES

- Follow the problem code index
(page 20-8).

NO

- GO TO STEP 3.

3. Front Wheel Speed Sensor Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the following:
-

A33

[2]

[1)

ABS modulator 18P connector (page 20-7)
PCM 33P (Black) connector (page 4-34)

Check for continuity between the ABS modulator
18P connector [1] and PCM 33P (Black) connector
[2] terminals.

Connection: Pink - A33
TOOL:
Test probe, 2 packs

p

07ZAJ-RDJA110

Is there continuity?
YES

- GO TO STEP 4.

NO

- Open circuit in the Pink wire

4. Front Wheel Speed Sensor Line Short Circuit
Inspection
Check for continuity between the wire harness side
PCM 33P (Black) connector [1] and ground.

[1]

Connection: A33 - Ground
TOOL:
Test probe, 2 packs

07ZAJ-RDJA110

Is there continuity?
YES

- Short circuit in the Pink wire

NO

- Replace the PCM with a known good one,
and recheck.
A33

12-51

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 68-1 (No.1 CLUTCH OPERATION
MALFUNCTION; CLUTCH SLIPS)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. DTC Recheck
Erase the OTCs (page 12-10).
Test-ride the motorcycle above 18 km/h (11 mph).
Stop the engine.
Check the OTC with the MCS.
Is DTC 66-1 indicated?
YES

- Refer to OTC 66-1 troubleshooting
(page 12-49).

NO

- GO TO STEP 2.

2. Clutch Clearance Inspection
Remove the No.1 clutch assembly and measure the
clutch clearance (page 12-66).
Is the clearance within the standard range?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty No.1 clutch assembly

DTC 69-1 (No.2 CLUTCH OPERATION
MALFUNCTION; CLUTCH SLIPS)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. DTC Recheck
Erase the OTCs (page 12-10).
Test-ride the motorcycle above 18 km/h (11 mph).
Stop the engine.
Check the OTC with the MCS.
Is DTC 66-1 indicated?
YES

- Refer to OTC 66-1 troubleshooting
(page 12-49).

NO

- GO TO STEP 2.

2. Clutch Condition Inspection
Remove the No.2 clutch assembly and measure the
clutch clearance (page 12-66).
Is the clearance within the standard range?

12-52

YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty No.2 clutch assembly.

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 71-1, 72-1 (INNER, OUTER
MAINSHAFT/COUNTERSHAFT SPEED
RATIO FAILURE)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. OTC Recheck 1
Check the OTC with the MCS.

Is OTC 53-1, 54-1 or 66-1 indicated?
YES

NO

OTC 53-1 is indicated (page 12-38).
• OTC 54-1 is indicated (page 12-40).
• OTC 66-1 is indicated (page 12-49).

- GO TO STEP 2.

2. OTC Recheck 2
Erase the OTCs (page 12-10).
Test-ride the motorcycle above 18 km/h (11 mph).
Stop the engine.
Check the OTC with the MCS.

Is OTC 71-1 or 72-1 indicated?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Intermittent failure

DTC 84-1 (CPU IN THE PCM
MALFUNCTION)
NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. OTC Recheck
Erase the OT Cs (page 12-10).
Check the OTC with the MCS.

Is OTC 84-1 indicated?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Intermittent failure

12-53

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
DTC 1-1 (SHIFT PEDAL ANGLE
SENSOR (OPTIONAL) MALFUNCTION)
NOTE:
• Before starting this inspection, check for loose or
poor contact on the shift pedal angle sensor 3P
(Blue) connector and PCM 33P connectors, and
recheck the OTC.
• If the PCM is replaced, perform the following:
- Clutch Initialize Learning Procedure (page 12-81)
- OCT Shift Pedal (Optional) Registration
(page 12-79)
• If the OCT shift pedal (Optional) is removed from the
vehicle, perform the OCT Shift Pedal Registration
Cancellation (page 12-80).

1. Recheck the DTC
Erase the DTCs (page 12-10).
Turn the ignition switch ON and engine stop switch
"O".
Operate the OCT shift pedal up and down several
times with the engine stopped.
Recheck the OTC with the MCS.
Is the OTC 1-1 indicated?

YES

- GO TO STEP 2.

NO

- Intermittent failure

2. Shift Pedal
Inspection

Angle

Sensor

Input

Voltage

Turn the ignition switch OFF.
Remove the left under side cowl (page 2-13)
Disconnect the shift pedal angle sensor 3P (Blue)
connector.
Turn the ignition switch ON.
Measure the voltage between the wire harness side
shift pedal angle sensor 3P {Blue) connector [1]
terminals.

[1]

Connection: Yellow/red (+) - Green/yellow ( - )
Is the voltage within 4. 75 - 5.25 V?

YES

- GO TO STEP 4.

NO

- GO TO STEP 3.

3. Shift Pedal
Inspection

Angle

Sensor

Open

Circuit

Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector
(page 4-34 ).
Check for continuity between the wire harness side
shift pedal angle sensor 3P (Blue) connector [1] and
PCM 33P (Gray) connector [2] terminals.

[2]

Connection: Green/yellow - 822
Yellow/red - 814
TOOL:
Test probe, 2 packs

07ZAJ-RDJA110

Is there continuity?

YES
NO

- Replace the PCM with a known good one,
and recheck.
-

• Open circuit in Green/yellow wire
• Open circuit in Yellow/red wire

[1]
~_,

822

814

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
4. Shift Pedal Angle Sensor Output Line Open
Circuit Inspection

Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector
(page 4-34 ).
Check for continuity between the wire harness side
shift pedal angle sensor 3P (Blue) connector [1] and
PCM 33P (Gray) connector [2] terminals.
Connection: Yellow/violet - 819
TOOL:
Test probe, 2 packs

Y/V

07ZAJ-RDJA110

Is there continuity?
YES

- GO TO STEP 5.

NO

- Open circuit in Yellow/violet wire
'-~

819

[1]

[2]

5. Shift Pedal Angle Sensor Output Line Short
Circuit Inspection

Check for continuity between the wire harness side
shift pedal angle sensor 3P (Blue) connector [1] and
ground.
Connection: Yellow/violet - Ground

[1]

~

Is there continuity?
YES

- Short circuit in Yellow/violet wire.

NO

- GO TO STEP 6.

6. Shift Pedal Angle Sensor Resistance Inspection

Measure the
pedal angle
terminals.
Connection:
Standard:

resistance at the sensor side shift
sensor 3P (Black) connector [1]
Yellow/red - Blue/green
4 - 6 kn (20°C/68°F)

[1]

Operate the OCT shift pedal to check that the
resistance changes in accordance with the pedal
operation.
Connection: Yellow/blue- Blue/green
When moving the pedal up:
Resistance decreases
When moving the pedal down:
Resistance increases

Are the resistance inspections normal?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Faulty shift pedal angle sensor, replace the
OCT shift pedal as an assembly.

12-55

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)

MODE/SHIFT INDICATOR CIRCUIT
TROUBLESHOOTING
If the mode indicator does not operate, check that the
combination meter shows following when the ignition
switch is turned ON with the engine stop switch "o".
-

MIL [1] and engine oil pressure indicator [2] stay on.
Shift indicator"-" [3] is blinking.
Tachometer and high coolant temperature indicator
do not come on.

If so, check the serial communication line (page 22-8).
If not so, replace the combination meter.

AT/MT MODE SWITCH
TROUBLESHOOTING
If the engine can be started but AT/MT mode cannot be
changed, perform this troubleshooting.
NOTE:
• Before starting the inspection, check for loose or
poor contact on the right handlebar switch and PCM
33P connectors, and recheck the AT/MT mode
switch operation.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81 ).

1. AT/MT mode
Inspection

switch

Power

Input

Voltage

Disconnect the right handlebar switch 6P (Black)
connector (page 22-18).
Turn the ignition switch ON with the engine stop
switch "O".
Measure the voltage between the wire harness side
right handlebar switch 6P (Black) connector [1]
terminal and ground.
Connection: Black/white(+) - Ground (-)

[1]

Is there battery voltage?
YES

- GO TO STEP 2.

NO

- Open circuit in the Black/white wire
between the right handlebar switch
connector and fuse box (Fl fuse)

2. AT/MT mode switch Inspection

Turn the ignition switch OFF.
Check for continuity between the switch side right
handlebar switch 6P (Black) connector [1] terminals
in each switch position.
Connection: Black/white - Blue/black

[1]

BI/W

Is there continuity with the switch pushed and
no continuity with the switch released?
YES

- GO TO STEP 3.

NO

- Faulty AT/MT mode switch

Bu/Bl

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
3. AT/MT mode switch Input Line Open Circuit
Inspection
Disconnect the PCM 33P (Black) connector
(page 4-34 ).
Check for continuity between the wire harness side
right handlebar switch 6P (Black) connector [1] and
PCM 33P (Black) connector [2] terminals.

[1]

[2]

Connection: White/yellow - A27
TOOL:
Test probe, 2 packs

W!Y
07ZAJ-RDJA 110

Is there continuity?
YES

- Replace the PCM with a known good one,
and recheck.

NO

- Open circuit in the White/yellow wire

A27

RIGHT ENGINE SIDE COVER
REMOVAL/INSTALLATION
Remove the right under side cowl (page 2-13).
Remove the three socket bolts [1] and right engine side
cover [2].
Installation is in the reverse order of removal.

RIGHT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-10).
Remove the following:
-

Side shelters (page 2-11)
Right under side cowl (page 2-13)
Right engine side cover (page 12-57)

Release the CKP sensor 2P (Red) connector [1] from
the stay and disconnect it.

12-57

DUAL CLUTCH TRANSMISSION (OCT) (CTX7000/ND)
Release the linear solenoid valve 4P (Green) connector
[1] from the stay and disconnect it.
Release the wire band [2] from the frame pipe.

Disconnect the clutch EOP sensor 3P connectors [1].
Remove the following:
-

Bolt [2] and shift spindle angle sensor [3]
Bolt [4] and wire clip stay [5]
Bolts [6] and wire clamps [7]

Remove the wire harness and shift spindle angle
sensor wire from the right crankcase cover.

Do not allow dust or
dirt to enter the oil
passages.

Remove the bolts [1] and right crankcase cover [2].

Remove the oil joint pipe [1] and dowel pins [2].
Remove the 0-rings from the joint pipe.
Remove the seal rings [3] from the mainshaft end.

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
LINEAR SOLENOID VALVE BODY
DISASSEMBLY
NOTE:
• Keep dust and dirt away from all the parts.
• Be careful not to damage the mating surfaces of the
valve body components.
Remove the right crankcase cover (page 12-57).
Remove the right crankcase cover wire clamp bolt [1]
and wire clamp [2].
Remove the wire grommets [3] from the right crankcase
cover.

Remove the bolts [1] and linear solenoid valve body [2).

Remove the separate plate [1] and dowel pins [2],

Remove the bolts [1] and valve body cover [2].
Remove the wire grommet [3] from the valve body
cover.

[2]

12-59

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Remove the bolt [1], linear solenoid valves [2] and
stopper plate [3] from the valve body.

[1]

Remove the stopper plate from the linear solenoid
valves.

Wash all the parts with a high flash point or nonflammable solvent and blow through all oil passages
with compressed air to clean completely.
Check the linear solenoid valves [1] and valve body [2]
for scratches, scoring or damage.

[2]

[3]

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
LINEAR SOLENOID VALVE BODY
ASSEMBLY
NOTE:
Clean all the parts with compressed air. Make sure that
there is no dust or lint on any parts.

VALVE BODY

LINEAR SOLENOID VALVE;-71
VALVE BODY COVER

WIRE CLAMP

Coat linear solenoid valves [1 J with engine oil.
Set the stopper plate [2] into the grooves in the solenoid
valves.

Install the linear solenoid valves [1] and stopper plate
[2] into the valve body.

~. [ ]
3
---.-

[2]

Apply locking agent to the threads of the stopper plate
bolt[3] (page 1-14).
Install the stopper plate bolt and tighten it.

TORQUE:12 N·m (1.2 kgf·m, 9 lbHt)

12-61

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
Set the wire grommet [1] into the groove in the body
cover [2].
Install the valve body cover onto the valve body and
tighten the bolts securely.

Check the oil filter screen [1] and packing [2] for
damage and replace them if necessary.
Install the dowel pins [3] and separate plate [4] onto the
right crankcase cover.

Install the valve body [1] and bolts [2], and tighten the
bolts in the sequence as shown.

Apply liquid sealant (TB1207B manufactured by Three
Bond or equivalent) to the CKP sensor wire grommet
and linear solenoid valve wire grommet sealing surface.
Set the linear solenoid valve wire grommet [1] and CKP
sensor wire grommet [2] into the groove in the right
crankcase cover.
Apply locking agent to the threads of the right
crankcase cover wire clamp bolts [3] (page 1-14).
Install the wire clamp [4] and tighten bolts.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)

Install the right crankcase cover (page 12-64 ).

12-62

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Oil GUIDE COLLAR REMOVAL/
INSTALLATION
Remove the right crankcase cover (page 12-57).
Remove the snap ring [1] from the right crankcase
cover.

TOOL:
[2] Bearing remover, 20 mm

07931-MA?OOOO
(Not available in
U.S.A.)

Remove the 0-rings from the oil guide collar.

Coat new 0-rings [1] with engine oil and install them ..,.._,,,___
into the grooves in the oil guide collar [2].
Install the oil guide collar into the right crankcase cover
until it is seated.
• Align the oil guide collar index mark and tabs with
the right crankcase cover index mark and slits.

Install the snap ring [1] into the right crankcase cover
groove with the chamfered edge facing in.
Install the right crankcase cover (page 12-64).

12-63

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
INSTALLATION
Do not allow dust or
dirt to enter the oil
passages.

Coat new 0-rings [1] with engine oil and install them
onto the oil joint pipe [2].
Install the oil joint pipe into the oil pump.

Install the dowel pins [1].
Apply engine oil to new seal rings [2] and install them
into the mainshaft grooves.
Pu.sh in the seal rings to seat them into the grooves.

Clean the right crankcase cover mating surfaces
thoroughly.
Apply liquid sealant (TB1207B manufactured by Three
Bond or equivalent) to the right crankcase cover mating
surface as shown.

Install the right crankcase cover [1].
Install the bolts [2] and tighten them in a crisscross
pattern in 2 or 3 steps.

1 ? ..~.4

•

,-1~

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Route the wire harness and shift spindle angle sensor
wire on the right crankcase cover properly (page 1-21).
Coat a new 0-ring [1] with engine oil and install it onto
the shift spindle angle sensor [2].
Install the shift spindle angle sensor by aligning the flat
surfaces of the sensor and spindle.

Install the following:
-

Wire clamps [1] and bolts [2]
Wire clip stay [3] and bolt [4]

Install the shift spindle angle sensor bolt [5] and tighten
it.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Connect the clutch EOP sensor 3P connectors [6].
(Connector with no mark to the upper sensor, connector
with "P" mark to the middle sensor and connector with
"1" mark to the lower sensor.)

Connect the linear solenoid valve 4P (Green) connector
[1] and install it to the ABS modulator stay.
Secure the wire band [2] to the frame pipe with the
starter motor cable.

Connect the CKP sensor 2P (Red) connector [1].
Install the following:
-

Side' shelters (page 2-11)
Right under side cowl (page 2-13)
Right engine side cover (page 12-57)

Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-9).

12-65

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)

DUAL CLUTCH
REMOVAL
Remove the right crankcase cover (page 12-57).
Align the gear teeth of the primary drive gear and subgear [1] by prying the gears through the holes [2] and
hold them with a 6 mm socket bolt [3].

Remove the ball bearing [1].
Remove the dual clutch assembly [2] from the
mainshaft.

Remove the seal rings [1] from the mainshaft grooves.

DISASSEMBLY
Remove clutch guide 1 [1], clutch guide 2 [2] and
washers [3] from the clutches.

[2]
~

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Remove the clutch assemblies [1] and 0-rings [2] from
the primary driven gear.
• Do not disassemble the clutch assembly.
• The No.1 clutch assembly (for inner mainshaft) and
No.2 clutch assembly (for outer mainshaft) are the
same parts.

[2]

CLUTCH CLEARANCE INSPECTION
Set a dial indicator on the end plate [1] with the plate
bottomed.
Measure the clearance by lifting the end plate against
the snap ring and record it.
Perform this inspection at three points in 120° apart.
SERVICE LIMIT: 2.0 mm (0.08 in)

If the measured value exceeds the service limit, replace
the clutch assembly.

ASSEMBLY
Coat new 0-rings [1] with engine oil and install them
into the grooves in the primary driven gear.
Install the clutch assemblies [2] onto the primary driven
gear.

\\

I

[11

Apply engine oil to the needle bearings in the primary
driven gear.

--:7J!l

~

18

[3]

• The primary driven gear has the index line [1] on its
flange for the installation direction. The dual clutch
assembly should be installed with the index line
facing the outside.
Line up the clutch disc tabs with the two wide grooves
[2] aligned as shown.
Install the washer [3] onto the clutch assembly.
Install clutch guide 1 [4] into the clutch on the index line
side by aligning the gear teeth with the clutch disc tabs.

[1]

12-67

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Turn over the dual clutch assembly while holding clutch
guide 1.
Apply engine oil to the needle bearings in the primary
driven gear.
Line up the clutch disc tabs with the two wide grooves
[1] aligned as shown.
Install the washer [2] onto the clutch assembly.
Install clutch guide 2 [3] into the clutch by aligning the
gear teeth with the clutch disc tabs.

INSTALLATION
Apply engine oil to new seal rings [1] and install them
into the mainshaft grooves.
Push in the seal rings to seat them into the grooves.

Install the dual clutch assembly [1] onto the mainshaft,
being careful not to damage the seal rings.
Install the ball bearing [2] onto clutch guide 1 [3] with
the marked side facing out.

Remove the 6 mm socket bolt [1] to free the primary
drive gear and sub-gear [2].
Install the right crankcase cover (page 12-64 ).

12-68

[2]

DUAL CLUTCH TRANSMISSION (DCT) {CTX700D/ND)

PRIMARY DRIVE GEAR/CKP SENSOR
ROTOR
REMOVAL
Remove the right crankcase cover (page 12-57).
Hold the primary drive gear and sub-gear with a 6 mm
socket bolt (page 12-66).
Install the special tool between the primary drive and
driven gears, and loosen the primary drive gear bolt [1].
TOOL:
[2] Gear holder, 2.5

07724-0010100 or
07724-001A100
(U.S.A. only)

Do not separate the
sub-gear from the
primary drive gear
unless necessary.

INSTALLATION
Install the primary drive gear/sub-gear [1] and CKP
sensor rotor [2] onto the crankshaft by aligning their
wide grooves with the wide tooth.

Apply engine oil to the primary drive gear bolt threads
and seating surface.
Install the washer [1] and primary drive gear bolt [2].
Install the special tool between the primary drive and
driven gears, and tighten the primary drive gear bolt.
TOOL:
[2] Gear holder, 2.5

07724-0010100 or
07724-001A100
(U.S.A. only)

TORQUE: 93 N·m (9.5 kgf·m, 69 lbMt)

Remove the 6 mm socket bolt (4] to free the primary
drive gear and sub-gear.
Install the right crankcase cover (page 12-64 ).

12-69

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)

SHIFT CONTROL MOTOR/REDUCTION
GEARS
REMOVAL
Remove the left crankcase rear cover (page 2-16).
Disconnect the shift control motor 2P (Black) connector

[1].
Remove the bolts [2] and shift control motor [3].

Remove the bolt [1], wire clip stay [2] and TR sensor [3].
Remove the 0-ring [4] from the TR sensor.

Remove the bolts [1] and reduction gear cover [2].

Remove the dowel pins [1] and gasket [2].
Remove the reduction gears [3].

1?-70

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
INSTALLATION

REDUCTION GEAR
CASE COVER

S~/II
. fi 0-RING

~

GASKETS

REDUCTION GEAR C
REDUCTION GEAR B
REDUCTION GEAR A

14 N·m (1.4 kgf·m, 10 lbf·ft)
14 N·m (1.4 kgf·m, 10 lbf-ft)

SHIFT CONTROL MOTOR

Apply 2 - 4 g (0.07 - 0.14 oz) of specified grease to the
reduction gear journals and teeth.
SPECIFIED GREASE: Unirex N3 grease
·
(Exxon Mobil)
Install the reduction gear B [1] and reduction gear C [2]
by aligning the gear ends with the ribs of the crankcase.
Check that the punch marks [3] on the gear and shift
spindle line up as shown.
Install reduction gear A [4].

Install the dowel pins [1] and a new gasket [2].

12-71

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Install the reduction gear cover [1] and bolts [2], then
tighten the bolts.
TORQUE: 14 N·m (1.4 kgf·m, 10 lbHt)

Coat a new 0-ring [1] with engine oil and install it into
the groove in the TR sensor [2].
Install the TR sensor into the crankcase by aligning the
flat surfaces of the sensor and shift drum end.

Install the wire clip stay [1] and TR sensor bolt [2], and
tighten the bolt.
TORQUE:12 N·m (1.2 kgf·m, 9 lbHt)

Coat a new 0-ring [1] with engine oil and install it into
the groove in the shift control motor [2].

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Install the shift control motor [1] and bolts [2], and
tighten the bolts.
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)

Connect the shift control motor 2P (Black) connector
[3].
Install the left crankcase rear cover (page 2-16).

GEARSHIFT LINKAGE
REMOVAL
Remove the following:
-

Shift control motor/reduction gears (page 12-70)
Dual clutch (page 12-66)
Gearshift spindle [1]
Washer [2]

-

Drum shifter collar [1]
Bolts [2]
Drum shifter guide plate/drum shifter assembly [3]

-

Guide plate distance collar [1]
Stopper arm side collar [2]
Shift drum center bolt [3]
Shift drum center [4]

12-73

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
-

Shift drum stopper arm [1]
Stopper arm return spring [2]
Stopper arm distance collar [3]
Shift drum center dowel pins [4]
8 x 20 mm dowel pins [5] if necessary

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Drum shifter guide plate
Drum shifter
Ratchet pawls
Plungers
Plunger springs

Replace if necessary.
GEARSHIFT SPINDLE

Check the return springs [1] for fatigue or damage
replace them if necessary.

[1]

Check the gearshift spindle [2] for wear or bend.
Check the spindle arm [3] for wear, damage or
deformation.
Replace the gearshift spindle as an assembly if
necessary.

[3]

INSTALLATION
Install the following:
-

8 x 20 mm dowel pins [1]
Shift drum center dowel pins [2]
Stopper arm distance collar [3]
Stopper arm return spring [4]
Shift drum stopper arm [5]

[2]

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Hold the shift drum stopper arm [1] with a screwdriver
and install the shift drum center [2] by aligning the
groove [3] with the dowel pin [4].

Apply locking agent to the threads of the shift drum
center bolt [1] (page 1-14).
Install the shift drum center bolt and tighten it.
TORQUE:23 N·m (2.3 kgf·m, 17 lbMt)

Install the stopper arm side collar [2] and guide plate
distance collar [3].

Install the plunger springs [1], plungers [2] and ratchet
pawls [3] into the drum shifter [4] and set them in the
drum shifter guide plate [5].

Install the drum
assembly [1].

shifter guide plate/drum

shifter

Apply locking agent to the threads of the guide plate
bolts [2] (page 1-14).
Install the guide plate bolts and tighten them.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)

Install the drum shifter collar [3] onto the drum shifter.

12-75

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Install the washer [1] onto the gearshift spindle [2] and
insert the spindle into the crankcase while aligning the
return spring ends with spring pin and the spindle arm
hole with the drum shifter collar.
Install the following:
-

Dual clutch (page 12-68)
Reduction gears/shift control motor (page 12-71)

MAINSHAFT SENSOR
REMOVAL/INSTALLATION
NOTE:
The mainshaft sensors and VS sensor are the same
parts.
Inner mainshaft
sensor:

Remove the fuel tank (page 7-7).
Disconnect the inner mainshaft sensor 3P (Black)
connector [1], then remove the bolt [2] and inner
mainshaft sensor [3].

Outermainshaft
sensor:

Remove the ABS modulator (page 20-23).
Disconnect the outer mainshaft sensor 3P (Black)
connector [4], then remove the bolt [5] and outer
mainshaft sensor (6].

[2]

Remove the 0-rings [7] from the mainshaft sensors.
Installation is in the reverse order of removal.
• Replace the 0-ring with a new one.
• Apply engine oil to a new 0-ring.

[3]

TR SENSOR
REMOVAL/INSTALLATION
Remove the left crankcase rear cover (page 2-16).
Release the TR sensor 3P (Black) connector [1] from
the stay and disconnect it.
Remove the two wire bands [2].

1?.7~

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
Release the TR sensor wire [1] from the stay [2] and
release the wire band boss [3].
Remove the bolt [4], wire clip stay [5] and TR sensor [6].

Remove the 0-ring [1] from the TR sensor.
Installation is in the reverse order of removal.
• Replace the 0-ring with a new one.
• Apply engine oil to a new 0-ring.
• Align the flat surfaces of the TR sensor and shift
drum end.
TORQUE:
TR sensor bolt: 12 N·m (1.2 kgf·m, 9 lbHt)

SHIFT SPINDLE ANGLE SENSOR
REMOVAL/INSTALLATION
Remove the following:
-

Right side shelter (page 2-11)
Right engine side cover (page 12-57)

Disconnect the shift spindle angle sensor 3P (Gray)
connector [1] and remove iUrom the ABS modulator
stay.

Remove the bolts [1] and clamps [2].
Remove the bolts [3] and wire clip stay [4].
Remove the shift spindle angle sensor wire clip [5] from
the clip stay.
Remove the shift spindle angle sensor bolt [6] and shift
spindle angle sensor [7].

12-77

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
Remove the 0-ring [1] from the shift spindle angle
sensor [2].
Installation is in the reverse order of removal.
• Replace the 0-ring with a new one.
• Apply engine oil to a new 0-ring.
• Align the flat surfaces of the shift spindle angle
sensor and gearshift spindle end.
TORQUE:
Shift spindle angle sensor bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

CLUTCH EOP SENSOR
REMOVAL/INSTALLATION
NOTE:
• These three clutch EOP sensors are the same parts.

Remove the right engine side cover (page 12-57).
Disconnect the following:
-

No.1 clutch EOP sensor 3P (Gray) connector [1]
No.2 clutch EOP sensor 3P (Gray) connector [2]
Clutch line EOP sensor 3P (Black) connector [3]

Remove the clutch EOP sensors [4] and 0-rings from
the right crankcase cover.

Coat a new 0-ring [1] with engine oil and install it into
the right crankcase cover.
Install the clutch EOP sensor [2] and tighten it.
TORQUE: 19.6 N·m (2.0 kgf·m, 14 lbf·ft)

Connect the 3P connector to the proper sensor.
NOTE:
Each sensor wires has the following identification mark
near the connector.

• 1: No.1 clutch (lower) EOP sensor
• P: Clutch line (middle) EOP sensor
• No mark: No.2 clutch (upper) EOP sensor
Install the right engine side cover (page 12-57).

S~/PA
·1r11

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)

EOT SENSOR
REMOVAL/INSTALLATION
Disconnect the EOT sensor 2P (Black) connector [1].
Remove the EOT sensor [2] and sealing washer [3]
from the crankcase.
Apply engine oil to the EOT sensor threads and seating
surface.
Install the EOT sensor with a new sealing washer and
tighten it.

TORQUE:14 N·m (1.4 kgf·m, 10 lbHt)
Connect the EOT sensor 2P (Black) connector.

DCT SHIFT PEDAL (OPTIONAL)
REGISTRATION (TO ENABLE THE
PEDAL)
NOTE:
• The following registration procedure must be
performed in order to enable the optional shift pedal.
• Make sure that the CLUTCH INITIALIZE LEARNING
(PCM) (page 12-81) is complete before starting the
registration.
• The registration will fail if any of the following
condition presents during the procedure.
- The vehicle is moved.
- The engine is started.
The transmission is in gear.
- The shift pedal is operated incorrectly.
- The shift pedal angle sensor 3P (Blue) connector
is disconnected.
1. Install the shift pedal to the vehicle and connect the
shift pedal angle sensor 3P (Blue) connector.
2. Turn the ignition switch ON and engine stop switch

"o...

After 2 seconds, "S" [1] and "D" [2] indicators will
start short blinking (0.5 seconds) simultaneously.
Within 5 seconds after blinking starts, move the shift
pedal [3] up and hold for 1 second.
Within 5 seconds after moving the shift pedal up,
move it down and hold for 1 second.
NOTE.:
• The short blinking (0.5 seconds) lasts 5 seconds.

Indicators start blinking
simultaneously.

~

\.

:fosf:

J~

[2]

~

""'

[1]

1: UP for 1 second.
(3]

2: DOWN for 1 second.

12-79

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3. If the "S" and "O" indicators start short blinking (0.5
seconds) alternately, registration is successful.

Successful:

Turn the ignition switch OFF.
NOTE:

• If the "S" and "O" indicators go OFF during the
procedure, registration is unsuccessful. Turn the
ignition switch OFF and perform the registration
procedure from step 2 again.
Indicators blink alternately.

Unsuccessful:

Both go OFF

REGISTRATION CANCELLATION (TO
DISABLE THE PEDAL)
NOTE:

• The registration must be cancelled after removing
the optional shift pedal from the vehicle. If the
registration is not cancelled, OTC 1-1 (OTC 1 blink)
"SHIFT PEDAL ANGLE SENSOR MALFUNCTION"
will be indicated.
• The cancellation will fail if any of the following
condition presents during the procedure.
- The vehicle is moved.
- The engine is started.
- The transmission is in gear.
- The shift switch(+)/(-) is operated incorrectly.
- The shift pedal angle sensor 3P (Blue) connector
is connected.
1. Remove the shift pedal from the vehicle and
disconnect the shift pedal angle sensor 3P (Blue)
connector.
2. While pressing down and holding the shift switch(+)
[1] and shift switch(-) [2], turn the ignition switch ON
and engine stop switch "O".
The "S" [3] and "D" [4] indicators will start short
blinking (0.5 seconds) simultaneously.
• Do not release the shift switch (+) and shift switch
(-) until the successful pattern described in the next
step is indicated.

[2]

'"

iP

/ ~
[4]

8

~

~~ ~
[3]

DUAL CLUTCH TRANSMISSION (DCT) (CTX700D/ND)
3. After 5 seconds, the "S" and "D" indicators will start , - - - - - - - - - - - - - - - - - - - ,
short blinking (0.5 seconds) alternately.
Successful:
If so, cancellation is successful.
Turn the ignition switch OFF.
NOTE:
• If the "S" and "D" indicators go OFF during the
procedure, cancellation is unsuccessful. Turn the
ignition switch OFF and perform the cancellation
procedure from step 1 again.

Indicators blink alternately.

Unsuccessful:

Both go OFF

CLUTCH INITIALIZE LEARNING (PCM)
NOTE:
• If the PCM and/or clutch assembly are replaced,
perform this procedure.
• Before starting this procedure, check the following:
- PGM-FI system and OCT system have no OTC.
- Engine idle speed is normal.
- Transmission is in neutral and cooling fan stops.
• Do not operate the throttle during clutch initialize
learning
1. Warm up the engine to the normal operating
temperature (engine oil temperature:
50 - 110°C/122 - 230°F) and stop it.
NOTE:
If the PCM is replaced with a new one, when the ignition
switch is turned on the "D" and "S" indicators [1] will
come on to indicate that the clutch initialization learning
procedure is necessary.
Furthermore, if the large "L" (extremely low oil
temperature indicator) (2], or small "L" (low oil
temperature indicator) [3] is displayed on the shift
indicator, the engine must be warmed before
proceeding.

Extremely low oil
temperature:

,

[1]

Low oil temperature:

[1]

f/A' km/h
[2]

[3]

12-81

DUAL CLUTCH TRANSMISSION (OCT) (CTX7000/ND)
2. Turn the ignition switch ON with the engine stop
switch "o" while pushing the D switch [1] of the N-D
shift switch. The MIL [2] will come on.
Release the D switch after the MIL goes off.
• When only the dual clutch assembly is replaced:
No indication appears on the shift indicator [3].
• When the PCM is replaced:
The "D" and "S" indicators [4] come on.

[2]

~~--\\'

. + c®):0~ N -l=''
AMOt·25
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3

LI

5

[4]

[3]

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i\JIIIIIIII

fl;.' km/h

Elllllllf

fl;.' km/h

3. Operate the N-D shift switch [1] in the sequence as
follows:
-

-

.
0

Push
Push
Push
Push
Push

the
the
the
the
the

D switch
D switch
N switch
D switch
N switch

~

When only the dual clutch assembly is replaced:
The PCM is ready to clutch initialize learning when
the "D" and "S" indicators [2] lights, and the "-" [3] is
displayed on the shift indicator and blinks at interval
of 2 seconds.
When the PCM is replaced:
The PCM is ready to clutch initialize learning when
the "-" is displayed on the shift indicator and blinks
at interval of 2 seconds.

NOTE:
When the engine is not warmed up enough, the large
"L" [4] (extremely low oil temperature) or small "L" [5]
(low oil temperature) is displayed on the shift indicator.
If so, warm up the engine until the "L" on the shift
indicator goes off. Stop the engine and perform the
steps 2 and 3 again.

s

x1000r/min

7

8

s

~

~ rrr'\Pti.-::::s;
\I

x1000r/mln

7

8

, [ljf=,~L&~/=
Lii
,

i\JIIIIIIII

~'km/h~ E
[4)

1?.R?

;;'i=-::::s;

[5)

DUAL CLUTCH TRANSMISSION (OCT) (CTX700D/ND)
4. Start the engine and let it idle. The"-" [1] on the shift
indicator starts blinking at interval of 2 seconds. The
Clutch Initialize Learning is successful, when the"-",
"D" and "S" indicators [2] go off.
Stop the engine.

[1]

(2)

NOTE:
The clutch initialize learning is unsucc;essful, if the "-"
starts blinking at interval of 0.5 second or it goes off,
and the "D" and "S" indicators stay on. Perform the
initialize learning procedure from step 2 again.

5. Stop the engine.
6. Restart the engine, push the D switch of the N-D
shift switch and check that the "D" indicator comes
on.

x1000r/min

S

7

,
&,km/h

Ll@@,F8111
iiilllll
E

=

12-83

MEMO

13. ALTERNATOR/STARTER CLUTCH

COMPONENT LOCATION .......................... 13-2

FLYWHEEL ................................................. 13.5

SERVICE INFORMATION ........................... 13.3

STARTER CLUTCH .................................... 13.7

TROUBLESHOOTING· ................................ 13.3

STATOR ...................................: ................ 13-10

ALTERNATOR COVER ............................... 13.4

13-1

Al TERNATOR/STARTER CLUTCH

COMPONENT LOCATION

157 N·m (16.0 kgf·m, 116 lbf·ft)

ALTERNATOR/STARTER CLUTCH

SERVICE INFORMATION
GENERAL
•
•
•
•

This section covers service of the alternator and starter clutch. All service can be done with the engine installed in the frame.
For alternator inspection (page 21-8).
For CKP sensor inspection (page 5-6).
For starter motor service (page 6-8).

TOOLS
Flywheel holder
07725-0040001

Rotor puller
07933-3290001

TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter reduction gear/shaft
• Damaged starter idle gear/shaft
• Damaged or faulty starter motor pinion gear
• Damaged starter driven gear

13-3

Al TERNATOR/STARTER CLUTCH

ALTERNATOR COVER
REMOVAL/INSTALLATION
Remove the following:
-

Right swingarm pivot cover (page 2-17)
Left crankcase rear cover (page 2-16)

Disconnect the following:
-

Battery negative H cable (page 21-5)
Alternator 3P (Gray) connector (page 21-7)

Release the wire band boss [1].
Release the following from the battery box:
-

Starter relay switch [2]
Fuse box [3] (CTX700D/ND only)

Pull out the alternator wire harness [4] from the frame.
Release the wire bands [1].

CTX700DIND only:

Release the shift pedal angle sensor 3P (Blue)
connector (Optional) [1] from the stay.
Loosen the alternator cover bolts [2] in a crisscross
pattern in 2 or 3 steps, and remove the bolts and stays
[3].
Remove the alternator cover [4].
NOTE:

The alternator cover (stator) is magnetically attracted to
the flywheel, be careful during removal.

Remove the dowel pins [1], oil orifice [2] and 0-ring [3].
• Replace the 0-ring with a new one.
Clean off any sealant from the alternator cover mating
surfaces.

[2]

AL TERNATOR/STARTER CLUTCH

NOTICE
Do not loosen the alternator cover sealing bolt [1].

[1]

Installation is in the reverse order of removal.
• Apply liquid sealant (TB1207B manufactured by
Three bond or equivalent) to the alternator cover
mating surface as shown.
• Apply liquid sealant (TB1207B manufactured by
Three bond or equivalent) to the alternator wire
grommet sealing surface.
• Do not apply more liquid sealant than necessary.
Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-9).

FLYWHEEL
REMOVAL
Remove the alternator cover (page 13-4 ).
Remove the starter idle gear shaft [1] and starter idle
gear [2].
Remove the starter reduction gear shaft [3] and starter
reduction gear [4].

Hold the flywheel [1] using the special tool and loosen
the flywheel mounting bolt [2].
TOOL:
[3] Flywheel holder

07725-0040001

NOTE:
The flywheel mounting bolt has left hand threads.
Remove the flywheel mounting bolt and washer [4].

13-5

ALTERNATOR/STARTER CLUTCH
Remove the flywheel [1] using the special tool.

TOOL:
[2] Rotor puller

07933-3290001

Remove the washer [1] and needle bearing [2].
Remove the woodruff key [3].
• Be careful not to damage the key groove and
crankshaft.

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Starter reduction gear shaft
Starter reduction gear
Woodruff key
Needle bearing

Replace if necessary.

INSTALLATION
Install the woodruff key [1].
• Be careful not to damage the key groove and
crankshaft.
Apply engine oil to the needle bearing rotating area.
Install the needle bearing [2] and washer [3].

AL TERNATOR/STARTER CLUTCH
Clean any oil from the crankshaft tapered area and
flywheel thoroughly.
Install the flywheel [1] to the crankshaft.
• Align the woodruff key with flywheel keyway.

Apply engine oil to the flywheel mounting bolt threads
and seating surface.
Install the washer [1] and flywheel mounting bolt [2].
Hold the flywheel [3] using the special tool and tighten
the flywheel mounting bolt to the specified torque.
TOOL:
(4] Flywheel holder

07725-0040001

TORQUE:157 N·m (16.0 kgf·m, 116 lbHt)
NOTE:

The flywheel mounting bolt has left hand threads.
Apply molybdenum oil solution to the starter reduction
and idle gear shaft outer surface.
Install the starter reduction gear [1] and shaft [2].
Install the starter idle gear [3] and shaft [4].
• Install the starter reduction gear with its "OUT' mark
[5] facing out.
Install the alternator cover (page 13-4 ).

STARTER CLUTCH
REMOVAL
Remove the flywheel (page 13-5).

[1]

Remove the starter driven gear [1] while turning the
starter driven gear counterclockwise.

13-7

Al TERNATOR/STARTER CLUTCH
Hold the flywheel [1] using the special tool and remove
the starter clutch socket bolt [2].

TOOL:
[3] Flywheel holder

[1]

[3]

07725-0040001

[2]

Remove the starter clutch assembly [1].

Remove the starter one-way clutch [1] from the starter
clutch outer [2].

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Starter driven gear
Starter clutch outer
Starter one-way clutch

Measure each part according to AL TERNATOR/
STARTER CLUTCH SPECIFICATIONS (page 1-8).
Replace any part if it is out of service limit.

[ ]
2

[ ]
1

AL TERNATOR/STARTER CLUTCH
INSTALLATION

STARTER DRIVEN GEAR

,

ONE-WAY CLUTCH

.c=.

FLYWHEEL

30 N·m (3.1 kgf-m, 22 lbf·ft)
Apply engine oil to the starter one-way clutch [1] sliding
surface.

~- [ )
1

Ii

Install the starter one-way clutch to the starter clutch
outer [2].

[2]
Install the starter clutch assembly [1].

13-9

AL TERNATOR/STARTER CLUTCH
Hold the flywheel [1] using the special tool.
TOOL:
[2] Flywheel holder

[1]

[2]

07725-0040001

Apply locking agent to the starter clutch socket bolt
threads (page 1-15).
Install and tighten the starter clutch socket bolt [3] to the
specified torque.
TORQUE: 30 N·m (3.1 kgf·m, 22 lbMt)

Install the starter driven gear [1] into the starter clutch
outer while turning the starter driven gear
counterclockwise.

[ ]
1

Recheck the one-way clutch operation (page 13-6).
Install the flywheel (page 13-6).

STATOR
REMOVAL
Remove the alternator cover (page 13-4).
Remove the alternator wire clamp bolt [1], wire clamp
[2] and grommet [3] from the alternator cover.

[5]

Remove the alternator stator mounting bolts [4] and
stator [5].

[4]

Al TERNATOR/STARTER CLUTCH
INSTALLATION

.Dm 10Nm(10kgf·m,)

I

Install the stator [1] to the alternator cover.
Apply locking agent to the alternator stator mounting
bolt threads (page 1-15).
Tighten the alternator stator mounting bolts [2] to the
specified torque.

TORQUE: 10 N·m (1.0 kgf·m, 7 lbMt)
Apply liquid sealant (TB1207B manufactured by Three
Bond or equivalent) to the alternator wire grommet [3]
sealing surface, then install it into the alternator cover
groove securely.
Apply locking agent to the alternator wire clamp bolt
threads (page 1-15).
Install the wire clamp [4] and alternator wire clamp bolt
[5].
Tighten the bolt to the specified torque.

TORQUE: 10 N·m (1.0 kgf·m, 7 lbMt)
Install the alternator cover (page 13-4).

13-11

MEMO

14. CRANKCASEfTRANSMISSION ALANCER

COMPONENT LOCATION .......................... 14-2

TRANSMISSION (CTX700/A/N/NA) ··········· 14-7

SERVICE INFORMATION ........................... 14.4

TRANSMISSION (CTX700D/ND) .............. 14-14

TROUBLESHOOTING ........................... ··· .. · 14-5

BALANCER .............................. :................ 14-21

CRANKCASE SEPARATION ...................... 14-6

CRANKCASE ASSEMBLY ....................... 14-23

-

14-1

CRANKCASE/TRANSMISSION/BALANCER

COMPONENT LOCATION
CTX700/A/N/NA:
39 N·m (4.0 kgf·m, 29 lbf-ft)

20 N·m (2.0 kgf·m, 15 lbf-ft) + 150°
24 N·m (2.4 kgf·m, 18 lbf-ft)

12 N·m (1.2 kgf·m, 9 lbHt)

12 N·m (1.2 kgf·m, 9 lbf-ft)
24 N·m (2.4 kgf·m, 18 lbf-ft)

'1.IL?

CRANKCASE/TRANSMISSION/BALANCER
CTX700D/ND:
24 N·m (2.4 kgf-m, 18 lbf·ft)
20 N·m (2.0 kgf·m, 15 lbf·ft) + 150°

12 N·m (1.2 kgf·m, 9 lbf-ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf-m, 9 lbf·ft)
24 N·m (2.4 kgf·m, 18 lbf·ft)

14-3

CRANKCASE/TRANSMISSION/BALANCER

SERVICE INFORMATION
GENERAL (CTX700/A/N/NA)
• The crankcase must be separated to service the following:
- Transmission
- Balancer
- Crankshaft (page 15-5)
- Piston/cylinder (page 15-14)
• The following components must be removed before separating the crankcase:
- Engine (page 16-5)
- Clutch (page 11-6)
- Primary drive gear/CKP sensor rotor (page 11-11)
- Gearshift linkage (page 11-13)
- Flywheel (page 13-5)
- Cylinder head (page 10-14)
- Oil strainer (page 9-11)
- Oil pump (page 9-7)
- Engine oil filter (page 3-10)
- Starter motor (page 6-8)
- EOP switch (page 22-14)
- VS sensor (page 22-12)
- Neutral switch (page 22-20)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly.

GENERAL (CTX700D/ND)
• The crankcase must be separated to service the following:
- Transmission
- Balancer
- Crankshaft (page 15-5)
- Piston/cylinder (page 15-14)
• The following components must be removed before separating the crankcase:
- Engine (page 16-14)
- Engine oil filter (page 3-10)
- EOP switch (page 22-14)
- Starter motor (page 6-8)
- Cylinder head (page 10-14)
- Flywheel (page 13-5)
- Shift control motor/reduction gears (page 12-70)
- Neutral switch (page 22-20)
- Dual clutch (page 12-66)
- Primary drive gear/CKP sensor rotor (page 12-69)
- Gearshift linkage (page 12-73)
- Oil pump (page 9-8)
- Mainshaft sensors (page 12-76)
- VS sensor (page 22-12)
- EOT sensor (page 12-79)
- Oil strainer (page 9-11)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly.

14-4

CRANKCASE/TRANSMISSION/BALANCER
TOOLS
Driver, 15 x 280L
07949-3710001

Attachment, 42 x 47 mm
07746-0010300

Pilot, 20 mm
07746-0040500

TROUBLESHOOTING
Hard to shift
Improper clutch operation
Incorrect engine oil weight
Bent shift fork
Bent shift fork shaft
Bent shift fork claw
Damaged shift drum groove
Bent gearshift spindle
- CTX700/A/N/NA (page 11-13)
- CTX700D/ND (page 12-73)
Transmission jumps out of gear
Worn gear dogs
Worn gear shifter groove
Bent shift fork shaft
Worn or bent shift forks
Broken shift drum stopper arm
- CTX700/A/N/NA (page 11-13)
- CTX700D/ND (page 12-73)
Broken shift drum stopper arm return spring
- CTX700/A/N/NA (page 11-13)
- CTX700D/ND (page 12-73)
Broken gearshift spindle return spring
- CTX700/A/N/NA (page 11-13)
- CTX700D/ND (page 12-73)
Excessive engine noise
• Worn or damaged transmission gear
• Worn or damaged transmission bearings

14-5

CRANKCASE/TRANSMISSION/BALANCER

CRANKCASE SEPARATION
For Service Information for removal of necessary parts
before separating the crankcase (page 14-4 ).
Remove the cam chain [1] from the crankshaft.

Remove the crankcase 8 mm bolts [1] and sealing
washer [2].

Place the engine upside down.
Loosen the crankcase 10 mm bolt [1 ], 8 mm bolts [2],
8 x 45 mm bolts [3] and 6 mm bolts [4] in a crisscross
pattern in 2 or 3 steps, and remove the bolts.

Loosen the crankcase main journal bolt [1] in a
crisscross pattern in 2 or 3 steps, and remove them.
Separate the lower crankcase [2] from the upper
crankcase.
• Do not pry the crankcase halves with a screwdriver.

14-6

CRANKCASE/TRANSMISSION/BALANCER
Remove the dowel pins [1] and oil orifices [2].
Clean any sealant off from the crankcase mating
surface.
Clean the oil orifices in solvent thoroughly.
Check the oil orifices for clogs, and replace them if
necessary.

TRANSMISSION (CTX700/A/N/NA)
REMOVAL/DISASSEMBLY
MAINSHAFT/COUNTERSHAFT

Separate the crankcase halves (page 14-6).
Remove the countershaft assembly [1].
Remove the dowel pin [2] and countershaft bearing set
ring [3].
Disassemble the countershaft assembly.
Clean all disassembled parts in solvent thoroughly.
• Keep track of the disassembled parts (gears,
bushings, washers, and snap rings) by sliding them
onto a tool or a piece of wire.
• Do not expand the snap ring more than necessary
for removal. To remove a snap ring, expand the
snap ring and pull it off using the gear behind it.
Remove the mainshaft bearing set plate bolts [1] and
set plate [2].

Remove the right mainshaft bearing [1] from the upper
crankcase.

14-7

CRANKCASE/TRANSMISSION/BALANCER
Remove the mainshaft assembly [1].
Disassemble the mainshaft assembly.
Clean all disassembled parts in solvent thoroughly.
• Keep track of the disassembled parts (gears,
bushings, washers, and snap rings) by sliding them
onto a tool or a piece of wire.
• Do not expand the snap ring more than necessary
for removal. To remove a snap ring, expand the
snap ring and pull it off using the gear behind it.

SHIFT DRUM/SHIFT FORK

Remove the shift drum bearing set plate bolts [1] and
set plate [2].

Remove the fork shaft [1] and shift forks [2}.

Remove the shift drum [1] and shift drum bearing [2].

CRANKCASE/TRANSMISSION/BALANCER
INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Transmission gears
Transmission bushings
Transmission bearings
Shift drum/bearing
Shift forks
Shift fork shaft

Measure each part according to CRANKCASE/
TRANSMISSION SPECIFICATIONS (page 1-9).
Replace any part if it is out of service limit.

LEFT MAINSHAFT BEARING
REPLACEMENT
Remove the following:
-

Crankshaft (page 15-5)
Piston (page 15-14)
Countershaft/mainshaft (page 14-7)

To avoid burns, wear heavy gloves when handling the
heated upper crankcase.
Do not use a torch
to heat the upper

Heat the upper crankcase to 80°C (176° F) evenly using
a heat gun.

crankcase; it may
cause warping.

Tap the upper crankcase lightly and remove the left
mainshaft bearing [1].

Apply engine oil to a new left mainshaft bearing [1].
Drive in a new
bearing squarely
with the marking
side facing toward
the inside of the
crankcase.

Drive the left mainshaft bearing into the upper
crankcase until it is fully seated using the special tools.
TOOLS:
[2] Driver, 15 x 280L
[3] Attachment, 42 x 47 mm
[4] Pilot, 20 mm

07949-3710001
077 46-0010300
077 46-0040500

Install the removed parts in the reverse order of
removal.

14-9

CRANKCASE/TRANSMISSION/BALANCER
TRANSMISSION ASSEMBLY
Clean all parts in solvent, and dry them thoroughly.
Apply engine oil to the gear teeth, rotating surface and
bearing.
Apply molybdenum oil solution to the spline bushing
outer surface, bushing inner and outer surface, shift fork
grooves.
Assemble the mainshaft and countershaft.

MAINS HAFT

THRUST WASHER

THRUST WASHER

14-10

M2 GEAR (19T)

CRANKCASE/TRANSMISSION/BALANCER
COUNTERS HAFT
NEEDLE BEARING CAP
NEEDLE BEARING
THRUST WASHER

C4 GEAR BUSHING
C4 GEAR (30T)

C3 GEAR BUSHING

1

OIL SEAL

Assemble the transmission gears and shafts.
• Coat each gear with clean engine oil and check for
smooth movement.
• Align the lock washer tabs with the spline washer
grooves.
• Always install the thrust washers and snap rings with
the chamfered (rolled) edge facing away from the
thrust load.
• Install the snap rings [1] so that the end gap aligns
with the groove of the splines.
• Make sure that the snap rings are fully seated in the
shaft groove after installing them.

CORRECT

INCORRECT

[1]

14-11

CRANKCASE/TRANSMISSION/BALANCER
INSTALLATION
MAINSHAFT/COUNTERSHAFT

Install the mainshaft assembly [1] into the upper
crankcase.

Apply engine oil to the right mainshaft bearing [1].
Install the right mainshaft bearing into the upper
crankcase.
• Install the bearing into the crankcase with the
marked side facing out.

Apply locking agent to the mainshaft bearing set plate
bolts threads (page 1-15).
Install the mainshaft bearing set plate [1] with its "OUT
SIDE" mark [2] facing out.
Install and tighten the mainshaft bearing set plate bolts
[3] to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)

Install the dowel pin [1] onto the upper crankcase hole.
Install the countershaft bearing set ring [2] to the
countershaft bearing groove.
Install the countershaft assembly [3].
• Align the needle bearing cap hole with the dowel pin.
• Align the set ring with the upper crankcase groove.
Install the shift drum/shift fork (page 14-13).
Assemble the crankcase (page 14-23).

CRANKCASE/TRANSMISSION/BALANCER
SHIFT DRUM/SHIFT FORK

Apply engine oil to the shift drum bearing [1].
Install the shift drum [2] and shift drum bearing into the
lower crankcase.

The shift forks have the following identification marks:
-

"L" mark [1]: left shift fork
"C" mark [2]: center shift fork
"R" mark [3]: right shift fork

Apply molybdenum oil solution to the shift fork guide
area and guide pin.

[1] [2]
Apply molybdenum oil solution to the shift fork shaft
outer surface.
Install the shift forks [1] into the shift drum guide
grooves with the identification marks facing toward the
right side of the engine and insert the fork shaft [2].

Apply locking agent to the shift drum bearing set plate
bolt threads (page 1-15).
Install the set plate [1] and shift drum bearing set plate
bolts [2].
Tighten the shift drum bearing set plate bolts to the
specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf-ft)

Install the mainshaft/countershaft (page 14-12).
Assemble the crankcase (page 14-23).

14-13

CRANKCASE/TRANSMISSION/BALANCER

TRANSMISSION (CTX700D/ND)
REMOVAL/DISASSEMBLY
MAINSHAFT/COUNTERSHAFT

Separate the crankcase halves (page 14-6).
Remove the countershaft assembly [1].
Remove the dowel pin [2] and countershaft bearing set
ring [3].
Disassemble the countershaft assembly.
Clean all disassembled parts in solvent thoroughly.
• Keep track of the disassembled parts (gears,
bushings, washers, and snap rings) by sliding them
onto a tool or a piece of wire.
• Do not expand the snap ring more than necessary
for removal. To remove a snap ring, expand the
snap ring and pull it off using the gear behind it.
Remove the mainshaft bearing set plate bolts [1] and
set plate [2].

Remove the right mainshaft bearing [1] from the upper
crankcase.

Remove the mainshaft assembly [1].
Disassemble the mainshaft assembly.
Clean all disassembled parts in solvent thoroughly.
• Keep track of the disassembled parts (gears,
bushings, washers, and snap rings) by sliding them
onto a tool or a piece of wire.
• Do not expand the snap ring more than necessary
for removal. To remove a snap ring, expand the
snap ring and pull it off using the gear behind it.

1.4.1.4

CRANKCASE/TRANSMISSION/BALANCER
SHIFT DRUM/SHIFT FORK

Remove the shift drum bearing set plate bolts [1] and
set plate [2].

Remove the fork shafts [1] and shift forks [2].

Remove the shift drum [1] and shift drum bearing [2].

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Transmission gears
Transmission bushings
Transmission bearings
Shift drum/bearing
Shift forks
Shift fork shaft

Measure each part according to CRANKCASE/
TRANSMISSION SPECIFICATIONS (page 1-9).
Replace any part if it is out of service limit.

14-15

CRANKCASE/TRANSMISSION/BALANCER
LEFT MAINSHAFT BEARING
REPLACEMENT
Remove the following:
-

Crankshaft (page 15-5)
Pistons/connecting rods (page 15-14)

To avoid burns, wear heavy gloves when handling the
heated upper crankcase.
Do not use a torch
to heat the upper
crankcase; it may
cause warping.

Heat the upper crankcase to 80°C (176°F) evenly using
a heat gun.
Tap the upper crankcase lightly and remove the left
mainshaft bearing [1].

Apply engine oil to a new left mainshaft bearing [1].
Drive in a new
bearing squarely
with the marking
side facing toward
the inside of the
crankcase.

Drive the left mainshaft bearing into the upper
crankcase until it is fully seated using the special tools.
TOOLS:
[2] Driver, 15 x 280L
[3] Attachment, 42 x 47 mm
[4] Pilot, 20 mm

07949-3710001
07746-0010300
077 46-0040500

Install the following:
-

1.4.1~

Pistons/connecting rods (page 15-18)
Crankshaft (page 15-6)

CRANKCASE/TRANSMISSION/BALANCER
TRANSMISSION ASSEMBLY
Clean all parts in solvent, and dry them thoroughly.
Apply engine oil to the gear teeth, rotating surface and
bearing.
Apply molybdenum oil solution to the spline bushing
outer surfaces, bushing inner and outer surfaces, and
gear shifter grooves.
Assemble the mainshaft and countershaft.

MAINS HAFT
INNER MAINSHAFT/M1 GEAR (15T)

SPLINE WASHER
M6 GEAR (37T)
M6 GEAR BUSHING

NEEDLE BEARING

OUTER MAINSHAFT/M2 GEAR (21T)
NEEDLE BEARING

,

: Gear teeth, rotating surfaces and bearing

-:7j :Bushing surfaces and gear shifter grooves

14-17

CRANKCASE/TRANSMISSION/BALANCER
COUNTERSHAFT
~

OILSEAL

COUNTERSHAFT
BEARING SET RING

COUNTERSHAFT

C1 GEAR BUSHING
C1 GEAR (40T)

C2 GEAR (40T)

C6 GEAR (31T)

NEEDLE BEARING
NEEDLE BEARING CAP

-"'1 :

Gear teeth, rotating surfaces and bearing

~

: Bushing surfaces and gear shifter grooves

1.4-1 R

CRANKCASE/TRANSMISSION/BALANCER
NOTE:

• Coat each gear with clean engine oil and check for
smooth movement.
• Align the lock washer tabs with the spline washer
grooves.
• Always install the thrust washers and snap rings with
the chamfered (rolled) edge facing away from the
thrust load.
• Install the snap rings [1] so that the end gap aligns
with the groove of the splines.
• Make sure that the snap rings are fully seated in the
shaft groove after installing them.

CORRECT

INCORRECT

[1]

INSTALLATION
MAINSHAFT/COUNTERSHAFT

Install the mainshaft assembly [1] into the upper
crankcase.

Apply engine oil to the right mainshaft bearing [1].
Install the right mainshaft bearing into the upper
crankcase.
• Install the bearing into the crankcase with the
marked side facing out.

Apply locking agent to the mainshaft bearing set plate
bolts threads (page 1-15).
Install the mainshaft bearing set plate [1] with its "OUT
SIDE" mark [2] facing out.
Install and tighten the mainshaft bearing set plate bolts
[3] to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)

14-19

CRANKCASE/TRANSMISSION/BALANCER
Install the dowel pin [1] onto the upper crankcase hole.
Install the countershaft bearing set ring [2] into the
countershaft bearing groove.
Install the countershaft assembly [3].
• Align the needle bearing cap hole with the dowel pin.
• Align the set ring with the upper crankcase groove.
• Align the oil seal flange [4] with the upper crankcase
groove.
Install the shift drum/shift fork (page 14-20).
Assemble the crankcase (page 14-23).

SHIFT DRUM/SHIFT FORK

Apply engine oil to the shift drum bearing [1].
Install the shift drum [2] and shift drum bearing into the
lower crankcase.

The shift forks have the following identification marks:
-

"D2M L" mark [1]: Mainshaft left shift fork
"D2M R" mark [2]: Mainshaft right shift fork
"D2C L" mark [3]: Countershaft left shift fork
"D2C R" mark [4]: Countershaft right shift fork

Apply molybdenum oil solution to the shift fork shaft
outer surfaces, shift fork claws and guide pins.
Install the countershaft shift forks [1] into the shift drum
outer guide grooves with the identification marks facing
toward the right side of the engine and insert the shift
fork shaft [2].
Jnstall the mainshaft shift forks [3] into the shift drum
inner guide grooves with the identification marks facing
toward the right side of the engine and insert the shift
fork shaft.

14-20

[1]

[2]

CRANKCASE/TRANSMISSION/BALANCER
Apply locking agent to the shift drum bearing set plate
bolt threads (page 1-15).
Install the shift drum bearing set plate [1] and bolts [2].
Tighten the bolts to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Install the mainshaft/countershaft (page 14-19).
Assemble the crankcase (page 14-23).

BALANCER
REMOVAL
Separate the crankcase halves (page 14-6).
Remove the balancer shaft bearing set plate bolts [1]
and set plate [2].

Remove the balancer shaft [1] and right balancer shaft
bearing [2].

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Balancer driven gear
Balancer driven sub-gear
Springs
Balancer shaft
Balancer shaft bearings

Replace if necessary.

14-21

CRANKCASE/TRANSMISSION/BALANCER
LEFT BALANCER SHAFT BEARING
REPLACEMENT
Drive out the left balancer shaft bearing [1] from the
lower crankcase.

Apply engine oil to a new left balancer shaft bearing [1].
Drive in a new
bearing squarely
with the marking
side facing toward
the inside of the
crankcase.

Drive the left balancer shaft bearing into the lower
crankcase until it is fully seated using the special tools.
TOOLS:
[2] Driver, 15 x 280L
[3] Attachment, 42 x 47 mm
[4] Pilot, 20 mm

07949-3710001
077 46-0010300
077 46-0040500

INSTALLATION
Apply engine oil to the right balancer shaft bearing [1].
Install the balancer shaft [2] and right balancer shaft
bearing into the lower crankcase.
• Install the bearing into the crankcase with the
marked side facing out.

Apply locking agent to the balancer shaft bearing set
plate bolts threads (page 1-15).
Install the balancer shaft bearing set plate [1] with its
"OUT SIDE" mark [2] facing out.
Install and tighten the balancer shaft bearing set plate
bolts [3] to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)

14-22

CRANKCASE/TRANSMISSION/BALANCER

CRANKCASE ASSEMBLY
Apply liquid sealant {TB1207B manufactured by Three
Bond or equivalent) to the crankcase mating surface as
shown.
• Do not apply more liquid sealant than necessary.
• Do not apply liquid sealant to the crankcase main
journal bolts area and the oil passage area as
shown.

Install the oil orifices [1] onto the upper crankcase [2].
• Install the oil orifices with its narrow hole side facing
upper crankcase.

Install the dowel pins [1] onto the upper crankcase [2].

Align the balancer driven gear [1] and balancer driven
sub gear [2] teeth then install a 6 x 14 mm socket bolt
[3] to the balancer driven gear and balancer driven sub
gear holes at the lower crankcase inspection hole [4].
Apply molybdenum oil solution to the main journal
bearing sliding surfaces on the lower crankcase.

14-23

CRANKCASE/TRANSMISSION/BALANCER
Align the index line [1] on balancer drive gear with
upper crankcase top surface while the "S' mark [2] is
facing in an upward direction.

Install the lower crankcase onto the upper crankcase.
Make sure that the index line [1] on the balancer drive
gear is positioned between the index lines [2] on the
balancer driven gear as shown.
Remove the 6 x 14 mm socket bolt [3].

Install new crankcase main journal bolts [1].
NOTE:

• Tighten the crankcase main journal bolts using the
Plastic Region Tightening Method.
• Do not reuse the crankcase main journal bolts,
because the correct axial tension will not be
obtained.
• The crankcase main journal bolts are pre-coated
with an oil additive for axial tension stability. Do not
remove the oil additive from the new crankcase main
journal bolt surfaces.
Make sure the upper and lower crankcase are seated
securely.
Tighten the crankcase main journal bolts in numerical
order as shown in a crisscross pattern in 2 or 3 steps to
the specified torque.
Further tighten the crankcase main journal bolts 150°.
TORQUE:20 N·m (2.0 kgf·m, 15 lbf·ft) + 150°

Apply locking agent to the crankcase 8 x 45 mm bolt
threads (page 1-15).

1=w

Install and tighten the crankcase bolts to the specified
torque in a crisscross pattern in 2 or 3 steps.

[3]

TORQUE:
[1) Crankcase 10 mm bolt:
39 N·m (4.0 kgf·m, 29 lbf·ft)
[2] Crankcase 8 mm bolt:
24 N·m (2.4 kgf·m, 18 lbf-ft)
[3] Crankcase 8 x 45 mm bolt:
24 N·m (2.4 kgf·m, 18 lbf·ft)
[4] Crankcase 6 mm bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

CRANKCASE/TRANSMISSION/BALANCER
Place the engine with the lower side down.
Install the crankcase 8 mm bolts [1] and a new sealing
washer [2].
• The sealing washer location is indicated on the
upper crankcase by the "8' mark [3].
Tighten the crankcase 8 mm bolts to the specified
torque.
TORQUE: 24 N·m (2.4 kgf·m, 18 lbHt)

Install the cam chain [1] to the crankshaft.
Install the removed parts in the reverse order of
removal (page 14-4 ).

14-25

MEMO

15. CRANKSHAFT/PISTON/CYLINDER

COMPONENT LOCATION .......................... 15-2

MAIN JOURNAL BEARING·· .. ···················· 15-8

SERVICE INFORMATION··························· 15-3

CRANKPIN BEARING .............................. 15-11

TROUBLESHOOTING············· .................... 15.4

PISTON/CYLINDER .................................. 15-14

'

CRANKSHAFT ............................................ 15.5

Ill

15-1

CRANKSHAFT/PISTON/CYLINDER

COMPONENT LOCATION
10 N·m (1.0 kgf·m, 7 lbHt) + 90°

1
,_,--c_~--c-=-,

~1

CRANKSHAFT/PISTON/CYLINDER

SERVICE INFORMATION
GENERAL

I

NOTICE

This motorcycle's engine uses cracking connecting rods. Be sure to install each part in its original position, as noted during removal.
Do not reuse connecting rods and bearing caps that have been improperly installed, because their mating surfaces will be
damaged.
• The crankcase must be separated to service the following:
- Crankshaft (page 15-5)
- Piston/cylinder (page 15-14)
• Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassembly.
• The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bearings from
the code tables. After selecting new bearings, recheck the oil clearance with plastigauge. Incorrect oil clearance can cause
major engine damage.
• Clean the oil passages in the upper crankcase with compressed air before installing the pistons.

TOOLS
Piston pin tool set
07PAF-0010000

Piston base head
07PAF-0010400

Piston base heqd insert
07PAF-0010500

TIu

uD

(Not available in U.S.A.)
Piston base head/insert (U.S.A. only)
O?TGF-001 OOOA

Piston pin pilot
07PAF-OO 10300

Piston base spring
07973-6570600

, v)
_,/';

Piston base
07973-6570500

Pilot collar, 18 mm
07PAF-0010640

Insert pin
07PAF-0010700

15-3

CRANKSHAFT/PISTON/CYLINDER
Insert adjuster
O?PAF-0010800

TROUBLESHOOTING
Cylinder compression is too low, hard to starting or poor performance at low speed
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
Cylinder compression too high, overheating or knocking
• Excessive carbon built-up on piston head or combustion chamber
Excessive smoke
• Worn cylinder, piston or piston ring
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
Abnormal noise
• Worn piston pin or piston pin hole
• Worn connecting rod small end
• Worn cylinder, piston or piston rings
• Worn main journal bearings
• Worn crankpin bearings
Engine vibration
• Excessive crankshaft runout

CRANKSHAFT/PISTON/CYLINDER

CRANKSHAFT
Separate the crankcase halves (page 14-6).

SIDE CLEARANCE INSPECTION
Measure the connecting rod side clearance.
SERVICE LIMIT: 0.45 mm (0.018 in)

If the clearance exceeds the service limit, replace the
connecting rod.
Recheck and if still out of limit, replace the crankshaft.

REMOVAL

I

NOTICE

Do not interchange the bearing inserts. They must be
installed in their original locations or the correct bearing
oil clearance may not be obtained, resulting in engine
damage.
Mark the bearing caps and bearings as you remove r - - - - - - - - - - - - - - - - - ~
them to indicate the correct cylinder for reassembly.
Remove the crankpin bearing cap bolts [1] and bearing
caps [2].
Remove the crankshaft [3].

I

NOTICE

I

Before removal, position all the pistons at TDC (Top
Dead Center) to prevent damaging the crankpin with
the connecting rod.

Remove the main journal bearings [1] from both
crankcase halves.
Remove the crankpin bearings [2] from the connecting
rods and bearing caps.

I NOTICE I
Do not interchange the bearing inserts. They must be
installed in their original locations or the correct bearing
oil clearance may not be obtained, resulting in engine
damage.

15-5

CRANKSHAFT/PISTON/CYLINDER
INSPECTION
Support the crankshaft on both end journals.
Set a dial gauge on the crankshaft.
Rotate the crankshaft two revolutions (720°) and read
the runout.
SERVICE LIMITS:
[1] Right side: 0.03 mm (0.001 in)
[2] Left side: 0.03 mm (0.001 in)

Check the balancer drive gear [3] teeth for abnormal
wear or damage.

[3]

INSTALLATION
The bearing tabs
should be aligned
with the grooves in
the crankcase.

Install the main journal bearings [1] and crankpin
bearings [2] into the original locations.

j NOTICE j
Do not interchange the bearing inserts. They must be
installed in their original locations or the correct bearing
oil clearance may not be obtained, resulting in engine
damage.
Apply molybdenum oil solution to the main journal
bearing sliding surfaces on the upper crankcase and
crankpin bearing sliding surfaces on the connecting
rods.

Apply molybdenum oil solution to the thrust surfaces of
the crankshaft as shown.

Install the crankshaft [1] onto the upper crankcase.
Set the connecting rods [2] to the crankpins.

CRANKSHAFT/PISTON/CYLINDER
Clean the mating surface of the connecting rods and
crankpin bearing caps with cleaning solvent and blow
them with compressed air.

Apply molybdenum oil solution to the crankpin bearing
sliding surfaces on the crankpin bearing caps [1].
Install the crankpin bearing caps.

I NOTICE I
Be sure to install each part in its original position, as
noted during removal. Do not reuse connecting rods
and bearing caps that have been improperly installed,
because their mating surfaces will be damaged.
• Align the 1.0. code number on the connecting rods.

The crankpin
bearing cap bolts
cannot be reused.
Once the bolts have
been loosened
replace them with
new ones.

Apply engine oil to new crankpin bearing cap bolt
threads and seating surfaces.
Install and tighten new crankpin bearing cap bolts [1] to
the specified torque in 2 or 3 steps alternately.
Further tighten the bolts 90°.
TORQUE: 10 N·m {1.0 kgf·m, 7 lbf·ft) + 90°

Assemble the crankcase halves (page 14-23).

15-7

CRANKSHAFT/PISTON/CYLINDER

MAIN JOURNAL BEARING

I NOTICE I
Do not interchange the bearing inserts. They must be
installed in their original locations or the correct bearing
oil clearance may not be obtained, resulting in engine
damage.
Remove the crankshaft (page 15-5).

BEARING INSPECTION
Inspect the main journal bearing inserts [1] on the upper
and lower crankcase halves for unusual wear or
peeling.
Check the bearing tabs for damage.

OIL CLEARANCE INSPECTION
Clean off any oil from the bearing inserts and main
journals.
Install the crankshaft [1] onto the upper crankcase.

Put a strip of plastigauge [1] lengthwise on each main
journal avoiding the oil hole.
• Do not rotate the crankshaft during inspection.

CRANKSHAFT/PISTON/CYLINDER
Install the dowel pins [1] and oil orifices [2] onto the
upper crankcase [3].
• Install the oil orifices with its narrow hole side facing
upper crankcase.

[3]

Install the
crankcase.

lower crankcase

[1]

onto the

upper

~- [ ]
2

Iii

Apply engine oil to the crankcase main journal bolt
(reuse) threads and seating surfaces.
Install the crankcase main journal bolts [2].
Make sure the upper and lower crankcase are seated
securely.
Tighten the crankcase main journal bolts in numerical
order as shown in a crisscross pattern in 2 or 3 steps to
the specified torque.
Further tighten the crankcase main journal bolts 120°.
TORQUE:20 N·m (2.0 kgf·m, 15 lbHt) + 120°

[1]

Remove the crankcase main journal bolt and lower
crankcase.
Measure the compressed plastigauge at its widest point
on each main journal to determine the oil clearance.
SERVICE LIMIT: 0.05 mm (0.002 in)

If the oil clearance exceeds the service limit, select a
replacement bearing.

BEARING SELECTION
Letters (A, B or C) Record the crankcase bearing support I.D. code letters
on the left side of [1] from left side of the upper crankcase as shown.
upper crankcase
are bearing support
I.D. codes from left
to right.

15-9

CRANKSHAFT/PISTON/CYLINDER
Numbers (1, 2 or 3)
on the crank weight
are main journal
O.D. codes from left
to right.

If you are replacing the crankshaft, record the
corresponding main journal 0.0. code numbers [1] from
the crank weight.
If you are reusing the crankshaft, measure the crankpin
0.0. with a micrometer.

[1]

Cross-reference the main journal and bearing support
codes to determine the replacement bearing color code
[1].
MAIN JOURNAL BEARING THICKNESS:

A:
B:
C:
D:
E:

Blue: Thickest
Black:
Brown:
t
Green:
Yellow: Thinnest

[1]
MAIN JOURNAL BEARING SELECTION TABLE:

BEARING SUPPORT 1.0. CODE
B
37.000 - 37.006 mm 37.006 - 37.012 mm 37.012 - 37.018 mm
(1.4567 - 1.4569 in) (1.4569-1.4572 in) (1.4572-1.4574 in)

c

A

MAIN JOURNAL
0.0. CODE

34.010 34.016 mm
(1.3390 - 1.3392 in)
34.004 - 34.010 mm
2
(1.3387-1.3390 in)
33.998 - 34.004 mm
3
(1.3385 - 1.3387 in)
1

E (Yellow)

D (Green)

C (Brown)

D (Green)

C (Brown)

B (Black)

C (Brown)

B (Black)

A (Blue)

NOTICE
After selecting new bearings, recheck the clearance
with a plastigauge. Incorrect clearance can cause
severe engine damage.

BEARING INSTALLATION
Clean the bearing outer surfaces and crankcase
bearing supports.
Install the main journal bearing inserts [1] onto the
crankcase bearing supports, aligning each tab with
each groove.

1~.1n

CRANKSHAFT/PISTON/CYLINDER

CRANKPIN BEARING

I

NOTICE

I

Do not interchange the bearing inserts. They must be
installed in their original locations or the correct bearing
oil clearance may not be obtained, resulting in engine
damage.

Remove the crankshaft (page 15-5).

BEARING INSPECTION
Check the bearing inserts for unusual wear or peeling.
Check the bearing tabs for damage.

OIL CLEARANCE INSPECTION
Clean the mating surface of the connecting rod and
crankpin bearing cap with cleaning solvent and blow
them with compressed air.

Clean off any oil from the bearing inserts and crankpins.
Carefully install
crankcase.

the

crankshaft

onto

the

upper

Set the connecting rods onto the crankpins.
Put a strip of plastigauge [1) lengthwise on each
crankpin avoiding the oil hole.
• Do not rotate the crankshaft during inspection.

15-11

CRANKSHAFT/PISTON/CYLINDER
Install the crankpin bearing caps [1].

I

NOTICE

I

Be sure to install each part in its original position, as
noted during removal. Do not reuse connecting rods
and bearing caps that have been improperly installed,
because their mating surfaces will be damaged.
• Align the I.D. code number on the connecting rods.

Use the removed
crankpin bearing
cap bolts when
checking the oil
clearance.

Apply engine oil to the crankpin bearing cap bolt (reuse)
threads and seating surfaces.
Install and tighten the crankpin bearing cap bolts [1] to
the specified torque in 2 or 3 steps alternately.
Further tighten the bolts 90°.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) + 90°

Remove the bearing caps and measure the
compressed plastigauge at its widest point on the
crankpin to determine the oil clearance.
SERVICE LIMIT: 0.05 mm (0.002 in)

If the oil clearance exceeds the service limit, select the
correct replacement bearings.

BEARING SELECTION
Numbers (1, 2, 3 or
4) on the
connecting rods are
the connecting rod
I.D. codes.

Record the connecting rod I.D. code number [1] or
measure the I.D. with the crankpin bearing cap installed
without bearing inserts.

[1 J

1 !i-1?

CRANKSHAFT/PISTON/CYLINDER
Letters (A, 8, C or
DJ on the crank
weight are the
crankpin 0.0.
codes from left to
right.

If you are replacing the crankshaft, record the
corresponding crankpin 0.0. code letter [1].
If you are reusing the crankshaft, measure the crankpin
0.0. with a micrometer.

[1]

Cross-reference the connecting rod and crankpin codes
to determine the replacement bearing color code [1].
CRANKPIN BEARING THICKNESS:
B: Black: Thickest
C: Brown:
D: Green:
E: Yellow:
t
F: Pink:
G: Red:
H: White: Thinnest

CRANKPIN BEARING SELECTION TABLE:

CONNECTING ROD 1.0. CODE

3
2
1
4
43.000 - 43.006 mm 43.006-43.012 mm 43.012 43.018 mm 43.018 - 43.024 mm
(1.6929-1.6931 in) (1.6931 -1.6934 in) (1.6934 - 1.6936 in) (1.6936 - 1.6939 in)
CRAN KP IN
O.D. CODE

39.994 - 40.000 mm
(1.5746 1.5748 in)
39.988 - 39.994 mm
B (1.5743 - 1.5746 in)
- 39.988 mm
c 39.982
(1.5741-1.5743 in)
39.976- 39.982 mm
D
(1.5739 - 1.5741 in)
A

H (White)

G (Red)

F (Pink)

E (Yellow)

G (Red)

F (Pink)

E (Yellow)

D (Green)

F (Pink)

E (Yellow)

D (Green)

C (Brown)

E (Yellow)

D (Green)

C (Brown)

B (Black)

NOTICE
After selecting new bearings, recheck the clearance
with a plastigauge. Incorrect clearance can cause
severe engine damage.

BEARING INSTALLATION
Clean the bearing outer surfaces, crankpin bearing cap
and connecting rod.
Install the crankpin bearings [1] onto the bearing cap
and connecting rod, aligning each tab with each groove.

Align

15-13

CRANKSHAFT/PISTON/CYLINDER

PISTON/CYLINDER
PISTON/CONNECTING ROD
REMOVAL

I NOTICE I
• Before piston removal, place a clean shop towel
around the connecting rod to prevent damaging the
cylinder sleeve.
• Do not try to remove the piston/connecting rod
assembly from bottom of the cylinder; the assembly
will get stuck in the gap between the cylinder liner
and the upper crankcase.
• Do not interchange the bearing inserts. They must
be installed in their original locations or the correct
bearing oil clearance may not be obtained, resulting
in engine damage.
Mark the bearing caps and bearings as you remove
them to indicate the correct cylinder for reassembly.
Remove the crankpin bearing cap bolts [1] and bearing
caps [2].
Remove the crankshaft [3].
Remove the countershaft.
-

CTX700/A/N/NA (page 14-7)
CTX700D/ND (page 14-14)

Remove the piston/connecting rod assembly [1] from
the top of the cylinder.

I NOTICE I
Do not try to remove the connecting rod/piston
assembly from the bottom of the cylinder; the assembly
will be locked when the oil ring expands in the gap
between the cylinder liner and the upper crankcase.

PISTON RING REMOVAL
Be careful not to
damage the piston
ring by spreading
the ends too far.

15-14

Spread each piston ring ends and remove them by
lifting up at a point opposite the gap.

CRANKSHAFT/PISTON/CYLINDER
Never use a wire
brush; it will scratch
the groove.

Clean carbon deposits from the piston ring grooves with
a ring that will be discarded.

PISTON REMOVAL
Assemble the special tools as shown.
TOOLS:
Piston pin tool set
- [1] Piston base head
- [2] Piston pin pilot
- [3] Piston base spring
- [4] Piston base

07PAF-0010000
07PAF-0010400
07PAF-0010300
07973-6570600
07973-6570500

U.S.A. TOOLS:
[1] Piston base head/insert
[2] Piston pin pilot
[3] Piston base spring
[4] Piston base

07TGF-001 OOOA
07PAF-0010300
07973-6570600
07973-6570500

Temporarily install the pilot collar [1] to the piston pin
pilot, and adjust the piston base head inserts [2] as
shown, then tighten the screws [3].

[1]

[2]

[4]

[3]

[ ]
1

[2]

TOOLS:
Piston pin tool set
07PAF-0010000
- [1] Pilot collar, 18 mm
07PAF-0010640
- [2]/[3] Piston base head insert 07PAF-0010500
U.S.A. TOOLS:
[1] Pilot collar, 18 mm
[2]/[3] Piston base head/insert

1.0 mm (0.04 in)

07PAF-0010640
07TGF-001000A

Remove the pilot collar.
Assemble and adjust the length of the insert pin [1] and
insert adjuster [2] to 44.0 mm (1.73 in).
TOOLS:
[1] Insert pin
[2] Insert adjuster

44.0 mm (1.73 in)

07PAF-0010700
07PAF-0010800

[1]

[2]

15-15

CRANKSHAFT/PISTON/CYLINDER
Place the piston assembly [1] on the special tools [2].

[1]

• Be sure to position the piston flat area against the
piston base head inserts as shown.
Place the pilot collar [3] and insert pin/insert adjuster [4]
on the piston assembly.

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation.
-

Cylinder
Piston
Piston rings
Piston pin
Connecting rod small end

Measure each part and calculate the clearance
to
CRANKSHAFT/PISTON/CYLINDER
according
SPECIFICATIONS (page 1-10).
Replace any part if it is out of service limit.

PISTON INSTALLATION
Face the connecting rod oil jet [1] to the piston "IN"
mark [2] side.

1~.1R

[1]

[2]

CRANKSHAFT/PISTON/CYLINDER
Temporarily install the pilot collar [1] to the piston pin
pilot, and adjust the piston base head inserts [2] as
shown, then tighten the screws [3].

[ ]
1

TOOLS:
Piston pin tool set
07PAF-0010000
07PAF-0010640
- [1] Pilot collar, 18 mm
- [2]/[3] Piston base head insert 07PAF-0010500
U.S.A. TOOLS:
[1] Pilot collar, 18 mm
[2]/[3] Piston base head/insert

1.0 mm (0.04 in)

07PAF-0010640
07TGF-001000A

Remove the pilot collar.
Apply engine oil to the piston pin outer surface.

[4]

[1]/[2]

Adjust the length of the insert pin [1] and insert adjuster
[2] to 44.0 mm (1.73 in).
TOOLS:
[1] Insert pin
[2] Insert adjuster

07PAF-0010700
07PAF-0010800

-r.-1~_4.0 mm

Insert the pilot collar [3] into the piston [4] and
connecting rod [5].
TOOL:
[3] Pilot collar, 18 mm

07PAF-0010640

Place the piston, connecting rod and pilot collar on the
special tools [6].
TOOLS:
Piston pin tool set
- Piston base head insert
- Piston base head
- Piston pin pilot
- Piston base spring
- Piston base
U.S.A. TOOLS:
Piston base head/insert
Piston pin pilot
Piston base spring
Piston base

·(1.73 in)

[3]

07PAF-0010000
07PAF-0010500
07PAF-0010400
07PAF-0010300
07973-6570600
07973-6570500

[7]

[6]

07TGF-001 OOOA
07PAF-0010300
07973-6570600
07973-6570500

~

NOTE:
Be sure to position the piston flat area against the
piston base head inserts as shown.
Place the piston pin [7], insert pin/insert adjuster on the
pilot collar.
Place the piston [1], connecting rod [2], piston pin [3] i--:::::------.11111111111111111
and special tools on the hydraulic press.
Press the piston pin until special tools fully seated.

15-17

CRANKSHAFT/PISTON/CYLINDER
PISTON RING INSTALLATION
Clean the piston ring grooves thoroughly and install the
piston rings.

[1],

• Apply engine oil to the piston ring sliding surface.
• Avoid piston and piston ring damage during
installation.
• Install the piston rings with the marked side facing
up.
- "R" mark: top ring [1]
- "2R" mark: second ring [2]
• To install the oil ring [3], install the spacer (4) first,
then install the side rails [5].
Stagger the piston ring end gaps 120° apart from each
other.
Stagger the side rail end gaps as shown.
After installation, the rings should rotate freely in the
ring groove.

PISTON/CONNECTING ROD
INSTALLATION
Apply engine oil to the piston and cylinder sliding
surface.
Install the piston/ Install the piston/connecting rod assemblies [1] into the
connecting rod cylinders using a commercially available piston ring
assembly with the compressor tool [2].
"IN" mark [3] facing When reusing the connecting rods, they must be
the intake side. installed in their original locations.

I NOTICE I
• While installing the piston, be careful not to damage
the top surface of the cylinder, especially around the
cylinder bore.
• Be careful not to damage the cylinder sleeve with
the connecting rod.

Use the handle of a plastic hammer or equivalent tool to
tap the piston into the cylinder.
compressor tool sits Install the following:
Make sure the
piston ring

flush on the top
surface of the
cylinder.

-

Countershaft
- CTX?OOIA/N/NA (page 14-12)

-

- CTX700D/ND (page 14-19)
Crankshaft (page 15-6)

[1]
~

[2]
~
[3]

~

,
[4]

20 mm (0.8 in)
OR MORE

[5],

16. ENGINE REMOVAL/INSTALLATION

COMPONENT LOCATION .......................... 16-2

ENGINE INSTALLATION
(CTX700/A/N/NA)········································ 16-9

SERVICE INFORMATION ···························16-4
ENGINE REMOVAL (CTX700D/ND) ... ·.. ··· 16-14
,
ENGINE REMOVAL (CTX700/A/N/NA) ······16-5
ENGINE INSTALLATION
(CTX700D/ND) ···················· .. ···················· 16-18

16-1

ENGINE REMOVAL/INSTALLATION

COMPONENT LOCATION
CTX700/A/N/NA:

54 N·m (5.5 kgf·m, 40 lbf·ft)

59 N·m
(6.0 kgf·m, 44 lbf·ft)

54N·m
(5.5 kgf·m, 40 lbf·ft)

27 N·m
(2.8 kgf·m, 20 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

10 N·m
(1.0 kgf·m, 7 lbf·ft)

ENGINE REMOVAL/INSTALLATION
CTX700D/ND:

54 N·m (5.5 kgf·m, 40 lbf·ft)

54 N·m
(5.5 kgf·m, 40 lbf·ft)

----+--1---1---

/

27 N·m
(2.8 kgf·m, 20 lbf·ft)

16-3

ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION
GENERAL
• A hoist or equivalent is required to support the motorcycle when removing and installing the engine.
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence. If
you mistake the torque or sequence, loosen all mounting fasteners, then tighten them again to the specified torque in the correct
sequence.
• The following components can be serviced with the engine installed in the frame.
- Starter motor (page 6-8)
- Throttle body (page 7-14)
- Water pump (page 8-9)
- Oil pump (CTX700/A/N/NA) (page 9-7)
- Oil pump (CTX700D/ND) (page 9-8)
- Rocker arm (page 10-7)
- Clutch (CTX700/A/N/NA) (page 11-6)
- Gearshift linkage (CTX700/A/N/NA) (page 11-13)
- Primary drive gear/CKP sensor rotor (CTX700/A/N/NA) (page 11-11)
- Dual clutch (CTX700D/ND) (page 12-66)
- Gearshift linkage (CTX7000/ND) (page 12-73)
- Primary drive gear/CKP sensor rotor (CTX700D/ND) (page 12-69)
- CKP sensor (page 5-9)
Flywheel (page 13-5)
- Stator (page 13-10)
• The following components require engine removal for service.
- Camshaft (page 10-12)
- Cylinder head/valves (page 10-14)
- Transmission (CTX700/A/N/NA) (page 14-7)
- Transmission (CTX700D/ND) (page 14-14)
- Balancer (page 14-21)
- Crankshaft (page 15-5)
- Piston/cylinder (page 15-14)

1R ....4

ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL (CTX700/A/N/NA)
Drain the engine oil (page 3-10).
Drain the coolant (page 8-4 ).
Fully slacken the drive chain (page 3-13).
Relieve the fuel pressure and disconnect the quick
connect fitting from the fuel injector side (page 7-4).
Remove the following:
-

Main steps (page 2-14)
Left crankcase rear cover (page 2-16)
Exhaust pipe/muffler (page 2-19)
Swingarm pivot covers (page 2-17)
Radiator (page 8-7)
Radiator reserve tank (page 8-11)
Fuel tank (page 7-7)
Throttle body (page 7-14)

Remove the two socket bolts [1] and right engine side
cover [2].
Remove the bolts [3] and clutch cable guide [4], then
disconnect the clutch cable [5] from the clutch lifter arm
[6].

Disconnect the fuel injector 2P (Gray) connectors [1]
and ECT sensor 2P (Black) connector [2].
CTX700AINA only:

Release the clip [3] from the fuel rail.
Release the wire band boss [4] and main wire harness
[5] from the wire clamp [6].

Loosen the band screw [1] and disconnect the water
hose [2] from the thermostat cover.

16-5

ENGINE REMOVAL/INSTALLATION
Disconnect the VS sensor 3P (Black) connector [1].
Release the CKP sensor 2P (Red) connector [2] from
the stay and disconnect it.
Release the wire band [3] from the frame pipe.

Release the rubber cap [1].
Remove the starter motor terminal nut [2] and starter
motor cable [3].
Remove the bolt [4] and ground cable [5].

Disconnect the neutral switch connector [1].
Remove the wire bands [2], bolt [3] and setting plate [4].
Release the all wires and hoses from the guide [5].

Disconnect the following:
-

Battery negative(-) cable (page 21-5)
Alternator 3P (Gray) connector (page 21-7)

Release the wire band boss [1].
Release the starter relay switch [2] from the battery box
as shown.
Pull out the alternator wire harness [3] from the frame.

16-6

ENGINE REMOVAL/INSTALLATION
Loosen the band screw [1] and disconnect the water
hose [2] from the water pump.
Disconnect the horn wire connectors [3] and spark plug
cap [4].
Remove the wire band [5] and release the spark plug
wire clamp [6] from the frame.
Remove the bolts [7] and left main step base plate
assembly [8].

Remove the bolt [1], reservoir cover [2] and rear master
cylinder reservoir [3].
Remove the bolts [4] and rear brake bracket assembly
[5] from the frame.

Remove the bolts [1] and right main step base plate
assembly [2].

Disconnect the spark plug cap [1].
Release the spark plug wire clamp [2] from the frame.
Disconnect the EOP switch 1P (Gray) connector [3].

16-7

ENGINE REMOVAL/INSTALLATION
Remove the drive sprocket bolt [1], washer [2] and drive
sprocket [3].

The jack height
must be continually
adjusted to relieve
stress for ease of
bolt removal.

Support the engine using a jack or other adjustable
support to ease of engine hanger bolts removal.
Remove the upper engine hanger bolts [1] and collar

[2].

Remove the front lower hanger bolts [1] and collars [2].

Remove the rear engine hanger nuts [1], collars [2] and
bolts [3].
Carefully maneuver the engine and remove it out of the
frame to the right.
• During engine removal, hold the engine securely
and be careful not to damage the frame and engine.

16-8

ENGINE REMOVAL/INSTALLATION

ENGINE INSTALLATION
(CTX700/A/NINA)
NOTE:

• All the engine mounting bolts and nuts loosely
install, then tighten the bolts and nuts to the
specified torque in the specified sequence.
• Note the direction of the engine hanger bolts.
• Note the install position of the collars.
- Front lower right side: 20 mm collar [1]
- Front lower left side: 41 mm collar [2]
- Upper right side: 10 mm collar [3]
- Rear upper side: 37 mm collar (right side) [4] and
47 mm collar (left side) [5]
- Rear lower side: 10 mm collar (right side) [6]
• Place the jack or other adjustable support under the
engine.
• The jack height must be continually adjusted to
relieve stress for ease bolt installation.
• Carefully align the mounting points with the jack to
prevent damage to engine, frame, water hose, wires
and cables.
During engine
installation, hold the
engine securely
and be careful not
to damage the
frame and engine.

[3]
[4]

[6]

Place the engine in the frame, then loosely install all the
bolts, nuts and collars.
Tighten the rear lower engine hanger nut [1] to the
specified torque.
TORQUE: 59 N·m (6.0 kgf-m, 44 lbf·ft}

Tighten the left front lower engine hanger bolt [1] to the
specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbHt}

Tighten the right front lower engine hanger bolt [2] to
the specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbHt}

16-9

ENGINE REMOVAL/INSTALLATION
Tighten the left upper engine hanger bolt [1] to the
specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbHt)

Tighten the right upper engine hanger bolt [2] to the
specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbHt)

Tighten the rear upper engine hanger nut [1] to the
specified torque.
TORQUE:54 N·m (5.5 kgf·m, 40 lbHt)

Install the drive sprocket [1], washer [2] and drive
sprocket bolt [3].
Tighten the drive sprocket bolt to the specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)

Secure the spark plug wire clamp [1] to the tab of the
frame.
Connect the spark plug cap [2].
Connect the EOP switch 1P (Gray) connector [3].

16-10

ENGINE REMOVAL/INSTALLATION
Set the right main step base plate assembly [1 ], then
install the bolts [2].
Tighten the bolts to the specified torque.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)

Set the rear brake bracket assembly [1] and install the
bolts [2].
Tighten the bolts to the specified torque.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf-ft)

Install the rear master cylinder reservoir [3], reservoir
cover [4] and bolt [5].
Tighten the bolts to the specified torque.
TORQUE:10 N·m (1.0 kgf·m, 7 lbHt)

Set the left main step base plate assembly [1] and
install and tighten the bolts [2] to the specified torque.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)

Connect the horn wire connectors [3] and spark plug
cap [4].
Install the wire band [5] and secure the spark plug wire
clamp [6] to the tab of the frame.
Connect the water hose [7] to the water pump.
Tighten the water hose band screw [8] to the specified
range (page 8-8).

Route the alternator wire harness [1] into the frame and
install the wire band boss [2].
Install the starter relay switch [3] to the battery box.
Connect the following:
-

Battery negative(-) cable (page 21-5)
Alternator 3P (Gray) connector (page 21-7)

16-11

ENGINE REMOVAL/INSTALLATION
Secure the all wires and hoses into the guide [1].
Install the setting plate [2] by aligning the hole with the
crankcase boss.
Install and tighten a new bolt [3].
Install the wire bands [4].
Connect the neutral switch connector [SJ.

Install the ground cable [1] and starter motor mounting
bolt [2].
Tighten the mounting bolt securely.
Install the starter motor cable [3] and starter motor
terminal nut [4].
Tighten the starter motor terminal nut to the specified
torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbMt)

Reposition the rubber cap [5] properly on the starter
motor terminal.

Connect the VS sensor 3P (Black) connector [1].
Connect the CKP sensor 2P (Red) connector [2] and
secure it to the stay.
Secure the wire band [3] to the frame pipe.

Connect the water hose [1] to the thermostat cover by
aligning the paint mark with cover tab.
Tighten the water hose band screw [2] to the specified
range (page 8-8).

16-12

ENGINE REMOVAL/INSTALLATION
Connect the fuel injector 2P (Gray) connectors [1] and
ECT sensor 2P (Black) connector [2].
CTX700AINA only:

Install the clip [3] to the fuel rail.
Install the wire band boss [4] and main wire harness [5]
to the wire clamp [6].

Connect the clutch cable [1] to the clutch lifter arm [2].
Install clutch cable guide [3] and bolts [4].
Tighten the bolts securely.
Install the right engine side cover [5] and socket bolts
[6].
TORQUE: 10 N·m (1.0 kgf·m, 7 lbHt)

Install the following:
-

Throttle body (page 7-16)
Fuel tank (page 7-7)
Radiator reserve tank (page 8-11)
Radiator (page 8-7)
Swingarm pivot covers (page 2-17)
Exhaust pipe/muffler (page 2-19)
Left crankcase rear cover (page 2-16)
Main steps (page 2-14)

Inspect the following:
-

Throttle grip freeplay (page 3-4)
Clutch lever freeplay (page 3-20)

Adjust the drive chain slack (page 3-13).
Fill the engine with the recommended engine oil
(page 3-9).
Connect the quick connect fitting to the fuel injector side
(page 7-5).
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-4).
Check the exhaust system and cooling system for
leaks.

16-13

ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL (CTX700D/ND)
Drain the engine oil (page 3-10).
Drain the coolant (page 8-4 ).
Fully slacken the drive chain (page 3-13).
Relieve the fuel pressure and disconnect the quick
connect fitting from the fuel injector side (page 7-4).
Remove the following:
-

Main steps (page 2-14)
Left crankcase rear cover (page 2-16)
Right engine side cover (page 12-57)
Exhaust pipe/muffler (page 2-19)
Swingarm pivot covers (page 2-17)
Radiator (page 8-7)
Radiator reserve tank (page 8-11)
Fuel tank (page 7-7)
Throttle body (page 7-14)

Disconnect the fuel injector 2P (Gray) connectors [1]
and ECT sensor 2P (Black) connector [2].
Release the clip [3] from the fuel rail.
Release the wire band boss [4] and main wire harness
[5] from the wire clamp [6].

Loosen the band screw [1] and disconnect the water
hose [2] from the thermostat cover.

Release the following connectors from the each stays
and disconnect them.
-

Linear solenoid valve 4P (Green) connector [1]
Shift spindle angle sensor 3P (Gray) connector [2]
CKP sensor 2P (Red) connector [3]

Release the wire band [4] from the frame pipe.

ENGINE REMOVAL/INSTALLATION
Disconnect the clutch EOP sensor 3P connectors [1].
Remove the bolts [2] and clamps [3].
Remove the bolt [4] and clip stay [5].
Remove the main wire harness clip [6] from the clip
stay.

Release the rubber cap [1].
Remove the starter motor terminal nut [2] and starter
motor cable [3].
Remove the bolt [4] and ground cable [5].

Disconnect the VS sensor 3P (Black) connector [1] and
EOT sensor 2P (Black) connector [2].
Release the TR sensor 3P (Black) connector [3] from
the stay and disconnect it.
Remove the wire bands [4]

Release the shift pedal angle sensor 3P (Blue)
connector (Optional) [1] from the stay.
Remove the sidestand switch wire clamp [2] from the
stay.
Disconnect the shift control motor 2P (Black) connector
[3] and neutral switch connector [4].
Release the all wires and hoses from the guide [5].

16-15

ENGINE REMOVAL/INSTALLATION
Disconnect the following:
-

Battery negative(-) cable (page 21-5)
Alternator 3P (Gray) connector (page 21-7)

Release the wire band boss [1J.
Release the starter relay switch [2J and fuse box [3]
from the battery box as shown.
Pull out the alternator wire harness [4] from the frame.

Loosen the band screw [1] and disconnect the water
hose [2] from the water pump.
Disconnect the horn wire connectors [3] and spark plug
cap [4].
Remove the wire band [5] and release the spark plug
wire clamp [6] from the frame.
Remove the bolts (7] and left main step base plate
assembly [8].

Remove the bolt [1], reservoir cover (2] and rear master
cylinder reservoir [3].
Remove the bolts [4] and rear brake bracket assembly
(5] from the frame.

Remove the bolts [1] and right main step base plate
assembly [2].

[2]

ENGINE REMOVAL/INSTALLATION
Disconnect the spark plug cap [1].
Release the spark plug wire clamp [2] from the frame.
Disconnect the EOP switch 1P (Gray) connector [3].

Remove the drive sprocket bolt [1], washer [2] and drive
sprocket [3].

The jack height
must be continualfy
adjusted to relieve
stress for ease of
bolt removal.

Support the engine using a jack or other adjustable
support to ease of engine hanger bolts removal.
Remove the upper engine hanger bolts [1] and collar

[2].

Remove the front lower hanger bolts [1] and collars [2].

16-17

ENGINE REMOVAL/INSTALLATION
Remove the rear engine hanger nuts [1], collars [2] and
bolts [3].
Carefully maneuver the engine and remove it out of the
frame to the right.
• During engine removal, hold the engine securely
and be careful not to damage the frame and engine.

ENGINE INSTALLATION (CTX700D/ND)
NOTE:

• All the engine mounting bolts and nuts loosely
install, then tighten the bolts and nuts to the
specified torque in the specified sequence.
• Note the direction of the engine hanger bolts.
• Note the install position of the collars.
- Front lower right side: 20 mm collar [1]
- Front lower left side: 41 mm collar [2]
- Upper right side: 10 mm collar [3]
- Rear upper side: 37 mm collar (right side) [4] and
4 7 mm collar (left side) [5]
- Rear lower side: 10 mm collar (right side) [6]
• Place the jack or other adjustable support under the
engine.
• The jack height must be continually adjusted to
relieve stress for ease bolt installation.
• Carefully align the mounting points with the jack to
prevent damage to engine, frame, water hose, wires
and cables.
During engine
installation, hold the
engine securely
and be careful not
to damage the
frame and engine.

Place the engine in the frame, then loosely install all the
bolts, nuts and collars.
Tighten the rear lower engine hanger nut [1] to the
specified torque.
TORQUE: 59 N·m (6.0 kgf·m, 44 lbMt)

Tighten the left front lower engine hanger bolt [1] to the
specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbMt)

Tighten the right front lower engine hanger bolt [2] to
the specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbMt)

[4]

[6]

[2]

ENGINE REMOVAL/INSTALLATION
Tighten the left upper engine hanger bolt [1] to the
specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbHt)

Tighten the right upper engine hanger bolt [2] to the
specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbHt)

Tighten the rear upper engine hanger nut [1] to the
specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbHt)

Install the drive sprocket [1], washer [2] and drive
sprocket bolt [3].
Tighten the drive sprocket bolt to the specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)

Secure the spark plug wire clamp [1] to the frame.
Connect the spark plug cap [2].
Connect the EOP switch 1P (Gray) connector [3].

16-19

ENGINE REMOVAL/INSTALLATION
Set the right main step base plate assembly [1], then
install the bolts [2].
Tighten the bolts to the specified torque.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbMt)

Set the rear brake bracket assembly [1] and install the
bolts [2).
Tighten the bolts to the specified torque.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbMt)

Install the rear master cylinder reservoir [3], reservoir
cover [4] and bolt [5].
Tighten the bolts to the specified torque.
TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)

Set the left main step base plate assembly [1] and
install and tighten the bolts [2] to the specified torque.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbMt)

Connect the horn wire connectors [3] and spark plug
cap [4].
Install the wire band [5] and secure the spark plug wire
clamp [6] to the tab of the frame.
Connect the water hose [7] to the water pump.
Tighten the water hose band screw [8] to the specified
range (page 8-8).

Route the alternator wire harness [1] into the frame and
install the wire band boss [2].
Install the fuse box [3] and starter relay switch [4] to the
battery box.
Connect the following:
-

Battery negative (-) cable (page 21-5)
Alternator 3P (Gray) connector (page 21-7)

ENGINE REMOVAL/INSTALLATION
Secure the all wires and hoses into the guide [1].
Connect the shift control motor 2P (Black) connector [2]
and neutral switch connector [3].
Secure the sidestand switch wire clamp [4] to the stay.
Secure the shift pedal angle sensor 3P (Blue)
connector (Optional) [5] to the stay.

Install the wire bands [1]
Connect the TR sensor 3P (Black) connector [2] and
secure it to the stay.
Connect the VS sensor 3P (Black) connector [3] and
EOT sensor 2P (Black) connector [4].

Install the ground cable [1] and starter motor mounting
bolt [2].
Tighten the mounting bolt securely.
Install the starter motor cable [3] and starter motor
terminal nut [4].
Tighten the starter motor terminal nut to the specified
torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbHt)

Reposition the rubber cap [5] properly on the starter
motor terminal.

Connect the clutch EOP sensor 3P connectors [1].
Install the bolts [2] and clamps [3].
Install the bolt [4] and clip stay [5).
Secure the main wire harness clip [6) to the clip stay.

16-21

ENGINE REMOVAL/INSTALLATION
Connect the following connectors and secure them to
the each stays.
-

Linear solenoid valve 4P (Green) connector [1]
Shift spindle angle sensor 3P (Gray) connector [2]
CKP sensor 2P (Red) connector [3]

Install the wire band [4] to the frame pipe.

Connect the water hose [1] to the thermostat cover by
aligning the paint mark with cover tab.
Tighten the water hose band screw [2] to the specified
range (page 8-8).

Connect the fuel injector 2P (Gray) connectors [1] and
ECT sensor 2P (Black) connector [2].
Install the clip [3] to the fuel rail.
Secure the wire band boss [4] and main wire harness
[5] to the wire clamp [6].
Install the following:
-

Throttle body (page 7-16)
Fuel tank (page 7-7)
Radiator reserve tank (page 8-11)
Radiator (page 8-7)
Swingarm pivot covers (page 2-17)
Exhaust pipe/muffler (page 2-19)
Right engine side cover (page 12-57)
Left crankcase rear cover (page 2-16)
Main steps (page 2-14)

Inspect the throttle grip freeplay (page 3-4).
Adjust the drive chain slack (page 3-13).
Fill the engine with the recommended engine oil
(page 3-9).
Connect the quick connect fitting to the fuel injector side
(page 7-5).
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-4 ).
Check the exhaust system and cooling system for
leaks.

16-22

17. FRONT

HEEUSUSPENSION/STEERING

COMPONENT LOCATION .......................... 17-2

FRONT WHEEL ........................................ 17-14

SERVICE INFORMATION ........................... 17-3

FORK ......................................................... 17 -18

TROUBLESHOOTING ................................. 17.4

STEERING STEM ....................: ................ 17-24

HANDLEBAR .............................................. 17.5

1111

17-1

FRONT WHEEL/SUSPENSION/STEERING

COMPONENT LOCATION
CTX700NA shown:

103 N·m (10.5 kgf·m, 76 lbf·ft)

22 N·m (2.2 kgf·m, 16 lbf·ft)

22 N·m (2.2 kgf-m, 16 lbf·ft)
74 N·m (7.5 kgf·m, 55 lbf·ft)

17-2

FRONT WHEEL/SUSPENSION/STEERING

SERVICE INFORMATION
GENERAL
• When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• Do not operate the brake lever and pedal after removing the caliper and front wheel.
• After the front wheel installation, check the brake operation by applying the brake lever.
• Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE".
• For brake system information (page 19-5).

TOOLS
Bearing remover head, 20 mm
077 46-0050600

Bearing remover shaft
07GGD-0010100

Driver
07749-0010000

Attachment, 42 x 47 mm
077 46-0010300

Attachment, 52 x 55 mm
07746-0010400

Pilot, 20 mm
077 46-0040500

Fork seal driver
07947-KA50100

Fork seal driver attachment
07947-KF00100

Steering stem socket
07916-3710101

------:-------0
) ) _.._- .:·.i:\

..\)

~,~<ii
. ~/--·····

, · .·.- -.>·(
..

-

'd
\.
\:::::.·

Ball race remover set
07953-MJ 10000

.... ··

.·

Remover attachment
07953-MJ10100

Remover handle
07953-MJ 10200

07953-MJ1000B (U.S.A. only) with
commercially available tool

(Not available in U.S.A.)

/ //yf"
.

/

(~

~

(Not available in U.S.A.)

17-3

FRONT WHEEL/SUSPENSION/STEERING
Bearing remover
07946-3710500

Attachment, 30 mm I.D.
07746-0030300

TROUBLESHOOTING
Hard steering
• Steering stern adjusting nut too tight
• Damaged steering head bearings
• Insufficient tire pressure
• Faulty tire
Steers to one side or does not track straight
• Bent fork pipe
• Bent axle
• Worn wheel bearing
• Unequal fork fluid quantity in each fork pipe
• Faulty steering head bearing
• Bent frame
• Faulty wheel bearing
• Weak front fork
• Loose steering stern adjusting nut
Front wheel wobbling
• Bent rim
• Worm wheel bearing
• Faulty tire
• Insufficient tire pressure
• Axle not tightened properly
• Unbalanced tire and wheel
Wheel hard to turn
• Faulty wheel bearing
• Bent axle
• Brake drag
Soft suspension
• Weak fork spring
• Insufficient fork fluid
• Insufficient tire pressure
• Incorrect fork fluid viscosity
Stiff suspension
• Incorrect fork fluid viscosity
• Bent fork pipe
• Clogged fork fluid passage
• Damaged fork pipe and/or fork slider
• Fork pipe binds
• High tire pressure
Front suspension noisy
• Insufficient fork fluid
• Loose fork fasteners
• Bent fork pipe

17 ...A

FRONT WHEEL/SUSPENSION/STEERING

HANDLEBAR
REMOVAL (CTX700/A/N/NA}
Remove the handlebarweights (page 17-13).

[1]

Remove the rearview mirrors [1].
Release the wire band [2] and two wire clamps [3] from
the handlebar.

Disconnect the brake light switch connectors [1].
Remove the bolts [2], holder [3] and master cylinder [4].
• Keep the brake master cylinder upright to prevent air
from entering the hydraulic system.

Remove the screws [1].
Separate the right handlebar switch housing [2].

Remove the screws [1].
Separate the throttle housing [2].
Disconnect the throttle cables [3] from the throttle pipe
[4], then remove the throttle pip~ [5].

17-5

FRONT WHEEL/SUSPENSION/STEERING
Disconnect the clutch switch connectors [1].
Remove the bolts [2], holder [3] and clutch lever bracket
[4].

Remove the screws [1] and separate the left handlebar
switch housing [2].
Remove the left handlebar grip rubber [3].

Remove the following:
-

Caps [1]
Bolts [2]
Holders [3]
Handlebar [4]

INSTALLATION (CTX700/A/N/NA)
Clean the inside surface of the handlebar grip and
outside surface of the handlebar and throttle pipe.
Apply Honda bond A or Pro Honda Handgrip Cement
(U.S.A. only) or equivalent to the inside surface of the
grips and to the clean surface of the left handlebar and
throttle pipe.
Allow the adhesive Wait 3 - 5 minutes and install the grip.
to dry for 1 hour Rotate the grips for even application of the adhesive.
before using.

17-~

FRONT WHEEL/SUSPENSION/STEERING
Install the handlebar [1] onto the top bridge by aligning
the punch marks with the top bridge top surface.
Hold the handlebar and install the holders [2] with its
punch marks [3] facing forward.
Install the handlebar holder bolts [4].
Tighten the upper bolts first, then the lower bolts to the
specified torque.
Install the caps (5]

Install the left handlebar switch housing (1] by aligning
the locating pin with the handlebar hole.

Install the screws [1] and tighten the upper screw first,
then tighten the lower screw to the specified torque.
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbHt)

Install the clutch lever bracket [1], holder [2] ("UP" mark
[3] facing up) and bolts [4].
Align the end of the clutch lever bracket with the punch
mark on the handlebar, and tighten the upper bolt first,
then the lower bolt.
Connect the clutch switch connectors [5].

17-7

FRONT WHEEL/SUSPENSION/STEERING
Apply grease to the throttle cable end and throttle pipe
flange groove.
Install the throttle pipe [1] to the handlebar.
Connect the throttle cable [2] end to the throttle pipe.
Install the throttle housing [3] by aligning locating pin
with the handlebar hole.
Install and tighten the screws [4] securely.

Install the right handlebar switch housing [1] by aligning
the locating pin with the handlebar hole.

Install the screws [1] and tighten the upper screw first,
then tighten the lower screw to the specified torque.

[1]

TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbMt)

Install the master cylinder [1], holder [2] ("UP" mark [3]
facing up) and bolts [4].
Align the end of the master cylinder with the punch
mark on the handlebar and tighten the upper bolt first,
then the lower bolt to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Connect the brake light switch connectors [5].

17-R

[1 J

Align

[2}

FRONT WHEEL/SUSPENSION/STEERING
Install the rearview mirrors [1].

[1)

Secure the wire band [2] and install the two wire clamps
[3] to the handlebar.
Install the handlebar weights (page 17-13).
Adjust the following:
-

Clutch lever freeplay (page 3-20)
Throttle grip free play (page 3-4)

REMOVAL (CTX700D/ND)
Remove the handlebar weights (page 17-13).

[1 J

Remove the rearview mirrors [1].
Release the wire band [2] and two wire clamps [3] from
the handlebar.

Disconnect the parking brake switch connectors [1].
Remove the socket bolts [2], holder [3] and parking
brake lever bracket [4].

Remove the screws [1] and separate the left handlebar
switch housing [2].

[ )
1

Remove the left handlebar grip rubber [3].

17-9

FRONT WHEEL/SUSPENSION/STEERING
Disconnect the brake light switch connectors [1].

[4]

[3]

Remove the bolts [2], holder [3] and master cylinder [4].
• Keep the brake master cylinder upright to prevent air
from entering the hydraulic system.

Remove the screws [1].
Separate the right handlebar switch housing [2].

Disconnect the throttle cables [1] from the throttle pipe
[2], then remove the throttle pipe.

Remove the following:
-

17.10

Caps [1]
Bolts [2]
Holders [3]
Handlebar [4]

[2]

FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION (CTX700D/ND)
Clean the inside surface of the handlebar grip and
outside surface of the handlebar and throttle pipe.
Apply Honda bond A or Pro Honda Handgrip Cement
(U.S.A. only) or equivalent to the inside surface of the
grips and to the clean surface of the left handlebar and
throttle pipe.
Allow the adhesive
to dry for 1 hour
before using.

Wait 3 - 5 minutes and install the grip.
Rotate the grips for even application of the adhesive.

Install the handlebar [1] onto the top bridge by aligning
the punch marks with the top bridge top surface.
Hold the handlebar and install the holders [2] with its
punch marks [3) facing forward.
Install the handlebar holder bolts [4).
Tighten the upper bolts first, then the lower bolts to the
specified torque.
Install the caps [5]

Apply grease to the throttle cable end and throttle pipe
flange groove.
Install the throttle pipe [1) to the handlebar.
Connect the throttle cable [2) end to the throttle pipe.
Install the right handlebar switch housing [3].
• Align the switch housing locating pin with the
handlebar hole.

Install the screws [1] and tighten the upper screw first,
then tighten the lower screw to the specified torque.
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbHt)

17-11

FRONT WHEEL/SUSPENSION/STEERING
Install the master cylinder [1], holder (2] ("UP" mark [3]
facing up) and bolts [4].
Align the end of the master cylinder with the punch
mark on the handlebar and tighten the upper bolt first,
then the lower bolt to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)

Connect the brake light switch connectors [5].

Install the left handlebar switch housing (1].
• Align the switch housing locating pin with the
handlebar hole.

Install the screws [1] and tighten the upper screw first,
then tighten the lower screw to the specified torque.
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbHt)

Install the parking brake lever bracket [1].
• Align the parking brake lever bracket locating pin
with the handlebar hole.

17 .. 1?

[1]

Align

[2]

FRONT WHEEL/SUSPENSION/STEERING
Install the holder [1] and socket bolts [2].
Tighten the socket bolts securely.
Connect the parking brake switch connectors [3].

Install the rearview mirrors [1].

[1)

Secure the wire band [2] and install the two wire clamps
[3] to the handlebar.
Install the handlebar weight (page 17-13).
Adjust the throttle grip freeplay (page 3-4 ).
Check the parking brake lock operation (page 3-18).

HANDLEBAR WEIGHT
HANDLEBAR WEIGHT REMOVAL/INSTALLATION

Hold the handlebar weight [1] and remove the
handlebar weight mounting screw [2], then remove both
handlebar weights.
Install the handlebar weight to both handlebars aligning
each cutout.
Hold the handlebar weight.
Install and tighten a new handlebar weight mounting
screw to the specified torque.
TORQUE:10 N·m (1.0 kgf·m, 7 lbMt)

INNER WEIGHT REPLACEMENT

Remove the throttle pipe or grip rubber from the
handlebar.
-

[5)

li7J

CTX700/A/N/NA (page 17-5)
CTX700D/ND (page 17-9)

Straighten the retainer ring tab [1] by the screwdriver or
punch.
Apply lubricant
spray through the
tab locking hole [4]
to the rubber
cushions [5] for
easy removal.

[4]

[1)

Temporarily install the handlebar weight [2] and screw,
then remove the inner weight assembly [3] by turning
the handlebar weight.

[3]

[2]

~
17-13

FRONT WHEEL/SUSPENSION/STEERING
Remove the screw [1], handlebar weight [2], retainer
ring [3] and rubber cushions [4] from the inner weight

[5]

[5].
Install the rubber cushions and new retainer ring onto
the inner weight.
Install the handlebar weight to the inner weight align
with each cut-outs of the inner weight and handlebar
weight.
Install and tighten the handlebar weight screw.

Install the inner weight assembly [1] into the handlebar.
Turn the inner weight and hook the weight retainer tab
[2] with the tab locking hole [3] in the handlebar.

[2]

~

Remove the screw and handlebar weight.
Install the throttle pipe and grip rubber to the handlebar.
-

[3]

CTX700/A/N/NA (page 17-6)
CTX700D/ND (page 17-11)

'~
[1 J

FRONT WHEEL
REMOVAL
Remove the brake pads (page 19-9).
CTX700A!DINAIND
only:

Remove the bolts [1] and front wheel speed sensor [2]
from the caliper bracket.
Check that there is no iron or other magnetic deposits
between the pulser ring and front wheel speed sensor.
Remove any deposits.
Check the sensor tip for deformation or damage (e.g.,
chipped pulser ring teeth).
Replace the front wheel speed sensor if necessary
(page 20-21 ).

Loosen the front axle pinch bolt [1] and front axle [2].
Support the motorcycle using a safety stand or hoist,
raise the front wheel off the ground.
Remove the front axle and front wheel.
• Do not operate the brake lever after removing the
front wheel.

17 .. 1.4

FRONT WHEEL/SUSPENSION/STEERING
Remove the side collars [1].

INSPECTION
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the outer race fits tightly in the wheel hub.
Inspect the following parts for damage, abnormal wear, deformation and bend.
-

Front axle
Spoke
Wheel rim

Measure each part according to FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS (page 1-10).
Replace any part if it is out of service limit.
WHEEL BALANCE
NOTE:
• Carefully check balance before installing the wheel.
• The wheel balance must be checked when the tire is
remounted.
• For optimum balance, the tire balance mark [1] (light
mass point: a paint dot on the side wall) must be
located next to the valve stem [2]. Remount the tire if
necessary.

[2]

[1]

Note the rotating direction marks [1] on the tire, and
upon tire installation, always fit the tire so the marks
face the same direction.
Mount the wheel, tire and brake disc assembly on an
inspection stand.
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) part of the wheel with chalk.
Do this 2 or 3 times to verify the heaviest area.
If the wheel is balanced, it will not stop consistently in
the same position.
To balance the wheel, install a new balance weight on
the lightest side of the rim, on the side opposite the
chalk marks. Add just enough weight so the wheel will
no longer stop in the same position when it is spun.
Do not add more than 60 g (2.1 oz) to the wheel.

17-15

FRONT WHEEL/SUSPENSION/STEERING
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the front wheel as following illustration.
• Install the front wheel dust seal until it is flush with the wheel hub surface.
• Install the front brake disc with the "¢" marked side facing out.

fl 4 2 N · m { ~ lbtff)
BRAKE DISC

~

~.,

lilliijjilll

BEARING (6204UU)

PULSER RING
(CTX700A/D/NA/ND)

DISTANCE, COLLAR

S~ -~ DUST SEAL

flt
WHEEL BEARING REPLACEMENT

Install the bearing remover head [1] into the bearing [2].
From the opposite side, install the bearing remover
shaft [3] and drive out the bearing from the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
[1] Bearing remover head, 20 mm
[3] Bearing remover shaft

17-1n

07746-0050600
07GGD-0010100

BEARING (6204UU)

FRONT WHEEL/SUSPENSION/STEERING
Drive in a new right side bearing [1 J squarely with its
marked side facing up until it is fully seated.
bearing has been Install the distance collar.

Never install the old
bearing, once the
removed, the
bearing must be
replaced with a new
one.

Drive in a new left side bearing squarely with its marked
side facing up until it is seated on the distance collar.
TOOLS:
[2] Driver
[3] Attachment, 42
[4] Pilot, 20 mm

x 47 mm

077 49-0010000
07746-0010300
07746-0040500

INSTALLATION
Install the side collars [1 ].

Install the front wheel between the fork legs.
Apply a thin coat of grease to the front axle sliding
surface.
Install the front axle [1] from left side.
Tighten the front axle to the specified torque.
TORQUE:74 N·m (7.5 kgf-m, 55 lbHt)

CTX700A!D!NAIND
only:

Install the front wheel speed sensor [1] and bolts [2].
Tighten the bolts securely.
Check the air gap between the front wheel speed
sensor and pulser ring (page 20-20).
Install the brake pads (page 19-9).

17-17

FRONT WHEEL/SUSPENSION/STEERING
With the front brake applied, pump the forks up and
down several times to seat the axle and check brake
operation.
Tighten the front axle pinch bolt [1] to the specified
torque.
TORQUE:22 N·m (2.2 kgf·m, 16 lbHt)

FORK
REMOVAL
Remove the following:
Do not suspend the
brake caliper!
bracket assembly
from the brake
hose. Do not twist
the brake hose.

Front wheel (page 17-14)
Front fender (page 2-10)

Remove the brake caliper mounting bolts [1) and brake
caliper/bracket assembly [21.

[2]

Loosen the top bridge pinch bolts [1].
When the fork is ready to be disassembled, loosen the
fork cap [2].
Hold the fork legs [31 and loosen the bottom bridge
pinch bolts [41 and lower the fork legs, then remove it.

DISASSEMBLY
Be careful not to
scratch the fork
pipe.

17 .. 1R

Remove the dust seal [11 and stopper ring [2].

FRONT WHEEL/SUSPENSION/STEERING
Remove the following:
-

Fork cap [1]
0-ring [2]
Spring collar [3]
Spring seat [4]

[1]

[3]

\

Remove the fork spring [1].

[1]

Drain the fork fluid by pumping the fork pipe several
times.

Do not over-tighten
the vise on the fork
slider.

Set the fork slider [1 J in a vise with a piece of wood or
soft jaws to avoid damage.

If the fork piston
turns with the
socket bolt,
temporarily install
the fork spring,
spring seat, spring
collar and fork cap.

Remove the fork socket bolt [2] and sealing washer [3].

Do not remove the
fork piston ring [4],
unless it is
necessary to
replace with a new
one.

Remove the fork piston [1] and rebound spring [2] from
the fork pipe [3].

[4]

[2]

[1 J

[3]

17-19

FRONT WHEEL/SUSPENSION/STEERING
Using quick successive motions, pull the fork pipe out of
the fork slider.

Remove the oil lock piece [1] from the fork slider [2].

[2]

[1]
Remove the following:
Do not remove the
fork tube bushing,
unless it is
necessary to
replace with a new
one.

[1]

[2]

[3]

[4]

Oil seal [1]
Back-up ring [2]
Guide bushing [3]

Carefully remove the slider bushing [4] by prying the
bushing gap with a screwdriver until the bushing can be
pulled off by hand.

INSPECTION
Inspect the following parts for damage, abnormal wear, bend, deformation, scoring and teflon coating wear.
-

Fork tube
Fork slider
Fork spring
Rebound spring
Piston ring
Fork piston
Oil lock piece
Guide bushing
Back-up ring

Measure each part according to FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS (page 1-10).
Replace any part if it is out of service limit.

17-20

FRONT WHEEL/SUSPENSION/STEERING
ASSEMBLY
FORK PISTON RING

FORK PISTON

~

22 N·m (2.2 kgf-m, 16 lbf·ft)

J

I

ff:::INGtt
~ R I N G COLLAR

SPRING SEAT

FORK SLIDER

Do not open the
bushing slit more
than necessary.

Install the oil seal
with its marked side
facing up.

u\

REBOUND SPRING

FORK SPRING

Install the slider bushing [1] being careful not to damage i - - - - - - - - - - - - - - - - - - - - .
the coating of the bushing, if it has been removed.
[3]
[2]
[1]
Remove the burrs from the bushing mating surface,
being careful not to peel off the coating.
Apply fork fluid to a new oil seal lips.
Install the guide bushing [2], back-up ring [3] and oil
seal [4] onto the fork pipe.

sf,

[4]

Install the rebound spring [1] to the fork piston [2] and r - - - - - - - - - - - - - - - - ~
install them into the fork pipe [3].
(1]
[2]
(3]

17-21

FRONT WHEEL/SUSPENSION/STEERING
Install the oil lock piece [1] onto the fork piston [2] end.
Install the fork pipe [3] into the fork slider [4].

Do not over-tighten
the vise on the fork
slider.

If the fork piston
turns with the
socket bolt,

Set the fork slider in a vise with a piece of wood or soft
jaws to avoid damage.
Install a new sealing washer [1] to the fork socket bolt
[2].
Apply locking agent to the fork socket bolt threads and
install it.

Tighten the fork socket bolt [1] to the specified torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbHt)

temporarily install
the fork spring,
spring seat, spring
collar and fork cap.

Drive the oil seal [1] until the stopper ring groove [2] is
visible using the special tools.
TOOLS:
[3] Fork seal driver
[4] Fork seal driver attachment

17-22

07947-KA50100
07947-KF00100

FRONT WHEEL/SUSPENSION/STEERING
Install the stopper ring [1] into the groove of the fork
slider securely.
Apply fork fluid to a new dust seal lips.
Install the dust seal [2].

Pour the specified amount of recommended fork fluid
into the fork pipe.

103 mm (4.1 in)

RECOMMENDED FORK FLUID:
Pro Honda Suspension Fluid SS-47 (10W)
FORK FLUID CAPACITY:
518 ± 2.5 cm 3 (17.5 ± 0.08 US oz, 18.2 ± 0.09 Imp oz)

Slowly pump the fork pipe several times to remove any
trapped air from the lower portion of the fork pipe.
Compress the fork pipe fully and measure the fluid level
from the top of the fork pipe.
FLUID LEVEL: 103 mm (4.1 in)

Pull the fork pipe up and install the fork spring [1] with
the tightly wound coil side facing down.
Install the spring seat [2] and spring collar [3].

DOWN

Apply fork fluid to a new 0-ring [1] and install it onto the
fork cap [2].
Tighten the fork cap
after installing the
fork pipe into the
fork bridges.

I qt [

1
]

[2]

Loosely install the fork cap by pushing it to the fork pipe

[3].

17-23

FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Install the fork leg through the bottom bridge and top
bridge while aligning top surface of fork pipe with the
top surface of top bridge.
Tighten the bottom bridge pinch bolts [1] to the
specified torque.
TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft)

If the fork cap [2] is loosened, tighten the fork cap to the
specified torque.
TORQUE:22 N·m (2.2 kgf·m, 16 lbf·ft)

Tighten the top bridge pinch bolts [3] to the specified
torque.

,,

TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)

Install the front brake caliper/bracket assembly [1] and
tighten new brake caliper mounting bolts [2] to the
specified torque.

[218

TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)

Install the following:
-

Front fender (page 2-10)
Front wheel (page 17-17)

[1 J

STEERING STEM
REMOVAL
Remove the following:
-

Handlebar
CTX700/AN/NA (page 17-5)
- CTX700D/ND (page 17-9)
Center shelter (page 2-12)
Headlight assembly (page 2-8) (CTX700N/NA/ND)

Disconnect the ignition switch 2P (Brown) connector [1].
Remove the wire band [2] and release the wire harness
[3] from the clamp [4].

CTX700AID:

Release the two wire band bosses [1].
Release the following from the wire guides [2]:
-

17-24

Throttle cables [3]
Front brake hose [4]
Clutch cable (CTX700A)/parking
(CTX7000) [5]

brake

cable

FRONT WHEEL/SUSPENSION/STEERING
CTX700NINA!ND:

Disconnect the
connector [1].

combination

meter

16P

(Gray)

Remove the four wire band bosses [2].
Remove the two bolts [3] and combination meter stay
assembly [4].

Remove the cap [1] and steering stem nut [2].

Remove the bolt [1] and brake hose guide [2].

CTX700/N:

[2]

17-25

FRONT WHEEL/SUSPENSION/STEERING
Straighten the lock washer tabs [1].
Remove the steering stem adjusting lock nut [2] and
lock washer.

Loosen the steering stem adjusting nut [1] using a
special tool.
TOOL:
[2] Steering stem socket

07916-3710101

Hold the steering stem and remove the steering stem
adjusting nut.

Remove the following:
-

Dust seal [1]
Upper bearing inner race [2]
Upper steering head bearing [3]
Steering stem [4]
Lower steering head bearing [5]

BEARING REPLACEMENT
Replace the Remove the upper outer race [1] using a special tool.
bearing, outer and
inner races as a TOOLS:
07953-MJ 10000
set. Ball race remover set

[2] Remover attachment
[3] Remover handle
U.S.A, TOOLS:
Ball race remover attachment

17.?R

07953-MJ 10100
07953-MJ10200

07953-MJ10000
with commercially
available tool

[2]

FRONT WHEEL/SUSPENSION/STEERING
Remove the lower bearing outer race [1] using the
special tool and suitable shaft.
TOOL:
[2] Bearing remover

07946-3710500

[2]

Temporarily install the steering stem nut [1] onto the r - - - - - - - - - [- - - - - - - - 31
steering stem [2] to prevent the threads from being
damaged when removing the lower inner race [3] from
the steering stem.
Remove the lower inner race with a chisel or equivalent
tools, being careful not to damage the steering stem.
Remove the steering head bearing dust seal [4].

[4]

[1]

Apply specified grease to a new steering head bearing
dust seal lips (page 1-19).
Install the steering head bearing dust seal [1] to the
steering stem.
Install a new lower inner race [2] using a hydraulic
press and special tool.
TOOL:
[3] Attachment, 30 mm I.D.

077 46-0030300

Drive in a new upper outer race [1] using the special
tools.
TOOLS:
[2] Driver
[3] Attachment, 42 x 47 mm

077 49-0010000
07746-0010300

17-27

FRONT WHEEL/SUSPENSION/STEERING
Drive in a new lower outer race [1] using the special .,...............
tools.
TOOLS:
[2] Driver
[3] Attachment, 52 x 55 mm

077 49-0010000
07746-001 0400

[3]

/

INSTALLATION
LOCK NUT
LOWER OUTER RACE

~

LOWERBEARING
LOWER INNER RACE
LOWER DUST SEAL

~

~

~ L O C K WASHER

~

~

\

ft

ADJUST:NG NUT

\

\

UPPER OUTER RACE

\

\

\I
\1

STEERING STEM

~ : BEARINGS

39 N·m (4.0 kgf·m, 29 lbHt)
Apply 3 - 5 g (0.1 - 0.2 oz) of specified grease to each
steering head bearing inner races and outer races
sliding surface (page 1-19).
Apply specified grease to a new steering head bearing
dust seal lips (page 1-19).
Install the bearings [1] in the lower inner race and upper
outer race.
Install the steering stem [2], upper inner race [3] and
dust seal [4].

17.?R

S :BEARING RACES
: DUST SEALS

FRONT WHEEL/SUSPENSION/STEERING
Apply engine oil to the steering stem adjusting nut [1]
threads.

[2]

Install and tighten the steering stem adjusting nut to the
specified torque using a special tool.
TOOL:
[2] Steering stem socket

07916-3710101

TORQUE:23 N·m (2.3 kgf·m, 17 lbHt)

,[1]

Move the steering stem left and right, lock-to-Jock five
times to seat the bearings.

Retighten the adjusting nut [1] to the specified torque
using a special tool.
TOOL:
[2] Steering stem socket

07916-3710101

TORQUE:23 N·m (2.3 kgf·m, 17 lbHt)

Install a new lock washer [1], aligning its short bent tabs
with the grooves in the steering stem adjusting nut.
Install the Jock nut [2] until it contacts with the lock
washer.

[2]

s~

[3]

Further tighten the lock nut, within 90°, to align its
grooves with the tabs of the lock washer.
Bend up the long lock washer tabs [3] into the grooves
of the lock nut.

17-29

FRONT WHEEL/SUSPENSION/STEERING
Install the brake hose guide [1] and bolt [2].

CTX700/N:

Tighten the bolt securely.

Install the top bridge [1].
Install the steering stem nut [2], but do not tighten it yet.
Install the fork legs (page 17-24 ).
Tighten the steering stem nut to the specified torque.
TORQUE: 103 N·m (10.5 kgf·m, 76 lbf·ft)

Turn the steering stem left and right, lock-to-Jock
several times to make sure the steering stem moves
smoothly without play or binding.
Install the cap [3] to the steering stem nut.

CTX700!AID:

Route the following to the wire guides [1]:
-

Throttle cables [2)
Front brake hose [3]
Clutch cable (CTX700/A)/parking
(CTX700D) [4]

Secure the two wire band bosses [5].

17.~n

brake

cable

[2]

FRONT WHEEL/SUSPENSION/STEERING
CTX700NINAIND:

Install the combination meter stay assembly [1] by
routing the wires, cable and hose into the stay
(page 1-21).
Install and tighten the bolts [2].
Secure the wire band bosses [3].
Connect the combination meter 16P (Gray) connector

[4].

Install the wire harness [1] to the clamp [2].
Connect the ignition switch 2P (Brown) connector [3]
and install the wire band [4].
Install the following:
-

Handlebar
- CTX700/A/N/NA (page 17-5)
- CTX700D/ND (page 17-9)
Center shelter (page 2-12)
Headlight assembly (page 2-8) (CTX700N/NA/ND)

17-31

MEMO

18. REAR

EEUSUSPENSION

COMPONENT LOCATION .......................... 18-2

SHOCK LINKAGE ....................................... 18-9

SERVICE INFORMATION ........................... 18-3

SHOCK ABSORBER ................................ 18-11

TROUBLESHOOTING ................................. 18-4

SWINGARM .............................,................. 18-13

REAR WHEEL ............................................. 1.8-5

18-1

REAR WHEEL/SUSPENSION

COMPONENT LOCATION
CTX700NA shown:

44 N·m (4.5 kgf·m, 32 lbf·ft)

44 N·m (4.5 kgf·m, 32 lbf·ft)

44 N·m (4.5 kgf·m, 32 lbf·ft)

18-2

98 N·m (10.0 kgf·m, 72 lbf·ft)

REAR WHEEL/SUSPENSION

SERVICE INFORMATION
GENERAL
• When servicing the rear wheel and suspension, support the motorcycle using a safety stand or hoist.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• After the rear wheel installation, check the brake operation by applying the brake pedal.
• Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE".
• Use Honda Genuine replacement bolts and nuts for all suspension pivot and mounting point.
• For brake system information (page 19-5).

TOOLS
Driver
077 49-0010000

Attachment, 22 x 24 mm
07746-0010800

Attachment, 28 x 30 mm
07946-1870100

Attachment, 42 x 47 mm
07746-0010300

Attachment, 37 mm
07ZMD-MBW0200

Pilot, 17 mm
07746-0040400

Pilot, 20 mm
077 46-0040500

Pilot, 28 mm
07746-0041100

Pilot, 30 mm
077 46-0040700

r~
a
u.
_,,,s' / ~

~~j';\"...:;;,.,.ifil"

Pilot, 32 mm
07MAD-PR90200

Bearing remover head, 20 mm
07746-0050600

Bearing remover shaft
07GGD-0010100

18-3

REAR WHEEL/SUSPENSION
Bearing remover set, 17 mm
07936-3710300

Remover handle
07936-3710100

Remover weight
07741-0010201

or 07936-371020A (U.S.A. only)
Driver, 15 x 280L
07949-3710001

TROUBLESHOOTING
Steers to one side or does not track straight
• Drive chain adjusters not adjusted equally
• Bent axle
• Bent frame
• Worn swingarm pivot components
Rear wheel wobbling
• Bent rim
• Worn wheel bearing
• Worn driven flange bearing
• Faulty tire
• Bent frame or swingarm
• Axle not tightened properly
• Unbalanced tire and wheel
• Insufficient tire pressure
Wheel hard to turn
• Brake drag
• Faulty wheel bearing
• Faulty driven flange bearing
• Bent axle
• Drive chain too tight (page 3-13)
Soft suspension
• Weak shock absorber spring
• Oil leakage from damper unit
• Insufficient tire pressure
Stiff suspension
• Bent shock absorber damper rod
• Damaged suspension or swingarm pivot bearing
• Bent swingarm pivot or frame
Rear suspension noisy
• Loose suspension fasteners
• Faulty shock absorber

18-4

REAR WHEEL/SUSPENSION

REAR WHEEL
REMOVAL
Remove the two socket bolts [1] and muffler end cover
[2].
Support the motorcycle using a safety stand or hoist,
raise the rear wheel off the ground.

CTX700AIDINAIND
only:

Remove the bolts [1] and rear wheel speed sensor [2].

Loosen the lock nut [1], drive chain adjusting nut [2] and
axle nut [3].
Push the rear wheel forward.
Derail the drive chain [4] from the driven sprocket.
Remove the axle nut, washer [5] and adjusting plate [6].
Do not operate the
brake pedal after
removing the rear
wheel.

Remove the axle [7], adjusting plate and rear wheel.

Remove the side collars [1].

18-5

REAR WHEEL/SUSPENSION
INSPECTION
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the outer race fits tightly in the wheel hub.
Inspect the following parts for damage, abnormal wear, deformation and bend.
-

Rear axle
Spoke
Wheel rim

Measure each part according to REAR WHEEL/SUSPENSION SPECIFICATIONS (page 1-10).
Replace any part if it is out of service limit.

DISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear wheel as following illustration.
• For wheel balance service (page 17-15)
• Install the rear wheel dust seal until it is flush with the wheel hub surface.
• Install the rear brake disc with the "¢" marked side facing out.
DRIVEN FLANGE

@

@

0\
S ~ . .~

108 N·m (11.0 kgf-m, 80 lbf·ft)

DUST SEAL

fl/

DRIVEN SPROCKET

BEARING (6204UU)
DISTANCE COLLAR

S~

BEARING (6204UU)

DISASSEMBLY
Drive out the rear wheel distance collar B [1].
TOOLS:
[2] Driver
[3] Attachment, 22 x 24 mm
[4] Pilot, 20 mm

18-6

07749-0010000
077 46-0010800
077 46-0040500

REAR WHEEL/SUSPENSION
Install the bearing remover head [1] into the bearing.
From the opposite side, install the bearing remover
shaft [2] and drive out the bearing from the wheel hub.
TOOLS:
[1] Bearing remover head, 20 mm
[2] Bearing remover shaft

07746-0050600
07GGD-0010100

Remove the distance collar and drive out the other
bearing.

ASSEMBLY
Never install the old Drive in a new right side bearing [1] squarely until it is
bearing, once the fully seated.
bearing has been
removed, the TOOLS:
bearing must be [2] Driver
077 49-0010000
replaced with new [3] Attachment, 42 x 47 mm
07746-0010300
ones. [4] Pilot, 20 mm
077 46-0040500

l"l"""""""'=-

[2]

[5]

Install the distance collar [5].
Drive in a new left side bearing [6] squarely until it is
seated on the distance collar.

Drive the rear wheel distance collar B [1] to a new
driven flange bearing [2].
TOOLS:
[3] Driver
[4] Attachment, 28 x 30 mm
[5] Pilot, 20 mm

077 49-0010000
07946-1870100
077 46-0040500

~
[218

Drive in the driven flange bearing/collar [1] squarely
with its collar side facing down until it is fully seated.
TOOLS:
[2] Driver
[3] Attachment, 42 x 47 mm
[4] Pilot, 20 mm

[2]

07749-0010000
07746-0010300
077 46-0040500

-

[1]

18-7

REAR WHEEL/SUSPENSION
INSTALLATION
Install the right side collar [1] and left side collar [2].

Install the brake caliper/bracket assembly [1] to the .....,................_
swingarm.
• Align the bracket groove with swingarm tab.

Be careful not to
damage the brake
pads.

Install the rear wheel in the swingarm aligning the brake
disc between the brake pads.
Install the drive chain [1] over the driven sprocket.
Apply a thin coat of grease to the rear axle outer
surface.
Install the rear axle [2] from the left side through the
axle adjusting plate [3], swingarm, rear wheel and
collars.
Install the adjusting plate, washer [4] and rear axle nut
[5].
Tighten the rear axle nut to the specified torque.
TORQUE: 98 N·m (10.0 kgf·m, 72 lbMt)

Adjust the drive chain slack (page 3-13).

1R.R

REAR WHEEL/SUSPENSION
CTX700A!D!NAIND
only:

Install the rear wheel speed sensor [1] and bolts [2].
Tighten the bolts securely.

Install the muffler end cover [1] and two socket bolts [2].
Tighten the socket bolts to the specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
CTX700A!DINA!ND
only:

Check the air gap between the rear wheel speed sensor
and pulser ring (page 20-20).

CTX700DIND only:

Check the parking brake lock operation (page 3-18).

SHOCK LINKAGE
REMOVAL/INSTALLATION
Support the motorcycle using a safety stand or hoist,
raise the rear wheel off the ground.
Remove the following:
-

Shock link bolt [1] and nut [2]
Shock absorber lower mounting bolt [3] and nut [4]
Shock arm bolt [5] and nut [6]
Shock linkage assembly [7]

Installation is in the reverse order of removal.
TORQUE:
Shock absorber mounting nut:
44 N·m (4.5 kgf-m, 32 lbf·ft)
Shock arm nut:
44 N·m (4.5 kgf·m, 32 lbf·ft)
Shock link nut:
44 N·m (4.5 kgf·m, 32 lbf·ft)

18-9

REAR WHEEL/SUSPENSION
DISASSEMBLY/INSPECTION/ASSEMBLY
Remove the shock link bolt [1], nut [2] and shock links
[3] from the shock arm [4].

[4)

[1]/[2]

Remove the collars [1] from the shock arm [2].

[2]

Assembly is in the reverse order of disassembly.
TORQUE:
Shock link nut: 44 N·m (4.5 kgf·m, 32 lbHt)

[1]

INSPECTION
Inspect the following parts for damage, abnormal wear, deformation and crack.
-

Shock arm plates
Shock link
Pivot collars
Needle bearings

Replace if necessary.

BEARING REPLACEMENT
Remove the needle bearings [1] using the special tools.
TOOLS:
[2] Bearing remover set, 17 mm 07936-3710300
07936-3710100
[3] Remover handle
077 41-0010201 or
[4] Remover weight
07936-371020A
(U.S.A. only)

REAR WHEEL/SUSPENSION
Never install the old
bearing, once the
bearing has been
removed, the
bearing must be
replaced with a new
one.

Apply molybdenum disulfide grease to new needle
bearings rotating area.
Install the needle bearings [1] with the marked and dust
seal side facing out until it is flush with the shock arm
surface using a hydraulic press and special tools as
shown.
TOOLS:
[2] Driver
[3] Attachment, 22 x 24 mm
[4] Pilot, 17 mm

077 49-0010000
07746-0010800
07746-0040400

SHOCK ABSORBER
REMOVAL/INSTALLATION
Support the motorcycle using a safety stand or hoist,
raise the rear wheel off the ground.
Remove the right swingarm pivot cover (page 2-17).
Remove the shock arm bolt [1] and nut [2].
Remove the shock absorber lower mounting bolt [3]
and nut[4].

Remove the shock absorber upper mounting nut [1].
Remove the shock absorber upper mounting socket
bolt [2] and shock absorber.
Installation is in the reverse order of removal.
TORQUE:
Shock absorber mounting nut:
44 N·m (4.5 kgf·m, 32 lbHt)
Shock arm nut:
44 N·m (4.5 kgf·m, 32 lbHt)

INSPECTION
Visually inspect the shock absorber for wear or
damage.

[2]

[1]

Check the following:
-

Damper rod [1 J for bend or damage
Damper unit [2] for deformation or oil leaks
Rubber bumper [3] for wear or damage
Bushing [4] for wear or damage

Replace the shock absorber as an assembly if
necessary.

18-11

REAR WHEEL/SUSPENSION
Remove the collar [1] and dust seals [2].
Check the needle bearings [3] for damage or loose fit,
replace it if necessary (page 18-12).
Check the collar for wear or damage, replace it if
necessary.
·
Apply molybdenum disulfide grease to the needle
bearings rotating area and new dust seal lips.
Install the dust seals until it is flush with the shock
absorber surface.
Install the collar.

[1]

BEARING REPLACEMENT
Drive the needle bearing [1] out of the lower pivot using
a hydraulic press and special tool.
TOOLS:
[2] Driver 15 x 280L
[3] Attachment, 22 x 24 mm
[4] Pilot, 17 mm

[2]

07949-3710001
07746-0010800
077 46-0040400

[4]
Never install the old Apply molybdenum disulfide grease to new needle
bearing, once the bearings rotating area.
bearing has been
Install the needle bearing [1] into the lower pivot to the
removed, the
specified range using a hydraulic press and special
bearing must be
tools as shown.
replaced with a new
one. TOOLS:

[2] Driver
[3] Attachment, 22 x 24 mm
[4] Pilot, 17 mm

[1]

[2]

5.0-5.5 mm
(0.20 - 0.22 in)

07749-0010000
07746-0010800
077 46-0040400

[4]

REAR WHEEL/SUSPENSION
SHOCK ABSORBER DISPOSAL PROCEDURE
Center punch the shock absorber to mark the drilling
point.
Wrap the shock absorber inside a plastic bag.
Support the shock absorber in a vise as shown.
Through the open end of the bag, insert a drill motor
with a sharp 2 - 3 mm (5/64 -1/8 in) drill bit.

31 mm
(1.2 in)

I NOTICE I
• Do not use a dull drill bit which could cause a buildup of excessive heat and pressure inside the
damper, leading to an explosion and severe injury.
• The shock absorber contains nitrogen gas and oil
under high pressure. Do not drill any further down
the damper case than the measurement given
above, or you may drill into the oil chamber. Then
high pressure oil may cause serious injury.
• Always wear eye protection to avoid getting metal
shavings in your eyes when the gas pressure is ' - - - - - - - - - - - - - - - - - - - _ _ ]
released. The plastic bag is only intended to shield you from the escaping gas.
Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air
from the motor and help keep the bag from getting caught in the bit when you start.

SWINGARM
DRIVE CHAIN SLIDER INSPECTION
Check the drive chain slider for wear or damage.
The drive chain slider must be replaced if it is worn to
the wear indicator [1] (page 18-14).

REMOVAL
Remove the following:
-

Swingarm pivot covers (page 2-17)
Chain cover (page 2-18)
Rear wheel (page 18-5)

Remove the two socket bolts [1] and brake hose guides

[2].

18-13

REAR WHEEL/SUSPENSION
CTX700DIND only:

Remove the screws [1] and parking brake cable guides - - - - - - •
[2].

Remove the shock link bolt [1] and nut [2].
Remove the shock absorber lower mounting bolt [3]
and nut [4].

Remove the swingarm pivot nut [1], washer [2], pivot
bolt [3] and swingarm [4].

DISASSEMBLY/INSPECTION
Remove the drive chain slider mounting screws [1] and
washers [2].

[3]

Remove the drive chain slider [3] by releasing the slider
slit [4] from the swingarm tab and slider tabs [5] from
the swingarm holes.

[4]

1 S:L1A

REAR WHEEL/SUSPENSION
Remove the pivot collars [1], dust seals [2] and distance
collar [3] from the swingarm pivot.
Check the collar for wear, damage or fatigue.
Check the needle bearings [4] for damage or loose fit,
replace it if necessary (page 18-15).

Remove the collar [1] form the shock absorber bracket.
Check the collar for wear, damage or fatigue.
Check the needle bearings [2] for damage or loose fit,
replace it if necessary (page 18-15).

INSPECTION
Inspect the following parts for damage, abnormal wear and deformation.
-

Swingarm
Pivot collars
Bearings
Drive chain slider (page 18-13)

Replace if necessary.

PIVOT BEARING REPLACEMENT
Remove the snap ring [1] from the right pivot.

[1 J

18-15

REAR WHEEL/SUSPENSION
Drive the needle bearing [1] and ball bearing [2] out of
the right pivot using a hydraulic press and special tool.
TOOLS:
[3] Driver, 15 x 280L
[4] Pilot, 28 mm

07949-3710001
07746-0041100

[4]
[2]

''
''

Drive the needle bearing [1] out of the left pivot using a
hydraulic press and special tool.
TOOLS:
[2] Driver, 15 x 280L
[3] Pilot, 32 mm

07949-3710001
07MAD-PR90200

/

/

,,

/

/
/
/

Remove the needle bearings [1] out of the shock
absorber bracket using the special tools.
TOOLS:
[2] Bearing remover set, 17 mm 07936-3710300
07936-3710100
[3] Remover handle
07741-0010201 or
[4] Remover weight
07936-371020A
(U.S.A. only)

UJT-------1

Apply molybdenum disulfide grease to a new needle ~[;i-]liiiiiii/l~iir:[331.]/~[4
2
bearing rotating area.
Install the needle bearing [1] into the left pivot with the
marked side facing up to the specified range using a
hydraulic press and special tools as shown.
TOOLS:
[2] Driver
[3] Attachment, 37 mm
[4] Pilot, 28 mm

18-16

077 49-0010000
07ZMD-MBW0200
07746-0041100

4.5-5.0 mm
(0.18 - 0.20 in)

REAR WHEEL/SUSPENSION
Apply grease to a new ball bearing rotating area.
Install the ball bearing [1] into the right pivot with the
marked side facing out until it is fully seated using a
hydraulic press and special tools as shown.
TOOLS:
[2] Driver
[3] Attachment, 37 mm
[4] Pilot, 20 mm

077 49-0010000
07ZMD-MBW0200
077 46-0040500

Apply molybdenum disulfide grease to a new needle
bearing rotating area.
Install the needle bearing [1J into the right pivot with the
marked side facing out until it is fully seated using a
hydraulic press and special tools as shown.
TOOLS:
[2] Driver
[3] Attachment, 37 mm
[4] Pilot, 30 mm

077 49-0010000
07ZMD-MBW0200
077 46-0040700

Apply molybdenum disulfide grease to a new needle
bearing rotating area.
Install the needle bearings [1J into the shock absorber
bracket with the marked side facing out until it is flush
with the bracket surface using a hydraulic press and
special tools as shown.
TOOLS:
[2] Driver
[3] Attachment, 22 x 24 mm
[4] Pilot, 17 mm

077 49-0010000
07746-0010800
077 46-0040400

Install the snap ring [1J into the right pivot groove
securely.
• Do not reuse the snap ring which could easily spin in
the groove.
• Make sure that the snap ring is firmly seated in the
groove.

18-17

REAR WHEEL/SUSPENSION
ASSEMBLY
SNAP RING

g
~

NEEDLE BEARING

~

Sjp ~BEARING
DISTANCE COLLAR

S~
S

~

~

~

~

PTCOL~R

DUSTSEAL ~ -

~

NEEDLE BEARING

i

~

g

NEEDLE BEARING

~DUSTSEAL

SWINGARM

PIVOT COLLAR~~

~

'\.

\\

NEEDLE BEARING

COLLAR

Install the collar [1] to the shock absorber bracket.

Apply molybdenum disulfide grease to new dust seal
lips.
Install the distance collar [1] and dust seals [2] to the
swingarm pivot.
• Install the dust seal flush with the pivot surface.
Install the wide pivot collar [3] to the swingarm right
pivot.
Install the narrow pivot collar [4] to the swingarm left
pivot.

1R .. 1R

~

I~

e~

DRIVE CHAIN ADJUSTERS

REAR WHEEL/SUSPENSION
Install the drive chain slider [1].
• Align the drive chain slider slit [2] from the swingarm
tab.
• Align the drive chain slider tabs [3] from the
swingarm holes.
Install the washers [4] and drive chain slider mounting
screws [5].
Tighten the drive chain slider mounting screws to the
specified torque.
TORQUE: 5.9 N·m (0.6 kgf·m, 4.4 lbHt)

INSTALLATION
Apply a thin coat of grease to the swingarm pivot bolt
sliding surface.
Set the drive chain [1] onto the swingarm [2] and install
the swingarm to the frame.
Install the swingarm pivot bolt [3] from the left side.

Install the washer [1] and swingarm pivot nut [2].
Tighten the swingarm pivot nut to the specified torque.
TORQUE: 98 N·m (10.0 kgf·m, 72 lbHt)

Set the shock arm [1] and install the shock absorber
lower mounting bolt [2].
Install and tighten the shock absorber lower mounting
nut [3] to the specified torque.
TORQUE: 44 N·m (4.5 kgf·m, 32 lbHt)

Set the shock links [4] and install the shock link bolt [5].
Install and tighten the shock link nut [6] to the specified
torque.
TORQUE: 44 N·m (4.5 kgf·m, 32 lbHt)

18-19

REAR WHEEL/SUSPENSION
CTX700DIND only:

Install the parking brake cable guides [1] and screws
[2].
Tighten the screws securely.

Install the rear wheel speed sensor wire [1] (CTX700A/
DINA/ND only) and brake hose [2] to the brake hose
guides [3].
Install the brake hose guide and socket bolts [4].
;:ii'fighten the socket bolts securely.
Install the following:
-

18-20

Rear wheel (page 18-8)
Chain cover (page 2-18)
Swingarm pivot covers (page 2-17)

19. HYDRAULIC BRAKE

COMPONENT LOCATION ······················ .. ··19-2

REAR MASTER CYLINDER ..................... 19-14

SERVICE INFORMATION .......................... ,19.5

FRONT BRAKE CALIPER ........................ 19-16

TROUBLESHOOTING ................................. 19-6

REAR BRAKE CALIPER ..........: ............... 19-18

BRAKE FLUID REPLACEMENT/
AIR BLEEDING ........................................... 19.7

BRAKE PEDAL ......................................... 19-19

BRAKE PAD/DISC ...................................... 19.9
FRONT MASTER CYLINDER ................... 19-12

PARKING BRAKE CALIPER
(CTX700D/ND) .......................................... 19-19
PARKING BRAKE LEVER
(CTX700D/ND) .......................................... 19-24

19-1

HYDRAULIC BRAKE

COMPONENT LO
CTX700NAshowo

CATION

12 N·m (1 2

·~

'~
~

... /gf·m.
34 N·m (3 5

- ~<
34 N·m (3 .5 kgf·m, 25 lbHt)

CTX700/N:

30 N·m (3 · 1 kgf·m, 22 lbHt)

1Q ..?

25 lbfft)

HYDRAULIC BRAKE
CTX700/A/N/NA:

34 N·m (3.5 kgf·m, 25 lbMt)
12 N·m (1.2 kgf-m, 9 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

27 N·m (2.8 kgf·m, 20 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)

22 N·m (2.2 kgf·m, 16 lbf·ft)

19-3

HYDRAULIC BRAKE
CTX700D/ND:

12 N·m (1.2 kgf·m, 9 lbf·ft)

10 N·m (1.0 kgf-m, 7 lbf·ft)

27 N·m (2.8 kgf-m, 20 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)

ff(f"'-.r,,J 1)--.lL)j)

~

/
22 N·m (2.2 kgf-m, 16 lbf-ft)

31 N·m (3.2 kgf·m, 23 lbf·ft)

10.Ll

HYDRAULIC BRAKE

SERVICE INFORMATION
GENERAL

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

NOTICE

I

Spilling brake fluid will severely damage instrument lenses and painted surface. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir cover; make sure the front reservoir is horizontal first.

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
Check the brake system by applying the brake lever or pedal after the air bleeding.
Never allow contaminates (dirt, water, etc.) to get into an open reservoir.
Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid, they
may not be compatible.
Always check brake operation before riding the motorcycle.
This section covers service of the conventional brake components of the brake system. For Anti-lock Brake System (ABS)
service (page 20-4).

TOOL
Snap ring pliers
07914-SA50001

19-5

HYDRAULIC BRAKE

TROUBLESHOOTING
Brake lever/pedal soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pad/disc
• Worn caliper piston seal
• Worn master cylinder piston cups
• Worn brake pad/disc
• Contaminated caliper
• Contaminated master cylinder
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Bent brake lever/pedal
Brake lever/pedal hard
• Clogged/restricted hydraulic system
• Sticking/worn caliper piston
• Caliper not sliding properly
• Worn caliper piston seal
• Sticking/worn master cylinder piston
• Bent brake lever/pedal
Brake drags
Contaminated brake pad/disc
Misaligned wheel
Badly worn brake pad/disc
Warped/deformed brake disc
Caliper not sliding properly
Clogged/restricted hydraulic system
Sticking/worn caliper piston
Clogged master cylinder port
Sticking master cylinder piston

10 ..~

HYDRAULIC BRAKE

BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
Front brake:

Turn the handlebar until the reservoir is parallel to the
ground.

[1]

[3]

Remove the following:
-

Rear brake:

Screws [1]
Reservoir cover [2]
Set plate [3]
Diaphragm [4]

Support the motorcycle in an upright position.

[2]

Remove the bolt [1], reservoir cover [2] and rear master
cylinder reservoir [3].
Temporarily install the reservoir and mounting bolt to
the stay.
Remove the cover cap [4], set plate [5] and diaphragm

~

~·

[4]

Connect a bleed hose [1] to the caliper bleed valve [2].

Front side shown:

Loosen the bleed valve and pump the brake lever/pedal
until no more fluid flows out of the bleed valve.

[1)

BRAKE FLUID FILLING/AIR BLEEDING
Do not mix different
types of fluid; they

Fill the reservoir with DOT 4 brake fluid from a sealed
container.

are not compatible.

Connect a automatic refill system to the reservoir.

Front side:

If an automatic refill system is not used, add fluid when
the fluid level in the reservoir is low.
• Check the fluid level often while bleeding the brake
to prevent air from being pumped into the system.
• When using a brake bleeding tool, follow the
manufacturer's operating instructions.

19-7

HYDRAULIC BRAKE
Connect a commercially available brake bleeder [1] to
the bleed valve [2].
Operate the brake bleeder and loosen the bleed valve.
If air enters the
bleeder from
around the bleed
valve threads, seal

Perform the bleeding procedure until the system is
completely flushed/bled.
Close the bleed valve and operate the brake lever/
pedal. If it still feels spongy, bleed the system again.

the threads with
teflon tape.

After bleeding the system completely, tighten the brake
caliper bleed valve to the specified torque.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbMt)

If the brake bleeder is not available, perform the
following procedure.
Pump up the system pressure with the brake lever/
pedal until the lever/pedal resistance is felt.
Connect a bleed hose [1] to the bleed valve [2].
1. Squeeze the brake lever/pedal all the way and
loosen the bleed valve 1/4 turn. Wait several
seconds and then close the bleed valve.
NOTE:

• Do not release the brake lever/pedal until the bleed
valve has been closed.
2. Release the brake lever/pedal slowly and wait
several seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding the system completely, tighten the brake
caliper bleed valve to the specified torque.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbHt)
Do not mix different
types of fluid; they
are not compatible.

Fill the reservoir with DOT 4 brake fluid from a sealed
container to the casting ledge [1] (Front side)/upper
level line [2] (Rear side).

Front brake:

Install the diaphragm [1], set plate [2], reservoir cover
[3] and reservoir cover screws [4], then tighten the
screws to the specified torque.
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbMt)

Front side:
[1 J

HYDRAULIC BRAKE
Rear brake:

Install the diaphragm [1], set plate [2] and reservoir cap , - - - - - - - - - - - - - - - - - -

~

~Remove the rear master cylinder reservoir mounting
bolt [4] and reservoir [5] from the stay.
Set the reservoir cover [6] and reservoir to the stay,
then install and tighten the mounting bolt to the
specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbHt)

[4]

[3]

BRAKE PAD/DISC
FRONT BRAKE PAD REMOVAL/
INSTALLATION
NOTE:

• Always replace the brake pads in pairs to assure
even disc pressure.
• Check the brake fluid level in the brake master
cylinder reservoir as this operation causes the level
to rise.
Do not operate the
brake lever after
removing the brake
pads.

Remove the brake pad pin [1 J and brake pads [2].

Install the brake pads [1] to the brake caliper so their
ends seat against the retainer.
• Make sure that the retainer is installed to the caliper
bracket.
Check that the brake pad pin stopper ring is in good
condition, replace if necessary.
Apply silicone grease to the brake pad pin stopper ring
[2] and install it to the brake pad pin [3] groove.
Install the brake pad pin by pushing the pads against
the pad spring to align the brake pad pin holes in the
pads and brake caliper.
Tighten the front brake pad pin to the specified torque.
TORQUE: 17 N·m (1.7 kgf·m, 13 lbHt)

Operate the brake lever to seat the caliper piston
against the pads.

19-9

HYDRAULIC BRAKE
REAR BRAKE PAD REMOVAL/
INSTALLATION
NOTE:
• Always replace the brake pads in pairs to assure
even disc pressure.
• Check the brake fluid level in the brake master
cylinder reservoir as this operation causes the level
to rise.
Remove the brake pad pin [1] and rear brake caliper
mounting bolt [2].

Do not operate the
brake pedal after
removing the brake
pads.

Lift the caliper and remove the brake pads [1].
Install the brake pads to the brake caliper so their ends
seat against the retainer.
• Make sure that the retainer and pad spring are
installed to the brake caliper.
Lower the caliper.

Loosely install a new rear brake caliper mounting bolt

[1 ].
Check that the brake pad pin stopper ring [2] is in good
condition, replace it if necessary.
Apply silicone grease to the brake pad pin stopper ring.
Install the brake pad pin [3] by pushing the pads against
the pad spring to align the brake pad pin holes in the
pads and brake caliper.

Tighten the rear brake caliper mounting bolt [1] to the
specified torque.

TORQUE:22 N·m (2.2 kgf·m, 16 lbHt)
Tighten the brake pad pin [2] to the specified torque.

TORQUE:17 N·m (1.7 kgf-m, 13 lbf·ft)
Operate the brake pedal to seat the caliper pistons
against the pads.

HYDRAULIC BRAKE
BRAKE DISC INSPECTION
Visually inspect the brake discs for damage or crack.
Measure the brake disc according to HYDRAULIC
BRAKE SPECIFICATIONS (page 1-11) and replace if
necessary.

PARKING BRAKE PAD
REPLACEMENT (CTX700D/ND)
Loosen the parking brake pad pins [1].

Remove the brake caliper mounting bolt [1] and caliper
[2] from the bracket.

Remove the parking brake pad pins [1] and pads [2].
Make sure the pad spring is installed in position.
Install new parking brake pads and pad pins.
Install the parking brake caliper and new mounting bolts
and tighten the bolt to the specified torque.
TORQUE:31 N·m (3.2 kgf·m, 23 lbMt)

Tighten the parking brake pad pins to the specified
torque.
TORQUE:17 N·m (1.7 kgf·m, 13 lbHt)

19-11

HYDRAULIC BRAKE

FRONT MASTER CYLINDER
REMOVAL/INSTALLATION
Drain the brake fluid from the hydraulic system
(page 19-7).

CTX700N shown:

Release the dust cover [1].
Loosen the lock nut [2] and remove the rearview mirror.
Disconnect the brake light switch connectors [3].

Remove the brake hose oil bolt [1], sealing washers [2]
and brake hose [3].

CTX 700N shown:

• When removing the oil bolt, cover the end of the
brake hose to prevent contamination.

Remove the bolts [1], holder [2] and master cylinder [3].
Installation is in the reverse order of removal.
• Install the master cylinder holder with the "UP" mark
[4] facing up.
• Align the end of the master cylinder with the
handlebar punch mark.
• Tightening the front master cylinder holder bolts,
upper bolt first, then the lower bolt to the specified
torque.
• Replace the sealing washers with new ones.
• Install the brake hose eyelet joint against the master
cylinder stopper.
TORQUE:
Front master cylinder holder bolt:
12 N·m (1.2 kgf·m, 9 lbMt)
Brake hose oil bolt:
34 N·m (3.5 kgf·m, 25 lbMt)

Fill the reservoir to the upper level and bleed the front
brake system (page 19-7).

19-12

CTX700N shown:

[2]

HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the front master cylinder as
following the illustration.
• When removing and installing the snap ring, use the
special tool.

TOOL:
07914·SA50001

Snap ring pliers

• Install the snap ring with the chamfered edge facing
the thrust road side and be certain it is firmly seated
in the groove. Do not reuse the snap ring which
could easily spin in the groove.
• Replace the piston and cups as a set.
• Do not allow the piston cup lips to turn inside out.
• Align the switch boss with the master cylinder hole properly.

A SECONDARY
II PISTON CUP

PRIMARY
PISTON CUP

A

Ii

1.0 N·m (0.1 kgf-m, 0.7 lbHt)

~

0.10 g (0.004 oz)

BRAKE LEVER

5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

INSPECTION
Inspect the following parts for scoring, scratches,
deterioration and damage.
-

Master cylinder
Master piston
Piston cups
Spring
Boot

Measure each part according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-11 ).
Replace any part if it is out of service limit.

19-13

HYDRAULIC BRAKE

REAR MASTER CYLINDER
REMOVAL/INSTALLATION
Drain the brake fluid from the hydraulic system
(page 19-7).
Remove the right main step (page 2-14).
Remove the bolt [1], cover [2] and rear master cylinder
reservoir [3].
Release the rear brake light switch 2P (Black)
connector [4] from the stay [5] and disconnect it.

Remove the brake hose oil bolt [1], sealing washers [2]
and brake pipe [3].
• When removing the oil bolt, cover the end of the
brake pipe to prevent contamination.
Remove the mounting bolts [4] and rear brake bracket
assembly (5].

Remove and discard the cotter pin [1].
Remove the joint pin [2] and disconnect the push rod
joint from the brake pedal.
Remove the master cylinder mounting bolts [3] and
master cylinder [4] from the right step holder.
Installation is in the reverse order of removal.
• Replace the cotter pin and sealing washers with new
ones.
• Install the brake hose eyelet joint against the master
cylinder stopper.
TORQUE:
Rear master cylinder mounting bolt:
12 N·m (1.2 kgf·m, 9 lbMt)
Rear brake bracket mounting bolt:
27 N·m (2.8 kgf-m, 20 lbHt)
Brake hose oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)

Fill the reservoir to the upper level and bleed the rear
brake system (page 19-7).

1Q .. 14

HYDRAULIC BRAKE
DISASSEMBlY/ASSEMBlY
Disassemble and assemble the rear master cylinder as
following the illustration.
• When removing and installing the snap ring, use the
special tool.
TOOL:
Snap ring pliers

07914-SA50001

• Install the snap ring with the chamfered edge facing
the thrust road side and be certain it is firmly seated
in the groove. Do not reuse the snap ring which
could easily spin in the groove.
• Replace the piston, spring and cup as a set.
• Apply brake fluid to the master piston and cups.
• Do not allow the piston cup lips to turn inside out.

._-,A.II

0-RING lllllii,illl

MASTER CYLINDER

1.5 N·m (0.2 kgf·m, 1.1 lbMt)

Lu

MASTER PISTON

SECONDARY
PISTONCUP

I

A

.II

PUSH ROD
When the push rod has been disassembled, adjust the
push rod length so that the distance from the center of
the master cylinder lower mounting bolt hole to the
center of the joint pin hole is standard length as shown.
If the length is adjusted to the longer position, make
sure that the lower end of the push rod thread [1] is
visible inside the joint.
After adjustment, tighten the joint nut [2] to the specified
torque.
TORQUE:17 N·m (1.7 kgf·m, 13 lbHt)

64.0- 66.0 mm
(2.52 - 2.60 in)

19-15

HYDRAULIC BRAKE
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
-

Master cylinder
Master piston
Piston cups
Spring
Boot

Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-11 ).
Replace any part if it is out of service limit.

FRONT BRAKE CALIPER
REMOVAL/INSTALLATION
Drain the brake fluid from the front brake
system (page 19-7).
CTX700A!DINAI
ND:

When removing the
oil bolt, cover the
end of brake hose
to prevent
contamination.

Remove the following:
-

Bolt [1] and wire clamp [2]
Two bolts [3] and front wheel speed sensor [4]

-

Brake pads (page 19-9)
Oil bolt [1 J
Sealing washers [2]
Brake hose [3]
Mounting bolts [4]
Brake caliper [5]

-

Installation is in the reverse order of removal.
• Replace the brake caliper mounting bolts and
sealing washers with new ones.
• Be sure to rest the eyelet stopper pin against the
caliper body when tightening the oil bolt.
• Before installing the wheel speed sensor, wipe the
sensor tip and mounting area to remove any foreign
material (CTX?OOA/D/NA/ND only).
TORQUE:
Front brake caliper mounting bolt:
30 N·m (3.1 kgf·m, 22 lbf·ft)
Brake hose oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)

19-16

HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the front brake caliper as
following illustration.
Mark the pistons to ensure that they are reinstalled
in their original locations.
When removing the caliper pistons with compressed
air, place a shop towel over the pistons to prevent
damaging the pistons and caliper body. Do not use
high pressure or bring the nozzle too close to the
fluid inlet.
Install the pistons with the opening toward the pads.

0.4 g (0.01 oz)
.

~

CALIPER PIN
22 N·m (2.2 kgf-m)

I~

CALIPER PIN BOOT

~ ~
r.:::;;;:::i,
s
DUST SEAL

~ ' CALIPER BRACKET

//'!

/K ~

,

PISTON SEAL

BLEED VALVE
5.4 N·m (0.6 kgf-m) _ _ _ __,...

\ /(
\.

~/

~

'1

\

l ---

PAD RETAIN~R*

}/~
~-/
~

//

0,4 g (0,01 o,)

I

CALIPER PISTON - .

//

PAD SPRING:

)I(

\'

BRAKE PAD PIN
17 N·m (1.7 kgf·m)

PAD SPRING
BRACKET PIN
BOOT

BRAKE PADS

*Apply Honda Bond A or equivalent to the retainer seating surface.

INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
-

caliper cylinders
caliper pistons

Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-11).
Replace any part if it is out of service limit.

19-17

HYDRAULIC BRAKE

REAR BRAKE CALIPER
REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic
system (page 19-7).
Remove the following:
When removing the
oil bolt, cover the
end of brake hose to
prevent
contamination.

-

-

Brake pads (page 19-10)
Oil bolt [1]
Sealing washers [2]
Brake hose [3]
Brake caliper [4]
Caliper pin boot [5]

Installation is in the reverse order of removal.
• Replace the and sealing washers with new ones.
• If the pad retainer [6] was removed, apply Honda
Bond A to the retainer seating surface.
• Apply 0.4 g of silicone grease to the sliding area of
the caliper pin bolt.
• Be sure to rest the eyelet stopper pin against the
caliper body when tightening the oil bolt.
TORQUE:
Brake hose oil bolt: 34 N·m (3.5 kgf·m)

Fill and bleed the rear brake hydraulic system
(page 19-7).

DISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear brake caliper as
following illustration.
• When removing the caliper piston with compressed
air, place a shop towel over the piston to prevent
damaging the piston and caliper body. Do not use
high pressure or bring the nozzle too close to the
fluid inlet.
• Install the piston with the opening toward the pads.

~

~.

llltiijiilll~

DUST SEAL

SI~A
II
BLEED VALVE

O
~

5.4 N·m (0.6 kgf·m)

~

0.4 g (0.01 oz)

~

I
CALIPER PIN BOLT

27 N·m (2.8 kgf·m)

PAD SPRING:

CALIPER SLEEVE
BRAKE PADS

~

PAD SPRING
SLEEVE BOOT

19-18

0.4 g (0.01 oz)

HYDRAULIC BRAKE
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
-

caliper cylinder
caliper piston

Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-11) and replace if
necessary.

BRAKE PEDAL
REMOVAL/INSTALLATION
Remove the right main step (page 2-14).
Unhook the brake light switch spring [1] from the brake
pedal [2].

Remove and discard the cotter pin [1].
Remove the joint pin [2] and disconnect the push rod
lower joint from the brake pedal [3].
Remove the snap ring [4], washer [5].
Remove the brake pedal by releasing the return spring
[6].
Installation is in the reverse order of removal.
• Apply grease to the brake pedal pivot sliding area.
• Replace the cotter pins with new ones.

PARKING BRAKE CALIPER (CTX700D/ND)
REMOVAL/INSTALLATION
Remove the parking brake pads (page 19-11 ).
Disconnect the parking brake cable [1] from the brake
arm [2] and remove it from cable stay [3] of the caliper
body.
Installation is in the reverse order of removal.
Check the parking brake lock operation (page 3-18).

19-19

HYDRAULIC BRAKE
DISASSEMBLY
Remove the caliper pin bolt [1].

[1 J
Remove the following:
-

[1]

Caliper bracket [1]
Pad spring [2]
Bracket pin boot [3]
Caliper pin boot [4]
Sleeve [5]

[3]

[5]

[4]

Remove the parking brake adjuster bolt lock nut [1]
while holding the brake arm [2].
Remove the brake arm.

[1]

Remove the brake shaft boot [1].

1a.?n

[1 J

HYDRAULIC BRAKE
Remove the adjuster bolUpiston [1] while holding the
brake shaft [2].
Remove the brake shaft.
• Do not disassemble the adjuster bolUpiston.

Remove the dust seal [1].
Clean the caliper cylinder and brake shaft sliding
surface.

INSPECTION
Inspect the following parts for scoring, scratches or
damage.
-

Caliper cylinder
Caliper piston

Replace if necessary.

19-21

HYDRAULIC BRAKE
ASSEMBLY
BRACKET

DUSTSEAL

~

flt
0.4 g (0.01 oz)

ADJUSTER BOLT/PISTON
PAD PIN

~

~.,

17 N·m (1.7 kgf·m, 13 lbf·ft) ..__.,

0.4 g (0.01 oz)

SLEEVE

CALIPER PIN BOOT

~

0.4 g (0.01 oz)

LOCK NUT

; ; ; m (1.7 kgf·m, 13 lbf·ft)

CALIPER BODY
BRAKE SHAFT BOOT

~

BRAKE SHAFT
~

0.4 g (0.01 oz)

0.4 g (0.01 oz)

Install a new dust seal [1] into the seal groove in the
caliper.
• Install the dust seal with its flat surface facing inside.

S~
Apply 0.4 g (0.01 oz) minimum of silicone grease to the
outer surface of the brake shaft [1].
Position the brake shaft so that the punch mark [2] is
between the index lines [3] (installation range), and
screw the shaft into the caliper.
Make sure that the punch mark is positioned between
the index lines with the shaft fully installed.

1Q_??

~

[1]
[1]

[2]

HYDRAULIC BRAKE
Apply 0.4 g (0.01 oz) minimum of silicone grease to the
adjuster bolt threads and piston sliding surface.
Install the adjuster bolt/piston [1] while holding the
brake shaft [2].

Apply 0.4 g (0.01 oz) minimum of silicone grease to the
brake shaft boot lips.

(1]~

Install the brake shaft boot [1 J to the caliper groove.

Install the brake arm [1] by aligning with the punch
marks.

Align

Install the lock nut [1] and tighten it to the specified
torque while holding the brake arm [2].
TORQUE: 17 N·m (1.7 kgf·m, 13 lbHt)

[2]

[1]

19-23

HYDRAULIC BRAKE
Apply 0.4 g (0.01 oz) minimum of silicone grease of
silicone grease to the bracket pin and sleeve sliding
surface.

[4]

(5]

Install the following:
-

Sleeve [1]
Caliper pin boots [2]
Bracket pin boot [3]
Pad spring [4]
Caliper bracket [5]
(3]

~[1]

[2]

Apply locking agent to the parking brake caliper pin bolt
threads.
Install the parking brake caliper pin bolt [1] and tighten it
to the specified torque.
TORQUE:22 N·m (2.2 kgf·m, 16 lbf-ft)

[1)~

PARKING BRAKE LEVER (CTX700D/ND)
REMOVAL/INSTALLATION
Remove the following:
-

Left rearview mirror (page 17-9)
Parking brake switch (page 22-17)

Loosen the parking brake cable mounting nut [1].
Remove the socket bolts [2], holder [3] and parking
brake lever bracket [4].

Remove the parking brake adjuster bolt lock nut [1]
while holding the brake arm [2].
Remove the brake arm and release the parking brake
cable [3] from the cable guide [4].

HYDRAULIC BRAKE
Turn the parking brake lever bracket [1] and remove the
parking brake cable joint (21, from the bracket.
Disconnect the parking brake cable [3].

Installation is in the reverse order of removal.
• Align the parking brake lever bracket locating pin
with the handlebar hole.
TORQUE:
Parking brake adjuster bolt lock nut:
17 N·m (1.7 kgf·m, 13 lbMt)
Parking brake cable mounting nut:
10 N·m (1.0 kgf·m, 7 lbMt)

Check the parking brake lock operation (page 3-18).

DISASSEMBLY
Remove the lower holder cap [1].

Remove the spring pin [1] and release shaft [2].

[2]

[1]

19-25

HYDRAULIC BRAKE
Remove the E-clip [1], washer [2] and parking brake
lever [3].

[1]

Remove the ratchet B [1].

Remove the ratchet A [1] and springs [2].

ASSEMBLY
Apply grease to the ratchet A teeth and sliding surface.
Install the springs [1] and ratchet A [2].

[2]

HYDRAULIC BRAKE
Apply grease to the ratchet B teeth and sliding surface.

[1]~

Install the ratchet B [1] with its tab [2] facing up.

Apply grease to the parking brake lever sliding surface.
Install the parking brake lever [1].
• Align the parking brake lever hole with the ratchet B
tab.

[1]
Apply grease to the washer sliding surface.
Install the washer [1] and E-clip [2].

[2]

[1]~

Install the release shaft [1] and new spring pin [2] while
aligning the hole of the release shaft, ratchet A and
parking brake lever bracket.

19-27

HYDRAULIC BRAKE
Install the lower holder cap [1].

1Q.?R

20. ANTI-LOCK BRAKE SYSTEM (ABS) {CTX700A/D/NA/ND)

ABS SYSTEM LOCATION .......................... 20-2

ABS INDICATOR CIRCUIT
TROUBLESHOOTING .............................. 20·10

ABS SYSTEM DIAGRAM ............................ 20-3
ABS TROUBLESHOOTING ...................... 20-12
SERVICE INFORMATION ........................... 20-4
WHEEL SPEED SENSOR ........................ 20-20
ABS TROUBLESHOOTING
INFORMATION····· ....................................... 20-5

ABS MODULATOR ................................... 20-23

DTC INDEX .................................................. 20-8

El

20-1

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)

ABS SYSTEM LOCATION

ABS MODULATOR
FUSE BOX

DLC

BATTERY

FRONT WHEEL SPEED SENSOR

REAR WHEEL SPEED SENSOR

20-2

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)

ABS SYSTEM DIAGRAM
FUSE BOX
CLOCK!TURN
(7.5A)

MAIN
(30A)

RIW

R
R

e-

FRONT BRAKE
LIGHT SWITCH

IGNITION
SWITCH

ILLUMI/STOP/
HORN
(7.5A)

Bl

R/BI

Bl } -

P/Bu

e, ~ O N

~

Bl

BRAKE/TAIL
LIGHT

M-rt-i1
G/Y

REAR BRAKE
LIGHT SWITCH

G

ABS MAIN
(7.5A)

P/Bu

R/BI

n
-

R/BI

G/R

7

ABS
INDICATOR

+

COMBINATION METER

BATTERY

ABSM.
(30A)

GIY---i"""I

Bl

SOLENOID VALVE

(@J) (3-1, 3-2, 3-3,
3-4, 3-7, 3-8)

i ,..-----------

u
0
W

FRONT WHEEL
SPEED SENSOR

(@) (4-1, 4-2)

Bu/Y

Bu

FRONT PULSER RING
(@)(2-1)

~
Bu

~

(@)(1-3, 1-4, 1-5)
IW/BI

W

ABS MODULATOR

REARWHEEL
SPEED S E N S O R ~

®''"

0

(@)(8-1)

REAR PULSER RING
(@)(2-3)
(@)( )

= ABS Problem code number
= Short terminals for reading
ABS problem code
ABS MODULATOR 18P (Black) CONNECTOR (MODULATOR SIDE)

Bl
Br
Bu
G
O
P
R
V
W
Y

Black
Brown
Blue
Green
Orange
Pink
Red
Violet
White
Yellow

20-3

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)

SERVICE INFORMATION
GENERAL

NOTICE
• The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing, the excessive
voltage may damage the control unit. Always turn off the ignition switch before servicing.
• Spilling brake fluid will severely damage plastic parts and painted surfaces. It is a/so harmful to some rubber parts.
• The ABS control unit is integrated in the ABS modulator. Do not disassemble the ABS modulator. Replace the ABS modulator
as an assembly when the it is faulty.
• The ABS control unit performs pre-start self-diagnosis to check whether the ABS functions normally until the vehicle speed
reaches 10 km/h (6 mph). After pre-start self-diagnosis, the ABS control unit monitors the ABS functions and vehicle running
condition constantly until the ignition switch is turned OFF (ordinary self-diagnosis).
• When the ABS control unit detects a problem, it stops the ABS function, switches back to the conventional brake operation, and
turns on or blinks the ABS indicator. Take care during the test-ride.
• Read "ABS TROUBLESHOOTING INFORMATION" carefully, inspect and troubleshoot the ABS according to the diagnostic
troubleshooting flow chart. Observe each step of the procedures one by one. Write down the OTC and probable faulty part
before starting diagnosis and troubleshooting.
• Use a fully charged battery. Do not diagnose with a charger connected to the battery.
• After troubleshooting, erase the OTC and test-ride the motorcycle to check that the ABS indicator operates normally during prestart self-diagnosis (page 20-5).
,
• Problems not caused by the faulty ABS (e.g. brake disc squeak, unevenly worn brake pad) cannot be detected by the ABS
diagnosis system.
• When the wheel speed sensor and/or pulser ring is removed, be sure to check the air gap after installing them (page 20-20).
• Be careful not to damage the wheel speed sensor and pulser ring when removing and installing the wheel.
• For pulser ring service:
- Front pulser ring (page 17-16)
- Rear pulser ring (page 18-6)
• The following color codes are used throughout this section.
Bl: Black
Bu: Blue

Br: Brown
G: Green

0: Orange
P: Pink

TOOLS
SCS service connector
070PZ-ZY30100

Test probe, 2 packs
07ZAJ-RDJA 110

R: Red
W: White

Y: Yellow

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)

ABS TROUBLESHOOTING INFORMATION
SYSTEM DESCRIPTION
SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM
The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When
there is any abnormality, the problem and the associated part can be detected by reading the Diagnostic Trouble Code (OTC).
When the motorcycle is running, pulse signals generated at the front and rear wheel speed sensors are sent to the ABS control unit.
When the vehicle speed reaches approximately 6 km/h (4 mph), the ABS control unit operates the pump motor to check it. When
the vehicle speed reaches 10 km/h (6 mph), the ABS control unit turns off the ABS indicator if the system is normal and the pre-start
self-diagnosis is completed.
If any problem is detected, the ABS indicator brinks or comes on and stays on to notify the rider of the problem.
The ordinary self-diagnosis is also made while the motorcycle is running after the pre-start diagnosis is completed. When the ABS
indicator brinks or stays on, the cause of the problem can be identified by retrieving the OTC (page 20-6).
If the ABS indicator does not come on when the ignition switch is turned ON, or the ABS indicator stays on after the pre-start selfdiagnosis is completed although the ABS is normal, the ABS indicator circuit may be faulty. Follow the troubleshooting
(page 20-10).
Pre-start serf-diagnosis when the system is normal:
IGNITION
SWITCH

ON
OFF

Running
ENGINE

VEHICLE
SPEED

Stop

0

- - - - - - - - - - - - - - - - - - - - - - - _ , ~ h (4 mph) oc abo,e

ON

--------------------------------------------------------------------------.--~.......,

PUMP
MOTOR

OFF

ABS
INDICATOR

ON
OFF

L
t

Pre-start serf-diagnosis is
completed at 10 km/h (6 mph)
PRE-START SELF-DIAGNOSIS PROCEDURE (Daily check)
1. Turn the ignition switch ON and engine stop switch "O".
2. Make sure the ABS indicator comes on.
3. Start the engine.
4. Ride the motorcycle and increase the vehicle speed to approximately 10 km/h (6 mph).
5. The ABS is normal if the ABS indicator goes off.

20-5

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
OTC INDICATION PATTERN

NOTE:
• The ABS indicator indicates the OTC by blinking a specified number of times.
The indicator has two types of blinking, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for
0.3 seconds. For example, when one long blink is followed by two short blinks, the OTC is 1-2 (one long blink= 1 blink, plus two
short blinks = 2 blinks).
• When the ABS control unit stores some OTCs, the ABS indicator shows the DTCs in the order from the lowest number to highest
number. For example, when the ABS indicator indicates code 1-2, then indicates code 2-3, two failures have occurred.
IGNITION
SWITCH

ON

1.3 sec.

. : :..

OFF

1.3 sec.

. :..

_..,.,.~:-

: 2 sec.
ABS
INDICATOR

ON
OFF

~

.....
:..1--

0.3 sec.

1.3 sec. :
--...;

Pattern repeated

.........

3.6 sec.

OTC start signal
~

~

I----3.6 sec.

i4
.:
.

0.4 sec.

----;e-

'---y----l

Lowest number OTC
(Example: Code 1-2)

Highest number OTC
(Example: Code 2-3)

When the OTC is not stored:

. 2 sec..

ABS
INDICATOR

ON
OFF

:..

..:..

3.6 sec.

..:

MCS INFORMATION
Refer to the PGM-FI system (page 4-8).

DTC READOUT
NOTE:
• The OTC is not erased by turning the ignition switch to OFF while the OTC is being output. Note that turning the ignition switch
ON again does not indicate the OTC. To show the OTC again, repeat the OTC readout procedures from the beginning.
• Be sure to record the indicated OTC.
• After diagnostic troubleshooting, erase the OTC and perform the pre-start self-diagnosis procedure to be sure that there is no
problem in the ABS (page 20-5).
• Do not apply the brake during OTC readout.
Connect the MCS to the DLC (page 20-6).
Read the OTC, stored data and follow the OTC index (page 20-8).
• If the MCS is not available, perform the following.

Reading OTC with the ABS indicator
1. Turn the ignition switch OFF.
Remove the seat (page 2-14).
Remove the OLC [1] from the battery box.
Remove the dummy connector from the DLC.
Short the DLC terminals using a special tool.

Connection: Brown - Green
TOOL:
[2] SCS service connector

070PZ-ZY30100

2. Turn the ignition switch ON and engine stop switch

"o".

The ABS indicator should come on for 2 seconds (start signal), then
goes off for 3.6 seconds and starts OTC indication.
The OTC is indicated by the number of the times of the ABS indicator blinking.
If the OTC is not stored, the ABS indicator stays on.

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
ERASING STORED DTC
NOTE:
• The stored OTC can not be erased by simply disconnecting the battery negative cable.

Connect the MCS to the DLC (page 20-6).
Erase the OTC with the MCS while the engine is stopped.
To erase the OTC without MCS, refer to the following procedure.

How to erase the OTC without MCS
1. Connect the SCS connector [1 J to the DLC (page 20-6).
2. Turn the ignition switch ON and engine stop switch "O" while squeezing
either brake lever. The ABS indicator should come on for 2 seconds and
go off.
3. Release the brake lever immediately after the ABS indicator goes off.
The ABS indicator should come on.
4. Squeeze the brake lever immediately after the ABS indicator comes on.
The ABS indicator should go off.
5. Release the brake lever immediately after the ABS indicator goes off.
When the OTC is erased, the ABS indicator blinks 2 times and stays on.
If the ABS indicator does not blink 2 times, the self-diagnostic memory
has not been erased, so try again.

CIRCUIT INSPECTION
INSPECTION AT ABS MODULATOR CONNECTOR
Remove the fuel tank (page 7-7).
Turn the ignition switch OFF.
Disconnecting procedure:
Turn the lock lever [1] to this side while pressing the lock tab [2] to release it.
Be sure the lock lever is turned all the way and disconnect the ABS
modulator 18P (Black) connector [3].
Connecting procedure:
Be sure to seat the lock lever against the wire side of the connector fully.
Connect the ABS modulator 18P (Black) connector by pressing it straight at
the area as shown (arrow) until the lock tab clicks.
Make sure the connector is locked securely.

20-7

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
• Always clean around and keep any foreign material away from the
connector before disconnecting it.
• A faulty ABS is often related to poorly connected or corroded
connections. Check those connections before proceeding.
• In testing at ABS modulator 18P (Black) connector terminals (wire
harness side; except No. 9 and No. 18 terminals), always use the test
probe [1]. Insert the test probe into the connector terminal, then connect
the digital multimeter probe to the test probe.

[1]

TOOL:
[1] Test probe

07ZAJ-RDJA110

TERMINAL LAYOUT:

(~

~

8 7 6 5 4 3 2

Gl~\

1615141~~_1

(Terminal side of the wire harness)

DTCINDEX
NOTE:

• The ABS indicator might blink in the following cases. Correct the faulty part.
- Incorrect tire pressure.
- Tires not recommended for the motorcycle were installed (incorrect tire size).
- Deformation of the wheel or tire.
• The ABS indicator might blink while riding under the following conditions. This is temporary failure. Be sure to erase the OTC
(page 20-7). Then, test-ride the motorcycle above 30 km/h (19 mph) and check the OTC (page 20-6). Ask the rider for the riding
conditions in detail when the motorcycle is brought in for inspection.
- The motorcycle has continuously run bumpy roads.
- The front wheel leaves the ground for a long time when riding (wheelie).
- Only either the front or rear wheel rotates.
- The ABS operates continuously.
- The ABS control unit has been disrupted by an extremely powerful radio wave (electromagnetic interference).
Function failure

DTC

-

1-1

1-2

1-3

1-4

20-8

Detection
B
A

..
..
.

ABS indicator malfunction
ABS modulator voltage input line
Indicator related wires
Combination meter
ABS modulator
ABS MAIN fuse (7.5 A)
Front wheel speed sensor circuit malfunction
Wheel speed sensor or related wires
Front wheel speed sensor malfunction
Wheel speed sensor, pulser ring or related
wires
Electromagnetic interference
Rear wheel speed sensor circuit malfunction
Wheel speed sensor or related wires
Rear wheel speed sensor malfunction
Wheel speed sensor, pulser ring or related
wires
Electromagnetic interference

.
.
.
.
.
.

Symptom/Fail-safe function

• ABS indicator never comes
ON at all
• ABS indicator stays ON at all

Refer
to

20-10

20-10

0

0

.

Stops ABS operation

. Stops ABS operation

0
0

0
0

20-12

20-12

.
.

Stops ABS operation

20-14

Stops ABS operation
20-14

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
OTC
1-5
2-1
2-3
3-1
3-2
3-3
3-4
3-7
3-8
4-1
4-2
4-3
5-1

5-4

6-1
6-2
7-1
8-1

Function failure
Front or rear wheel speed sensor circuit
malfunction (short circuit)
Wheel speed sensor or related wires
Front pulser ring
Pulser ring or related wires
Rear pulser ring
Pulser ring or related wires
Solenoid valve malfunction (ABS modulator)

.

Detection
A
B

0

.
.

0

.
.

Front wheel lock
Riding condition
Front wheel lock (Wheelie)
Riding condition
Rear wheel lock
Riding condition
Pump motor lock
Pump motor (ABS modulator) or related wires
• ABS M. fuse (30 A)
Power supply relay malfunction
Power supply relay (ABS modulator) or related
wires
ABS M. fuse (30 A)
Power circuit uhder voltage
Input voltage (too low)
ABS MAIN fuse (7.5 A)
Power circuit over voltage
Input voltage (too high)
Tire malfunction
Tire size
ABS control unit
ABS control unit malfunction (ABS modulator)

.
.
.
.
..

.

Refer
to
20-16

• Stops ABS operation

. Stops ABS operation

.

20-12
20-14

Stops ABS operation

0

0

20-17

.

Stops ABS operation
20-12

0
0
0

.
.

Stops ABS operation

20-14

Stops ABS operation

0

20-18
• Stops ABS operation

0

0

0

0

20-18

. Stops ABS operation
0

.

.

. Stops ABS operation

0
0

0

Symptom/Fail-safe function

0
0

0

0

.

20-19
Stops ABS operation

. Stops ABS operation
• Stops ABS operation

20-20
20-20

(A) Pre-start self-diagnosis (page 20-5)
(B) Ordinary self-diagnosis: diagnoses while the motorcycle is running (after pre-start self-diagnosis)

20-9

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)

ABS INDICATOR CIRCUIT
TROUBLESHOOTING
ABS INDICATOR DOES NOT COME ON
(when the ignition switch turned ON)
NOTE:
• Before starting this inspection, check the initial
function of the combination meter (page 22-7).
1. Indicator Operation Inspection
Turn the ignition switch OFF.
Disconnect the ABS modulator 18P (Black)
connector (page 20- 7).
Turn the ignition switch ON and engine stop switch

"o".

Check the ABS indicator.

Does the ABS indicator come on?
YES

- Faulty ABS modulator

NO

- GO TO STEP 2.

2. Indicator Signal Line Short Circuit Inspection
Turn the ignition switch OFF.
Check for continuity between the wire harness side
ABS modulator 18P (Black) connector [1] terminal
and ground.
TOOL:
07ZAJ-RDJA 110
Test probe

[

1

1

CONNECTION: 13- Ground
Is there continuity?
YES

- Short circuit in the Orange/black wire

NO

- Faulty combination meter

ABS INDICATOR STAYS ON (Indicator
does not go off when the motorcycle is
running, but DTC is not stored)
1. Service Check Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Check for continuity between the wire harness side
ABS modulator 18P (Black) connector [1] terminal
and ground.
TOOL:
07ZAJ-RDJA 110
Test probe
CONNECTION: 14 - Ground
Is there continuity?

?n.1n

YES

- Short circuit in the Brown wire

NO

- GO TO STEP 2.

1
[ 1

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
2. Indicator Signal Line Open Circuit Inspection

Short the wire harness side ABS modulator 18P r - - - - - - - - - - - - - - - - - - - ,
(Black) connector [1] terminal to the ground with a [11
jumper wire [2].
TOOL:
Test probe

07ZAJ-RDJA 110

CONNECTION: 13 - Ground

[2]

Turn the ignition switch ON and engine stop switch

"o".

Check the ABS indicator.

Does it go off?
YES

- GO TO STEP 3.

NO

-

• Open circuit in the Orange/black wire
• Faulty combination meter (if the
Orange/black wire is OK)

3. Modulator Ground Line Open Circuit Inspection
Turn the ignition switch OFF.
Check for continuity between the wire harness side
ABS modulator 18P (Black) connector [1] terminal
and ground.

[1]

CONNECTION: 9 - Ground

Is there continuity?
YES

- GO TO STEP 4.

NO

- Open circuit in the Green/yellow wire

4. Fuse Inspection

Remove the seat (page 2-14).
Remove the fuse box cover and check the ABS
MAIN fuse (7.5 A) [1] in the fuse box for blown.
Is the fuse blown?
YES

- GO TO STEP 5.

NO

- GO TO STEP 6.

20-11

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
5. Power Input Line Short Circuit Inspection
With the ABS MAIN fuse (7.5 A) removed, check for
continuity between the wire harness side ABS
modulator 18P (Black) connector [1] and ground.
TOOL:
Test probe
07ZAJ-RDJA110

l1l

CONNECTION: 7- Ground
Is there continuity?
YES

- Short circuit in Red/black wire

NO

- Intermittent failure. Replace the ABS MAIN
fuse (7.5 A) with a new one, and recheck.

6. Power Input Line Open Circuit Inspection
Install the ABS MAIN fuse (7.5 A).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
ABS modulator 18P (Black) connector [1] terminal
and ground.
TOOL:
07ZAJ-RDJA110
Test probe
CONNECTION: 7 (+) - Ground (-)
Is there battery voltage?
YES

- Faulty ABS modulator

NO

- Open circuit in Red/black wire

ABS TROUBLESHOOTING
NOTE:
• Perform inspection with the ignition switch OFF,
unless otherwise specified.
• All connector diagrams in the troubleshooting are
viewed from the terminal side.
• Use a fully charged battery. Do not diagnose with a
charger connected to the battery.
• When the ABS modulator assembly is detected to be
faulty, recheck the wire harness and connector
connections closely before replacing it.
• After diagnostic troubleshooting, erase the OTC
(page 20-7) and test-ride the motorcycle to check
that the ABS indicator operates normally during prestart self-diagnosis (page 20-5).

DTC 1-1, 1-2, 2-1, 4-1 or 4-2 {Front
Wheel Speed Sensor Circuit/Front
Wheel Speed Sensor/Front Pulser
Ring/Front Wheel Lock)
NOTE:
• The ABS indicator might blink under unusual riding
conditions (page 20-8). This is temporary failure.
Erase the DTC (page 20-7) and test-ride the
motorcycle above 30 km/h (19 mph) to check that
the ABS indicator operates normally (page 20-5).
• If OTC 4-1 is indicated, check the front brake for
drag.

20-12

[1 J

7

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
1. Speed Sensor Air Gap Inspection

Measure the air gap between the front wheel speed
sensor and pulser ring (page 20-20).
Is the air gap correct?
YES

- GO TO STEP 2.

NO

- Check each part for deformation and
looseness
and
correct accordingly.
Recheck the air gap.

2. Speed Sensor Condition Inspection
Inspect the area around the front wheel speed
sensor:
Check that there is iron or other magnetic deposits
between the pulser ring [1] and wheel speed sensor
[2], and the pulser ring slots for obstructions.
Check the installation condition of the pulser ring or
wheel speed sensor for looseness.
Check the pulser ring and sensor tip for deformation
or damage.
Are the sensor and pulser ring in
condition?

good

YES

- GO TO STEP 3.

NO

- Remove any deposits. Install properly or
replace faulty part.

3. Front Wheel Speed Sensor Line Short Circuit
Inspection (at sensor side)
Turn the ignition switch OFF.
Disconnect the front wheel speed sensor 2P (Blue)
connector (page 20-21 ).
Check for continuity between each terminal of the
sensor side front wheel speed sensor 2P (Blue)
connector [1] and ground.
CONNECTION: White - Ground
Blue - Ground

[1]

Is there continuity?
YES

- Faulty front wheel speed sensor

NO

- GO TO STEP 4.

4. Front Wheel Speed Sensor Line Short Circuit
Inspection

Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Check for continuity between each terminal of the
wire harness side front wheel speed sensor 2P
(Blue) connector [1] and ground.
CONNECTION: Blue/yellow - Ground
White/yellow - Ground

[ ]
1

Is there continuity?
• Short circuit in the Blue/yellow wire
• Short circuit in the White/yellow wire

YES

-

NO

- GO TO STEP 5.

20-13

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
5. Speed Sensor Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the following:
-

ABS modulator 18P (Black) connector
(page 20-7)
Front wheel speed sensor 2P (Blue) connector
(page 20-21)

Short the wire harness side ABS modulator 18P
(Black) connector [1] terminals with a jumper wire
[2].
CONNECTION: 8-17
Check for continuity between the wire harness side
front wheel speed sensor 2P (Blue) connector [3]
terminals.
CONNECTION: Blue/yellow - White/yellow
Is there continuity?
YES

- GO TO STEP 6.

NO

- Open circuit in the Blue/yellow or White/
yellow wire

6. Failure Reproduction with a New Speed Sensor
Replace the front wheel speed sensor with a new
one (page 20-21 ).
Connect the ABS modulator 18P (Black) and front
wheel speed sensor 2P (Blue) connectors.
Erase the OTC (page 20-7).
Test-ride the motorcycle above 30 km/h (19 mph).
Recheck the OTC (page 20-6).
Is the OTC 1-1, 1-2, 2-1, 4-1 or 4-2 indicated?
YES

- Faulty ABS modulator

NO

- Faulty original wheel speed sensor

DTC 1-3, 1-4, 2-3, or 4-3 (Rear Wheel
Speed Sensor Circuit/Rear Wheel
Speed Sensor/Rear Pulser Ring/Rear
Wheel Lock)
NOTE:

• The ABS indicator might blink under unusual riding
conditions (page 20-8). This is temporary failure.
Erase the OTC (page 20-7) and test-ride the
motorcycle above 30 km/h (19 mph) to check that
the ABS indicator operates normally (page 20-5).
• If OTC 4-3 is indicated, check the rear brake for
drag.

1. Speed Sensor Air Gap Inspection
Measure the air gap between the rear wheel speed
sensor and pulser ring (page 20-20).
Is the air gap correct?

20-14

YES

- GO TO STEP 2.

NO

- Check each part for deformation and
correct accordingly.
looseness and
Recheck the air gap.

[1)

[3]

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
2. Speed Sensor Condition Inspection

Inspect the area around the rear wheel speed
sensor:
Check that there is iron or other magnetic deposits
between the pulser ring [1] and wheel speed sensor
[2], and the pulser ring slots for obstructions.
Check the installation condition of the pulser ring or
wheel speed sensor for looseness.
Check the pulser ring and sensor tip for deformation
or damage.

Are the sensor and pulser ring in good
condition?
YES

- GO TO STEP 3.

NO

- Remove any deposits. Install properly or
replace faulty part.

3. Rear Wheel Speed Sensor Line Short Circuit
Inspection (at sensor side)

Turn the ignition switch OFF.
Disconnect the rear wheel speed sensor 2P (Gray)
connector (page 20-22).
Check for continuity between each terminal of the
sensor side rear wheel speed sensor 2P (Gray)
connector [1] and ground.
CONNECTION: Blue - Ground
White - Ground

Is there continuity?
YES

- Faulty rear wheel speed sensor

NO

- GO TO STEP 4.

4. Rear Wheel Speed Sensor Line Short Circuit
Inspection

Check for continuity between each terminal of the
wire harness side rear wheel speed sensor 2P
(Gray) connector [1] and ground.
CONNECTION: White/black - Ground
Blue - Ground

[1]

~

Is there continuity?
• Short circuit in the White/black wire
• Short circuit in the Blue wire

YES

-

NO

- GO TO STEP 5.

20-15

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
5. Speed Sensor Line Open Circuit Inspection

Turn the ignition switch OFF.
Disconnect the following:
-

[1]

ABS modulator 18P (Black) connector
(page 20-7)
Rear wheel speed sensor 2P (Gray) connector
(page 20-22)

B

Short the wire harness side ABS modulator 18P
(Black) connector [1] terminals with a jumper wire
[2].
CONNECTION: 6 -15

W/81

Check for continuity between the wire harness side
rear wheel speed sensor 2P (Gray) connector [3]
terminals.
CONNECTION: White/black - Blue
Is there continuity?

YES

- GO TO STEP 6.

NO

- Open circuit in the White/black or Blue wire

6. Failure Reproduction with a New Speed Sensor
Replace the rear wheel speed sensor with a new
one (page 20-22).
Connect the ABS modulator 18P (Black) and rear
wheel speed sensor 2P (Gray) connectors.
Erase the OTC (page 20-7).
Test-ride the motorcycle above 30 km/h (19 mph).
Recheck the OTC (page 20-6).
Is the DTC 1·3, 1-4, 2·3, or 4-3 indicated?

YES

- Faulty ABS modulator

NO

- Faulty original wheel speed sensor

DTC 1-5 (Front or Rear Wheel Speed
Sensor Circuit: Short)
1. Front Wheel Speed Sensor Line Short Circuit
Inspection (at sensor side)

Turn the ignition switch OFF.
Disconnect the front wheel speed sensor 2P (Blue)
connector (page 20-21 ).
Check for continuity between each terminal of the
sensor side front wheel speed sensor 2P (Blue)
connector [1] and ground.
CONNECTION: White - Ground
Blue - Ground
Is there continuity?

20-16

YES

- Faulty front wheel speed sensor

NO

- GO TO STEP 2.

[1]

[3]

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
2. Front Wheel Speed Sensor Line Short Circuit
Inspection

Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Check for continuity between each terminal of the
wire harness side front wheel speed sensor 2P
(Blue) connector [1] and ground.
CONNECTION: Blue/yellow - Ground
White/yellow - Ground

[1]

Is there continuity?

YES

- • Short circuit in the Blue/yellow wire
• Short circuit in the White/yellow wire

NO

- GO TO STEP 3.

3. Rear Wheel Speed Sensor Line Short Circuit
Inspection (at sensor side)

Turn the ignition switch OFF.
Disconnect the rear wheel speed sensor 2P (Gray)
connector (page 20-22).
Check for continuity between each terminal of the
sensor side rear wheel speed sensor 2P (Gray)
connector [1] and ground.
CONNECTION: Blue - Ground
White - Ground

[1 J

~

Is there continuity?

YES

- Faulty rear wheel speed sensor

NO

- GO TO STEP 4.

4. Rear Wheel Speed Sensor Line Short Circuit
Inspection

Check for continuity between each terminal of the
wire harness side rear wheel speed sensor 2P
(Gray) connector [1] and ground.
CONNECTION: White/black - Ground
Blue - Ground
Is there continuity?

YES

- • Short circuit in the White/black wire
• Short circuit in the Blue wire

NO

- Faulty ABS modulator

DTC 3-1, 3-2, 3-3, 3-4, 3-7 or 3-8
(Solenoid Valve)
1. Failure Reproduction
Erase the OTC (page 20-7).
Test-ride the motorcycle above 30 km/h (19 mph).
Recheck the OTC (page 20-6).
Is the DTC 3-1, 3-2, 3-3, 3-4, 3-7 or 3-8 indicated?

YES

- Faulty ABS modulator

NO

- Solenoid valve
failure).

is

normal (intermittent

20-17

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
DTC 5-1 or 5-4 (Pump Motor Lock/
Power Supply Relay)
1. Fuselnspection

Turn the ignition switch OFF.
Remove the seat {page 2-14).
Remove the fuse box cover and check the ABS M.
fuse {30 A) [1] in the fuse box for blown.
Is the fuse blown?

YES

- GO TO STEP 2.

NO

- GO TO STEP 3.

2. Motor Power Input Line Short Circuit Inspection
Disconnect the ABS modulator 18P {Black)
connector {page 20-7).
With the ABS M. fuse (30 A) removed, check for
continuity between the wire harness side ABS
modulator 18P (Black) connector [1] terminal and
ground.
CONNECTION: 18- Ground

[1]

Is there continuity?

YES

- Short circuit in the Violet/white wire
between the fuse box and ABS modulator
18P (Black) connector

NO

- Intermittent failure. Replace the ABS M.
fuse (30 A) with a new one, and recheck.

3. Motor Power Input Line Open Circuit Inspection
Install the ABS M. fuse (30 A).
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Measure the voltage between the wire harness side
ABS modulator 18P (Black) connector [1] terminal
and ground.
CONNECTION: 18 (+)-Ground(-)
Is there battery voltage?

YES

- GO TO STEP 4.

NO

- Open circuit in the Black or Violet/white
wire between the battery and ABS
modulator 18P (Black) connector

4. Failure Reproduction
Turn the ignition switch OFF.
Connect the ABS modulator 18P (Black) connector.
Erase the OTC (page 20-7).
Test-ride the motorcycle above 30 km/h (19 mph).
Recheck the OTC (page 20-6).
Is the DTC 5-1 or 5-4 indicated?

20-18

YES

- Faulty ABS modulator

NO

- Pump motor is normal (intermittent failure).

[1]

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
DTC 6-1 or 6-2 (Power Circuit)
1. Fuse Inspection
Turn the ignition switch OFF.
Remove the seat (page 2-14).
Remove the fuse box cover and check the ABS
MAIN fuse (7.5 A) [1] in the fuse box for blown.

Is the fuse blown?
YES

- GO TO STEP 2.

NO

- GO TO STEP 3.

2. Power Input Line Short Circuit Inspection
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
With the ABS MAIN fuse (7.5 A) removed, check for
continuity between the wire harness side ABS
modulator 18P (Black) connector [1] and ground.

TOOL:
Test probe

[1 J

07ZAJ-RDJA 110

CONNECTION: 7 - Ground
Is there continuity?
YES

- Short circuit in Red/black wire

NO

- Intermittent failure. Replace the ABS MAIN
fuse (7.5 A) with a new one, and recheck.

3. Power Input Line Open Circuit Inspection
Install the ABS MAIN fuse (7.5 A).
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Turn the ignition switch ON and engine stop switch

[1]

"o".
Measure the voltage between the wire harness side
ABS modulator 18P (Black) connector [1] terminal
and ground.

TOOL:
Test probe

7

07ZAJ-RDJA 110

CONNECTION: 7 (+) - Ground (-)
Is there battery voltage?
YES

- GO TO STEP 4.

NO

- Open circuit in Red/black wire

4. Failure Reproduction
Turn the ignition switch OFF.
Connect the ABS modulator 18P (Black) connector.
Erase the OTC (page 20-7).
Test-ride the motorcycle above 30 km/h (19 mph).
Recheck the OTC (page 20-6).

Is the DTC 6-1 or 6-2 indicated?
YES

- Faulty ABS modulator

NO

- Power circuit is normal (intermittent failure)

20-19

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
DTC 7-1 (Tire Size)
NOTE:
• Check the following and correct the faulty part.
- Incorrect tire pressure.
- Tires not recommended for the motorcycle were
installed (incorrect tire size).
- Deformation of the wheel or tire.

1. Failure Reproduction
If the above items are normal, recheck the OTC:
Erase the OTC (page 20-7).
Test-ride the motorcycle above 30 km/h (19 mph).
Recheck the OTC (page 20-6).

Is the DTC 7-1 indicated?
YES

- Faulty ABS modulator

NO

- Tire size is normal (intermittent failure)

DTC 8-1 (ABS Control Unit)
1. Failure Reproduction
Erase the OTC (page 20-7).
Test-ride the motorcycle above 30 km/h (19 mph).
Recheck the OTC (page 20-6).

Is the DTC 8-1 indicated?
YES

- Faulty ABS modulator

NO

- ABS control unit is normal (intermittent
failure)

WHEEL SPEED SENSOR
AIR GAP INSPECTION
Support the motorcycle securely using a hoist or ....,._.....,_......_
equivalent and raise the wheel off the ground.
Measure the clearance (air gap) between the sensor
and pulser ring at several points by turning the wheel
slowly.
It must be within specification.

STANDARD: 0.54-1.14 mm (0.021 - 0.045 in)
The clearance (air gap) cannot be adjusted.
If it is not within specification, check each part for
deformation, looseness or damage.
Check the wheel speed sensor for damage, and
replace if necessary.
Check the pulse ring for deformation or damage, and
replace if necessary.
-

20-20

Front pulser ring (page 17-16)
Rear pulser ring (page 18-6)

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
WHEEL SPEED SENSOR
REPLACEMENT
NOTE:
Refer to procedure for the pulser ring
installation.
-

removal/

Front pulser ring (page 17-16)
Rear pulser ring (page 18-6)

FRONT WHEEL SPEED SENSOR REMOVAL/
INSTALLATION
Remove the fuel tank (page 7-7).
Pull down the radiator (page 8-7).
Disconnect the front wheel speed sensor 2P (Blue)
connector [1].
Release the sensor wire [2] from the clamp [3].

Release the sensor wire [1] from the clamps [2].
Remove the bolt [3] and wire clamp [4], then release the
speed sensor wire.
Remove the bolt [5] and brake hose clamp [6], then
release the speed sensor wire.

Release the sensor wire [1] from the clamp [2].
Remove the bolt [3] and front wheel speed sensor wire
guide [4].
Remove the bolts [5] and front wheel speed sensor [6].
Clean around the mounting area of the caliper bracket
thoroughly, and be sure that no foreign material is
allowed to enter the mounting hole.
Installation is in the reverse order of removal.
• Make sure the radiator mounting rubber slits facing
down.
• Align radiator lower stay slit with cylinder head tab.

20-21

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)
REAR WHEEL SPEED SENSOR REMOVAL/
INSTALLATION

Remove the following:
-

Right side shelter (page 2-11)
Right swingarm pivot cover (page 2-17)

Release the rear wheel speed sensor 2P (Gray)
connector [1] from the stay and disconnect it.
Release the clamp [2].

Remove the socket bolts [1] and brake hose guide [2].
Release the brake hose [3] and rear wheel speed
sensor wire [4] from the brake hose guide.

Release the rear wheel speed sensor wire [1] from the
clamp [2].
Remove the wire band boss [3].
Remove the bolts [4] and stay [5], rear wheel speed
sensor [6].
Clean around the mounting area of the caliper bracket
thoroughly, and be sure that no foreign material is
allowed to enter the mounting hole.
Installation is in the reverse order of removal.

,n.,,

ANTI-LOCK BRAKE SYSTEM (ABS) (CTX700A/D/NA/ND)

ABS MODULATOR
REMOVAL/INSTALLATION
NOTE:

Be careful not to bend or damage the brake pipes
during assembly or removal.

CTX700D/ND

[6]

Remove the center cross plate (page 2-20).
Release the following from the ABS modulator stay and
disconnect them.
-

Linear solenoid valve 4P (Green) connector [1]
Shift spindle angle sensor 3P (Gray) connector [2]
TR sensor 3P (Black) connector [3]
Junction D [4]

Loosen the brake pipe joint nuts [5] and disconnect the
brake pipes from the ABS modulator.
• Be careful not to bend or damage the brake pipes.
Remove the ABS modulator assembly [6].

[5]
Remove the ABS modulator mounting bolts [1] and
ABS modulator [2] from the ABS modulator stay [3].
Installation is in the reverse order of removal.

[3]

[2]

• Apply brake fluid to the joint nut threads.
TORQUE:
Brake pipe joint nut: 14 N·m (1.4 kgf·m, 10 lbMt)

20-23

MEMO

21. BATIERY/CHARGING SYSTEM

SYSTEM LOCATION··· ................................ 21-2

BATTERY .................................................... 21-5

SYSTEM DIAGRAM .................................... 21-2

CHARGING SYSTEM INSPECTION .......... 21-6

SERVICE INFORMATION ........................... 21-3

REGULATOR/RECTIFIER ....... :.................. 21-7

TROUBLESHOOTING ................................. 21-4

AL TERNATOR CHARGING COIL .............. 21-8

El

21-1

BATTERY/CHARGING SYSTEM

SYSTEM LOCATION
CTX700NA shown:

BATTERY

MAIN FL!SE 30 A

ALTERNATOR

REGULATOR/RECTIFIER

SYSTEM DIAGRAM

MAIN FUSE 30 A

Bl

Bl

~l

G

EB

R

Y

Y

Y

_ _~I-~

8
BATTERY

REGULATOR/RECTIFIER

ALTERNATOR

Bl: Black
G: Green
R: Red
Y: Yellow

21-2

BATTERY/CHARGING SYSTEM

SERVICE INFORMATION
GENERAL

• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or call a physician
immediately.

NOTICE

I

• Always turn OFF the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.

• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every two weeks or keep it connected to a battery tender.
• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
• The maintenance free (MF) battery must be replaced when it reaches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions
contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2
- 3 years.
• Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop quickly and eventually die
out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in
the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage
does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level
goes down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the motorcycle.
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent
sulfation from occurring.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 21-4).
• For alternator service (page 13-10).
• The following color codes are used throughout this section.
G = Green

R= Red

Y =Yellow

BATTERY CHARGING
• Turn power ON/OFF at the charger, not at the battery terminal.
• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending
the charging time may damage the battery.
• Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the battery tester's Operation Manual for the recommended battery testing procedure.
The recommended battery tester puts a "load" on the battery so the actual battery condition of the load can be measured.
RECOMMENDED BATTERY TESTER: Micro 404XL (U.S.A. only), BM-210 or equivalent

TOOLS
Battery tester
Micro 404XL (U.S.A. only)

Christie battery charger
MC1012/2T or OptiMate pro 4 (U.S.A.
only)

or BM-210 or equivalent

21-3

BATTERY/CHARGING SYSTEM

TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove the battery (page 21-5).
Check the battery condition using the recommended battery tester.

RECOMMENDED BATTERY TESTER: Micro 404XL (U.S.A. only), BM-210 or equivalent
Is the battery good condition?

YES

- GO TO STEP 2.

NO

- Faulty battery

2. CURRENT LEAKAGE TEST
Install the battery (page 21-5).
Check the battery current leakage test (page 21-6).
Is the current leakage below 0.2 mA?

YES

- GO TO STEP 3.

NO

- GO TO STEP 6.

3. CHARGING VOLTAGE INSPECTION
Measure and record the battery voltage using a digital multimeter (page 21-5).
Start the engine.
Measure the charging voltage (page 21-6).
Compare the measurement to result of the following calculation.

STANDARD:
Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage
• CV = Charging Voltage
Is the measured charging voltage within the standard voltage?

YES

- Faulty battery

NO

- GO TO STEP 4.

4. REGULATOR/RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/rectifier connector (page 21-7).
Are the results of checked voltage and resistance correct?

YES

- GO TO STEP 5.

NO

- • Open circuit in related wire
• Loose or poor contacts of related terminal
• Shorted wire harness

5. ALTERNATOR CHARGING COIL INSPECTION
Check the alternator charging coil (page 21-8).
Is the alternator charging coil resistance within 0.1- 0.5

YES

- Faulty regulator/rectifier

NO

- Faulty charging coil

n (20°C/68°F)?

6. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTOR
Disconnect the regulator/rectifier 3P (Black) connector and recheck the battery current leakage.
Is the current leakage below 0.2 mA?

YES
NO

21-4

- Faulty regulator/rectifier
• Shorted wire harness
• Faulty ignition switch

BATTERY/CHARGING SYSTEM

BATTERY
REMOVAL/INSTALLATION
Remove the seat (page 2-14).
Always turn the
ignition switch OFF
before removing the
battery.

Remove the battery holder band [1].
Disconnect the battery negative (-) cable [2] first, then
disconnect the battery positive(+) cable [3].
Remove the battery [4].
Installation is in the reverse order of removal.
• Connect the positive (+) cable first, then connect the
negative(-) cable.
• For digital clock setting procedure (page 22-11 ).

VOLTAGE INSPECTION
Remove the seat (page 2-14).
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (20°C/68°F):
Fully charged:
13.0 -13.2 V
Needs charging: Below 12.4 V

BATTERY TESTING
Remove the battery (page 21-5).
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery tester

Micro 404XL (U.S.A.
only), BM-210 or
equivalent

BATTERY CHARGING (U.S.A. only)
Remove the battery (page 21-5).
Refer to the instructions that are appropriate to the
battery charging equipment available to you.
TOOL:
Christie battery charger

MC1012/2Tor
OptiMate pro 4
(U.S.A. only)

21-5

BATTERY/CHARGING SYSTEM

CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE TEST
Remove the seat (page 2-14).
Turn the ignition switch OFF, disconnect the negative
(-) cable [1] from the battery.
Connect the ammeter(+) probe [2] to the negative (-)
cable and the ammeter (-) probe [3] to the battery (-)
terminal.
With the ignition switch OFF, check for current leakage.
00

NOTE:

• When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the range
[1 J
selected may blow the fuse in the tester.
• While measuring current, do not turn the ignition ' - - - - - - - - - - - - - - - - - - _ _ . J
switch ON. A sudden surge of current may blow the
fuse in the tester.
SPECIFIED CURRENT LEAKAGE: 0.2 mA maximum

If current leakage exceeds the specified value, a
shorted circuit is the probable cause.
Locate the short by disconnecting connections one by
one and measuring the current.

CHARGING VOLTAGE INSPECTION
NOTE:

Make sure the battery is in good condition before
performing this test.
Start the engine and warm it up to the operating
temperature; then stop the engine.
Remove the seat (page 2-14).
Connect the multimeter between the positive terminal
[1] and negative terminal [2] of the battery.
NOTE:

• To prevent a short, make absolutely certain which
are the positive and negative terminals or cable.
• Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tester or electrical components.
With the headlight on high beam, restart the engine.
Measure the voltage on the multimeter when the engine
runs at 5,000 rpm.
STANDARD:
Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage (page 21-5)
• CV = Charging Voltage

If the charging voltage reading is out of the
specification, inspect the regulator/rectifier (page 21-7).

[1 J

BATTERY/CHARGING SYSTEM

REGULATOR/RECTIFIER
REMOVAL/INSTALLATION
Remove the trim clip [1] and open the lid [2].
Remove the bolts [3] and regulator/rectifier [4].
Disconnect the alternator 3P (Gray) connector [5] and
regulator/rectifier 3P (Black) connector [6].
Installation is in the reverse order of removal.

SYSTEM INSPECTION
Check connectors for loose contact or corroded
terminals.
Inspect the following items:
-

Battery charging line (page 21-7)
Ground line (page 21-7)
Charging coil (page 21-8)

If all components of the charging system are normal
and there are no loose connections at the regulator/
rectifier connectors, replace the regulator/rectifier.

BATTERY CHARGING LINE
INSPECTION
Turn the ignition switch OFF.

[1]

Disconnect the regulator/rectifier 3P (Black) connector
[1] (page 21-7).
Measure the voltage between the regulator/rectifier 3P
{Black) connector terminal at the wire side and ground.

R

CONNECTION: Red (+) - Ground (-)
STANDARD:
Battery voltage
There should be battery voltage at all times.

GROUND LINE INSPECTION
Turn the ignition switch OFF.
Disconnect the regulator/rectifier 3P (Black) connector
[1] (page 21-7).

[1]

G

Check for continuity between the regulator/rectifier 3P
(Black) connector at the wire side and ground.

CONNECTION: Green - Ground
There should be continuity at all times.

21-7

BATTERY/CHARGING SYSTEM

ALTERNATOR CHARGING COIL
CHARGING COIL INSPECTION
It is not necessary
to remove the stator
coil to conduct this
test.

Disconnect the alternator 3P (Gray) connector [1]
(page 21-7).

[1]

Measure the resistance between the alternator 3P
(Black) connector terminals at the wire side.
CONNECTION: Yellow - Yellow
0.1 - 0.5 Q (20°C/68°F)
STANDARD:

Check for continuity between the alternator 3P (Gray)
connector [1] terminals at the wire side and ground.
CONNECTION: Yellow - Ground
No continuity
STANDARD:
Replace the stator if the resistance is out of
specification, or if any wire has continuity to ground.
For alternator/starter replacement (page 13-10).

21-8

[ ]
1

22. LIGHTS/ ETERS/SWITCHES

SYSTEM LOCATION ................................... 22·2

FUEL LEVEL SENSOR··················· .. ········22-15

SERVICE INFORMATION ···························22-3

PARKING BRAKE INDICATOR/SWITCH
(CTX700D/ND) .......................................... 22-16

HEADLIGHT ················································22-4
IGNITION SWITCH·············· .. ····················22-17
TURN SIGNAL UGHT······················ .. ·········22-4
HANDLEBAR SWITCHES ........................ 22-18
BRAKE/TAIL UGHT····················· .. ·············22-6

BRAKE LIGHT SWITCH ........................... 22-19

LICENSE LIGHT························· ................. 22-6
CLUTCH SWITCH (CTX700/A/N/NA) ....... 22-19
COMBINATION METER .............................. 22-7
NEUTRAL SWITCH .................................. 22-20
SPEEDOMETERNS SENSOR .................. 22-12
SIDESTAND SWITCH·· ............................. 22-21
TACHOMETER· ......................................... 22-12
HORN ........................................................ 22-22
HIGH COOLANT TEMPERATURE
INDICATOR/ECT SENSOR ....................... 22-13
ENGINE OIL PRESSURE INDICATOR/
EOP SWITCH ............................................ 22-14

TURN SIGNAL/HAZARD RELAY ............. 22-22
HAZARD DIODE ....................................... 22-24

El

22-1

LIGHTS/METERS/SWITCHES

SYSTEM LOCATION
CTX700/A/NINA:
FRONT BRAKE LIGHT SWITCH

FUEL LEVEL SENSOR
ECT SENSOR

CLUTCH SWITCH

TURN SIGNAL/
HAZARD RELAY

EOP SWITCH

HORN
REAR BRAKE LIGHT SWITCH

NEUTRAL SWITCH

SIDESTAND SWITCH

CTX700D/ND:
FRONT BRAKE LIGHT SWITCH

FUEL LEVEL SENSOR
ECT SENSOR

PARKING BRAKE SWITCH

TURN SIGNAL/
HAZARD RELAY

IGNITION SWITCH

EOPSWITCH

HORN
VS SENSOR
REAR BRAKE LIGHT SWITCH

22-2

NEUTRAL SWITCH

SIDESTAND SWITCH

LIGHTS/METERS/SWITCHES

SERVICE INFORMATION
GENERAL

NOTICE
• Note the following when replacing the halogen headlight bulb.
- Wear clean gloves while replacing the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the
bulb and cause it to fail.
- If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.

• Be sure to install the dust cover after replacing the headlight bulb.
• A halogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after it is turned OFF. Be sure
to let it cool down before servicing.
• Check the battery condition before performing any inspection that requires proper battery voltage.
• Use an electric heating element to heat the water/coolant mixture for the ECT sensor inspection. Keep flammable materials
away from the electric heating element. Wear protective clothing, insulated gloves and eye protection.
• A continuity test can be made with the switches installed on the motorcycle.
• The following color codes are used throughout this section.
Bu= Blue
Bl= Black

G = Green
Gr= Gray

P = Pink
R= Red

V = Violet
W = White

Y=Yellow

TOOLS
Test probe, 2 packs
07ZAJ-RDJA110

SCS service connector
070PZ-ZY30100

22-3

LIGHTS/METERS/SWITCHES

HEADLIGHT
BULB REMOVAL/INSTALLATION
CTX700fAJD
Remove the dust cover [1].
Unhook the bulb retainer [2] and remove the headlight
bulb [3].

I

NOTICE

I

Avoid touching halogen headlight bulb. Finger prints
can create hot spots that cause a bulb to break.
Installation is in the reverse order of removal.
• Install the dust cover with its "TOP" mark [4] and
arrow mark [5] facing up.

CTX700N/NA/ND

Remove the headlight assembly (page 2-8).

[3)

Remove the dust cover [1].
Unhook the bulb retainer [2] and remove the headlight
bulb [3].

I

NOTICE

I

Avoid touching halogen headlight bulb. Finger prints
can create hot spots that cause a bulb to break.
Installation is in the reverse order of removal.
• Install the dust cover with its "TOP" mark [4] and
arrow mark [5] facing up.

TURN SIGNAL LIGHT
BULB REMOVAL/INSTALLATION
Remove the screw [1], collar [2] and turn signal light
lens [3] by releasing the tab [4].
While pushing in the bulb [5], turn it counterclockwise to
remove it.
Check the packing [6] is installed in position and is in
good condition, replace it with a new one if necessary.
Installation is in the reverse order of removal.

[1]

22-4

LIGHTS/METERS/SWITCHES
FRONT TURN SIGNAL LIGHT UNIT
REMOVAL/INSTALLATION
CTX700/A/D

Disconnect the front turn signal/position light 3P
connector [1].

[1]

Remove the nut [2] and mounting plate [3].
Remove the turn signal light unit [4] by pulling out the
wire from the hole of the mounting rubber [5].
Installation is in the reverse order of removal.

[4]
CTX700N/NA/ND

Remove the headlight side cover assembly (page 2-8).

[5]

Remove the turn signal light special screw [1], mounting
plate [2].
Remove the turn signal light unit [3] from the headlight
side cover [4] by pulling out the wire from the hole of the
mounting rubber [5].
Installation is in the reverse order of removal.
TORQUE:
Turn signal light special screw:
1.5 N·m (0.2 kgf·m, 1.1 lbHt)
[3]

[4]

REAR TURN SIGNAL LIGHT UNIT
REMOVAL/INSTALLATl ON
REAR

Remove the rear fender A (page 2-17).
Remove the turn signal light special screw [1] and plate
[2].
Remove the turn signal light unit [3] by pulling out the
wire from the hole of the mounting rubber [4].
Installation is in the reverse order of removal.
TORQUE:
Turn signal light special screw:
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

[4]

22-5

LIGHTS/METERS/SWITCHES

BRAKE/TAIL LIGHT
INSPECTION
Turn the ignition switch ON and engine stop switch "o".
Check the brake/tail light operation.
Check that LEDs in the brake/tail light light unit illuminate as shown with the lighting switch ON.
Check that LEDs in the brake/tail light unit illuminate with the front brake lever and/or rear brake pedal applied.
If any LED does not turn on, replace the rear combination light unit.

REMOVAL/INSTALLATION
Remove the rear fender A (page 2-17).

[1]/[2]

Remove the two nuts [1] washers [2] and brake/tail light
unit [3].

' ·<~@!

Installation is in the reverse order of removal.
[3]

LICENSE LIGHT
BULB REMOVAL/INSTALLATION
Remove the two screws [1 ], lens [2] and bulb [3].

[3]

[2]

Check the packing [4] is in good condition, replace it
with a new one if necessary.
Installation is in the reverse order of removal.

[4]

[1]

REMOVAL/INSTALLATION
Remove the rearfender A (page 2-17).
Remove the two nuts [1] collars [2] and license light unit
assembly from the rear fender A [3].
Remove the two screws [4] and mounting stay [5].
Remove the two nuts [6], collars [7] and license light
unit [8] from the bracket [9].
Replace the packing [1 OJ if necessary.

[8]

Installation is in the reverse order of removal.

[10]

22-6

[6]/[7]

[3]

LIGHTS/METERS/SWITCHES

COMBINATION METER
SYSTEM INSPECTION
NOTE:
Check for loose or poor contact terminals at the
combination meter 16P (Gray) connector.
Turn the ignition switch ON and engine stop switch "O",
check that the tachometer segment [1] move to full
scale and then tachometer segment go off.
If the tachometer segment does not show initial
function, check the combination meter power input line
(page 22-7).
fJ

I

2

3

~

S'

e'fJDDDrJtrWJ

lllllllllllllllllllllllllllllll/llllllll

If the power and ground lines are OK, replace the
combination meter (page 22-7).
If the MIL and engine oil pressure indicator are stay on
and tachometer, high coolant temperature indicator
does not come on, inspect the following;
-

OTC with the MCS (page 4-9)
Serial communication line (page 22-8)

[1 J

REMOVAL/INSTALLATION
• For CTX700/A/D (page 2-6).
CTX700NINAIND:

Remove the headlight assembly (page 2-8).
Pull off the dust cover and disconnect the combination
meter 16P (Gray) connector [1].
Remove the screws [2], washer [3] and combination
meter [4].
Installation is in the reverse order of removal.

TORQUE:
Combination meter mounting screw:
1.0 N·m (0.1 kgf·m, 0.7 lbMt)

POWER/GROUND LINE INSPECTION
POWER INPUT LINE
Disconnect
connector.
-

the

combination

meter

16P

(Gray)

[ ]
1

CTX700/A/D (page 2-6)
CTX700N/NA/ND (page 22-7)

Measure the voltage at the combination meter 16P
(Gray) connector [1] of the wire harness side and
ground.

P/Bu

CONNECTION: Pink/blue(+) - Ground (-)
STANDARD:
Battery voltage
There should be battery voltage with the ignition switch
turned ON.
If there is no voltage, check the following:
-

Open circuit in the Pink/blue wire
Blown sub fuse 7.5 A (ILLUMI/STOP/HORN)

22-7

LIGHTS/METERS/SWITCHES
BACK-UP VOLTAGE LINE

Disconnect the combination
connector (page 22-7).
-

meter

16P

(Gray)

[1 J

CTX700/A/D (page 2-6)
CTX700N/NA/ND (page 22-7)

Measure the voltage at the combination meter 16P
(Gray) connector [1] of the wire harness side and
ground.

RIW

CONNECTION: Red/white (+) - Ground (-)
STANDARD:
Battery voltage

There should be battery voltage at all times.
If there is no voltage, check the following:
-

Open circuit in the Red/white wire
Blown sub fuse 7.5 A (CLOCK/TURN)

GROUND LINE

Check for continuity at the combination meter 16P
(Gray) connector [1] of the wire harness side and
ground.

(1]

CONNECTION: Green/red - Ground

There should be continuity.

G/R

If there is no continuity, check for open circuit in Green/
red wire.

SERIAL COMMUNICATION LINE
INSPECTION
NOTE:

• Check the following items before starting the inspection:
- Check for loose or poor contact on the combination meter 16P (Gray) connector and ECM/PCM 33P
connector, then recheck the OTC.
- Inspect the sub fuse 7.5 A (ENG STOP)
• If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 12-81) (CTX700D/ND).
Turn the ignition switch ON with the engine stop switch
"O" and check the combination meter.

[2]

The serial communication line is abnormal if the
combination meter shows following:
-

MIL [1] and engine oil pressure indicator [2] stay on.
Tachometer and high coolant temperature indicator
do not come on.
Shift indicator"-" [3] is blinking. (CTX700D/ND only)

NOTE:

• If the ignition switch is turned ON with the engine
stop switch turned "gi", the same condition will
occur.
If the serial communication line is abnormal, check the
following.

??-R

[3] (CTX700D/ND only)

LIGHTS/METERS/SWITCHES
1. Combination Meter Serial Line Short Circuit
Inspection
Turn the ignition switch OFF.

[1]

Disconnect the following:
-

Combination meter 16P (Gray) connector
- CTX700/A/D (page 2-6)
- CTX700N/NA/ND (page 22-7)
ECM 33P (Black) connector (CTX700/A/N/NA)
(page 4-34)
PCM 33P (Gray) connector (CTX700D/ND)
(page 4-34)

R/Bu

Check for continuity between the combination meter
16P (Gray) connector [1 J of the wire harness side
and ground.
Connection: Red/blue - Ground
Is there continuity?

YES

- Short circuit in Red/blue wire

NO

- GO TO STEP 2.

2. Combination Meter Serial Line Open Circuit
Inspection
Check for continuity between the combination meter
16P (Gray) connector [1) and ECM/PCM 33P
connector [2) of the wire harness side.
Connection: Red/blue - Red/blue

TOOL:
Test probe, 2 packs

[1]

07ZAJ-RDJA 110

[2]

R/Bu

Is there continuity?

R/Bu

YES

- GO TO STEP 3.

NO

- Open circuit in Red/blue wire

3. Combination Meter Serial Line Output Voltage
Inspection
Connect the
connector.

combination

meter

16P

(Gray)

Turn the ignition switch ON and engine stop switch
"O" while pushing and holding combination meter A
button [1] and B button [2] over 10 seconds.
NOTE:

The combination meter enters the communication
diagnostic mode.

[1]

[2]

22-9

LIGHTS/METERS/SWITCHES
Measure the voltage at the ECM/PCM 33P
connector [1] of the wire harness side and ground.

[1]

Connection: Red/blue (+) - Ground (-)
Standard:
8 V or more (Every 5 seconds)
TOOL:
Test probe, 2 packs

07ZAJ-RDJA 110
R/Bu

Does the standard voltage exist?

YES

- GO TO STEP 4.

NO

- Replace the combination meter
(page 22-7).

4. ECM Serial Line Output Voltage Inspection
Turn the ignition switch OFF.
Remove the DLC [1] from the battery box.
Remove the dummy connector from the DLC.
Short the DLC terminals using a special tool.

Connection: Brown - Green
TOOL:
[2] SCS service connector

070PZ-ZY30100

Rotate and hold the throttle grip [1] to the fully open
position.
Turn the ignition switch ON while holding the throttle
grip at the fully open position over 10 seconds.
NOTE:
The
ECM/PCM
diagnostic mode.

enters

the

communication

Measure the voltage at the combination meter 16P
(Gray) connector [1] of the wire harness side and
ground.

[1]

Connection: Red/blue(+) - Ground (-)
Standard:
8 V or more (Every 5 seconds)
Does the standard voltage exist?

YES

- Inspect the combination meter
(page 22-7).

NO

- Replace the ECM/PCM with a known good
one, and recheck.

77 .. 10

R/Bu

LIGHTS/METERS/SWITCHES
COMBINATION METER DIGITAL
CLOCK SET PROCEDURE
Turn the ignition switch ON and engine stop switch "O".
Push and hold both the combination meter A button [1]
and B button [2] until the minute digits (3] indicate "1",
"2" or "3".
NOTE:
The combination meter enter the back light setting
mode.

[1]

[2]

[3]

Push the A button, then hour digits [1] start blinking.
NOTE:
The combination meter enter the clock setting mode.
:
:

•"\

.. . ··················, ···············:

.

-., -.,,. '
: ,-··-•w
·
_•ff -

_'-.,/-.,
_,•___gLd ::
I=-.,..,,

i ...- --------------,,~·
__ :
.
[1]

Push the B button until the desired hour [1] and AM/PM
are displayed.
NOTE:
Push and hold to advance the hour fast.

[_,';_~_,, ____ } ' ; \ i
:-·· ··1 • ···························,-···············:

: '-.,/-., '
:-·-">-•LH -

._/
_' ,_,._,..,ltJ
::

[1]
Push the A button, then the minute digits [1] start
blinking.

: -~ I

/

l-'~·-":IL..t -

,

I

/

:

'~.!jLL!

:.,If; ~ _, ---' ----- -------''-_ ·_,...1,_ \

[1]

22-11

LIGHTS/METERS/SWITCHES
Push the B button until the desired minute [1] is
displayed.
NOTE:
Push and hold to advance the minute fast.

Push the A button, then digital clock is set.

.···············, ······································,

Push the A button and B button.

: '-'d.!.-WLC ___. (.J.!.L LC :
j__ IL _";J, __ r, ............ ''" _",..11__ \

NOTE:
The combination meter return to the normal mode.

:

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

/

......,.; ,Merl

/

:

Turn the ignition switch OFF.
[1]

SPEEDOMETERNSSENSOR
SYSTEM INSPECTION
If the speedometer does not operate, check the
following:
-

Combination meter system inspection (page 22-7)
MIL blinking: If the MIL blinks 11, check the VS
sensor system (page 4-10)

If the above items are OK, replace the combination
meter (page 22-7).

VS SENSOR REMOVAL/
INSTALLATION
Disconnect the VS sensor 3P (Black) connector [1].
Remove the bolt [2] and VS sensor [3].
Remove the 0-ring [4].
Installation is in the reverse order of removal.
• Replace the 0-ring with a new one.
• Apply engine oil to a new 0-ring.

TACHOMETER
SYSTEM INSPECTION
If the tachometer does not operate, check the following:
-

Combination meter system inspection (page 22-7)
Serial communication line (page 22-8)
CKP sensor (page 5-7)

If the above items are OK, replace the combination
meter (page 22-7).

?? .. 1?

LIGHTS/METERS/SWITCHES

HIGH COOLANT TEMPERATURE
INDICATOR/ECT SENSOR
SYSTEM INSPECTION
If the high coolant temperature indicator [1] does not
operate properly, check the following:
-

Combination meter system inspection (page 22-7)
Serial communication line (page 22-8)
MIL blinking: If the MIL blinks 7, check the ECT
sensor system (page 4-10).
ECT sensor (page 22-13)

If the above items are OK, replace the combination
meter (page 22-7).

x1000r!"

7

B_

If the MIL and engine oil pressure indicator stay on, and
tachometer, high coolant temperature indicator does
not come on and shift indicator"-" (CTX700D/ND only)
is blinking, inspect the following;
-

OTC with the MCS (page 4-9)
Serial communication line (page 22-8)

ECT SENSOR UNIT INSPECTION
Remove the ECT sensor (page 4-33).
Suspend the ECT sensor [1] in a pan of coolant
(50 - 50 mixture) on an electric heating element and
measure the resistance through the sensor as the
coolant heats up.
• Soak the ECT sensor in coolant up to its threads
with at least 40 mm (1.6 in) from the bottom of the
pan to the bottom of the sensor.
• Keep the temperature constant for 3 minutes before
testing. A sudden change of temperature will result
in incorrect readings. Do not let the thermometer or
ECT sensor touch the pan.

Measure the resistance between the ECT sensor
terminals [1].
Temperature
Resistance

40°C (104°F)
1.0-1.3 kO

100°C (212°F)
0.1 - 0.2 kO

Replace the ECT sensor if it is out of specification.

[1 J

22-13

LIGHTS/METERS/SWITCHES

ENGINE OIL PRESSURE INDICATOR/
EOP SWITCH
SYSTEM INSPECTION
The engine oil pressure indicator [1] comes on when
the ignition switch is turned ON, then goes off when the
engine starts.
If the engine oil pressure indicator does not come on
with the ignition switch turned ON, check the
combination meter system inspection (page 22-7).
The engine oil pressure indicator does not go out when
the engine running, check the following:
-

Engine oil level (page 3-9)
Serial communication line (page 22-8)
MIL blinking: If the MIL blinks 87, check the EOP
switch system (page 4-10)
Engine oil pressure (page 9-6)
EOP switch line (page 22-14)
Replace the EOP switch, and recheck (page 22-14).

If the above items are OK, replace the combination
meter (page 22-7).
If the MIL and engine oil pressure indicator stay on and
tachometer, high coolant temperature indicator do not
come on, inspect the following;
-

OTC with the MCS (page 4-9)
Serial communication line (page 22-8)

EOP SWITCH LINE INSPECTION
Turn the ignition switch OFF.
Disconnect the EOP switch 1P (Gray) connector [1 ].
Check for continuity between the EOP switch connector
terminal and ground.

CONNECTION: Light green - Ground
-

If there is continuity, the Light green wire has a short
circuit.
If there is no continuity, replace the ECM/PCM with
a known good one, and recheck.

NOTE:
If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 12-81) (CTX700D/ND).

EOP SWITCH REMOVAL/
INSTALLATION
Remove the radiator reserve tank (page 8-11 ).
Disconnect the EOP switch 1P (Gray) connector [1].
Remove the EOP switch [2] from the crankcase.
Installation is in the reverse order of removal.

TORQUE:18 N·m (1.8 kgf·m, 13 lbf·ft)
• Apply sealant to the EOP switch threads.
Check the engine oil level (page 3-9).

[1 J

~

.... "!::?: ....
!J

I

TOTAL

>
~

\

2

•

'""'

'I

.,
5

5

Ltkm,h

x;o

LIGHTS/METERS/SWITCHES

FUEL LEVEL SENSOR
FUEL LEVEL SENSOR INSPECTION
Remove the fuel pump unit (page 7-10).
Connect the ohmmeter to the fuel pump unit 3P (Black)
connector [1] terminals.
CONNECTION: Red/black - Black/white

Inspect the resistance of the float [2] at the top and
bottom positions.

FULL

IResistance

EMPTY
80-83 Q

4-60

[2]

[1]

FUEL METER INSPECTION
If the fuel meter blinks as shown [1] with ignition switch
is ON, perform the inspection as follow:
Disconnect
connector.
-

the

combination

meter

16P

:i

(Gray)

CTX700/A/D (page 2-6)
CTX700N/NA/ND (page 22-7)

E~

Disconnect the fuel pump unit 3P (Black) connector
(page 7-10).
Check for continuity between the combination meter
16P (Gray) connector [2] and fuel pump unit 3P (Black)
connector [3] of the wire harness side.
CONNECTION: Black/green - Black/green

If there is no continuity, check for open circuit in Black/
green wire and loose contact of the wire harness
connectors.
If the Black/green wire is OK, check the fuel level
sensor (page 22-15).
If the fuel level sensor is OK, replace the combination
meter.

[2]

[3]

81/G

81/G

22-15

LIGHTS/METERS/SWITCHES

PARKING BRAKE INDICATOR/SWITCH
(CTX700D/ND)
SYSTEM INSPECTION
If the parking brake indicator [1] does not operate
properly, check the combination meter system
inspection (page 22-7).

'"10:25

5oa..

7

ro

If the combination meter system inspection is OK,
check the parking brake switch line as follows:
Turn the ignition switch OFF.
Disconnect the parking brake switch connectors [1].
Connect the connector terminals with a jumper wire.
Turn the ignition switch ON and engine stop switch

"o".

The parking brake indicator should come on.
If the indicator does not come on, check for open circuit
in the Black, Brown and Green wires.
If the indicator comes on, check the parking brake
switch (page 22-16).

PARKING BRAKE SWITCH
INSPECTION
Disconnect the parking brake switch connectors.
Check for continuity between the parking brake switch
terminals [1].
There should be continuity with the parking brake lever
pulled, and no continuity with the lever released.
If the parking brake switch does not operate properly,
replace the switch (page 22-17).

22-16

LIGHTS/METERS/SWITCHES
PARKING BRAKE SWITCH REMOVAL/
INSTALLATION
Remove the parking brake lever holder cover [1] by
releasing the tab [2] and slots [3].

Disconnect the parking brake switch connectors [1].
Remove the following:
-

Parking brake switch screw [2]
Washer [3]
Parking brake switch [4]
Switch spring [5]

Installation is in the reverse order of removal.
• Apply grease to the parking brake switch spring
sliding surface.
TORQUE:
Parking brake switch screw:
1.2 N·m (0.1 kgf·m, 0.9 lbHt)

IGNITION SWITCH
INSPECTION
Remove the right side shelter (page 2-11 ).
Disconnect the ignition switch 2P (Brown) connector [1].
Check for continuity between the wire terminals of the
ignition switch connector in each switch position.
Refer to the wiring diagram for the terminals and switch
status:
-

CTX700/A/N/NA (page 23-2)
CTX?OOD/ND (page 23-3)

22-17

LIGHTS/METERS/SWITCHES
REMOVAL/INSTALLATION
Remove the following:
-

Center shelter (page 2-12)
Headlight assembly (CTX?OON/NA/ND) (page 2-8)

Disconnect the ignition switch 2P (Brown) connector [1].
Remove the wire band [2] and release the ignition
switch wire [3] from the wire clamp [4].

Remove the ignition switch mounting bolts [1] and
ignition switch [2].
Installation is in the reverse order of removal.
TORQUE:
Ignition switch mounting bolt:
25 N·m (2.5 kgf·m, 18 lbHt)

• Replace the ignition switch mounting bolts with new
ones.

HANDLEBAR SWITCHES
INSPECTION
CTX700/AININA:

Remove the following:
-

Front side cowls (page 2-6) (CTX700/A)
Radiator side covers (page 2-10) (CTX700N/NA)

Disconnect the following:
-

Left handlebar switch 14P (Gray) connector [1]
Right handlebar switch 8P (Blue) connector [2]

Check for continuity between the wire terminals of the
handlebar switch connector in each switch position.
Refer to the wiring diagram for the terminals and switch
status (page 23-2).

CTX700DIND:

Remove the side shelters (page 2-11 ).
Disconnect the following:
-

Left handlebar switch 14P (Gray) connector [1]
Left handlebar switch 6P (Black) connector [2]
Right handlebar switch SP (Blue) connector [3]
Right handlebar switch 6P (Black) connector [4]

Check for continuity between the wire terminals of the
handlebar switch connector in each switch position.
Refer to the wiring diagram for the terminals and switch
status (page 23-3).

22-18

LIGHTS/METERS/SWITCHES

BRAKE LIGHT SWITCH
FRONT
Disconnect the front brake light switch connectors and
check for continuity between the terminals.
There should be continuity with the brake lever applied,
and there should be no continuity with the brake lever
released.

REAR
Remove the under cowl lid (page 2-12).
Disconnect the rear brake light switch 2P (Black)
connector [1] and check for continuity between the
terminals.
There should be continuity with the brake pedal applied,
and there should be no continuity with the brake pedal
released.

CLUTCH SWITCH (CTX700/A/N/NA)
Disconnect the clutch switch connectors and check for , - - - - - ~ - - , - - - continuity between the terminals.
There should be continuity with the clutch lever applied,
and there should be no continuity with the clutch lever
released.

22-19

LIGHTS/METERS/SWITCH ES

NEUTRAL SWITCH
INSPECTION (CTX700/A/N/NA)
Make sure that the neutral indicator comes on with the
ignition switch turned ON and transmission is in neutral.
If the neutral indicator does not come on, inspect as
follows:
Remove the left crankcase rear cover (page 2-16).
Disconnect the neutral switch connector [1].
Check for continuity between the switch terminal and
engine ground.
There should be continuity when the transmission is in
neutral, and no continuity when the transmission is into
gear.
If the continuity inspection is normal, open circuit in
Light green wire between the neutral switch connector
and neutral diode or Light green/red wire between the
neutral diode and neutral indicator.
If the continuity inspection is abnormal, replace the
neutral switch (page 22-20).

INSPECTION (CTX700D/ND)
Make sure that the neutral indicator comes on when the
ignition switch is turned ON and transmission is in
neutral and goes off when the transmission is in gear.
If the neutral indicator does not operate properly, check
the shift indicator blinking with the ignition switch ON
and the engine stop switch "o".
If OTC 52 is indicated with the shift indicator, check the
neutral switch system (page 12-11 ).
If the shift indicator does not indicate any OTC and the
neutral indicator does not light with the transmission in
neutral, check for open circuit in the Light green wire
between the combination meter and neutral switch.
If the Light green wire is OK, replace the combination
meter (page 22-7).

REMOVAL/INSTALLATION
Drain the engine oil (page 3-10).
Remove the following:
-

Left crankcase rear cover (CTX700/A/N/NA)
(page 2-16)
Shift control motor/reduction gears (CTX700D/ND)
(page 12-70)
·

Disconnect the neutral switch connector [1].
Remove the neutral switch [2] and sealing washer [3].
Install the neutral switch with a new sealing washer.
Tighten the neutral switch to the specified torque.
TORQUE:12 N·m (1.2 kgf·m, 9 lbHt)
Connect the neutral switch connector.
Install the removed parts in the reverse order of
removal.
Fill the engine with the recommended engine oil
(page 3-9).

22-20

LIGHTS/METERS/SWITCHES

SIDESTAND SWITCH
INSPECTION
Remove the left side shelter (page 2-11 ).
Release the sidestand switch 2P (Gray) connector [1)
from the stay and disconnect it.
Check for continuity between the wire terminals of the
sidestand switch 2P (Gray) connector switch side.
CONNECTION: Green/white - Green

Continuity should exist only when the sidestand is up.

REMOVAL/INSTALLATION
Remove the following:
-

Left side shelter (page 2-11)
Left crankcase rear cover (page 2-16)

Release the sidestand switch 2P (Gray) connector [1)
from the stay and disconnect it.

Remove the wire bands [1] and sidestand switch wire , - - - - - - - - - - - - , - - - - - - - - - ~
band boss [2].
CTX700/A/N/NA:
CTX700D/ND:
Release the sidestand switch wire [3] from the stays [4].

[4]

Remove the sidestand switch mounting bolt [1] and
sidestand switch [2].
Installation is in the reverse order of removal.
• Replace the sidestand switch mounting bolt with a
new one.
• Align the sidestand switch tab with the sidestand
hole.
• Align the sidestand switch groove with the return
spring holding pin.
TORQUE:
Sidestand switch bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)

22-21

LIGHTS/METERS/SWITCHES

HORN
INSPECTION
Remove the under center cowl (page 2-13).
Disconnect the wire connectors.
Connect the 12 V battery to the horn terminal directly.
The horn is normal if it sounds when the 12 V battery is
connected across the horn terminals.

REMOVAL/INSTALLATION
Remove the under center cowl (page 2-13).
Disconnect the wire connectors [1].
Remove the bolt [2] and horn [3].
Installation is in the reverse order of removal.

TURN SIGNAL/HAZARD RELAY
SYSTEM INSPECTION
Remove the left rear side cowl (page 2-15).
Turn the ignition switch OFF.
Release the turn signal/hazard relay [1] from the rear
fender B.
Disconnect the turn signal/hazard relay 4P connector

[2].
Check the following at the wire harness side 4P
connector.

22-22

LIGHTS/METERS/SWITCHES
1. Battery Power
Inspection

Source

Line

Open

Circuit

Measure the voltage between the 4P connector [1]
terminal and ground.
Connection: Red/white{+) - Ground {-)

[1 J

Is there battery voltage?
YES

- GO TO STEP 2.

NO

-

• Open circuit in the Red/white wire
• Blown sub fuse 7.5 A (CLOCK/TURN)

2. Ground Line Open Circuit Inspection
Check for continuity between the 4P connector [1]
terminal and ground.
Connection: Green - Ground
Is there continuity?
YES

- GO TO STEP 3.

NO

- Open circuit in the Green wire

3. Turn Signal/hazard Switch Line Open Circuit
Inspection
Connect the 4P connector [1] terminals with a r - - - - - - - - - - - - - - - - - - jumper wire.
[1]
Connection: Red/white - Gray
Operate the turn signal switch or push the hazard
switch.
Do the turn signal light illuminate?
YES

- GO TO STEP 4.

NO

- • Open circuit in the Gray wire
• Faulty turn signal switch or hazard
switch (left handlebar switch)
• Faulty turn signal light circuits

R/W

22-23

LIGHTS/METERS/SWITCHES
4. Ignition Switch Power Source Line Open Circuit
Inspection
Turn the ignition switch ON and engine stop switch
"O".
Measure the voltage between the 4P connector [1]
terminal and ground.

[1]

Connection: Pink/blue (+) - Ground (-)
Is there battery voltage?
YES

- System is normal, replace the turn signal/
hazard relay.

NO

- • Open circuit in the Pink/blue wire
• Blown sub fuse 7.5 A (ILLUMI/STOP/
HORN)

HAZARD DIODE
INSPECTION
Remove the left side shelter (page 2-11 ).
Remove the hazard diode [1].

Check for continuity between the diode [1] terminals.
When there is continuity, a small resistance value will
register.
If there is continuity, in one direction, the diode is
normal.

c
B

22-24

23. WIRING DIAGRAM

CTX700/A/N/NA··· ........................................ 23-2

CTX700D/ND ............................................... 23-3

El

23-1

MEMO

MEMO

WIRING DIAGRAM

CTX700/A/N/NA
COMBINATION
METER

ABS
type
only

SIDESTAND

~

~~1li1li

8P~
(Bu)~

lb
I!:

,,~
;

~

SHIELD
WIRE

·-----~

~

J
CTX700/A only

f,1, l,.,'loU,..,._

~

'~ w

'

4P

2p '~

"'~

(Gr)t;:.;1

fa,

2P
(Br) ~

~co

3P ~
(Gr)~

~

'.:-ffl

~G~i

VS SENSOR

REAR BRAKE
LIGHT SWITCH

I

~ ~

1P
(Bl)

t!;-J

G,J

2P

~1

11

2P

EXHAUST
PIPE

I
·1

I•

33P
(Bl)

L1-·J

~

.,

(Bl)~

Q

VA~LVE

.I (Bl) ..,,
I !!!iii

~ w

t:i,~

1Ew;P·-1

II SOLENOID
~gOL
i
I

I

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C:~i]

50 state model
only

m,rr :
1

11 W

ffi(O

·

II • ;

DLC

I

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I
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I

d'
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rt;,,;. VIR ....;,.l,l,l, p
I : i..µ- GIR i'
i.~~k_~ __ _J

·~

;:iii~"'

FAN

TURN
SIGNAL
RELAY

IGNITION
SWITCH

FUEL
PUMP
UNIT

..

I I

!!-I

i

I

I'

I I
-- :,,

____ _
,

..

LICENS
LIGHT
12V5W

3P

.~

, p1eu..f"'l,l,,,e110, ~
-

II

G

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-~- -- .

1-

-

_.._ -_ ·- -

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f

1,1

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~

DIODE

Br
O
Lb
Lg
P
Gr

BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK
GRAY

23-2

WIRING DIAGRAM

CTX700D/ND
R

TURN
SIGNAU
HAZARD
RELAY

FUEL
PUMP
UNIT

EXHAUST
PIPE

ABS MODULATOR

~f:..J

~ ~

ALARM
(OPTIONAL)!!;'-"

REAR RIGHT
TURN SIGNAL
LIGHT
12V21W

::Jc,

3Pki~2P
~~(lb)

r~) _.,!
lb ,w

~e,::Je,

P~u

G/i r:

~

I
~

P~u

GN -

1,

Ql')

2P

n•

BRAKE/
TAI L LIGHT

(O)~
Ql')

~

REGULATOR I
PRECTIFIER

gi,

8

REAR LEFT
TURN SIGNAL
LIGHT
12V21W

2

~(Gr)

0

<>

REAR
WHEEL
SPEED
SENSOR

SHIFT DOWN SHIFT UP
SWITCH
SWITCH

MAP
TP
SENSOR SENSOR
SENSOR UNIT

23-3

2

3 4

FUSE
7.5A (OP)
7.5A (SUB PVB)
30A rVB)
7.5A ABS MAIN)
30A (ABS M.)
7.5A (ILLUMI/STOP/ HORN)
15A (Fl)
7.5A (ENG STOP)
9 15A (HEAD LIGHT)
10 7.5A (CLOCK/TURN)
11 15A (FAN)

7 8 9 10 11
FUSEBOX

Br BROWN
BLACK
0 ORANGE
YELLOW
Lb LIGHT BLUE
Bu BLUE
Lg LIGHT GREEN
G GREEN
p PINK
R RED
Gr GRAY
WHITE
v VIOLET
TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
Bl

y

w

MEMO

INDEX
ABS INDICATOR CIRCUIT TROUBLESHOOTING ···20-10
ABS MODULATOR····················································· 20-23
ABS SYSTEM DIAGRAM ·············································20-3
ABS SYSTEM LOCATION············································ 20-2
ABS TROUBLESHOOTING········································20-12
ABS TROUBLESHOOTING INFORMATION················20-5
AIR CLEANER ································································3-5
AIR CLEANER HOUSING ············································7-13
ALTERNATOR CHARGING COIL ································21-8
ALTERNATOR COVER ················································13-4
AT/MT MODE SWITCH TROUBLESHOOTING ·········12-56
BALANCER·································································14-21
BANK ANGLE SENSOR·············································· ·4-33
BATTERY······································································21-5
BODY PANEL LOCATIONS ···········································2-3
BRAKE FLUID·······························································3-16
BRAKE FLUID REPLACEMENT/AIR BLEEDING ········19-7
BRAKE LIGHT SWITCH
LIGHTS/METERS/SWITCHES······························· 22-19
MAINTENANCE ·······················································3-18
BRAKE LOCK OPERATION (CTX700D/ND)················3-18
BRAKE PAD/DISC························································19-9
BRAKE PADS WEAR ···················································3-17
BRAKE PEDAL··························································· 19-19
BRAKE SYSTEM ··························································3-18
BRAKE/TAIL LIGHT······················································22-6
CABLE & HARNESS ROUTING··································· 1-21
CAM CHAIN TENSIONER··········································10-10
CAMSHAFT ································································10-12
CENTER CROSS PLATE············································· 2-20
CENTER SHELTER······················································ 2-12
CHAIN COVER ·····························································2-18
CHARGING SYSTEM INSPECTION ····························21-6
CKP SENSOR·································································5-9
CLUTCH········································································ 11-6
CLUTCH EOP SENSOR·············································12-78
CLUTCH INITIALIZE LEARNING (PCM)···················· 12-81
CLUTCH OIL FILTER (CTX700D/ND) ··························3-11
CLUTCH SWITCH (CTX700/A/N/NA)·························22-19
CLUTCH SYSTEM (CTX700/A/N/NA) ··························3-20
COMBINATION METER ···············································22-7
COMPONENT LOCATION
AL TERNATOR/STARTER CLUTCH ················ ······ ·· 13-2
CLUTCH/GEARSHIFT LINKAGE
(CTX700/A/N/NA) ····················································· 11-2
CRANKCASE/TRANSMISSION/BALANCER·········· 14-2
CRANKSHAFT/PISTON/CYLINDER························ 15-2
CYLINDER HEADNALVES ·····································10-2
DUAL CLUTCH TRANSMISSION (OCT)
(CTX700D/ND) ························································· 12-2
ENGINE REMOVAL/INSTALLATION·······················16-2
FRONT WHEEL/SUSPENSION/STEERING ······· ···· 17-2
FUEL SYSTEM···························································7-2
HYDRAULIC BRAKE················································ 19-2
REAR WHEEL/SUSPENSION ·································18-2
COOLANT REPLACEMENT···········································8-4
COOLING SYSTEM······················································3-12
CRANKCASE ASSEMBLY········································· 14-23
CRANKCASE BREATHER ·············································3-6
CRANKCASE SEPARATION········································14-6
CRANKPIN BEARING················································ 15-11
CRANKSHAFT·················································'"··········· 15-5
CYLINDER COMPRESSION TEST···················· .. ········10-5
CYLINDER HEAD············ .................. ························· 10-14
CYLINDER HEAD COVER ........................................... 10-5
OCT ELECTRICAL SYSTEM LOCATION ····················12-5
OCT SHIFT PEDAL (OPTIONAL)················ .. ············· 12-79
OCT SYMPTOM TROUBLESHOOTING····· .. ··············· 12-5
OCT SYSTEM DIAGRAM ············ ·· ····· ················ ·· ··· ····· 12-6

OCT TROUBLESHOOTING INFORMATION ............... 12-7
DRIVE CHAIN······························································· 3-13
OTC INDEX
ANTI-LOCK BRAKE SYSTEM (ABS) ············· ········· 20-8
DUAL CLUTCH TRANSMISSION (OCT)
(CTX700D/ND)······················································· 12-11
PGM-FI SYSTEM····················································· 4-10
OTC TROUBLESHOOTING
DUAL CLUTCH TRANSMISSION (OCT)
(CTX700D/ND)······················································· 12-16
PGM-FI SYSTEM····················································· 4-12
DUAL CLUTCH··························································· 12-66
ECM/PCM ········· ···· ················ ···· ··· ···· ··· ··· ····· ·········· ···· ···· 4-34
ECT SENSOR ····· ···· ············· ········· ······ ········ ········· ···· ···· 4-33
EMISSION CONTROL SYSTEMS······························· 1-47
ENGINE IDLE SPEED·················································· 3-11
ENGINE INSTALLATION (CTX700/A/N/NA)················ 16-9
ENGINE INSTALLATION (CTX700D/ND)·················· 16-18
ENGINE OIL··································································· 3-9
ENGINE OIL FILTER···················································· 3-10
ENGINE OIL PRESSURE INDICATOR/
EOP SWITCH····························································· 22-14
ENGINE REMOVAL (CTX700/A/N/NA)'--······················ 16-5
ENGINE REMOVAL (CTX700D/ND)·························· 16-14
EOT SENSOR···························································· 12-79
EVAP CANISTER (50 STATE MODEL)······················· 7-22
EVAP PURGE CONTROL SOLENOID VALVE
(50 STATE MODEL)····················································· 7-22
EVAPORATIVE EMISSION CONTROL SYSTEM
(50 STATE MODEL ONLY)·········································· 3-13
EXHAUST PIPE/MUFFLER·········································· 2-19
FAN CONTROL RELAY ............................................... 8-11
FLYWHEEL .................................................................. 13-5
FORK······························· .. ········································· 17-18
FRONT BRAKE CALIPER·········································· 19-16
FRONT CENTER COWL (CTX700/A/D) ························ 2-5
FRONT FENDER······· .. ················································· 2-10
FRONT INNER COVER (CTX700/A/D)·························· 2-5
FRONT MASTER CYLINDER···································· 19-12
FRONT SIDE COWL (CTX700/A/D)······························· 2-6
FRONT SPOILER (CTX700/A/D) ··································· 2-7
FRONT WHEEL·························································· 17-14
FUEL CUT RELAY······················································· 7-21
FUEL INJECTOR·············································· .. ········· 7-18
FUEL LEVEL SENSOR·············································· 22-15
FUEL LINE ····································································· 3-4
FUEL LINE REPLACEMENT-········································· 7-4
FUEL PUMP UNIT························································ 7-10
FUEL TANK···································································· 7-7
GEARSHIFT LINKAGE
CLUTCH/GEARSHIFT LINKAGE
(CTX700/A/N/NA)·································· .. ··············· 11-13
DUAL CLUTCH TRANSMISSION (OCT)
(CTX700D/ND)······················································· 12-73
GEARSHIFT PEDAL .................................................. 11-16
HANDLEBAR································································ 17-5
HANDLEBAR SWITCHES·········································· 22-18
HAZARD DIODE············ .. ··········································· 22-24
HEADLIGHT································································· 22-4
HEADLIGHT (CTX700/A/D)········· ................................... 2-8
HEADLIGHT (CTX700N/NA/ND)···································· 2-8
HEADLIGHT AIM·························································· 3-19
HIGH COOLANT TEMPERATURE INDICATOR/
ECT SENSOR···························································· 22-13
HORN········································································· 22-22
IACV ············································································· 7-20
IAT SENSOR································································ 4-32
IGNITION COIL······························································ 5-8
IGNITION SWITCH····················································· 22-17

INDEX
IGNITION SYSTEM INSPECTION·- ............................... 5-6
IGNITION TIMING·························································· 5-8
LEFT CRANKCASE REAR COVER·· .. ························· 2-16
LEFT REAR UNDER COVER .. ···································· 2-17
LICENSE LIGHT·························································· 22-6
LUBRICATION & SEAL POINTS································· 1-19
LUBRICATION SYSTEM DIAGRAM······························ 9-2
MAIN JOURNAL BEARING·········································· 15-8
MAIN STEP .................................................................. 2-14
MAINSHAFT SENSOR· ... ,.......................................... 12-76
MAINTENANCE SCHEDULE ......................................... 3-2
METER COVER (CTX700/A/D) ...................................... 2-6
MIL CIRCUIT TROUBLESHOOTING··· .. ······················ 4-32
MODE/SHIFT INDICATOR CIRCUIT
TROUBLESHOOTING··············································· 12-56
MODEL IDENTIFICATION ····· ····· ········· ·· ·· ········ ·············· 1-3
NEUTRAL DIODE (CTX700/A/N/NA) .. ························· 6-11
NEUTRAL SWITCH···················································· 22-20
NUTS, BOLTS, FASTENERS ······································ 3-21
02 SENSOR································································· 4-36
OIL FILTER BOSS ························································· 9-6
OIL PRESSURE INSPECTION······································ 9-6
OIL PUMP (CTX700/A,'.N/NA) .. ······································· 9-7
OIL PUMP (CTX700D/ND) ............................................. 9-8
OIL STRAINER-······· ..................................................... 9-11
PARKING BRAKE CALIPER (NC700XD) ·················· 19-19
PARKING BRAKE INDICATOR/SWITCH
(CTX700D/ND) ··························································· 22-16
PARKING BRAKE LEVER (CTX700D/ND) ................ 19-24
PGM-FI SYMPTOM TROUBLESHOOTING··················· 4-7
PGM-FI SYSTEM DIAGRAM ········································· 4-3
PGM-FI SYSTEM LOCATION .... ···································· 4-2
PGM-FI TROUBLESHOOTING INFORMATION············ 4-7
PISTON/CYLINDER··················································· 15-14
PRIMARY DRIVE GEAR/CKP SENSOR ROTOR
CLUTCH/GEARSHIFT LINKAGE
(CTX700/A/N/NA) ·················································· 11-11
DUAL CLUTCH TRANSMISSION (DCT)
(NC700XD) ···························································· 12-69
RADIATOR····································································· 8-7
RADIATOR COOLANT .. ··············································· 3-12
RADIATOR RESERVE TANK ...................................... 8-11
RADIATOR SIDE COVER (CTX700N/NA/ND) ............ 2-10
RADIATOR SIDE INNER COVER (CTX700/A/D) .. ········ 2-7
REAR BRAKE CALIPER· ........................................... 19-18
REAR CENTER COWL· ............................................... 2-16
REAR FENDER A ........................................................ 2-17
REAR FENDER B ........................................................ 2-18
REAR GRIP (CTX700/A/D) .......................................... 2-15
REAR MASTER CYLINDER······································ 19-14
REAR SIDE COWL ...................................................... 2-15
REAR WHEEL··········· ................................................... 18-5
REGULATOR/RECTIFIER ........................................... 21-7
RIGHT CRANKCASE COVER
CLUTCH/GEARSHIFT LINKAGE
(CTX700/A/N/NA) .................................................... 11-4
DUAL CLUTCH TRANSMISSION (DCT)
(CTX700D/ND)······················································· 12-57
RIGHT ENGINE SIDE COVER (CTX700D/ND)···· .. ··· 12-57
ROCKER ARM ............................................................. 10-7
SEAT ............................................................................ 2-14
SENSOR UNIT POWER LINE INSPECTION ·············· 4-11
SERVICE INFORMATION
AL TERNATOR/STARTER CLUTCH ············· ......... · 13-3
ANTI-LOCK BRAKE SYSTEM (ABS) ...................... 20-4
BATTERY/CHARGING SYSTEM ............................ 21-3
CLUTCH/GEARSHIFT LINKAGE
(CTX700/A/N/NA) .................................................... 11-2
COOLING SYSTEM············· .. ···································· 8-3

CRANKCASE/TRANSMISSION/BALANCER·········· 14-4
CRANKSHAFT/PISTON/CYLINDER-······················· 15-3
CYLINDER HEADNALVES ································ .. ··· 10-3
DUAL CLUTCH TRANSMISSION (DCT)
(CTX700D/ND) ......................................................... 12-3
ELECTRIC STARTER················································6-4
ENGINE REMOVAL/INSTALLATION ...................... 16-4
FRAME/BODY PANELS/EXHAUST SYSTEM··········· 2-2
FRONT WHEEL/SUSPENSION/STEERING··········· 17-3
FUEL SYSTEM ·········· ···· ·· ···· ··· ····· ············ ·· ·· ·· ·· .. ·· ·· ·· ·· 7-3
HYDRAULIC BRAKE ····· ······ ·· ................................. · 19-5
IGNITION SYSTEM···················································· 5-4
LIGHTS/METERS/SWITCHES ................................ 22-3
LUBRICATION SYSTEM ........................................... 9-4
MAINTENANCE························································· 3-2
PGM-FI SYSTEM···· ............. ·································· .... 4-5
REAR WHEEL/SUSPENSION ................................. 18-3
SERVICE RULES ······· ············ ··········· ········· ·· ······· ........... 1-2
SHIFT CONTROL MOTOR/REDUCTION GEARS····· 12-70
SHIFT SPINDLE ANGLE SENSOR······················ .. ···· 12-77
SHOCK ABSORBER····················· .. ··························· 18-11
SHOCK LINKAGE························································· 18-9
SIDE SHELTER ............................................................ 2-11
SI DESTAND ................................................................. 3-20
SIDESTAND SWITCH ................................................ 22-21
SPARK PLUG ................................................................. 3-6
SPECIFICATIONS .......................................................... 1-5
SPEEDOMETERNS SENSOR ·· ···· .. ···················· .. ·· ·· 22-12
STARTER CLUTCH······················· ............................... 13-7
STARTER MOTOR··············· .. ·················· .. ····················6-8
STARTER RELAY (CTX700D/ND) .. ·····························6-12
STARTER RELAY SWITCH ......................................... 6-10
STATOR ..................................................................... 13-10
STEERING HEAD BEARINGS ..................................... 3-22
STEERING STEM········· .............................................. 17-24
SUSPENSION .............................................................. 3-21
SWINGARM······················· ......................................... 18-13
SWINGARM PIVOT COVER ········································2-17
SYSTEM DIAGRAM
BATTERY/CHARGING SYSTEM····· .. -· .. ··················21-2
ELECTRIC STARTER········- ....................................... 5_3
IGNITION SYSTEM································· .. ················· 5-3
SYSTEM FLOW PATTERN ............................................ 8-2
SYSTEM LOCATION
BATTERY/CHARGING SYSTEM········· .................... 21-2
ELECTRIC STARTER································· ............... 6-2
IGNITION SYSTEM .................................................... 5-2
LIGHTS/METERS/SWITCHES ································ 22-2
SYSTEM TESTING·· ... ,................................................... 8-4
TACHOMETER··············· ....... ····································· 22-12
THERMOSTAT/THERMOSTAT HOUSING···· ................ 8-5
THROTTLE BODY············· .. ·········································7-14
THROTTLE OPERATION···································· ........ ··· 3-4
TORQUE VALUES······················································· 1-12
TR SENSOR ............................................................... 12-76
TRANSMISSION (CTX700/A/N/NA) ............................. 14-7
TRANSMISSION (CTX700D/ND) ······························· 14-14
TROUBLESHOOTING
ALTERNATOR/STARTER CLUTCH············ .. ·········· 13-3
BATTERY/CHARGING SYSTEM·· .. ·························21-4
CLUTCH/GEARSHIFT LINKAGE
(CTX700/A/N/NA)········ .. ········· .. ································ 11-3
COOLING SYSTEM ................................................... 8-3
CRANKCASE/TRANSMISSION/BALANCER·········· 14-5
CRANKSHAFT/PISTON/CYLINDER························ 15-4
CYLINDER HEADNALVES ····································· 10-4
ELECTRIC STARTER························-....................... 5_5
FRAME/BODY PANELS/EXHAUST SYSTEM··········· 2-2
FRONT WHEEL/SUSPENSION/STEERING···· .. ····· 17-4

INDEX
HYDRAULIC BRAKE················································ 19-6
IGNITION SYSTEM····················································5-5
LUBRICATION SYSTEM············································9-5
REAR WHEEL/SUSPENSION ................................. 18-4
TURN SIGNAL LIGHT .................................................. 22-4
TURN SIGNAL/HAZARD RELAY ............................... 22-22
UNDER CENTER COWL····· .. ·······································2-13
UNDER COWL LID·······················································2-12
UNDER SIDE COWL .................................................... 2-13

VAL VE CLEARANCE ·· .. ·.. ····· ······· ···· ···· ··· ····· ·········· ·· ······ 3-7
WATER PUMP······························································· 8-9
WHEEL SPEED SENSOR········································· 20-20
WHEELS/TIRES··························································· 3-22
WIND SCREEN (CTX700/A/D)············;, ......................... 2-5
WIRING DIAGRAM
CTX700/A/N/NA ······················································· 23-2
CTX700D/ND ················· ....................................... ·· · 23-3

MEMO