HOW TO USE THIS MANUAL A Few Words About Safety Service Information The service and repair information contained in this manual is intended ior use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, sen/ice procedure or a tool that is not recommended by Honda, must determine the risks to their personal saiety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We stroneg recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer‘s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. AWARNING Improper service or repairs can create an unsafe condition that can cause your customer orothers to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. For Your Safety Because this manual is intended for the proiessional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts—wear gloves). If you have not received shop safety training or do not ieel confident about your knowledge oi saie servicing practice, we recommend that you do not attempt to perform the procedures described in this manual. Some oi the most important general service safety precautions are given below. However, we cannot warn you oi every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. AWARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful oi the following: ~ Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to periorm the tasks safely and completely. ~ Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, dri|l, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. ~ Use other protective wear when necessary, ior example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. ~ Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do othenNise. This will help eliminate several potential hazards: ~ Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine ~ Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. ~ Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. ~ Use only a nonilammable solvent, not gasoline, to clean parts. ~ Never drain or store gasoline in an open container. ~ Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts. 0-1 HOW TO USE THIS MANUAL How To Use This Manual This manual describes the service procedures tor the NC700X/XA/XD/S/SA/SD-C. Sections 1, 2 and 3 apply to the whole motorcycle. Section 2 illustrates procedures Ior removal/installation oI components that may be required to perIorm service described in the Iollowing sections. Section 4 through 23 describe parts oI the motorcycle, grouped according to location. It you are not iamiliar with this motorcycle, read Technical Feature in Section I. Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition. PerIorming the Iirst scheduled maintenance is very important. It compensates tor the initial wear that occurs during the break-in period. Find the section you want on this page, then turn to the table oi contents on the Iirst page ol the section. Most sections start with an assembly or system illustration, service inlormation and troubleshooting tor the section. The subsequent pages give detailed procedure. ReIer to the troubleshooting in each section according to the maliunction or symptom. In case oI an engine trouble, reier to PGM-Fl section troubleshooting Iirst. Your salety, and the salety oI others, is very important. To help you make inlormed decisions we have provided salety messages and other inlormation throughout this manual. OI 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 Iind important salety inlormation in a variety oI Iorms including: - Salety Labels — on the vehicle - Salety Messages — preceded by a salety alert symbol 1 and one oI three signal words, DANGER, WARNING, or CAUTION. These signal words mean: ADANGER You WILL be KILLED or SERIOUSLY HURT it you don’t IoIIow instructions. m You CAN be KILLED or SERIOUSLY HURT it you don’t IoIIow instructions. ACAUTION You CAN be HURT it you don’t IoIIow instructions. - Instructions — how to service this vehicle correctly and saIely. As you read this manual, you will Iind inlormation that is preceded by a m symbol. The purpose oI this message is to help prevent damage to your vehicle, other property, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRlTTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. © Honda Motor (20., le. SERVICE PUBLICATION OFFICE Date oi Issue: February 2012 HOW TO USE THIS MANUAL SYMBOLS The symbols used throughout this manual show specilic service procedures. ll supplementary inlormation is required pertaining to these symbols, it would be explained specilically in the text Without the use oi the symbols. «1' Replace the part(s) with new one(s) beiore assembly. Use the recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture ol the engine oil and molybdenum grease in a ratio oi 1:1). Use multi-burpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). 73 #73 ,6». 1% Use molybdenum disultide grease (containing more than 3% molybdenum disullide, NLGI #2 or equivalent). Example: ~ Molykote® BR-2 plus manulactured by Dow Corning U.S.A. ~ Multi-purbose M-2 manuiactured by Mitsubishi Oil, Japan Use molybdenum disultide paste (containing more than 40% molybdenum disuliide, NLGI #2 or equivalent). Example: ~ Molykote® G-n Paste manulactured by Dow Corning U.S.A. ~ Honda Moly 60 (U.S.A. only) ~ Rocol ASP manutactured by Rocol Limited, U.K. ~ Rocol Paste manulactured by Sumico Lubricant, Japan Use silicone grease. Apply locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake lluid. Use the recommended brake tluid unless otherwise specitied. Use iork or suspension iluid. CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE ENGINE/DRIVE TRAIN ELECTRICAL PG M-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM CYLINDER HEAD/VALVES CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) ALTERNATOR/STARTER CLUTCH CRAN KCASE/TRANSMISSION/BALANCER CRANKSHAFT/PISTON/CYLINDER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING q 2 _. a REAR WHEEL/SUSPENSION E HYDRAULIC BRAKE o ANTI-LOCK BRAKE SYSTEM (ABS) 4 BATTERY/CHARGING SYSTEM g g LIGHTS/METERS/SWITCHES Eg’ IMMOBILIZER SYSTEM (HISS) m WIRING DIAGRAM INDEX MEMO 1. GENERAL INFORMATION SERVICE RULES----- ----1-2 LUBRICATION 81 SEAL POINTS ---1-23 MODEL IDENTIFICATION CABLE & HARNESS ROUTING ------- -- 1-25 spEc|F|cAT|0Ns ....................................... "1.5 EM|35|0N CONTROL SYSTEMS TORQUE VALUES TECHMCAL FEATURES .......................... “1.37 GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. . Use the special tools designed lor this product to avoid damage and incorrect assembly. . Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable With English lasteners. . Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. . When tightening bolts or nuts, begin with the larger diameter or inner bolt tirst. Then tighten to the specified torque diagonally in . Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surlaces belore reassembly. . After reassembly, check all parts tor proper installation and operation. . Route all electrical wires as show in the Cable and Harness Routing (page 1-25). . Do not bend or twist control cables. Damaged control cables Will not operate smoothly and may stick or bind. ABBREVIATION Throughout this manual, the tollowing abbreviations are used to identily the respective parts or systems. 2 3 4 5 incremental steps unless a particular sequence is specilied. 6 7 8 9 Abbrev. term Full term ABS (NC700XA/XD/SA/SD) Anti-lock Brake System CKP sensor Crankshalt Position sensor DCT (NC700XD/SD) Dual Clutch Transmission DLC Data Link Connector DTC Diagnostic Trouble Code ECM (NC700X/XA/S/SA) Engine Control Module ECT sensor Engine Coolant Temperature sensor EEPROM Electrically Erasable Programmable Read Only Memory EOP sensor (NC700XD/SD) Engine Oil Pressure sensor EOP SWitch Engine Oil Pressure switch EOT sensor (NC700XD/SD) Engine Oil Temperature sensor HDS Honda Diagnostic System HISS Honda Ignition Security System lACV Idle Air Control Valve lAT sensor Intake Air Temperature sensor MAP sensor Maniiold Absolute Pressure sensor MIL Maltunction Indicator Lamp 02 sensor Oxygen sensor PCM (NC700XD/SD) Power Control Module PCV Proportional Control Valve PGM-FI Programmed Fuel Injection SCS connector Service Check Short connector TP sensor Throttle Position sensor TR sensor (NC700XD/SD) Transmission Range Sensor VS sensor Vehicle Speed sensor DESTINATION CODE Throughout this manual, the tollowing codes are used to identify individual types lor each region. DESTINATION CODE REGION . . type rance rance type Korea Russia Australia, New Zealand GENERAL INFORMATION MODEL IDENTIFICATION NC700XA shown: NC7OOSA shown: Thws manua‘ covers following types at NC700 models: 1.va NCTOOX NC700$ NC7DOX NC7DOXA NCTOOXD NC7DOS NC7DOSA NC700$D Standard brake o _ _ o _ _ ABS — O O - O 0 DOT — — O — — O Be sure to refer to the procedure tor the appropriate version at the Nc70t). GENERAL INFORMATION SERIAL NUMBERS The Vehicle Identification Number (V.I.N) [1] is stamped on the right side of the steering head. The registered number plate (E, F, ED, RU types) [1] and compliance plate (U type only) is attached on the left side of the steering head. The engine serial number [1] is stamped on the lower right side of the crankcase. The throttle body identification number [1] is stamped on the lower lelt side of the throttle body as shown. 1-4 GENERALINFORMAHON LABELS The color label [1] is attached on the right side oi the rear lrame. When ordering color-coded parts, always specify the designated color code. The Salety Certilication Label (KO type) [1] is located on the lelt side ol the rear lrame. The Emission Control Inlormation Label (KO type) [2] is located on the left side ol the rear frame. GENERAL INFORMATION Maximum weight capacity E, ED, F, RU, U type 209 kg 461 lbs SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length NC700X/XA/XD 2,210 mm (87.0 in) NC7OOS/SA/SD 2,195 mm (86.4 in) Overall width E, ED, F, NC700X/XA/XD 830 mm (32.7 in) RU. U type NC7OOS/SA/SD 760 mm (29.9 in) KO type NC700XA 825 mm (32.5 in) Overall height NC700X/XA/XD 1,285 mm (50.6 in) NC7OOS/SA/SD 1,130 mm (44.5 in) Wheelbase NC700X/XA/XD 1,540 mm (60.6 in) NC7OOS/SA/SD 1,525 mm (60.0 in) Seat height NC700X/XA/XD 830 mm (32.7 in) NC7OOS/SA/SD 790 mm (31.1 in) Footpeg height NC700X/XA/XD 341 mm (13.4 in) NC7OOS/SA/SD 310 mm (12.2 in) Ground clearance NC700X/XA/XD 165 mm (6.5 in) NC7008/SA/SD 140 mm (5.5 in) Curb weight E, ED, F, NC700X 214 kg (472 lbs) RU, U type NC700XA 218 kg (481 lbs) NC700XD 228 kg (503 lbs) Nc7oos 211 kg (465 lbs) NC7OOSA 215 kg (474 lbs) NC7OOSD 225 kg (496 lbs) KO type NC700XA 220 kg (435 lbs) ( ) ) KO type 189 kg (417 lbs FRAME Frame type Front suspension Front axle travel Rear suspension Rear axle travel Front tire size Rear tire size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Fuel tank capacity NC700X/XA/XD NC7008/SA/SD NC700X/XA/XD NC7008/SA/SD BRIDGESTONE METZELER BRIDGESTONE METZELER Diamond Telescopic Iork 137 mm (5.4 in) 107 mm (4.2 in) Swmgarm 150 mm (5.9 in) 120 mm (4.7 in) 120/7OZR17M/C (58W) 160/602R17M/C (69W) BT023F G ROADTEC 28 INTERACT E BT023R G ROADTEC 28 INTERACT Hydraulic single disc Hydraulic single disc 27“ 110 mm (4.3 in) 14.1 IIters (3.73 US gal, 3.1 Imp gal) GENERAL INFORMATION ITEM SPECIFICATIONS ENGINE Cylinder arrangement 2 cylinders in-Iine, slant angle 55° Bore and stroke 73.0 x 80.0 mm (2.87 x 3.15 in) Displacement 670 cm3 (40.9 cu-in) Compression ratio 10.7:1 Valve train Chain driven, OHC With rocker arm Intake valve opens at 1 mm (0.04 in) liit No.1:— 20° ETDC No.2: — 25° ETDC closes at 1 mm (0.04 in) lift 27“ AEDC Exhaust valve opens at 1 mm (0.04 in) liit 30° BEDC closes at 1 mm (0.04 in) lift No.1:— 15° ATDC No. .— 20° ATDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Paper element Engine dry weight NC700X/XA/S/SA 60.5 kg (133.4 lbs) NC700XD/SD 67.3 kg (148.4 lbs) Firing order 1 - 2 FUEL DELIVERY Type PGM-Fl (Programmed Fuel injection) SYSTEM Throttle bore 36 mm (1.4 in) DRIVE TRAlN Clutch system NC700X/XA/S/SA Multi-plate, wet NC700XD/SD 2 Multi-plate wet clutches Clutch operation system NC700X/XA/S/SA Cable operating NC700XD/SD Automatic Transmission Constant mesh, 6-speeds Primary reduction NC700X/XA/S/SA 1.731 (71/41) NC700XD/SD 1.921 (73/38) Final reduction NC700X/XA/S/SA 2.687 (43/16) NC700XD/SD 2.437 (39/16) Gear ratio NC700X/XA/S/SA 1st 2.812 (45/16) 2nd 1.894 (36/19) 3rd 1.454 (32/22) 4th 1.200 (30/25) 5th 1.033 (31/30) 6th 0.837 (31/37) NC700XD/SD Ist 2.666 (40/15) 2nd 1.904 (40/21) 3rd 1.454 (32/22) 4th 1.200 (30/25) 5th 1.033 (31/30) 6th 0.837 (31/37) Gearshiit pattern NC700X/XA/S/SA LeIt Ioot operated return system, 1-N-2-3-4-5-6 NC700XD/SD Automatic and electric sniit (leIt hand operated) return system, N-1-2-3-4-5-6 ELECTRlCAL ignition system Computer-controlled digital Starting system Cnarging system Regulator/rectifier Lighting system transistorized with electric advance Electric starter motor Triple phase output alternator FET snorted/triple phase tull wave rectification Battery GENERAL INFORMATION PGM-FI SPECIFICATIONS ITEM SPECIFICATIONS lAT sensor resistance (at 20°C/68"F) 2.2 — 2.7 k0 ECT sensor resistance (at 40°C/104"F) 1.0 — 1.3 k0 ln)ector resistance (at 20"C/68"F) 11 — 13 Q IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Spark plug (Iridium) lFRSG-11K(NGK) Spark plug gap 1.0 — 1.1 mm (0.039 — 0.043 in) Ignition coil peak voltage 100 V minimum CKP sensor peak voltage (at 20°C/68°F) 0.7 V minimum Ignition timing ("F" mark) 12° BTDC at idle ELECTRIC STARTER SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.0 — 13.0 (0.47 — 0.51) 6.5 (0.26) FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number GQ3UA Idle speed 1200 t 100 min‘ (rpm) Throttle grip treeplay 2 — 6 mm (1/16 — 1/4 in) Fuel pressure at idle 343 kPa (3.5 kgt/cm , 50 psi) Fuel pump flow (at 12 V) 230 cm (7.8 US oz, 8.1 Imp oz) minimum/10 seconds COOLING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1.69 liters (1.79 US qt, 1.49 lmp qt) At draining 1.41 liters (1.49 US qt, 1.24 lmp qt) Reserve tank 0.13 liter (0.14 US qt, 0.11 Imp qt) Radiator cap reliel pressure 108— 137 kPa(1.1—1.4 kgi/cm,16—20 psi) Thermostat Begin to open so — 84°C (176 —183°F) Fully open 95°C (203°F) Valve litt 8 mm (0.3 in) minimum Recommended antilreeze High quality ethylene glycol antilreeze containing silicate-tree corrosion inhibitors Standard coolant concentration 1 :1 (mixture With distilled water) GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil NC700X/XA/S/SA After draining 3.1 liters (3.3 US qt, 2.7 Imp qt) — “pm” 3?: $1329 3.4 liters (33 us gt, 3.0 Imp qt) — ng’ssembly 3.7 liters (3.9 us gt, 3.3 Imp qt) — NC700XD/SD After draining 3.2 liters (3.4 US qt, 2.8 Imp qt) — mgr'fh'jl'ggg/ 3.4 liters (33 us gt, 3.0 Imp qt) — nggsembly 4.1 liters (4.3 us gt, 3.6 Imp qt) — Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent API service classilication: 86 or higher (except oils labeled as energy conserving — on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA Oil pressure at engine oil lilter 470 kPa (4.8 kgt/cm , 68 psi) _ at 5000 min‘ (rpm)/(80°C/176°F) Oil pump rotor (NC700X/XA/S/SA) Tio clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 — 0.21 (0.006 — 0.008) 0.35 (0.014) Side clearance 0.04 — 0.09 (0.002 — 0.004) 0.12 (0.005) Engine oil pump rotor (NC700XD/SD) Tio clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 — 0.21 (0.006 — 0.008) 0.35 (0.014) Side clearance 0.04 — 0.09 (0.002 — 0.004) 0.12 (0.005) Clutch oil pump rotor (NC700XD/SD) Tip clearance 0.15 (0.006) — Body clearance 0.15 — 0.21 (0.006 — 0.008) — Side clearance 0.04 — 0.09 (0.002 — 0.004) — CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 470 min ‘(rpm) 1,775 kPa (18.1 kgt/cm , 257 psi) Valve clearance IN 0.17 t 0.02 (0.007 t 0.001) — EX 0.28 t 0.02 (0.011 t 0.001) — Rocker arm, Rocker arm |.D. 20.012 — 20.030 (0.7879 — 0.7886) 20.041 (0.7890) rocker arm Rocker arm shaIt O.D. 19.972 — 19.993 (0.7863 — 0.7871) 19.961 (0.7859) 503“ Rocker arm-to-shalt clearance 0.019 — 0.058 (0.0007 — 0.0023) 0.08 (0.003) Cam chain tensionerwedge B length — 6.0 (0.24) Gamma“ Ca’" '0“ he'gm IN 34.7397 — 35.0297 (1.36967 — 1.37912) 347697 (1 .36888) 34.9027 EX 34.9227—35.1627 (1.37491 —1.38436) (1.37412) Runout — 0.04 (0.002) Camshalt journal 0.0. 41935—41350 (16510—16516) 41.927 (1.6507) Valve, valve Valve stern O.D. IN 4.975 — 4.990 (0.1959 — 0.1965) 4.965 (0.1955) guide EX 4.965 — 4.330 (0.1955 — 0.1961) 4.355 (0.1351) Valve guide |.D. IN/EX 5000—5012(01969—01973) 5.04 (0.198) Stem-to-guide IN 0.010 — 0.037 (0.0004 — 0.0015) 0.075 (0.0030) clearance EX 0.020 — 0.047 (0.0008 — 0.0019) 0.085 (0.0033) Valve guide IN 17.7 — 18.0 (0.70 — 0.71) — ro ection above ‘C’ynlnderhead EX 19.6— 19.9 (0.77—0.73) — Valve seat width IN 0.90 — 1.10 (0.035 — 0.043) 1.5 (0.06) EX 1.30 — 1.50 (0.051 — 0.053) 1.9 (0.07) Valve spring tree length 49.07 (1.932) 48.1 (1.89) Cylinder head waroage — 0.10 (0.004) Cylinder head camshait1ournal |.D. 41.995 — 42.019 (1.6533 — 1.6543) 42.027 (1.6546) Cylinder head-to-camshait clearance 0.045 — 0.084 (0.0018 — 0.0033) 0.10 (0.004) 1-9 GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (NC700X/XA/S/SA) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch lever treeplay 10 — 20 (3/8 — 13/16) — Clutch Spring tree length 48.2 (1.70) 41.7 (1.64) Disc thickness 2.32 — 2.73 (0.103 — 0.109) 2.3 (0.09) Plate warpage — 0.80 (0.012) Clutch outer guide I.D. 21.991 — 22.016 (0.8658 — 0.8668) 22.03 (0.867) O.D. 31959—31975 (1.2532— 1.2589) 31.92 (1.257) Mainshalt O.D. at clutch outer guide 21.967 — 21.980 (0.8648 — 0.8654) 21.95 (0.334) Clutch outer guide-to-mainshalt clearance 0.011 — 0.049 (0.0004 — 0.0019) 0.08 (0.003) Primary driven gear |.D. 32.000 — 32.025 (1.2598 — 1.2608) 32.09 (1.268) Primary driven gear-to-clutch outer guide clearance 0.025 — 0.066 (0.0010 — 0.0026) 0.10 (0.004) DUAL CLUTCH TRANSMISSION SPECIFICATIONS (NC7OOXD/SD) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch clearance 0.9 — 1.1 (0.035 — 0.043) 2.0 (0.08) EOT sensor resistance (20°C/68°F) 2.5 — 2.8 M) — ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear boss O.D. 57.749 — 57.768 (2.2786 — 2.2743) 57.78 (2.273) Starter clutch outer |.D. 74.412 — 74.442 (2.9296 — 2.9308) 74.46 (2.931) CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS NC7OOX/XA/S/SA Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear |.D. M5, M6, C1 28.000 — 28.021 (1.1024— 1.1032) 28.04 (1.104) C2, C3, C4 31.000 — 81.025 (1.2205 — 1.2215) 31.04 (1.222) Gear bushing M5, M6 27.959 — 27.990 (1.1007 — 1.1013) 27.94 (1.100) O.D. 02 30955—30990 (1.2137— 1.2197) 30.93 (1.219) 03, 04 30950—30975 (1.2135— 1.2195) 30.93 (1.219) Gear-to-bushing M5, M6 0.020 — 0.032 (0.0003 — 0.0024) 0.03 (0.003) clearance 02 0.020 — 0.070 (0.0003 — 0.0023) 0.10 (0.004) 03, 04 0.025 — 0.075 (0.0010 — 0.0030) 0.11 (0.004) Gear bushing |.D. M5 25.000 — 25.021 (0.9343 — 0.9351) 25.04 (0.986) 02 27985—28006(1.1018—1.1026) 23.02 (1.103) MainshaIt O.D. At M5 bushing 24.972 — 24.993 (0.9881 — 0.9840) 24.95 (0.982) Countershalt O.D. At 02 bushing 27.967 — 27.990 (1.1011 — 1.1013) 27.95 (1.100) Bushing-to-shalt M5 0.007 — 0.049 (0.0003 — 0.0020) 0.09 (0.004) clearance 02 0.005 — 0.039 (0.0002 — 0.0015) 0.03 (0.002) Shift Iork, Fork |.D. 12.000 — 12.018 (0.4724 — 0.4781) 12.08 (0.474) fork shall Claw thickness 5.93 — 6.00 (0.233 — 0.236) 5.9 (0.28) ShiIl Iork shalt O.D. 11.957 — 11.968 (0.4707 — 0.4712) 11.95 (0.470) 1-10 GENERAL INFORMATION NC7OOXD/SD Unlt: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear |.D. M5 33.000 — 33.025 (1.2992 — 1.3002) 33.04 (1.301) M3 43.000 — 43.025 (1.3929 — 1.3939) 43.04 (1.394) 01 31.010—31.035(12209—12213) 31.03 (1.223) 02 25.000 — 25.021 (0.9343 — 0.9351) 25.03 (0.935) c3,c4 31000—31025(12205—12215) 31.04 (1.222) Gear bushing M5 32.955 — 32.930 (1.2974 — 1.2934) 32.93 (1.293) OD. M3 42.950 — 42.975 (1.3909 — 1.3919) 42.93 (1.390) 01 30.970 — 30.995 (1.2193 — 1.2203) 30.94 (1.213) 02 24.959 — 24.930 (0.9323 — 0.9335) 24.94 (0.932) 03, 04 30.950 — 30.975 (1.2135 — 1.2195) 30.93 (1.213) Gear-to-bushing M5 0.020 — 0.070 (0.0003 — 0.0023) 0.10 (0.004) clearance M3 0.025 — 0.075 (0.0010 — 0.0030) 0.11 (0.004) 01 0.015 — 0.035 (0.0003 — 0.0023) 0.10 (0.004) 02 0.020 — 0.032 (0.0003 — 0.0024) 0.09 (0.004) 03, 04 0.025 — 0.075 (0.0010 — 0.0030) 0.11 (0.004) Gear bushing |.D. M5 29935—30003 (1.1305— 1.1313) 30.03 (1.132) M3 40.007 — 40.023 (1.5751 — 1.5759) 40.033 (1 .5733) c1 23000—23021(11024—11032) 23.04 (1.104) 02 21.935 — 22.003 (0.3355 — 0.3334) 22.02 (0.337) '31? mamsm" A1 M5 bushing 29.957 — 29.970 (1.1794 — 1.1799) 29.93 (1.173) guse' ’"a'nSI‘a" A1 M3 bushing 39.975 — 39.991 (1.5733 — 1.5744) 39.935 (1.5734) Countershatt 0.0. A101 bushing 27.937 — 27.930 (1.1011 — 1.1013) 27.95 (1.100) A102 bushing 21.952 — 21.935 (0.3343 — 0.3343) 21.94 (0.334) Bushing-to-shatt M5 0.015 — 0.049 (0.0003 — 0.0019) 0.09 (0.004) clearance M3 0.013 — 0.053 (0.0003 — 0.0021) 0.10 (0.004) 01 0.020 — 0.054 (0.0003 — 0.0021) 0.03 (0.003) 02 0.020 — 0.054 (0.0003 — 0.0021) 0.03 (0.003) sniil Iork, Fork |.D. 12.000 — 12.013 (0.4724 — 0.4731) 12.03 (0.474) tork snali Claw thickness 5.93 — 3.00 (0.233 — 0.233) 5.9 (0.23) ShlIt Iork shaft O.D. 11.957 — 11.968 (0.4707 — 0.4712) 11.95 (0.470) CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cranksnait Connecting rod side dearance 0.15 — 0.35 (0.006 — 0.014) 0.45 (0.018) Runout Right side — 0.03 (0.001) LeIt side — 0.03 (0.001) Maln )ournal bearing oil c1earance 0.019 — 0.037 (0.0007 — 0.0015) 0.05 (0.002) Cylinder |.D. 73.000 — 73.015 (2.3740 — 2.3743) 73.07 (2.377) Out-oI-round — 0.10 (0.004) Taper — 0.10 (0.004) Warpage — 0.10 (0.004) Plston, iston Piston CD. at 13 mm 0.5 in irom rings 9 bomm ( ) 72.973 — 72.990 (2.3731 — 2.3733) 72.970 (2.3723) Piston pin bore |.D. 18.010 — 18.013 (0.7091 — 0.7092) 18.023 (0.7096) Piston pin 0.0. 17.993 — 13.000 (0.7035 — 0.7037) 17.933 (0.7032) Piston-to-piston pin clearance 0.010 — 0.017 (0.0004 — 0.0007) 0.035 (0.0014) Piston ring end Top 0.15 — 0.30 (0.003 — 0.012) 0.3 (0.02) gap Second 0.30 — 0.42 (0.012 — 0.017) 0.3 (0.02) on (side rail) 0.20 — 0.70 (0.003 — 0.023) 0.3 (0.03) Piston ring-to-ring Top 0.035 — 0.080 (0.0014 — 0.0032) 0.15 (0.006) groove clearance Second 0.030 — 0.055 (0.0012 — 0.0022) 0.13 (0.005) Cylinder-to-piston clearance 0.010 — 0.039 (0.0004 — 0.0015) 0.05 (0.002) Connectlng rod smal) end |.D. 17.964 — 17.977 (0.7072 — 0.7078) 17.935 (0.7081) Crankpin bearlng oil clearance 0.026 — 0.044 (0.0010 — 0.0017) 0.05 (0.002) 1-11 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 1.5 (0.06) Gold lire Driver only 250 kPa (2.50 kgi/cm , '36 psi) — pressure Driver and passenger 250 kPa (2.50 kgi/cm , '36 psi) — Axle runout — 0.2 (0.01) Wheel rim runout Radial — 2.0 (0.08) Axial — 2.0 (0.08) Wheel balance weight _ 60 g (2.1 oz) max. Fork Spring lree NC700X/XA/XD 394.9 (15.55) 387.0 (15.24) length NC7OOS/SA/SD 357.0 (14.06) 349.9 (13.78) Tube runput — 0.20 (0.008) Recommended lork fluid Honda ULTRA CUSHION OIL 88-47 _ (10W) or equivalent Fluid level NC700X/XA/XD 104 (4.1) — NC7OOS/SA/SD 103 (4.1) — Fluid capacity Ncmox/XA/XD 514 i 2.5 cm (17.4 i 0.08 US 02, 18.1 t _ 0.09 Imp oz) 518 i 2.5 Cm 17.5 i 0.08 US 02, 18.2 t NC7OOS/SA/SD (mg Imp OZ) ( — REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 2.0 (0.08) Gold lire pressure Driver only 290 kPa (2.90 kgi/cm , 42 psi) — Driver and passenger 290 kPa (2.90 kgi/cm , 42 psi) — Axle runout — 0.2 (0.01) Wheel rim runout Radial — 2.0 (0.08) Axial — 2.0 (0.08) Wheel balance weight _ 60 g (2.1 oz) max. Drive Size/link NC700X/ DID DID520VO-114LE — chain XA/S/SA RK RK52OMKO-114LE - NC700XD DID DID520VO-112LE — /SD RK RK52OMKO-112LE — Slack NC700X/XA/ D 30 — 40 (1.2 — 1.6) — NC7OOS/SA/SD 25 — 35 (1.0 — 1.4) — 1-12 GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specified brake tluid DOT 4 — Brake disc thickness 4.8 — 5.2 (0.19 — 0.20) 4.0 (0.16) Brake disc warpage — 0.30 (0.012) Master cylinder l.D. 11.000 — 11.043 (0.4331 — 0.4343) 11.055 (0.4352) Master piston 0.0. 10.957 — 10.934 (0.4314 — 0.4324) 10.945 (0.4309) Caliper cylinder l.D. (NC700X/S) 27.000 — 27.050 (1.0630 — 1.0650) 27.060 (1.0654) Caliper piston 0.0. (NC700X/S) 26.913 — 26.966 (1.0593 — 1.0617) 26.91 (1.059) Caliper cylinder )0. Cylinder A 22.650 — 22.700 (0.6917 — 0.6937) 22.712 (0.3941) (NC700XA/XD/SA/SD) Cylinder B 27.000 — 27.050 (1.0630 — 1.0650) 27.060 (1.0654) Caliper piston 0.0. Piston A 22.565 — 22.616 (0.6692 — 0.6905) 22.56 (0.336) (NC700XA/XD/SA/SD) Piston B 26.918 — 26.968 (1.0598 — 1.0617) 26.91 (1.059) Rear Specified brake tluid DOT 4 Brake disc thickness 4.6 — 5.2 (0.19 — 0.20) 4.0 (0.16) Brake disc warpage 0.30 (0.012) Master cylinder l.D. 14.000 — 14.043 (0.5512 — 0.5529) 14.055 (0.5533) Master piston O.D. 13.957 — 13.984 (0.5495 — 0.5506) 13.945 (0.5490) Caliper cylinder l.D. 38.18— 33.23 (1.503 — 1.505) 36.24 (1.506) Caliper piston O.D. 38.098 — 38.148 (1.4999 — 1.5019) 36.09 (1.500) Brake pedal neight 35.0 — 67.0 (3.35 — 3.43) BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Type YTZ12S Capacity 12 V — 11 Ah Current leakage 1.2 mA maximum Voltage Fully charged 13.0 — 13.2 V (20°C/68°F) Needs Below 124 V charging Charging current Normal 1.1 A/5 — 10 h Quick 5.5 N1 )1 Alternator Capacity 0.42 kW/5,000 min‘ (rpm) Charging coil resistance (20°C/68°F) 0.1 — 0.5 {'2 1-13 GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight 12 V — 60/55 W Position light 12 V — 5 W Brake/iaiI/license light 12 V — 21/5 W Turn signal light 12 V — 21 W x 4 Instrument light LED Turn signal indicator LED High beam indicator LED Neutral indicator LED Engine oil pressure indicator LED High coolant temperature indicator LED MIL LED HISS indicator LED ABS indicator (NC7ODXA/XD/SA/SD) LED Parking brake indicator (NC7ODXD/SD) LED Fuse Main luse 30 A PGM-FI Iuse 15 A Subtuse 15Ax2,7.5Ax4 ABS iuse (NC700XA/XD/SA/SD) 30 A x 2, 7.5 A DCT iuse (NC700XD/SD) 30 A, 7.5 A ECT sensor resistance 40°C (104°F) 1.0 — 1.3 k0 100°C (212°F) 0.1 — 0.2 m Fuel level sensor resistance Full 4 — 6 (2 Empty 80 — 83 fl 1-14 GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TVPE N_m (mm, M“) FASTENER TYPE Mm (kglm! M") 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt (Include SH llange bolt) 10 (1 .0, 7) 6 mm screw 9.0 (0.9, 6.6) and nut 6mm llange bo|t(|nc|ude NSHF) and 12 (1.2, 9) 3 mm bolt and nut 22 (2.2, 16) nut 10 mm bolt and nut '34 (3.5, 25) 8 mm llange bolt and nut 27 (2.8, 20) 12 mm bolt and nut 54 (5.5, 40) 10 mm llange bolt and nut 39 (4.0, 29) ENGINE 8: FRAME TORQUE VALUES FRAME BODV PANELS/EXHAUST SVSTEM . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgf—m, lbf-It) REMARKS Seat cowl assembly screw 2 4 0.9 (0.1 , 0.7) Brake/tail/Iicense light mounting 1 6 10 (1.0, 7) socket bolt Reflector mounting nut 1 5 1.7 (0.2, 1.3) Tum signal light mounting screw 4 6 2.5 (0.3, 1.8) Luggage box lid assembly screw 9 4 0.9 (0.1, 0.7) Luggage box lid lock plate 2 6 4.0 (0.4, 3.0) mounting screw Luggage box lid mounting socket 3 6 (1.2, 9) bolt Luggage box lid hinge nut 1 6 12 (1.2, 9) U-nut Gearshilt arm pinch bolt 1 6 12 (1.2, 9) ALOC bolt; replace with a new one. (NC700X/XA/S/SA) Muiller cover socket bolt 1 6 10 (1.0, 7) Mutiler band bolt 1 8 17.5 (1.8, 13) Exhaust pipe )oint nut 3 B 28 (2.9, 21) See page 2-34 Exhaust pipe stud bolt 3 8 — See page 2-35 1-15 GENERAL INFORMATION MAINTENANCE , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Air cleaner housing cover screw 6 5 1.1 (0.1, 0.8) Spark plug 2 14 22(2.2, 16) Valve adjusting screw lock nut 8 7 14 (1.4, 10) Apply engine oil to the threads and seating surlace. Camshalt maintenance cap 1 36 4.0 (0.4, 3.0) See page 3-12 Timing hole cap 1 14 10 (1.0, 7) Apply grease to the threads. Crankshaft hole cap 1 30 15 (1.5, 11) Apply grease to the threads. Engine Oil drain bolt 1 12 30 (3.1, 22) Engine Oil lilter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads. Oil iilter boss 1 20 — See page 3-14 Apply locking agent to the threads. Coating width; 6.5 i 1.0 mm (0.26 t 0.04 in) lrorn tip Rear axle nut 1 18 98 (10.0, 72) U-nut Drive chain adyuster lock nut 2 B 21 (2.1,15) Drive sprocket bolt 1 10 54 (5.5, 40) Driven sprocket nut 5 12 108 (11.0, 80) U-nut Master cylinder reservoir cover 4 4 1.5 (0.2, 1.1) screw Rear brake reservoir mounting bolt 1 6 10 (1.0, 7) Rear mastercylinder push rod lock 1 B 17 (1.7, 13) nut Parking brake adyuster bolt lock 1 B 17 (1 .7, 13) nut (NC700XD/SD) Sidestand pivot bolt 1 10 — See page 3-27 Apply grease to the sliding surtace. Sidestand pivot nut 1 10 39 (4.0, 29) U-nut Sidestand switch bolt 1 6 10 (1.0 7) ALOC bolt; replace with a new one. PGM-FI SYSTEM . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS ECT sensor 1 10 12(1.2,9) Bank angle sensor mounting bolt 2 6 10 (1.0, 7) 02 sensor 1 12 24.5(2.5,18) IGNITION SYSTEM . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Timing hole cap 1 14 10 (1.0, 7) Apply grease to the threads. Right crankcase cover Wire clamp 2 6 12 (1.2, 9) Apply locking agent to the threads. oolt (NC700XD/SD) Coating width; 6.5 11.0 mm (0.26 t 0.04 in) except 2.0 11.0 mm (0.08 i 0.04 in) lrorn tip ELECTRIC STARTER . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Starter motor terminal nut 1 6 10 (1 .0, 7) FUEL SVSTEM , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Fuel pump mounting nut 6 6 12 (1.2, 9) For tightening sequence (page 7-14) Air cleaner connecting hose band 1 4 1.5 (0.2, 1.1) screw insulator oand screw 2 5 — See page 7-18 1-16 GENERAL INFORMATION COOLING SYSTEM , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbt-lt) REMARKS Water hose band screw 6 — — See page 8-9 See page 8-10 See page 8-14 Fan motor snroud mounting bolt 3 6 3.4 (0.9, 6.2) Fan motor mounting screw 3 4 2.7 (0.3, 2.0) Cooling tan mounting nut 1 3 1.0 (0.1, 0.7) Apply locking agent to the threads. LUBRICATION SVSTEM . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgf—m, lbt-lt) REMARKS Engine Oil liltercartridge 1 20 26 (2.7, 19) Apply engine oil to the threads. CVLINDER HEAD/VALVES . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbt-lt) REMARKS Cylinder head cover socket bolt 3 6 10 (1.0, 7) Breather plate mounting bolt 8 6 12 (1.2, 9) Apply locking agent to the threads. Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) except2.0 11.0 mm (0.08 1 0.04 in) irom tip Rocker arm shait bolt 3 8 29 (3.0, 21) Apply engine oil to the threads and seating surtace. Camshaft maintenance cap 1 36 4.0 (0.4, 3.0) See page 10-11 See page 10-28 Cam chain tensioner bolt 2 6 12 (1.2, 9) Cam sprocket bolt 1 10 56 (5.7, 41) Apply engine oil to the threads and seating surtace. Water hose band screw 6 — — See page 10-16 Insulator band screw 1 5 — See page 10-25 Cylinder head special bolt 6 9 44 (4.5, 32) Apply molybdenum oi| solution to the threads and seating surtace. CLUTCH/GEARSHIFT LINKAGE (NC7OOX/XA/S/SA) , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbt-lt) REMARKS Clutch center lock not 1 18 128 (13.1, 94) Apply engine oil to the threads and seating surtace. Lock nut; replace with a new one and stake. Clutcn lilter plate bolt 4 6 12 (1.2, 9) Primary drive gear mounting bolt 1 10 93 (9.5, 69) Apply engine oil to the threads and seating surtace. Sniit drum stopper arm pivot bolt 1 6 12 (1.2, 9) Apply locking agent to the threads. Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) except2.0 11.0 mm (0.08 1 0.04 in) irom tip Sniit drum center socket bolt 1 8 23 (2.3, 17) Apply locking agent to the threads. Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) except2.0 11.0 mm (0.08 1 0.04 in) irom tip Gearshilt pedal adjuster lock nut 2 6 10 (1.0, 7) Gearshilt pedal pivot bolt 1 8 27 (2.3, 20) 1-17 GENERAL INFORMATION DUAL CLUTCH TRANSMISSION (DCT) (NC7ODXD/SD) , THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Solenoid valve stopper plate bolt 1 6 12 (1 .2, 9) Apply locking agent to the threads. Coating width: 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) from tip Right crankcase cover Wire clamp 2 6 2 (1 .2, 9) Apply locking agent to the threads. bolt Coating width: 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) from tip Linear solenoid valve body 6 6 — For tightening sequence (page 12- mounting bolt 101) Shift spindle angle sensor bolt 1 6 12 (1.2, 9) Primary drive gear mounting bolt 1 10 93 (9.5, 69) Apply engine oil to the threads and seating surface. Reduction gear cover bolt 8 6 14 (1.4, 10) TR sensor bolt 1 6 12 (1.2, 9) Shift control motor bolt 8 6 14 (1.4, 10) Shift drum center bolt 1 B 23 (2.3, 17) Apply locking agent to the threads. Coating width: 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) from tip Drum shifter guide plate bolt 2 6 12 (1.2, 9) Apply locking agent to the threads. Coating width: 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) from tip Clutch line EDP sensor 8 10 19.6 (2.0, 14) EOT sensor 1 10 14(1.4, 10) Apply engine oil to the threads and seating surface. ALTERNATOR/STARTER CLUTCH , THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Flywheel mounting bolt 1 12 157 (16.0, 116) Left hand thread Apply engine oil to the threads and seating surface. Starter clutch socket bolt 6 B 80 (3.1, 22) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) from tip Alternator stator mounting bolt 4 6 0 (1 .0, 7) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) from tip Alternator Wire clamp bolt 1 6 0 (1.0, 7) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) from tip 1-18 CRANKCASE/TRANSMISSION/BALANCER GENERAL INFORMATION , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbf-It) REMARKS MainshaIt bearing set plate bolt 3 6 12 (1.2; 9) Apply looking agent to the threads. Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) except2.0 11.0 mm (0.08 1 0.04 in) trom tip Shift drum bearing set plate bolt 2 6 12 (1.2; 9) Apply looking agent to the threads. Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) except2.0 11.0 mm (0.08 1 0.04 in) irom tip Balancer snaIt bearing set plate 3 6 12 (1.2; 9) Apply looking agent to the threads. bolt Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) except2.0 11.0 mm (0.08 1 0.04 in) irom tip Crankcase main journal bolt (new) 6 9 20 (2.0, 15)+150" See page 14-30 Replace with a new one. Crankcase 10 mm bolt 1 10 39 (4.0; 29) Crankcase 8 mm bolt 3 8 24 (2.4 18) Crankcase 8 x 45 mm bolt 1 8 24 (2. 18) Apply looking agent to the threads. Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) irom tip Crankoase 6 mm bolt 8 6 12 (1.2; 9) CRANKSHAFT/PISTON/CVLINDER . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgf—m, lbf-It) REMARKS Crankpin bearing cap bolt 4 6 10 (1.0; 7) + 90" See page 15-7 See page 15-12 Replace with a neW one. Apply engine oil to the threads and seating surtace. Crankcase main )ournal bolt 6 9 20 (2.0; 15) + 120° See page 15-9 (retightening) Apply engine oil to the threads and seating surtace. ENGINE REMOVAL/INSTALLATION , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbf-It) REMARKS Rear lower engine hunger nut 1 12 59 (6.0; 44) Front lower engine hunger bolt 2 12 54 (5.5; 40) Upper engine hunger bolt 2 12 54 (5.5; 40) Rear upper engine hunger nut 1 12 54 (5.5; 40) Step nolder mounting socket bolt 4 8 32 (3.3; 24) Drive sprocket bolt 1 10 54 (5.5; 40) Starter motor terminal nut 1 6 10 (1.0; 7) Water hose band screw 2 — — See page 16-18 See page 16-19 See page 16-24 See page 16-25 1-19 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING THREAD TORQUE (NC700X/XA/S/SA) "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Handlebar holder bolt 4 B 22 (2.2, 16) Handlebar switch housing screw 4 5 2.5 (0.3, 1.8) Front master cylinder holder bolt 2 6 12 (1.2, 9) Handlebar weight mounting screw 2 6 10 (1.0, 7) ALOC screw; replace With a new one. Front brake disc mounting bolt 5 8 42 (4.3, 31) ALOC bolt; replace with a new one. Front axle 1 18 74 (7.5, 55) Apply grease to the sliding surtace. Front axle pinch bolt 1 B 22 (2.2, 16) Fork socket bolt 2 B 20 (2.0, 15) Apply locking agent to the threads. Bottom bridge pinch bolt 2 10 39 (4.0, 29) Fork cap 2 37 22 (2.2, 16) Top bridge pinch bolt 2 B 22 (2.2, 16) Front brake caliper mounting bolt 2 B 30 (3.1, 22) ALOC bolt; replace with a new one. Steering stem ad)usting nut 1 26 23 (2.3, 17) See page 17-38 Apply engine oil to the threads. Steering stem ad)usting lock nut 1 26 — See page 17-38 Steering stem nut 1 24 103 (10.5, 76) See page 17-38 Clutch lever pivot bolt 1 6 1.0 (0.1 , 0.7) Apply grease to the sliding surtace. (NC700X/XA/S/SA) Clutch lever pivot nut 1 6 6.0 (0.6, 4.4) (NC700X/XA/S/SA) REAR WHEEL/SUSPENSION . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Driven sprocket nut 5 12 108 (11.0, 80) U-nut Rear brake disc mounting bolt 5 8 42 (4.3, 31) ALOC bolt; replace with a new one. Rear axle nut 1 18 98 (10.0, 72) U-nut Shock absorber mounting nut 2 10 44 (4.5, 32) U-nut Shock arm nut 1 10 44 (4.5, 32) U-nut Shock link nut 2 10 44 (4.5, 32) U-nut Drive chain slider mounting screw 2 5 5.9 (0.6, 4.4) Swingarm pivot nut 1 18 98 (10.0, 72) U-nut Step holder mounting socket bolt 4 B 32 (3.3, 24) Gearshilt arm pinch bolt 1 6 12 (1.2, 9) ALOC bolt; replace with a new one. 1-20 GENERAL INFORMATION HVDRAULIC BRAKE , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbf-lt) REMARKS Brake caliper bleed valve 2 8 5.4 (0.6, 4.0) (NC700X/S) Brake caliper bleed valve 3 8 5.4 (0.6, 4.0) (NC700XA/XD/SA/SD) Master cylinder reservoir cover 4 4 1.5 (0.2, 1.1) screw Rear brake reservoir mounting bolt 1 6 10 (1.0, 7) Brake pad pin 2 10 7 (1.7, 13) Rear brake caliper mounting bolt 1 B 22 (2.2, 16) ALOC bolt; replace with a new one. Front master cylinder holder bolt 2 6 12 (1 .2, 9) Brake hose oil bolt 4 10 34 (3.5, 25) (NC700X/S) Brake hose oil bolt 5 10 34 (3.5, 25) (NC700XA/XD/SA/SD) Front brake light switch screw 1 4 1.2 (0 1, 0.9) Front brake lever pivot bolt 1 6 1.0 (0 1, 0.7) Apply 0.10 g (0.004 02) silicone grease to the sliding suriace. Front brake lever pivot nut 1 6 5 9 (0.6, 4 4) Rear master cylinder mounting 2 6 12 (1.2, 9) bolt Step holder mounting socket bolt 4 B 32 (3.3, 24) Rear master cylinder hose joint 1 4 1.5 (0.2, 1.1) Apply locking agent to the threads. screw Rear mastercylinderpush rod lock 1 8 17 (1.7, 13) nut Front brake caliper pin 1 B 22 (2.2, 16) Apply locking agent to the threads. Apply 0.4 g (0.01 oz) silicone grease to the sliding surlace. Front brake caliper bracket pin 1 8 (1 .2, 9) Apply locking agent to the threads. Apply 0.4 g (0.01 oz) silicone grease to the sliding surlace. Front brake caliper mounting bolt 2 B 30 (3.1 , 22) ALOC bolt; replace with a new one. Rear brake caliper pin 1 12 27 (2.8, 20) Apply 0.4 g (0.01 oz) silicone grease to the sliding surlace. Parking brake caliper mounting 2 8 31 (3.2, 23) ALOC bolt; replace with a new one. bolt (NC700XD/SD) Parking brake caliper pin bolt 1 8 22 (2.2, 16) Apply locking agent to the threads. (NC700XD/SD) Parking brake pad pin 2 8 7 (1.7, 13) ALOC bolt; replace with a new one. (NC700XD/SD) Parking brake ad)uster bolt lock 1 8 7 (1.7, 13) nut (NC700XD/SD) Parking brake cable mounting nut 1 10 0 (1.0, 7) (NC700XD/SD) ANTI-LOCK BRAKE SYSTEM (ABS) (NC7OOXA/XD/SA/SD) , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbf-lt) REMARKS Step holder mounting socket bolt 4 B 32 (3.3, 24) Brake pipe )oint nut 14 10 14 (1.4, 10) Apply brake lluid to the threads and sliding surlace. PCV mounting bolt 2 6 12 (1.2, 9) Delay valve mounting bolt 2 6 12 (1.2, 9) 1-21 GENERAL INFORMATION LlGHTS/METERS/SWITCHES THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Turn signal light mounting screw 4 6 2.5 (0.3, 1.8) Combination meter mounting 3 5 1.0 (0.1, 0.7) screw Combination meter back cover 4 3 0.3 (0.03, 0.2) mounting screw (NC7005/SA/SD) EOP switch 1 PT 1/8 18 (1.8, 13) Apply sealant to the threads. ignition switch mounting bolt 2 B 25 2.5, 1 One way bolt; replace With a new one. Neutral switch 1 10 12 (1.2, 9) Parking brake switch screw 1 4 1.2 (0.1, 0.9) (NC700XD/SD) OTHERS , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Cam chain tensioner set plate bolt 1 6 12 (1.2, 9) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 t 0.04 in) except 2.0 11.0 mm (0.03 i 0.04 in) lrorn tip Camsnalt cap 1 20 30 (3.1, 22) Gearshilt spindle return spring pin 1 B 23 (2.3, 17) Main step rubber mounting bolt 2 5 5 1 (0.5, 3.8) ALOC bolt; replace with a new one. Main step cap bolt 2 6 12 (1 2, 9) 1-22 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Liquid sealant (Three Bond 1207B or equivalent) Oil pan mating surface See page 9-12 Right crankcase cover mating surface See page 11-6 CKP sensor wire grommet Linear solenoid valve wire grommet (NC700XD/SD) Alternator wire grommet Alternator cover mating surface See page 13-7 Crankcase mating surlace See page 14-28 Molybdenum oil solution (a mixture ot 1/2 engine oil and 1/2 molybdenum disullide grease) Rocker arm sliding surtace Rocker arm shalt outer surface Camshaft lobes, journals and thrust surface Valve stem (valve guide sliding surface) and stem end Clutch outer guide sliding surface (NC700X/XA/S/SA) Starter reduction and idle gear shalt outer surface M3/4, C5, CG gear (shift lork grooves) (NC7OOX/XA/S/SA) M3, M4, GS, CG gear (shift fork grooves) (NC700XD/SD) Each transmission spline collar outer surlace Each transmission collar inner and outer surlace Shilt fork guide area and guide pin Shilt fork shaft outer surface Main journal bearing sliding surlace Crankpin bearing sliding surlace Crankshalt thrust surface Engine oil Oil lilter cartridge O-ring Oil liller cap O-ring Timing hole cap O-ring Crankshalt hole cap O-ring Clutch oil tilter cover O-ring (NC700XD/SD) Oil joint pipe O-ring (NC700XD/SD) Clutch oil guide collar O-rings (NC700XD/SD) Oil strainer seal ring Starter motor O-ring Injector seal ring Water pump large O-ring Valve stem seal Clutch disc entire surface (NC7OOX/XA/S/SA) Clutch lifter rod A sliding surlace (NC700X/XA/S/SA) Clutch lifter rod B sliding surlace (NC700X/XA/S/SA) Mainshaft seal rings (NC700XD/SD) Starter one-way clutch Piston sliding surface Piston ring sliding surface Piston pin outer surtace Each bearing Each gear teeth and rotating sunace Each O-ring (except water sealing) Other rotating area and sliding surlace Multi-puroose grease Each oil seal lips Locking agent CKP sensor mounting bolt threads Coating width; 6.5 i 1.0 mm (0.26 i 0.04 in) excep12.0 11.0 mm (0.08 i 0.04 in) from tip Templex N3 grease (ESSO) Electric shilt reduction gear teeth and journal (NC700XD/SD) 2—4g (0.07—0.14 oz) 1-23 GENERALINFORMAHON FRAME MATERIAL LOCATION REMARKS Urea based multi-purpose grease with extreme pressure (example: Kyodo Yusni EXCELITE EPZ, Shell Stamina EP2 or equivalent) Steering head bearing sliding surface 3—5g(0.l —0.20z) Steering head dust seal lips Molybdenum disulfide grease 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 Multi-purpose grease Seat catch hook sliding area Luggage box lid catch sliding area Gearshift pedal pivot and dust seal lips (NC700X/XA/S/SA) Gearshift pedal tie-rod ball joint area (NC700X/XA/S/SA) Throttle cable end and throttle grip pipe flange groove Front wheel dust seal lips Rear wheel hub O-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 surlace (NC700XD/SD) Parking brake lever, washer sliding surface (NC700XD/SD) Parking brake switcn spring sliding surlace (NC700XD/SD) Main step sliding area Pillion step sliding area Cable lubricant Seat lock cable inside Luggage box lid lock cable inside Throttle cable A, E inside Clutch cable inside (NC700X/XA/S/SA) Parking brake cable inside (NC700XD/SD) Honda bond A, Cemedine #540 or equivalent Handlebar grip rubber inside Brake pad retainer mating surface Silicone grease Front brake lever sliding surface and lever-to-master piston contacting area 0.10 g (0.004 oz) Rear brake master cylinder pusn rod sliding surface and boot lifting area Brake caliper dust seals Rear brake caliper boot inside 0.4 g (0.01 oz) Brake pad pin stopper ring Parking brake shaft outer surface (NC700XD/SD) 0.4 g (0.01 oz) minimum Parking brake adjuster bolt threads and caliper piston sliding surlace (NC700XD/SD) 0.4 g (0.01 oz) minimum Parking brake shaft boot lips (NC700XD/SD) 0.4 g (0.01 oz) minimum Parking brake caliper bracket pin sliding surlace (NC700XD/ SD) 0.4 g (0.01 oz) minimum Parking brake caliper sleeve sliding surface (NC700XD/SD) 0.4 g (0.01 oz) minimum DOT 4 brake fluid Brake caliper piston and piston seals Brake master piston and cups Brake master cylinder inside Rear master cylinder reservoir hose joint O-ring Fork lluid Fork cap O-ring Fork dust seal and oil seal lips Drive chain lubricant designed specifically for use with O-ring chains, #80 — 90 gear oil or equivalent Drive cnain wnole surface 1-24 GENERAL INFORMATION CABLE & HARNESS ROUTING NC7DOX/XA: CLUTCH SWITCH WIRE BRAKE UGHT sw|TCH CONNECTOR RIGHT HANDLEBAR LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE o U 4/ T v N. T I NCTOOXD: THROTTLE CABLE A BRAKE LIGHT SWITCH RIGHT HANDLEBAR CONNECTOR SWITCH WIRE (Q4? THROTTLE CABLE B LEFT HANDLEBAR Ql/ SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE 1 -25 GENERAL INFORMATION NCTODS/SA: CLUTCH SWITCH WIRE BRAKE LIGHT SWITCH CONNECTOR FIIGHT HANDLEBAFI LEFT HANDLEBAR SWITCH WIRE SWITCH WIFIE NCTOOSD: BRAKE LIGHT SWITCH CONNECTOR FIIGHT HANDLEBAFI ) SWITCH WIRE LEFT HANDLEBAR SWITCH WIFIE RIGHT HANDLEBAFI SWITCH WIFIE 1-26 GENERAL INFORMATION NC700X/XA/XD: POSITION LIGHT WIRE FRONT LEFT TURN SIGNAL LIGHT 3P (ORANGE) CONNECTOR FRONT RIGHT TURN SIGNAL LIGHT fl 3P (BLUE) CONNECTOR 6‘ FRONT SUB HARNESS , a). FRONT SUB HARNESS 6P (BROWN) CONNECTOR NCTOOS/SA/SD: FRONT LEFT TURN SIGNAL LIGHT 3P (ORANGE) CONNECTOR ‘ POSITION \LIGHT WIRES ,' FRONT SUB HARNESS 6P (BROWN) CONNECTOR FRONT RIGHT TURN SIGNAL LIGHT 4 a SP (BLUE) CONNECTOR FRONT SUB HARNESS 1 -27 GENERAL INFORMATION NCTOOX: MAIN WIRE HARNESS COMBINATION METER 16F (GRAY) CONNECTOR THROTTLE CABLES BRAKE HOSE i l /7 CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE m3: E0 —¢:: 0—4 I: > E2 :30 my- rn u: 1: 3: LEFT HANDLEBAR SWITCH IMMOBILIZER 10P (GRAV) CONNECTOR RECEIVER WIRE IGNITION SWITCH 2P (BROWN) CONNECTOR FRONT SUB HARNESS 6P (BROWN) CONNECTOR HEADLIGHT 3P (BLACK) CONNECTOR MAIN WIRE HARNESS 1-28 GENERAL INFORMATION NCTOOXA: MAIN WIRE HARNESS COMBINATION METER 16P (GRAY) CONNECTOR .fi F gig“ « '71.? ‘ ‘ 7 A THROTTLE CABLES FRONT BRAKE HOSE A L ‘ g Q:\ 4 (Io ABS MODULATOR) l, ’ , CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE \ j/LEI=T HANDLEBAR SWITCH IMMOBILIZER 10P (GRAV) CONNECTOR RECEIVER WIRE IGNITION SWITCH / \ I 2P (BROWN) CONNECTOR / FRONT SUB HARNESS \ 6P (BROWN) CONNECTOR K ‘ W Front side \* 5 HEADLIGHT ' 5 SP (BLACK) CONNECTOR t MAIN WIRE HARNESS 1 -29 GENERAL INFORMATION NC700XD: COMBINATION METER 16F (GRAY) CONNECTOR MAIN WIRE HARNESS FRONT BRAKE HOSE A (I0 ABS MODULATOR) Fronl ,_ side « 'fig [2 THROTTLECALES a i] I e‘ ) LEFT HANDLEBAR SWITCH WIRE \ / LEFT HANDLEBAR SWITCH H 3P (BLACK) CONNECTOR 1! RIGHT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER WIRE IGNITION SWITCH 2P (BROWN) CONNECTOR LEFT HANDLEBAR SWITCH 10F (GRAY) CONNECTOR FRONT SUB HARNESS 6P (BROWN) CONNECTOR Front side \5 HEADLIGHT « (Q) 3F (BLACK) CONNECTOR MAIN WIRE HARNESS 1-30 GENERAL INFORMATION N07005: RIGHT HANDLEBAR SWITCH IGNITION SWITCH 8P (BLUE) CONNECTOR 2P (BROWN) CONNECTOR FRONT SUB HARNESS 6P (BROWN) CONNECTOR LEFT HANDLEBAR SWITCH 10F (GRAY) CONNECTOR IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR MAIN WIRE HARNESS HEADLIGHT 3P (BLACK) CONNECTOR BRAKE HOSE NCTOOSA: RIGHT HANDLEBAR SWITCH IGNITION SWITCH 8P (BLUE) CONNECTOR 2P (BROWN) CONNECTOR \ \ . LEFT HANDLEBAR SWITCH IMMOBILIZER RECEIVER 10F (GRAY) CONNECTOR 4P (BLACK) CONNECTOR MAIN WIRE HARNESS HEADLIGHT 3P (BLACK) CONNECTOR (y FRONT BRAKE HOSE D (from ABS MODULATOR) \ w / H) J FRONT WHEEL SPEED BRAKE SUB HOSE C SENSOR WIRE (from DELAY VALVE) 1-31 GENERAL INFORMATION NCTOOSD: RIGHT HANDLEBAR SWITCH IGNITION SWITCH 8P (BLUE) CONNECTOR 2P (BROWN) CONNECTOR FRONT SUB HARNESS 6P (BROWN) CONNECTOR IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR LEFT HANDLEBAR SWITCH 1UP (GRAY) CONNECTOR MAIN WIRE HARNESS RIGHT HANDLEBAR SWITCH HEADLIGHT 7P (GREEN) CONNECTOR 3P (BLACK) CONNECTOR LEFT HANDLEBAR SWITCH ) 7P (GREEN) CONNECTOR FRONT WHEEL SPEED BRAKE SUB HOSE C FRONT BRAKE HOSE D SENSOR WIRE (fmm DELAY VALVE) (Irom ABS MODULATOR) N07005: CLUTCH SWITCH THROTTLE CABLE A CONNECTORS FRONT BRAKE HOSE j CLUTCH CABLE L ((+7 THROTTLE CABLE B , ( LEFT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR | NITI N WIT HWIRE SWITCH WIRE 1 G 0 S C 1-32 GENERAL INFORMATION NCTOOSA: THROTTLE CABLE A CLUTCH SWITCH CONNECTORS FRONT BRAKE HOSE A (ta ABS MODULATOR) THROTTLE CABLE B LEFT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE NCTOOSD: THROTTLE CABLE B FRONT BRAKE HOSE A (to ABS MODULATOR) THROTTLE CABLE A PARKING BRAKE CABLE LEFT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR .7‘ SWITCH WIRE ; Ix IGNITION SWITCH WIRE 1 -33 GENERAL INFORMATION NC700X/XA: CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE COMBINATION METER 16F (GRAY) CONNECTOR Q TURN SIGNAL/HAZARD RELAY g2 Na.1 IGNITION COIL /‘ ‘ LEFT HANDLEBAR SWITCH ’ 10P (GRAV) CONNECTOR IGNITION SWITCH 2P (BROWN) CONNECTOR \\ FRONT SUB HARNESS GP (BROWN) CONNECTOR IGNITION SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE 1-34 GENERAL INFORMATION NC700XD: LEFT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH 10F (GRAY) CONNECTOR PARKING BRAKE CABLE COMBINATION METER 1GP (GRAY) CONNECTOR \ . kt TURN SIGNAL/HAZARD RELAY No.1 IGNITION COIL (1. LEFT HANDLEBAR SWITCH 3P (BLACK) CONNECTOR IGNITION SWITCH 2P (BROWN) CONNECTOR 7 FRONT SUB HARNESS 6P (BROWN) CONNECTOR IGNITION SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE 1 -35 GENERAL INFORMATION NCTODS/SA: CLUTCH CABLE g x ’3‘ I I. IATSENSOR /9’\§n (I 2P (BLACK) CONNECTOR E’- = 1 " TURN SIGNAL/HAZARD RELAY I I No.2 IGNITION COIL No.1 IGNITION COIL No.1 SPARK PLUG WIRE BATTERV BOX DRAIN HOSE 1-36 GENERAL INFORMATION NCTOOSD: PARKING BRAKE CABLE BLACK) CONNECTOR IAT SENSOR ( 3‘ 1‘26? (I 2P TURN SIGNAL/HAZARD RELAY MAIN WIRE HARNESS H. 0 C N D .H N m m N No.1 SPARK PLUG WIRE BATTERY BOX DRAIN HOSE 1 -37 GENERAL INFORMATION NC700X: THROTTLE CABLE A RIGHT HANDLEBAR THROTTLE CABLE B SWITCH WIFIE RIGHT HANDLEBAR SWITCH BRAKE HOSE aP (BLUE) CONNECTOR ) “1% H x K} I I ‘ THROTTLECABLEB IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR @fl THROTTLE CABLE A w} THROTTLE CABLE A THROTTLE CABLE B RIGHT HANDLEBAR SWITCH WIRE BRAKE HOSE IMMOBILIZER RECEIVER WIRE cLuTCH CABLE 1-38 GENERAL INFORMATION NC700XA: THROTTLE CABLE B RIGHT HANDLEBAR SWITCH THROTTLE CABLE A 8P (BLUE) CONNECTOR RIGHT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR FRONT BRAKE HOSE A (to ABS MODULATOR) FRONT BRAKE HOSE A (to ABS MODULATOR) THROTTLE CABLE A FRONT WHEEL SPEED SENSOR WIRE BRAKE SUB HOSE C (fmm DELAY VALVE) THROTTLE CABLE B FRONT BRAKE HOSE D (Irom ABS MODULATOR) CLUTCH CABLE FRONT BRAKE HOSE D (fmm ABS MODULATOR) BRAKE SUB HOSE C (Irom DELAY VALVE) FRONT WHEEL PEED FRONT WHEEL SPEED SENSOR SENSOR WIRE S 2P (BLUE) CONNECTOR RIGHT HANDLEBAR 'MMOBILIZER SWITCH WIRE RECEIVER WIRE FRONT WHEEL SPEED SENSOR WIRE 1 -39 GENERAL INFORMATION NC700XD: THROTTLE CABLE A FRONT BRAKE HOSE A RIGHT HANDLEBAR SWITCH (‘0 ABS MODULATOR) 8P (BLUE) CONNECTOR THROTTLE CABLE B RIGHT HANDLEBAR RIGHT HANDLEBAR SWITCH SWITCH WIRE 6P (BLACK) CONNECTOR FRONT BRAKE HOSE A (to ABS MODULATOR) THROTTLE CABLE B IMMOBILIZER RECEIVER 4P (BLACK) CONNECTOR THROTTLE CABLE A FRONT WHEEL SPEED SENSOR WIRE BRAKE SUB HOSE C (fmm DELAY VALVE) THROTTLE CABLE B FRONT BRAKE HOSE D (Irom ABS MODULATOR) PARKING BRAKE CABLE FRONT BRAKE HOSE D (Irom ABS MODULATOR) BRAKE SUB HOSE c (Imm DELAY VALVE) FRONT WHEEL SPEED SENSOR FRONT WHEEL SPEED 2P (BLUE) CONNECTOR SENSOR WIRE IMMOBILIZER RIGHT HANDLEBAR RECEIVER WIRE SWITCH WIRE FRONT WHEEL SPEED SENSOR WIRE 1 -4o GENERAL INFORMATION NC700X: 1-41 GENERAL INFORMATION NC700XA: FRONT BRAKE HOSE A ((0 ABS MODULATOR) FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE D (from ABS MODULATOR) BRAKE SUB HOSE C (lrom DELAV VALVE) 1 -42 GENERAL INFORMATION NC700XD: PARKING BRAKE CABLE I \ K ‘ I . a , A 7; \ fiy‘; % FRONT BRAKE HOSE A ' ‘ " y (ta ABS MODULATOR) a \ .4 ‘ ~ 2‘ M FRONT BRAKE HOSE D (from ABS MODULATOR) BRAKE SUB HOSE C (from DELAY VALVE) 1-43 GENERAL INFORMATION N07005: LEFT HANDLEBAR SWITCH WIRE CLUTCH CABLE THROTTLE CABLE A THROTTLE CABLE B K. ~ N l wfihfi :f ( "F: IGNITION COIL PRIMARY WIRES No.2 IGNITION COIL > SIPHON HOSE RESERVE TANK OVERFLOW HOSE HORN WIRES 02 SENSOR 1P (BLACK) CONNECTOR 1 -44 GENERAL INFORMATION NCTOOSA: LEFT HANDLEBAR THROTTLE CABLE A SWITCH WIRE CLUTCH CABLE THROTTLE CABLE B \ v (. ld‘ FRONT WHEEL SPEED SESOR k — Q / 2P (BLUE) CONNECTOR " ‘9 !’ ./" ‘ !- CLUTCH SWITCH WIRE “ “"QEV~\ ' I — FRONT BRAKE HOSE A (to ABS MODULATOR) IGNITION COIL PRIMARY WIRES FRONT BRAKE HOSE D (lrom ABS MODULATOR) No.2 IGNITION COIL SIPHON HOSE RESERVE TANK OVERFLOW HOSE I / flRONT WHEEL SPEED SENSOR WIRE \ BRAKE SUB HOSE C (lrom DELAY VALVE) \ ..k . Parallel 1-45 GENERAL INFORMATION NC7OOSD: PARKING BRAKE CABLE \ “hi-“é ¥ {5 I; FRONT WHEEL SPEED SENSOR w_ Q ~' J ‘v‘ N 2P (BLUE) CONNECTOR THROTTLE CABLE A IGNITION COIL FRONT BRAKE HOSE A (ta ABS MODULATOR) \ \ No.2 IGNITION COIL FRONT BRAKE HOSE D (Irom ABS MODULATOR) SIPHON HOSE RESERVE TANK OVERFLOW HOSE flHONT WHEEL SPEED SENSOR WIRE ‘ BRAKE SUB HOSE c (Imm DELAY VALVE) . . F ParaHe) 1 -46 GENERAL INFORMATION NC700X/XA/XD: SEAT LOCK CABLE LUGGAGE BOX LID LOCK CABLE NC700X/XA/XD: TURN SIGNAL/HAZARD RELAY TURN SIGNAL/HAZARD RELAV 4P CONNECTOR IGNITION COIL PRIMARY WIRE No.1 IGNITION COIL SEAT LOCK CABLE 1 -47 GENERAL INFORMATION NCTOOS/SA/SD: No.2 IGNITION COIL NCTOOS/SA/SD: SIDESTAND SWITCH LUGGAGE BOX LID LOCK CABLE 3P (GREEN) CONNECTOR FUEL PUMP 1P (BLACK) CONNECTOR 1 -48 GENERAL INFORMATION NCTOOS/SA/SD: LUGGAGE BOX LID LOCK CABLE TUFIN SIGNAL/HAZARD RELAV // r O O \ \ \ O J K9 © © 0 No.2 IGNITION COIL No.1 IGNITION COIL DLC JUNCTION B 14P (ORANGE) CONNECTOR JUNCTION G 14F (ORANGE) CONNECTOR 1-49 GENERAL INFORMATION NC700X/XA: IAT SENSOR 2P (BLACK) CONNECTOR DLC JUNCTION B TURN SIGNAL/HAZARD RELAV 14p (GRANGE) CONNECTOR JUNCTION G 14F (ORANGE) CONNECTOR No.2 IGNITION COIL IGNITION COIL PRIMARY WIRES LEFT HANDLEBAR SWITCH / ‘r‘ \ j 10P (GRAY) CONNECTOR ; 1 STARTER RELAY ‘ SWITCH IGNITION SWITCH IGNITION COIL 2P BR WN NNECTOR I O “:0 PRIMARY WIRES FUEL FEED HOSE Na.1 IGNITION COIL GROUND CABLE FUSE BOX STARTER MOTOR CABLE MAIN WIRE HARNESS CKP SENSOR 2P (RED) CONNECTOR 1-50 GENERAL INFORMATION NC700XD: IAT SENSOR 2P (BLACK) CONNECTOR DLC JUNCTION B TURN SIGNAL/HAZARD RELAY 14F (ORANGE) CONNECTOR JUNCTION G 14P (ORANGE) CONNECTOR No.2 IGNITION COIL IGNITION COIL PRIMARY WIRES LEFT HANDLEBAR SWITCH 1GP (GRAY) CONNECTOR \\ STARTER RELAY SWITCH 2 M LEFT HANDLEBAR SWITCI'\y 3P (BLACK) CONNECTOR IGNITION COIL PRIMARY WIRES FUEL FEED HOSE No.1 IGNITION COIL IGNITION SWITCH 2P (BROWN) CONNECTOR GROUND CABLE FUSE BOX STARTER MOTOR CABLE MAIN WIRE HARNESS CKP SENSOR 2P (RED) CONNECTOR 1-51 GENERAL INFORMATION NC700X/XA/S/SA: FAN MOTOR 3P (GRAY) CONNECTOR AIR CLEANER HOUSING DRAIN HOSE FUEL FEED HOSE RADIATOR LOWER WATER HOSE No.1 SPARK PLUG WIRE BATTERV BOX DRAIN HOSE 1 -52 GENERAL INFORMATION NC7DOXD/SD: FAN MOTOR 3P (GRAY) CONNECTOR AIR CLEANER HOUSING DRAIN HOSE FUEL FEED HOSE RADIATOR LOWER WATER HOSE No.1 SPARK PLUG WIRE BATTERV BOX DRAIN HOSE SHIFT PEDAL ANGLE SENSOR 3P (BLACK) CONNECTOR (Opuonau 1 -53 1 -54 GENERAL INFORMATION NCTODX/XA: RADIATOR UPPER WATER HOSE CLUTCH CABLE SIPHON HOSE FUEL FEED HOSE ECT SENSOR No.2 SPARK PLUG WIRE \ 2P CONNECTOR I I I I RESERVE TANK I OVERFLow HOSE " 02 SENSOR WIRE . '. HORN WIRES I I 02 SENSOR I I 1P (BLACK) CONNECTOR EOP SIIVITCH 1P (GRAY) CONNECTOR EOP SWITCH 1P (GRAY) CONNECTOR GENERAL INFORMATION NCTOOXD: RADIATOR UPPER WATER HOSE PARKING BRAKE CABLE ' SIPHON HOSE )\ O I v/ ‘ “ FUEL FEED HOSE No.2 SPARK PLUG WIRE ECT SENSOR 2P CONNECTOR | I I 'I I RESERVE TANK I OVERFLOW HOSE ‘I 02 SENSOR WIRE I ‘, HORN WIRES I I 02 SENSOR 'I 1P (BLACK) CONNECTOR I EOP SWITCH 1P (GRAV) CONNECTOR EOP SWITCH 1P (GRAV) CONNECTOR 1 -55 1-56 GENERAL INFORMATION NCTODS/SA: Upper side ‘ RADIATOR UPPER CLUTCH CABLE WATER HOSE K gJF/ fi kfig (I: (9% / @/ REAR BRAKE HOSE A III] (I!) ABS MODULATOR) REAR BRAKE HOSE E (from PCV) REAR WHEEL SPEED SENSOR WIRE 1 -83 GENERAL INFORMATION NC700XD/SD: REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE E ("om PCV) REAR BRAKE HOSE A (to ABS MODULATOR) NC7ODX/XA/XD/S/SA/SD: /" REAR LEFT TURN SIGNAL LIGHT I} 2P (ORANGE) CONNECTOR MAIN WIRE HARNESS REAR RIGHT TURN SIGNAL LIGHT 2P (LIGHT BLUE) CONNECTOR BRAKE/TAlL/LICENSE LIGHT 3P CONNECTOR 1 -84 GENERAL INFORMATION NC700X/XA/XD/S/SA/SD: side INDEX MARK Leflg 30:22.5” side g Q 1 -85 GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide (CO), oxides ol nitrogen (NOx) and hydrocarbons (HC). Control oi carbon monoxide, oxides ol nitrogen and hydrocarbons is Very important because, under certain conditions, they react to iorm photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co, Ltd. utilizes various systems (page 1-87) to reduce carbon monoxide, oxides ot 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. AIR CLEANER HOUSING THROTTLE BODY ' l <: FRESHAIR i 4— BLOW-BY GAS V 1 -86 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed ol a three-way catalytic converter and PGM-Fl system. The exhaust emission control system is separate lrom the crankcase emission control system. THREE-WAY CATALYTIC CONVERTER This motorcycle also 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 (COz), nitrogen (N2), and water vapor. No adjustment to these systems should be made although periodic inspection ol the components is recommended. NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOlSE EMlSSION CONTROL SYSTEM IS PROHIBITED: Local law prohibits the Iollowing acts or the causing thereol: (1) The removal or rendering inoperative by any person, other than tor the purposes ol maintenance, repair or replacement, ol any device or element ot design incorporated into any vehicle tor the purpose ol noise control prior to its sale or delivery to the ultimate customer or while it is in use; or (2) the use ol the vehicle atter such device or element ol design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTlTUTE TAMPERlNG ARE THE ACTS LISTED BELOW: 1. Removal ot or puncturing ol the muffler, batlles, header pipes or any other component which conducts exhaust gases. 2. Removal ot or puncturing oi any part ol the intake system. 3. Lack ol proper maintenance. 4. Replacing any moving parts ol the vehicle, or parts ol the exhaust or intake system, with parts other than those specitied by the manutacturer. TECHNICAL FEATURES CRACKING CONNECTING ROD This motorcycle provides cracking connecting rods to utilize productivity improvement and to trim weight. The cracking connecting rod is split lrom the single-piece connecting rod assembly into connecting rod and bearing cap. Since the connecting rod and bearing cap have complex mating surtaces to hold them each other, the dowel pin is not required when assembling connecting rod. In the Iollowmg case, the mating surfaces 0! connecting rod and bearing cap are damaged. Fleplace them i! false Installed. — Bearing cap is installed oppositely. — Interchange the connecting rods 0/ bearing caps. 1 -87 GENERAL INFORMATION ECM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION (NC700X/XA/S/SA) This motorcycle is equipped with the ECM-to-combination meter two-way serial communication system. ECM sends the tollowing inIormation to combination meter: — Engine speed signal — HlSS indicator signal, MIL signal, Engine oil pressure indicator signal, High coolant temperature indicator signal Combination meter sends the Iollowing intormation to the ECM. — VS sensor signal — EOP switch line open circuit iniormation NOTE ~ The combination meter detects a problem in the VS sensor and EOP switch line. ~ The combination meter diagnosis the VS sensor tailure, then send the DTC 11-1 to the ECM and ECM send the MIL signal to the combination meter. ~ The combination meter send the EOP switch line open circuit inIormation to the ECM, then ECM diagnosis the EOP switch line Iailure and send the DTC 87-1 signal to the combination meter. These signals are Iorwarded to the combination meter or ECM by asynchronous communication via one Wire. This wire is called the TXD/RXD line (serial communication line). COMBINATION ECT SENSOR —- METER TXD/RXD LINE VS SENSOR To COMBINATION METER: F — Engine speed signal :5 — HISS indicator signal EOP SWITCH -— _ MIL Signal I — Engine oil pressure indicator signal — High coolant temperature indicator signal .— Inn—— ECM To ECM: — VS sensor signal — EOP switch line open Circuit information '—’ HISS CKP SENSOR — ‘ 3 IE - IMMOBILIZER RECEIVER WHEN THERE IS A PROBLEM IN THE TXD/RXD LINE When an open or short circuit occurs in the TXD/RXD line, the combination meter indicate the Iollowing: — ML [1] come on. — Engine oil pressure indicator [2] come on. — Tachometer go oft. — High coolant temperature indicator go 0W. — HlSS indicator go 0“. When the ECM did not receive the meter intormation, the ECM store the DTC 86-1. Check the DTC 86-1 with the HDS pocket tester (page 4-12). Check the ECM by ECM communication diagnostic mode (page 22-11). Check the combination meter by combination meter communication diagnostic mode (page 22-11). 1 -88 GENERAL INFORMATION PCM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION (NC700XD/SD) This motorcycle is equipped with the PCM-to-combination meter two-way serial communication system. The PCM sends the lollowing inlormation to combination meter: — High coolant temperature indicator signal — Engine oil pressure indicator signal — Engine speed signal — MIL signal — HISS indicator signal — Gear position indicator signal Combination meter sends the ignition sWitch OFF time inlormation (elapsed time alter the ignition sWitch is turned OFF) to the PCM. The PCM uses this inlormation tor the EOP switch line open circuit detection with the VS sensor signal. These signals are communicated between the combination meter and PCM via one Wire. This wire is called the TXD/RXD line (serial communication line). COMBINATION ECT SENSOR —- METER TXD/RXD LINE To COMBINATION METE ‘ EOP SWITCH __ — High coolant temperature indicator signal ‘5. — Engine oil pressure indicator sugnal M — Engine speed signal — HISS indicator signal fig. — MIL signal — Gear position indicator signal CKP SENSOR — PCM To PCM: — Ignition swrtch OFF time information HISS TR SENSOR — ICI] w n U IMMOBILIZER RECEIVER WHEN THE SERIAL COMMUNICATION IS ABNORMAL It there is any problem in the TXD/RXD line, the combination meter shows iollowmg: — MIL [i] and engine oil pressure indicator [2] stay on. — Shilt indicator "—" [3] is blinking. — Tachometer, high coolant temperature indicator and HISS indicator do not come on. TXD/RXD line troubleshooting (page 22-11) It there is any problem in the serial communication, the PCM stores the DTC 86-1. Read the DTC (page 4-12). DTC troubleshooting (page 4-40) MIL troubleshooting (page 4-60) [3] 1 -89 GENERAL INFORMATION DUAL CLUTCH TRANSMISSION The dual clutch transmission on this motorcycle uses new dual clutch assembly and its hydraulic system is improved. The dual clutch assembly consists of the primary driven gear assembly, two clutch guides and hydraulic clutch assemblies. The linear solenoid valves are located inside the right crankcase cover and inner mainshatt has to oil passages instead ot the oil leed pipes. — For linear solenoid valve location (page 12-100) — For clutch operating oil flow (page 9-3) The transmission shitt mechanism and electric shift control system are same as the conventional dual clutch transmission. PRIMARY DRIVEN GEAR ASSEMBLY No.2 CLUTCH ASSEMBLY No.1 CLUTCH ASSEMBLV CLUTCH GUIDE 1 OIL PASSAGE FOR No.1 CLUTCH CLUTCH GUIDE 2 OIL PASSAGE FOR No.2 CLUTCH 1-90 2. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS CENTER COVER (NC700X/XA/XD) -----------2-16 n (Mc7oox/XA) ............................................... ..2.2 LUGGAGE Box BODY PANEL LOCATIONS (NC700XD)----------------- ---2-3 LUGGAGE BOX LID/ HINGE ASSEMBLY BODY PANEL LOCATIONS (Ncmos/SA) ............................................... ..2.4 LUGGAGE BODY PANEL LOCATIONS WIND REEN (NC7OOSD)- - SC 3 SERVICE INFORMATION FRONT 5'95 COWL (NC700X/XA/XD) ------2-24 TROUBLESHoonNG...................................2.5 METER STAY ("cmox/xA/XD)"'"mmm'"2'24 FRONT UNDER COVER PILLION SEAT (Nc7oox/XA/XD).........................................2.25 s|NGLE INNER UPPER COVER (Nc7oox/XA/XD).........................................2.25 GRAB RAIL ................................................. ..2.3 HEADLIGHT/FRONT CENTER COWL CENTER SEAT (Ncmox/XA/XD)............... ...2.25 SEAT HEADLIGHT/HEADLIGHT STAY (Nc7oos/sA/sp)..................... ...2.27 REAR FENDER MUD GUARD (u type) -----2-1o HEADLIGHT COVER (NC7OOS/SA/SD) 2-27 BRAKE/TAIL/LICENSE LIGHT/TAIL LIGHT COVER -- --2-10 FRONT FENDER- MUD GUARD ............................................. “2.11 LOWER REAR FENDER LEFT REAR REAR FENDER B RIGHT ENGINE SIDE COVER (Ncmoxp/SD).............. ...2.3o AIR DUCT (Nc7oox/XA/XD).......................2.13 GUARD PIPE (NC700XD/SD)---------------------2-30 SIDE COWL (NC7OOS/SA/SD)--------------------2-13 BATTERY SHROUD/SIDE COVER (NC700X/XA/XD)- CENTER CROSS PLATE - SHELTER/SIDE COVER EXHAUST PIPE/MUFFLER 2-32 (Mc7oos/sA/sp) ....................................... “2.15 2-1 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (NC700X/XA) [1 l [2] [3] [4] [5] [6] [7] [3] [9] Pillion seat Single seat Grab rail Center seat cowl Seat cow| Tail light cover Mud guard Rear lender A Rear lender B BODY PANEL REMOVAL CHART This chart shows removal order pl lrame covers by means of arrow. [1] Pillion seat [4] Center seat cowl page 2 7 [10] Air duct page 2-13 [19] Front under cover page 2 7 [11] Shroud page 2-14 [20] lnner upper cover page 2 B [12] Side cover page 2-14 [21] Front center cow| page 2 B [13] Center cover page 2-16 [22] Front lender page 2 9 [14] Luggage box lid page 2-17 [23] Lower cowl page 2 10 [15] Luggage box page 2-19 [24] Left rear cover page 2 11 [16] Windscreen page 2-23 [25] Battery box page 2 12 [17] Front side cowl page 2-24 [26] Center cross plate page 2-12 [18] Meter stay page 2-24 [2] Single seal [3] Grab rail *1 l [6] Tail lighl cover [5] Seat cowl [10] Air ducl l li—’l [7] Mud guard [1 1] Shroud [12] Side cover [13] Center cover —i l [8] Rear lender A l {— [9] Rear lender B [14] Luggage box lid [22] anl lender [23] Lower cowl [24] Lell rear cover —i a l [15] Luggage box l page 2-25 page 2-25 page 2-26 page 2-28 page 2-28 page 2-29 page 2-31 page 2-32 [25] Battery box [26] Center cross plate [17] Front srde cowl [1e] Windscreen ‘—i l [20] Inner upper cover [18] Meter stay l [19] Front under cover [21] Front cenler cowl 2-2 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (NC700XD) [1] [2] [14] [13] [10] [16] [4] [1’91 [22] [23] [23] [1] Pillion seat page 2-7 [11] Shroud page 2-14 [21] Front center cow| page 2—26 [2] Single seat page 2-7 [12] Side cover page 2-14 [22] Front tender page 2—28 [3] Grab rail page 2-8 [13] Center cover page 2-16 [23] Lower cow| page 2-29 [4] Center seat cowl page 2-8 [14] Luggage box lid page 2-17 [24] Left rear cover page 2—30 [5] Seat cowl page 2-9 [15] Luggage box page 2-19 [25] Right engine side [6] Tail light cover page 2-10 [16] Windscreen page 2-23 cover page 2—30 [7] Mud guard page 2-11 [17] Front side cowl page 2-24 [26] Guard pipe page 2—30 [8] Rear lender A page 2-12 [18] Meter stay page 2-24 [27] Battery box page 2-31 [9] Rear lender B page 2-12 [19] Front under cover page 2-25 [28] Center cross plate page 2-32 [10] Air duct page 2-13 [20] lnner upper cover page 2-25 BODY PANEL REMOVAL CHART This chart shows removal order at trame covers by means at arrow. [1] Pillion seat [2] Single seat [3] Grab rail [4] Center seat ccwl [6] Tail light cover [5] Seat ccwl [10] Air duct [14] Luggage box lid [11] Shroud [7] Mud guard [12] S‘de cover [13] Center cover [22] Front render —i l *1 l [8] Rear fender A [15] Luggage box l r— l [9] Rear fender B [27] Battery box [28] center cmss plate —i [23] Lower cowl [17] Front side ccwl [16] Windscreen [as] Guard pipe [garner “mm [15] Meier stay —1 *1 i [25] Right engine [19] Front under [21] Front center [24] Le" rear cover side cover cover cowl 2-3 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (NC7OOS/SA) E, ED, F, KO, RU type shown: [1?] [16] \\ [18] [19] [20] [1] Pillion seat page 2-7 [9] Rear lender B page 2-12 [17] Headlight cover page 2-27 [2] Single seat page 2-7 [10] Side cowl page 2-13 [18] Fronl lender page 2-28 [3] Grab rail page 2-8 [11] Shelter page 2-15 [19] Lower cowl page 2-28 [4] Center seat cowl page 2-8 [12] Side cover page 2-15 [20] Left rear cover page 2-29 [5] Seat cowl page 2-9 [13] Luggage box lid page 2-18 [21] Battery box page 2-31 [6] Tail light cover page 2-10 [14] Luggage box page 2-20 [22] Cenler cross plale page 2-32 [7] Mud guard page 2-11 [15] Windscreen page 2-23 [23] Rear lender mle [3] Rear lender A page 2-12 [16] Headlight slay page 2—27 guard (U type) page 2-10 BODY PANEL REMOVAL CHART This chart shows removal order pl lrame covers by means ol arrow. [23] Rear lender mud V guard (U type) [3] Grab rail [2] Single seat [4] Center seal cowl | l l l l l [1] Pillion seal [6] Tail lighl cover [5] Seal cowl [10] Side cowl [11] Shelter [7] Mud 9”“ [12] Side cover —' [8] Rear lender A [15] Windscreen ‘— [9] Rear lender B [14] Luggage box [16] Headlighl slay [13] Luggage box lid [19] Lower cowl [17] Headlighl cover —' [18] Front fender [20] Lelt rear cover [21] Battery box [22] Center cross plate 2-4 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (NC7OOSD) E, ED, F, KO, RU type shown: [1] [2] [4] [1a] [1] Pillion seat page 2-7 [10] Side cowl page 2-13 [19] Lower cowl page 2-29 [2] Single seat page 2-7 [11] Shelter page 2-15 [20] Left rear cover page 2-30 [3] Grab rail page 2-8 [12] Side cover page 2-15 [21] Right engine side [4] Center seat cowl page 2-8 [13] Luggage box lid page 2-18 cover page 2-30 [5] Seat cowl page 2-9 [14] Luggage box page 2-20 [22] Guard pipe page 2—30 [6] Tail light cover page 2-10 [15] Windscreen page 2-23 [23] Battery box page 2-31 [7] Mud guard page 2-11 [16] Headlight stay page 2-27 [24] Center cross plate page 2-32 [8] Rear lender A page 2-12 [17] Headlight cover page 2-27 [25] Rear lender mud [9] Rear lender B page 2-12 [18] Front lender page 2-28 guard (U type) page 2—1 0 BODY PANEL REMOVAL CHART This chart shows removal order pl lrame covers by means ol arrow. [25] Rear lender mud . guard (U type) [4] Center seal cowl [13] Luggage box lid [18] Front fender [6] Tail light cover [3] Grab rail [2] Single seat I l t t [7] Mud guard [1] Pillion seal [5] Seal cowl [10] Side cowl L—"—l [8] Rear fender A :‘rg‘iver [15] Windscreen f—l [19] Lower cowl [9] Rear fender B [16] Headlighl slay [21] Righl engine Slde cover [14] Luggage box [17] Headlighl cover —. %‘ [20] Left rear cover [22] Guard pipe [23] Battery box [24] Center cross plale 2-5 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL lirst, then tighten the mounting bolts. ~ Always inspect the exhaust system tor leaks aiter installation. This section covers removal and installation 01 the body panels and exhaust system. Serious burns may result it the exhaust system is not allowed to cool belore components are removed or serviced. Always replace the exhaust pipe gasket With new ones alter removing the exhaust pipe trom the engine. When installing the exhaust system, loosely install all ol the exhaust pipe lasteners. Always tighten the exhaust pipe joint nuts TORQUE VALUES , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgI-m, lbI-l‘t) REMARKS Seat cowl assembly screw 2 4 0.9 (0.1, 0.7) Brake/tail/license light mounting 1 6 10 (1.0, 7) socket bolt Reflector mounting nut 1 5 1.7 (0.2, 1.3) Turn signal light mounting screw 4 6 2.5 (0.3, 1.8) Luggage box lid assembly screw 9 4 0.9 (0.1, 0.7) Luggage box lid lock plate 2 6 4.0 (0.4, 3.0) mounting screw Luggage box lid mounting socket 3 6 (1.2, 9) bolt Luggage box lid hinge nut 1 6 12 (1 2, 9) U-nut Gearshilt arm pinch bolt 1 6 12 (1 2, 9) ALOC bolt; replace with a new one. (NC700X/XA/S/SA) Muffler cover socket bolt 1 6 10 (1.0, 7) Muffler band bolt 1 B 17.5 (1.8, 13) Exhaust pipe joint nut 3 B 28 (2.9, 21) See page 2-34 Exhaust pipe stud bolt 3 8 — See page 2-35 TROUBLESHOOTING Excessive exhaust noise ~ Broken exhaust system ~ Exhaust gas leak Poor perIormance ~ Delormed exhaust system ~ Exhaustgas leak ~ Clogged mulller FRAME/BODY PANELS/EXHAUST SYSTEM PILLION SEAT REMOVAL/INSTALLATION Open the pillion seat [1] using the ignition key. Remove the nuts [2], collars [3] and pillion seat. Remove the grommets [4] irom the piIIion seat stay. Installation is in the reverse order oI removal. NOTE Apply grease to the piIIion seat catch hook sliding area iI necessary. SINGLE SEAT REMOVAL/INSTALLATION (NC7OOX/ XA/XD) Open the pillion seat using the ignition key. Remove the mounting bolts [1]. Remove the single seat [2] by pulling it rearward. Remove the collars [3] and grommets [4] Irom the single seat. Install the grommets and collars to the single seat. Install the single seat by inserting its hook [5] into the seat bracket [6] under the luggage box hinge bracket. Install and tighten the mounting bolts securely. Close the pillion seat. [31/[4] REMOVAL/INSTALLATION (NC7DDS/ SA/SD) Open the pillion seat using the ignition key. Remove the mounting socket bolts [1] and washers [2]. Remove the single seat [3] by pulling it rearward. Remove the collars [4] and grommets [5] Irom the single seat. Install the grommets and collars to the single seat. Install the single seat by inserting its hook [6] into the seat bracket [7] under the luggage box hinge bracket. Install and tighten the mounting socket bolts securely. Close the pillion seat. [41/[5] 2-7 FRAME/BODY PANELS/EXHAUST SYSTEM GRAB RAIL Right grab rail: REMOVAL/INSTALLATION Open the pillion seat using the ignition key. Remove the clip [1], washer [2], spring [3] and pillion seat hinge [4] irom the pillion seat stay. Remove the caps [5] lrom the mounting socket bolts [6]. Remove the mounting socket bolts, washers [7] and grab rails [8] while holding the collars [9]. NOTE Be careiul not to let the collars lall into the seat cowl. Remove the collars from the grab rail. ll necessary, remove the clips [10], washers [i 1] and oillion seat hinge lrom the right grab rail. Installation is in the reverse order ol removal. [4] CENTER SEAT COWL REMOVAL/INSTALLATION Open the pillion seat using the ignition key. Remove the socket bolts [1]. Pull up the center seat cowl rear end and release the center seat cowl tabs [2] irom the seat cowl slits [3] by pulling the center seat cowl [4] reanNard. Installation is in the reverse order ol removal. FRAME/BODY PANELS/EXHAUST SYSTEM SEAT COWL REMOVAL/INSTALLATION Remove the lollowing: — Single seal (page 2-7) — Grab rail (page 2-8) Remove the socket bolts [1] and trim clips [2]. Release the seat cowl front side slits [3] and tabs [4] lrom the side cover tabs [5] and slits [6]. Remove the seat cowl assembly [7] by releasing the its rear side tabs [8] and slits [9] lrom the rear lender B slits [10] and labs [11]. Installation is in the reverse order bl removal. DISASSEMBLY/ASSEMBLY Remove the center seat cowl (page 2-8). Remove the seat cowl assembly screws [1] and separate the right and left seat COWlS [2]. Assembly l5 in the reverse order bl disassembly. TORQUE: Seat cowl assembly screw: 0.9 N-m (0.1 kgf—m, 0.7 mm) [1] 2-9 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER MUD GUARD (U type) REMOVAL/INSTALLATION Remove the screw [1], socket bolts [2] and rear tender mud guard [3]. [1] [3] BRAKE/TAIL/LICENSE LIGHT/TAIL LIGHT COVER REMOVAL/INSTALLATION Remove the rear tender mud guard (U type) (page 2- 10). Remove the screw [1] and open the cover [2]. Disconnect the lollowing: — Rear right turn signal light 2P (Light blue) connector [3] — Rear lelt turn signal light 2P (Orange) connector [4] — Brake/tail/license light 3P connector [5] Remove the brake/tail/license light mounting socket bolt [1] and collar [2]. Remove the socket bolts (E, ED, F, KO, RU type) [3] and brake/tail/license light assembly [4] and release the wire harnesses lrom the rear tender A. Installation is in the reverse order ol removal. NOTE Route the wire harness properly (page 1-25). TORQUE: Brake/tail/license light mounting socket bolt: 10 N-m (1.0 kgl-m, 7 lbl-ft) E, ED, F, KO, RU type shown: [2] [1] [31/ [41/ [5] 9 E, ED, F, KO, RU type shown: [3] 2-10 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the reflector mounting nut [1] and rellector [2]. Remove the screw [3], nuts [4], washers [5] and socket bolts [6] and separate the tail light covers [7] and brake/ tail/license light [8]. Remove the turn signal light mounting screw [9], setting plate [1 D] and turn signal light [11]. Remove the mounting rubber [12]. Assembly is in the reverse order ol disassembly. NOTE ' Align the tail light cover tabs with the brake/taiI/license light slots. ' Align the rellector tab [13] with the lelt tail light cover hole [14]. TORQUE: Reflector mounting nut: 1.7 N-m (0.2 kgf—m, 1.3 Ibf-tt) Turn signal light mounting screw: 2.5 N-m (0.3 kgf—m,1.8lbf—ft) MUD GUARD REMOVAL/INSTALLATION Remove the brake/tail/Iicense light assembly (page 2- 10) Remove the socket bolts [1], nuts [2], collars [3] and mud guard [4]. ll necessary, remove the brake/tail/license light assembly mounting collars [5] and grommets [6]. Installation is in the reverse order ol removal. 2-11 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER A REMOVAL/INSTALLATION Remove the lollowing: — Pillion seat (page 2-7) — Mud guard (page 2-11) Remove the clip [1], washer [2], spring [3] and pillion seat hinge [4] lrom the pilllon seat stay. Remove the rubber holder [5] lrom the rear lender A tabs. Remove the socket bolts [6], plllion seat stay [7] while holding the rear lender A [8]. Remove the rear lender A and release the wire harnesses. Installation is in the reverse order ol removal. NOTE Route the wire harness properly (page 1-25). REAR FENDER B REMOVAL/INSTALLATION Remove the lollowing: — Rear lender A (page 2-12) — Shroud/side cover (NC7ODX/XA/XD) (page 2-14) — Shelter/side cover (NC7ODS/SA/SD) (page 2-15) Remove the bolt [1] and rear brake reservoir stay/reservoir [2]. Remove the socket bolts [3]. Release the tab [4] lrom the lrame. Release the main wire harness [5] lrom guides [6] and remove the rear lender B [7]. Installation is in the reverse order ol removal. NOTE ' Align the rear brake reservoir stay With the lrame tab. ' Route the wire harness properly (page 1-25). [5] 2-12 FRAME/BODY PANELS/EXHAUST SYSTEM AIR DUCT (NC700X/XA/XD) REMOVAL/INSTALLATION Open the luggage box lid using the ignition key. Remove the trim clip [1] and screw [2]. Release the air duct tabs [3] lrpm the slits by pulling it rearward and remove the air duct [4]. Installation is in the reverse order pl removal. SIDE COWL (NC7OOS/SA/SD) LEFT SIDE COWL REMOVAL/INSTALLATION Remove the single seat (page 2—7). Open the luggage box lid using the ignition key. Remove the trim clip [1] and socket bolts [2]. Remove the left side cowl [3] by releasing the side cowl tabs [4] irom the right side cowl and side cover. Installation is in the reverse order pl removal. [2] [3] 2-13 FRAME/BODY PANELS/EXHAUST SYSTEM RIGHT SIDE COWL REMOVAL/INSTALLATION Remove the left side cowl (page 2-13). Remove the trim clip [1] and socket bolts [2]. Remove the right side cowl [3] by releasing the side cowl tabs [4] from the luggage box hinge bracket and side cover. Remove the screw [5] and center cover [6]. Installation is in the reverse order ol removal. SHROUD/SIDE COVER (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the lollowing: — Seat cowl (page 2-9) — Airduct (page 2-13) Remove the trim clips [1], screw [2] and socket bolts [3]. Remove the shroud/side cover [4] by releasing the side cover tabs [5] lrorn the grommet [6] and step holder [7]. Installation is in the reverse order ol removal. 2-14 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws [1]. Release the shroud tabs [2] lrom the side cover slits [3] and remove the shroud [4] lrom the side cover [5]. Assembly is in the reverse order oi disassembly. [4] SHELTER/SIDE COVER (NC7OOS/SA/SD) Right side: REMOVAL/INSTALLATION Remove the lollowing: — Seat cowl (page 2-9) — Side cowl (page 2—13) Release the lront wheel speed sensor 2P (Blue) connector (NC7DOSA/SD) [1] lrom the side cover. Remove the trim clip [2] and socket bolts [3]. Remove the shelter/side cover [4] by releasing the side cover tabs [5] irom the grommet [6] and step holder [7]. Installation is in the reverse order oi removal. NOTE Route the seat lock cable [8] to the shelter mounting screws [9] upper side. 2-15 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws [1]. Release the shelter tab [2] irom the side cover slit [3] and remove the shelter [4] lrom the side cover [5]. Assembly is in the reverse order bl disassembly. [3] CENTER COVER (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the air duct (page 2—13). Remove the trim clips [1] and socket bolts [2]. Lift the center cover [3] and remove the trim clip, screws [4], right cable under cover [5] and lelt cable under cover [6] NOTE Be careful not to damage the center cover, cable under cover and cable by lifting the center cover too lar. Disconnect the seat lock cable [7] and luggage box lid lock cable [8] lrbm the center cover and remove it. Installation is in the reverse order ol removal. NOTE Route the cable properly (page 1-25). l3] [2] FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws [1] and seat lock assembly from the center cover [2]. Remove the screws [3] and center inner cover [4]. Remove the clip [5], cable guide [6] and seat lock [7]. Assembly is in the reverse order ol disassembly. NOTE Align the seat lock tab [8] with the clip and cable guide cutouts [9]. LUGGAGE BOX LID REMOVAL/INSTALLATION (NC7OOX/XA/XD) Open the luggage box lid using the ignition key. % Remove the luggage box assembly screw (long) [1] and disconnect the band [2]. Remove the lollowing: Luggage box lid mounting socket bolts [3] Luggage box lid lock plate mounting screw [4] Luggage box lid assembly screws [5] lnner luggage box lid [6] Luggage box lid lock plate [7] Luggage box lid NB [8] 2-17 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the luggage box assembly screws [1]. Release the tabs [2] and remove the luggage box lids B [3] trom the luggage box lid A [4]. Installation is in the reverse order at removal. TORQUE: Luggage box lid assembly screw: 0.9 N-m (0.1 kgf—m, 0.7 Ibt-tt) Luggage box lid lock plate mounting screw: 4.0 N-m (0.4 kgf—m, 3.0 Ibt-tt) Luggage box lid mounting socket bolt: 12 N-m (1.2 kgt-m, 9 lbt-ft) REMOVAL/INSTALLATION (NC7OOS/SA/SD) Open the luggage box lid using the ignition key. Remove the luggage box assembly screw (long) [1] and disconnect the band [2]. Remove the tollowing: — Luggage box lid mounting socket bolts [3] — Luggage box lid lock plate mounting screw [4] — Luggage box lid assembly screws [5] — lnner luggage box lid [6] — Luggage box lid lock plate [7] — Center luggage box lid [8] — Left luggage box lid [9] — Right luggage box lid [10] Installation is in the reverse order at removal. TORQUE: Luggage box lid assembly screw: 0.9 N-m (0.1 kgf—m, 0.7 Ibt-tt) Luggage box lid lock plate mounting screw: 4.0 N-m (0.4 kgf—m, 3.0 Ibt-tt) Luggage box lid mounting socket bolt: 12 N-m (1.2 kgt-m, 9 lbt-ft) [10] [8] 2-18 FRAME/BODY PANELS/EXHAUST SYSTEM LUGGAGE BOX LID/HINGE ASSEMBLY REMOVAL/INSTALLATION Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the shelter/side cover (NC7OOS/SA/SD) (page 2-15). Remove the screw [1] and disconnect the band [2]. Remove the socket bolts [3] and bolts [4] and luggage box lid/hinge assembly [5]. Installation is in the reverse order ol removal. LUGGAGE BOX REMOVAL/INSTALLATION (NC7ODX/XA/XD) Remove the lollowing: p [6] [5] — Shroud/side cover (page 2-14) — Center cover (page 2-16) Release the lollowing: — Turn signal/hazard relay [1] lrom the luggage box tab — Seat lock cable [2] lrom the luggage box cable gUides — Option 6P connector [3] from the luggage box Remove the bolts [4], socket bolts [5] and luggage box [6]- lnstallation is in the reverse order ol removal. NOTE ' For luggage box lid removal/installation (page 2-17). ' Route the cable properly (page 1—25). 2-19 FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION (NC7OOS/SA/SD) Remove the shelter/side cover (page 2-15). Remove the socket bolts [1], cable guide [2] and seat lock assembly [3]. Release the luggage box lid lock cable [4]. Release the lollowing: — Tum signal/hazard relay [5] from the luggage box tab — Option 6P connector [6] from the luggage box Remove the bolts [7], socket bolts [8] and luggage box [9]. Installation is in the reverse order ol removal. NOTE ' For luggage box lld removal/installation (page 2-18). ' Route the cable properly (page 1-25). [5] [9] 2-20 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEM B LY/ASSEM B LY (NC7OOX/XA/XD) Remove the lollowing: — Luggage box lid (page 2-17) — Maintenance lid (page 21 -6) Remove the screw [1] and band [2]. Remove the trim clips [3], owners manual lid [4] and luggage box lid hinge cover [5]. Remove the socket bolts [6] and luggage box lid catch [7]. Remove the socket bolts and luggage box lid hinge assembly. [Reganove the luggage box lid hinge nut [8], washers [9], hinge bolt [lo] and hinge [11] lrom the hinge bracket Assembly is in the reverse order bl disassembly. NOTE ' Align the luggage box lid catch holes [13] with the luggage box tabs [14]. ' Apply grease to the luggage box lid catch sliding area. TORQUE: Luggage box lid hinge nut: 12 N-m (1.2 kgf—m, 9 lbl-l‘t) [3] [12] 2-21 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY (NC7OOS/SA/SD) Remove the lollowing: — Luggage box lid (page 2-18) — Maintenance lid (page 21-6) Remove the screw [1] and band [2]. Remove the trim clips [3] and owners manual lid [4]. Remove the socket bolts [5] and luggage box lid catch [6]. Remove the socket bolts and luggage box lid hinge assembly. Remove the luggage box lid hinge nut [7], washers [8], hinge bolt [9] and hinge [10] from the hinge bracket [1 1]. Assembly is in the reverse order ol disassembly. NOTE ' Align the luggage box lid catch hole [12] With the luggage box tab [13]. ' Align the hinge bracket holes [14] with the luggage box tabs [15]. ' Apply grease to the luggage box lid catch sliding area. TORQUE: Luggage box lid hinge nut: 12 N-m (1.2 kgl-m, 9 lbl-ft) 'fi, [6] [5] [3] [121 2-22 FRAME/BODY PANELS/EXHAUST SYSTEM WI NDSCREEN REMOVAL/INSTALLATION (NC7ODX/XA/XD) Remove the socket bolts [1], washers [2] and windscreen [3]. Remove the special nuts [4] and cushion rubbers [5] il necessary. Installation is in the reverse order ol removal. NOTE ll you wish the windscreen position upward, you can choose high position. — High position: Install the special nuts to the upper holes. — Low position: Install the special nuts to the lower holes. gal ‘i Low position High posmon REMOVAL/INSTALLATION (NC7OOS/SA/SD) Remove the socket bolts [1 ], plastic washers [2], rubbers [3] and windscreen [4]. Remove the special nuts [5] if necessary. Installation is in the reverse order ol removal. [4] [1] [2] 2-23 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT SIDE COWL (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the shroud/side cover (page 2—14). Remove the trim clips [1], socket bolt [2] and bolts [3]. Disconnect the lront turn signal light 3P connector [4] and remove the front side cowl [5]. Installation is in the reverse order ol removal. NOTE Route the wire harness properly (page 1-25). METER STAY (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the lollowing: — Windscreen (page 2-23) — Front side cowl (page 2-24) Disconnect the combination meter lSP (Gray) connector [1]. Remove the bolts [2] and meter stay [3]. Installation is in the reverse order ol removal. NOTE ' For combination meter removal/installation (page 22-9). ' For digital clock setting procedure (page 22-14). 2-24 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT UNDER COVER (NC700X/XA/ XD) REMOVAL/INSTALLATION Remove the trim clips [1] and screw [2]. Release the tabs [3] and remove the tram under cover [4]- Installatron is m the reverse order at removat. INNER UPPER COVER (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the tront side cowl (page 2-24). Remove the trim clips [1]. Release the tabs [2] and remove the inner upper cover [3]. Installatron is m the reverse order at removat. [4] [2] [3] 2-25 FRAME/BODY PANELS/EXHAUST SYSTEM HEADLIGHT/FRONT CENTER COWL (NC700X/XA/XD) REMOVAL/INSTALLATION Remove the lollowing: — Meter stay (page 2-24) — From under cover (page 2-25) — Inner upper cover (page 2-25) Release the lront turn signal light 3P connectors [1] irom the Wire bands [2]. Disconnect the headlight 3P (Black) connector [3] and iront sub harness 6P (Brown) connector [4]. Remove the bolts [5]. Release the headlight boss [6] lrom the lrame grommet [7] and remove the front center cowl/headlight [8]. Installation is in the reverse order ol removal. NOTE Route the wire harness properly (page 1-25). [5] [2] [3] [5] [6] l5] [7] DISASSEMBLY/ASSEMBLY Remove the bolts [1] and lront center cowl [2] lrom the headlight unit [3]. Remove the socket bolts [4] and headlight stay [5] lrorn the headlight unit. Assembly l5 in the reverse order ol disassembly. ll] [5] 2-26 HEADLIGHT/HEADLIGHT STAY (NC7OOS/SA/SD) FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION Remove the socket bolts [1] and collars [2]. Release the headlight stay tabs [3] lrorn the grommet [4]- Disconnect the headlight 3P (Black) connector [5], front sub harness 6P (Brown) connector [6] and remove the headlight/headlight stay [7]. Installation is in the reverse order ol removal. NOTE Route the wire harness and hoses properly (page 1- 25). DISASSEMBLY/ASSEMBLY Remove the windscreen (page 2-23). Disconnect the lollowing: — Front lelt turn signal light 3P (Orange) connector [1] — Front right turn signal light 3P (Blue) connector [2] Remove the bolts [3], washers [4] and headlight stays [5] lrorn the headlight unit [6]. Assembly is in the reverse order ol disassembly. HEADLIGHT COVER (NC7OOS/SA/SD) REMOVAL/INSTALLATION Remove the headlight/headlight stay (page 2-27). Remove the lollowing: Bolt [1] Main wire harness clamp [2] Bolts [3] Brake hose clamp (NC7ODS) [4] Washer (NC7OOSA/SD) [5] wire band (NC7DOSD) [6] Release the lollowing: — Front sub harness 6P (Brown) connector [7] — Right handlebar switch 8P (Blue) connector [8] — ignition switch 2P (Brown) connector/Lelt handlebar switch 10F (Gray) connector [9] — immobilizer receiver 4P (Black) connector [10] Remove the headlight cover [1 1]. Installation is in the reverse order ol removal. NOTE Route the wire harness and hoses properly (page 1- 25). [5] [5] [9] FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the bolts [1], hose guide [2], socket bolts [3], washers [4] and lront tender [5] lrom the iork legs. Remove the flange collars (E, ED, F, KO, RU type) [6], rellector (U type) [7], grommets [8], iront lender brace [9] and collars [10] lrom the lront lender. Installation is in the reverse order ol removal. NOTE Route the wire harness and hoses properly (page 1-25). E, ED, F, KO, RU type: LOWER COWL REMOVAL/INSTALLATION (NC7OOX/ XA/S/SA) Remove the socket bolts [1]. Release the bosses [2] lrom the grommets [3] and remove the lower cowl [4]. Installation is in the reverse order ol removal. [1] 2-28 FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION (NC700XD/ SD) Remove the socket bolts [1]. Release the bosses [2] lrom the grommets [3] and remove the lower cowl [4]. Installation is in the reverse order pl removal. DISASSEMBLY/ASSEMBLY Remove the screws [1]. Release the tabs [2] lrorn the slits [3] and separate the left lower cowl [4], right lower cowl [5] and center lower cowl [6]. Assembly l5 in the reverse order pl disassemply. NOTE Align the left and right lower cowl holes [7] with center lower cowl bosses [8]. LEFT REAR COVER REMOVAL/INSTALLATION (NC7OOX/ XA/S/SA) Remove the gearshift arm pinch bolt [1] and gearshift arm [2]. Remove the bolts [3] and Ielt rear cover [4]. Remove the drive chain guide plate [5] and collar [6] lrorn the left rear cover. Installation is in the reverse order pl removal. NOTE ' Align the gearshilt arm s|it with the punch mark. ' Replace the gearshiit arm pinch bolt with a new one. TORQUE: Gearshift arm pinch bolt: 12 N-m (1.2 kgf—m, 9 lbl-ft) 6] [41 gm [2] 2-29 Align FRAME/BODY PANELS/EXHAUST SYSTEM gEMOVAL/INSTALLATION (NC7OOXD/ D) Remove the lower cowl (page 2—29). Remove the bolts [1] and lelt rear cover [2]. Remove the drive chain guide plate [3] lrom the lelt rear cover. Installation is in the reverse order ol removal. RIGHT ENGINE SIDE COVER (NC700XD/SD) REMOVAL/INSTALLATION Remove the lower cowl (page 2—29). Remove the socket bolts [1] and right engine side cover [2]- lnstallation is in the reverse order ol removal. GUARD PIPE (NC700XD/SD) REMOVAL/INSTALLATION Remove the lower cowl (page 2—29). Release the shift pedal angle sensor 3P (Black) connector (Optional) [1] from the guard pipe [2] and clamp[3]. Remove the bolts [4], nuts [5] and guard pipe. Release the fuel tank drain hose B [6] and battew box ' drain hose [7]. ll necessary, remove the socket bolts [8] and motor guard [9]. Installation is in the reverse order ol removal. [4] l2] [7] l5] [41/[5] [9 2-30 FRAME/BODY PANELS/EXHAUST SYSTEM BATTERY BOX REMOVAL/INSTALLATION Remove the lollowing: — Battery (page 21-6) — Luggage box (page 2-19) Remove the bolts [1] and ignition coil stay [2] from the battery box [3]. Release the lollowing: Fuse box [4] Starter relay switch [5] CKP sensor harness [6] Battery negative (—) cable [7] Main wire harness [B] Junction B 14F (Orange) connector [9] Junction G 14F (Orange) connector [10] DLC [11] Battery positive (+) cable [12] Remove the socket bolts [13] and battery box while releasing the grommets [14] lrom the lrame bosses [15]. Disconnect the battery box drain hose [16]. Remove the grommet from the battery box. Installation is in the reverse order ol removal. NOTE Route the cable, wire harness and hoses properly (page 1-25). [6] [9] [10] [2] [14] 2-31 FRAME/BODY PANELS/EXHAUST SYSTEM CENTER CROSS PLATE REMOVAL/INSTALLATION Remove the luggage box (page 2-19). Disconnect the sidestand sw1tch 3P (Green) connector [1] and remove itfrom the ECM box [2]. Release the luel pump 1 P (Black) connector [3] from the ECM box. Remove the bolts [4] and ECM box from the center cross plate [5]. Disconnect the bank angle sensor 2P (Black) connector [6]. Release the luel tank drain hose A [7] from the ECM box. Remove the wire band (NC7ODS/SA/SD) [a] and seat lock cable (NC7OOS/SA/SD) [9] from the center cross plate. Remove the ABS modulator stay mounting bolts [10] and collars [11]. Remove the bolts [12] and ground terminals [13]. Remove the center cross plate to the left. Installation is in the reverse order ol removal. NOTE Route the wire harness and hoses properly (page 1-25). [1 01/[1 1l [2] EXHAUST PIPE/MUFFLER MUFFLER REMOVAL/INSTALLATION Loosen the mulller band bolt [1]. 2-32 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the mufller mounting nut [1], bolt [2] and washer [3]. Remove the mufller [4] and gasket [5]. Remove the mulller cover socket bolt. Remove the mulfler cover by releasing its slits lrom the mulller bosses. Installation is in the reverse order ol removal. NOTE - Replace the gasket with a new one. - Align the muffler band tab with the muffler upper right slit. TORQUE: Mufller cover socket bolt: 10 Nm (1.0 kgrm, 7 lbl-l‘t) Mufller band boll: 17.5 MM (1 .a kgtm, 13 lbl-ft) MUFFLER MOUNTING NUT WASHER MUFFLER MOUNTING BOLT 1o N-m (1.0 kgf-m, 7 lot-ft) 17.5 N-m (1.3 kgl-m,13lbf-ft) [4] [2]/[3] 2-33 FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE REMOVAL Remove the lower cowl (page 2-28). Disconnect the 02 sensor 1P (Black) connector [1]. Release the 02 sensor wire Irom the clamp [2] and radiator reserve tank guide [3]. Remove the bolt [1] and disconnect the ground wire [2]. Loosen the exhaust pipe mounting nut [3]. Remove the exhaust pipe joint nuts [4]. Remove the exhaust pipe mounting nut, bolt [5], washers [6] and exhaust pipe [7]. Remove the exhaust pipe gasket [8]. INSTALLATION Install a new exhaust pipe gasket [1] to the exhaust port of the cylinder head. Install the exhaust pipe and exhaust pipe joint nuts [2] but do not tighten yet. Install the exhaust pipe mounting bolt [1], washers [2] ’ x 4 5 and nut [3] but do not tighten yet. ’ [ VI ] Install the ground wire [4] and bolt [5] but do not tighten ' yet. NOTE Route the ground Wire properly (page 1-25). [1 1/[21/[31 2-34 FRAME/BODY PANELS/EXHAUST SYSTEM Install the muffler, then loosely install the muffler : mounting bolt, washer, nut and band bolt (page 2-32). Tighten the exhaust pipe joint nuts [1] to the specified torque in numerical order by stamped number on the exhaust pipe joint [2] in 2 or 3 steps. TORQUE:23 N-m (2.9 kgf‘m, 21 lbf‘ft) Install the 02 sensor wire to the clamp [1] and radiator reserve tank guide [2]. NOTE Route the 02 sensor Wire properly (page 1-25). Connect the 02 sensor 1P (Black) connector [3]. Tighten the mulller mounting nut and band bolt securely (page 2-32). Install the lower oowl (page 2-28). [1] STUD BOLT REPLACEMENT Remove the exhaust pipe/muffler (page 2-32). 30.0 — 31.0 mm Thread two nuts onto the stud and tighten them (1.13 — 1.22 in) together, and use a wrench on them to turn the stud bolt i out. (—Jr—# 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 i K/ \I 7“ / specification. \ ( Install the exhaust pipe/muffler (page 2-32). I \ / I i Z/’ 2-35 MEMO 3. MAINTENANCE SERV|CE INFORMATION.............................3.2 DmVE CHA|N MAINTENANCE SCHEDULE........................3_3 DmVE CHA|N SLIDER FUEL BRAKE FLU") .......................................... “3.21 THRon'LE OPERATION..............................3.5 BRAKE pADS Am BRAKE SYSTEM CRANKCASE BREATHER -- BRAKE LIGHT SWITCH SPARK BRAKE LOCK OPERATION (Nc7ooxo/SD)............... ...3.24 VALVE CLEARANCE..................................3.10 HEADLIGHT AIM ENGINE OIL- CLUTCH SYSTEM (NC700X/XA/S/SA)------3-26 ENG|NE o||_ Flu-ER...................................3.13 s|DEs1-AN[)3.27 CLUTCH OIL FILTER (NC700XD/SD) --------3-14 SUSPENSION ........................................... .. 3.23 ENGINE IDLE SPEED--- NUTS, BOLTS, FASTENERS---------------------3-29 RADIATOR COOLANT WHEELS/“RES..........................................3.29 COOLING SYSTEm.....................................3.15 STEERING HEAD BEARINGS 3-1 MAINTENANCE SERVICE INFORMATION GENERAL ~ Place the motorcycle on level surface belore starting any work. ~ Gasoline is extremely Ilammable and is explosive under certain conditions. ~ Work in a well ventilated area. Smoking or allowmg flames or sparks in the work area or where the gasoline is stored can cause a tire or explosion. ~ The exhaust contains poisonous carbon monoxide gas that may cause loss 01 consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. TORQUE VALUES , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgI-m, lbl-ft) REMARKS Air cleaner housing cover screw 6 5 1.1 (0.1, 0.8) Spark plug 2 14 22(2.2, 16) Valve adjusting screw lock nut 8 7 14 (1.4, 10) Apply engine oil to the threads and seating suriace. Camshait maintenance cap 1 36 4.0 (0.4, 3.0) See page 3-12 Timing hole cap 1 14 10 (1.0, 7) Apply grease to the threads. Crankshaft hole cap 1 30 15 (1.5, 11) Apply grease to the threads. Engine oil drain bolt 1 12 30 (3.1, 22) Engine oil Iilter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads. Oil iilter boss 1 20 — See page 3-14 Apply locking agent to the threads. Coating width; 6.5 i 1.0 mm (0.26 t 0.04 in) Irom tip Rear axle nut 1 18 98 (10.0, 72) U-nut Drive chain adiuster lock nut 2 8 21 (21,15) Drive sprocket bolt 1 10 54 5.5, 40) Driven sprocket nut 5 12 108 (11.0, 80) U-nut Master cylinder reservoircover 4 4 1.5 0.2, 1.1) screw Rear brake reservoir mounting bolt 1 6 10 (1.0, 7) Rear mastercylinderpush rod lock 1 B 17 (1.7, 13) nut Parking brake adiuster bolt lock 1 B 17 (1 .7, 13) nut (NC700XD/SD) Sidestand pivot bolt 1 10 — See page 3-27 Apply grease to the sliding surtace. Sidestand pivot nut 1 10 39 (4.0, 29) U-nut Sidestand switch bolt 1 6 10 (1.0, 7) ALOC bolt; replace with a new one. MAINTENANCE MAINTENANCE SCHEDULE NC700X/XA/S/SA Pertorm the Pre-ride inspection in the Owner's Manual at each Scheduled maintenance period. l: Inspect and Clean, Adjust, Lubricate or Replace it necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. The tollowmg items require some mechanical knowledge. Certain items (particularly those marked ‘ and ") may require more technical inlormation and tools. Consult a dealer. FREQUENCY ODOMETER READING (NOTE 1) ANNUAL REGULAR REFERTO X "000 km 1 ‘2 24 36 48 CHECK REPLACE PAGE ITEMS NOTE x1,000 ml 0.6 8 1s 24 32 * FUEL LINE i i i i i 3-5 * THROTTLE OPERATION i i i i i 3-5 * AIR CLEANER NOTE 2 R R 3-7 CRANKCASE BREATHER NOTE 3 C C C C C 3-8 * SPARK PLUG i R 3-8 * VALVE CLEARANCE i i i i 3-10 ENGINEOIL R R R R R R 312 ENGINE OIL FILTER R R R R R R 313 * ENGINE IDLE SPEED I I I I I I 315 RADIATOR COOLANT NOTE 4 I I I I I 3 YEARS 3-15 * COOLING SYSTEM I I I I I 316 DRIVE CHAIN EVERY 1,000 km 34 6 (000 ml) I, L DRIVE CHAIN SLIDER I I I I 3-20 BRAKE FLUID NOTE 4 I I I I I 2 YEARS 3-21 BRAKE PADS WEAR I I I I I 322 BRAKE SYSTEM I I I I I I 323 BRAKE LIGHT SWITCH I I I I I 3-24 HEADLIGHT AIM I I I I I 325 CLUTCH SYSTEM I I I I I I 326 SIDESTAND I I I I I 327 * SUSPENSION I I I I I 3-23 * NUTS, BOLTS, FASTENERS I I I I I I 329 " WHEELS/TIRES I I I I I 3-29 " STEERING HEAD BEARINGS I I I I I I 330 ' Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualilIed. " In the interest ol satety, we recommend these items be sen/iced only by a dealer. Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 1. At higher odometer readings, repeat at the lrequency interval established here. 2. Service more lrequently when riding in unusually wet or dusty areas. 3. Service more lrequently when riding in rain or at tull throttle. 4. Replacement requires mechanical ski||. MAINTENANCE NC700XD/SD Perlorm the Pre-ride inspection In the Owner‘s Manual at each scheduled maintenance period. I: Inspect and Clean, AdIust, Lubricate or Replace il necessary. C: Clean. R: Replace. A: AdIust. L: Lubricate. The lollowmg items require some mechanical Knowledge. Certain items (particularly those marKed ‘ and ") may require more technical inlormation and tools. Consult a dealer. FREQUENCY ODOMETER READING (NOTE 1) ANNUAL REGULAR REFERTO X "000 km 1 ‘2 24 36 48 CHECK REPLACE PAGE ITEMS NOTE x 1,000 mi 0.6 8 1s 24 32 ' FUEL LINE I | | I 3-5 ' THRO‘I'I'LE OPERATION I I I I I 3-5 ' AIR CLEANER NOTE 2 R R 3-7 CRANKCASE BREATHER NOTE 3 c C c C C 3-8 ' SPARK PLUG I R 3-8 ' VALVE CLEARANCE I I I I 310 ENGINEOIL R R R R R R 3-12 ENGINE OIL FILTER R R R R R R 313 CLUTCH OIL FILTER R R R 314 ' ENGINE IDLE SPEED I I I I I I 315 RADIATOR COOLANT NOTE 4 I I I I I 3 YEARS 3-15 ' COOLING SYSTEM I I I I I 313 DRIVE CHAIN EVERY I,000 Km 346 (000 mi) I, L DRIVE CHAIN SLIDER I I I I 320 BRAKE FLUID NOTE 4 I I I I I 2 YEARS 3-21 BRAKE PADS WEAR I I I I I 322 BRAKE SYSTEM I I I I I I 323 BRAKE LIGHT SWITCH I I I I I 324 ' BRAKE LOCK OPERATION I I I I I 324 HEADLIGHT AIM I I I I I 325 SIDESTAND I I I I I 327 ' SUSPENSION I I I I I 3-28 ' NUTS, BOLTS, FASTENERS I I I I I I 3-29 “ WHEELS/TIRES I I I I I 3-29 “ STEERING HEAD BEARINGS I I I I I I 330 ‘ Should be serviced by a dealer, unless the owner has proper tools and servIce data and Is mechanically qualilIed. " In the Interest ol salety, we recommend these items be serVIced only by a dealer. Honda recommends that a dealer should road test your motorcycle alter each periodic maIntenance is carried out. NOTES: 1. At hIgher odometer readings, repeat at the lrequency interval established here. 2. Sen/ice more frequently when riding in unusually wet or dusty areas. 3. Sen/ice more frequently when riding in raIn or at iull throttle. 4. Replacement requires mechanical skill. MAINTENANCE FUEL LINE INSPECTION Check the quick connect litting [1] lor looseness. Check the fuel teed hose [2] for deterioration, damage or leakage. Check the quick connect fittings lor dirt, and clean it necessary. Replace the iuel pump packing it necessary (page 7- 13). THROTTLE OPERATION Check for any deterioration or damage to the throttle cable. Check the throttle grip lor smooth operation. Check that the throttle opens and automatically closes in all steering positions. It the throttle grip does not return properly, lubricate the throttle cable, and overhaul and lubricate the throttle grip housing. It the throttle grip still do 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. It idle speed increases, check the throttle grip lreeplay and throttle cable connection. Measure the throttle grip freeplay at the throttle grip llange. FFtEEPLAY: 2 — 6 mm (1/16 — 1/4 in) MAINTENANCE Throttle grip treeplay can be adjusted at either end of the throttle cable. Minor adjustment l5 made with the upper adjuster at throttle housing adjuster. Release the dust cover (NC700XD/SD) [1]. Loosen the lock nut [2] and turning the adjuster [3]. Tighten the lock nut Whlle holding the adjuster and reposition the dust cover properly on the adjuster. Recheck the throttle operation. 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. NC7OOX/XA/S/SA: MAINTENANCE AIR CLEANER REMOVAL/INSTALLATION (NC7OOX/ XA/XD) Remove the center cover but do not disconnect the seat lock cable and luggage box lid lock cable (page 2-16). Remove the maintenance lid (page 21—6). Disconnect the IAT sensor 2P (Black) connector [1]. Remove the air cleaner housing cover screws [2] and air cleaner housing cover [3]. Release the air cleaner housing cover tabs [4] and remove the air cleaner element [5] lrcrn the air cleaner housing cover. Inspect the air cleaner element in accordance With the maintenance schedule (page 3-3) or any time it is excessively dirt or damaged. Install the air cleaner element in the reverse order oi removal. NOTE Check that the condition ol the packings [6], replace them il necessary. TORQUE: Air cleaner housing cover screw: 1.1 N-m (0.1 kgt-m, 0.3 Ibt-ft) REMOVAL/INSTALLATION (NC7DDS/ SA/SD) Remove the lollowing: — Side cowl (page 2—13) — Maintenance lid (page 21 -6) Remove the air cleaner housing cover screws [1]. Remove the air cleaner housing cover [2] to the Ielt side and disconnect the IAT sensor 2P (Black) connector [3]. Release the air cleaner housing cover tabs [4] and remove the air cleaner element [5] lrcrn the air cleaner housing cover. Inspect the air cleaner element in accordance With the maintenance schedule (page 3-3) or any time it is excessively dirt or damaged. Install the air cleaner element in the reverse order oi removal. NOTE Check that the condition ol the packings [6], replace them il necessary. TORQUE: Air cleaner housing cover screw: 1.1 N-m (0.1 kgt-m, 0.3 Ibt-ft) MAINTENANCE CRANKCASE BREATHER Service more lreouenrly when ridden in rain, ar loll lhrome, or alter the mororcycle is washed or overnrrned. Service ii the deposits level can be seen in the lransparenr secrrbn ol me air cleaner nousrng drain hose. Check the crankcase breather hose [1] lor deterioration, damage or loose connection. Make sure that the hoses are not kinked, pinched or cracked. Replace the crankcase breather hose it necessary. Check the air cleaner housing drain hose [1]. ll necessary, remove the drain plug [2] lrom the air cleaner housing drain hose and drain the deposits into a suitable container. Reinstall the drain plug securely. SPARK PLUG Clean around the spark plug base wlm compressed arr belore removing the spark plug, and be sure that no debris is allowed ro enrer me combusrlon chamber. REMOVAL/INSTALLATION Remove the lower cowl (page 2-28). Disconnect the spark plug caps [1]. Remove the spark plug [1] using the equipped spark plug wrench [2]. Inspect or replace the spark plug as described in the maintenance schedule (page 3-3). 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 kgfsm,16let) Connect the spark plug caps securely. Install the lower cowl (page 2-28). MAINTENANCE This mamrsycle s spark plug is equipped wlm an iridium eemer electrode. Replace me spark plug II me electrodes are contaminated. Always use specified spark plugs am [his mamrsycle. To prevent damaging me iridium eemer eleeirude, use a wire type Ieeler gauge is cheek me spark plug gap. Do not adjust me spark plug gap. II the gap Is our pl speel/lsarlan. replace with a new one. INSPECTION Check the Ipllowing and replace iI necessary (recommended spark plug: page 3-9) NOTE ' Insulator [1] Vol damage ' Center electrode [2] and side electrode [3] for wear ' Burning condition, coloration II the electrodes are contaminated with accumulated objects or dirt, replace the spark plug. Replace the plug iI the center electrode [1] is rounded as shown in the illustration. SPECIFIED SPARK PLUG: NGK: lFFIGG-11 K Check the spark plug gap between the center and side electrodes With a Wire type Ieeler gauge [1 ]. Make sure that the L1) 1.0 mm (0.04 in) plug gauge does not insert between the gap. II the gauge can be inserted into the gap, replace the plug With a new one. [2] [1] [3] [1] Ill MAINTENANCE VALVE CLEARANCE No.1 Cylinder: No.2 Cylinder: INSPECTION NOTE - Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F). - After the valve clearance inspection, check the engine idle speed (page 3-15). Inspection and adjustment of the valve clearance can be sen/iced with the engine installed in the frame. Remove the cylinder head cover (page 10-5). Remove the timing hole cap [1], crankshalt hole cap [2] and O-rings [3]. Remove the camshaft maintenance cap [1] and O-ring [2]. otate the crankshaft counterclockwise and align the IT" mark [1] on the flywheel With the index notch [2] on the alternator cover. Rotate the crankshaft counterclockwise and align the "2T" mark [3] on the Ilywheel with the index notch on the alternator cover. No.1 CVLINDER: /1/ [1] [2] No.2 CYLINDER: [3] [2] 3-10 MNNTENANCE No.1 Cylinder: Make sure that the “1" mark [1] on the cam sprocket is aligned With the upper cylinder head index line [2]. No.1 CVLINDER: [2] No.2 CYLINDER: [2] A No.2 Cylinder: Make sure that the “2" mark [3] on the cam sprocket is aligned With the upper cylinder head index line. ll th mark or "2" mark is facing lower cylinder head index line [4], turn the crankshaft counterclockwise one full turn (360°) and realign the “1T” mark or "2T" mark with the index notch. Check the valve clearance by inserting a feeler gauge [1] between the valve adjusting screw and valve stem. VALVE CLEARANCE: IN: 0.17 t 0.02 mm (0.007 t 0.001 in) EX: 0.20 t 0.02 mm (0.011 t 0.001 in) 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 NM (1.4 kngm, 10 mm) After tightening the lock nut. recheck the valve clearance. Apply engine oil to a new O—ring [1] and install it to the camshaft maintenance cap [2]. Temporarily Install the camshaft maintenance cap to the cylinder head. It the engine is removed from the frame. tighten the camshaft maintenance cap to the specified torque. TORQUE:4.0 NM (0.4 kgl-m, 3.0 lbl-ft) 3-11 MAINTENANCE It the engine is installed on the Irame, insert a Ieeler gauge (0.1 mm) [1] between the camshatt maintenance cap and cylinder head. Tighten the camshaft maintenance cap securely. Remove the leeler gauge. Further tighten the camshaft maintenance cap at 30". NOTE One concave area [2] size is equivalent with 30". Install the cylinder head cover (page 10-5). Apply engine oil to new O—rings [1] and install them to each hole cap. Apply grease to the timing hole cap [2] and crankshalt hole cap [3] threads. Install and tighten the timing hole cap and crankshaft hole cap to the specified torque. TORQUE: Timing hole cap: 10 N-m (1.0 kgI-m, 7 lbt-ft) Crankshatt hole cap: 15 N-m (1.5 kgI-m, 11 lbf-ft) ENGINE OIL omer visccsi'ties shown in the chart may be used when the average temperature in your riding area 15 within the indicated range. 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 tiller cap/dipstick [1] and wipe it clean. Reinstall the oil Iillercap/dipstick, but do not screw it. Remove the oil filler cap/dipstick and check the oil level. It the level is below or near the lower level [2] on the dipstick, fill the recommended engine oil to the upper level [3]. Check that the O-ring [4] is in good condition, replace it it necessary. Apply engine oil to the O-ring. Install the oil tiller cap/dipstick. RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle il" or an equivalent API classitication: $6 or higher (except oils labeled as energy conserving on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA [1] 10 10 -30 -20 -20 D -1 0 20 D 40 1D 20 30 40 50‘C 60 80 100 120'F 3-12 MAINTENANCE ENGINE OIL CHANGE Warm up the engine. Stop the engine and remove the oil Iiller cap/dipstick [1]. 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 0“ completely. Install a new sealing washer onto the drain bolt. Apply engine oil to the drain bolt threads and seating surlace. Install and tighten the drain bolt/sealing washer to the specified torque. TORQUE:3D N-m (3.1 kgI‘m, 22 let) Fill the engine with the recommended engine oil (page 3-12). ENGINE OIL CAPACITY: NC700X/XA/S/SA: 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 NC700XD/SD: 3.2 liters (3.4 US qt, 2.3 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 tiller cap/dipstick [1]. Check the engine oil level (page 3-12). Make sure there are no oil leaks. ENGINE OIL FILTER Drain the engine oil (page 3-13). Remove the oil lilter cartridge [1] using the special tool. TOOL: Oil Filter Wrench [2] 07HAA-PJ7D1D1 MAINTENANCE Check that the oil filter boss protrusion from the crankcase is specilied length as shown. SPECIFIED LENGTH: 16.5 t 0.5 mm (0.65 t 0.02 in) NOTE II the oil lilter boss is removed. apply locking agent to the oil lilter boss threads (page 3-2). Apply engine oil to a new oil lilter cartridge threads and O-ring. Install and tighten the oil IiIter cartridge [1] to the specified torque. TORQUE:26 N-m (2.7 kgf—m,19lbf—lt) Fill the engine With the recommended engine oil and check that there are no oil leaks (page 3-12). CLUTCH OIL FILTER (NC700XD/SD) NOTE Replace the engine oil Iilter when the clutch oil filter is replaced. Drain the engine oil (page 3-13). Remove the lower cowl (page 2—29). Remove the IoIIowing: — Bolts [1] — Clutch oil filter cover [2] — Spring [3] — Clutch oilfilter[4] O-ring [5] Install a new clutch oil litter With the "OUTSIDE" mark [6] lacing out. Installation is in the reverse order oI removal. NOTE - Replace the O-ring with a new one. - Apply engine oil to a new O-ring. Fill the engine With the recommended engine oil and check that there are no oil leaks (page 3-12). 16.5 t 0.5 mm (0.65 z 0.02 in) 3-14 MAINTENANCE ENGINE IDLE SPEED NOTE ' Inspect the idle speed atter all other engine maintenance items have been perlormed and are Within specilications. ' Belore checking the idle speed, inspect the iollowing items. — No DTC and MIL blinking — Spark plug condition (page 3-8) — Air cleaner element condition (page 3-7) ' The engine must be warm tor accurate idle speed inspection. ' This system eliminates the need tor manual idle speed adjustment compared to previous designs. Turn the ignition switch ON and engine stop SWitch Start the engine and let it idle. Check the idle speed. IDLE SPEED: 1,200 2100 min" (rpm) ll the idle speed is out ol the specilication, check the lollowing: — intake air leak or engine top-end problem (page 10- — Throttle operation and ireeplay (page 3-5) — lACV operation (page 7-22) RADIATOR COOLANT Check the coolant level oi the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" and "LOWER" level lines With the motorcycle in an upright position. ll necessary, add recommended coolant. RECOMMENDED ANTIFREEZE: High quality ethylene glycol antilreeze containing silicate-flee corrosion inhibitors Remove the lower cowl (page 2-28). [2] m Remove the reserve tank cap [1] and add the coolant to , i_ ’ - ' tne "UPPER" level line [2] with a 1:1 mixture oi distilled water and antiireeze (coolant preparation: page 8-6). Reinstall the reserve tank cap. Check to see ii there are any coolant leaks when the coolant level decreases very rapidly. ll the reserve tank becomes completely empty, there is a possibility ol air getting into the cooling system. Be sure to remove any air lrom the cooling system (page 8-6). 3-15 MAINTENANCE COOLING SYSTEM Check the radiator air passages ior clogging or damage. Straighten bent tins, and remove insects, mud or other obstructions With compressed air or low water pressure. Replace the radiator ii the air Ilcw is restricted over more than 20 % oi the radiating surface. Inspect the water hoses for cracks or deterioration, and replace them it necessary. Check the tightness ol all water hose band screws (page 8-10). DRIVE CHAIN Never inspect and adjust the drive chain wniie the engine is running. 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. DFIIVE CHAIN SLACK: NC7DOX/XA/XD: 30—40 mm (1.2—1.6in) NC7DOS/SA/SD: 25—35 mm (1.0—1.4in) - NC700X/XA/XD: Excessive chain slack, 60 mm (2.4 in) or more, may damage the frame. - NC7DOS/SA/SD: Excessive chain slack, 50 mm (2.0 In) or more, may damage the frame. ‘ NC7ODX/XA/XD130- 40 mm (1.2 — 1.6 in) NC7ODS/SA/SD: 25 - 35 mm (1.0 — 1.4 in) 3-16 MAINTENANCE ADJUSTMENT Loosen the rear axle nut [1]. Loosen the lock nuts [2] and turn the ad]usting 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 swingarm. Tighten the axle nut to the specified torque. TOROUE:98 N-m (10.0 kgl-m, 72 Ibl-ft) Hold the adjusting nuts and tighten the lock nuts to the specified torque. TOROUE:21 N-m (2.1 kgf—m,15lbf—ll) Recheck the drive chain slack and lree wheel rotation. Check the drive chain wear indicator label attached on the left swmgarm. If the drive chain adjuster arrow mark [1] reaches red zone [2] ol the indicator label, replace the drive chain with a new one (page 3-19). CLEANING AND LUBRICATION Clean the drive chain [1] with a chain cleaner designed specifically for O-ring chains or a neutral detergent. Use a soft brush ii the drive chain is dirty. 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 O—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. Lubricate the drive chain with drive chain lubricant [2] designed specifically for use with O—ring chains, #80 — 90 gear oil or equivalent. Do not use a chain lubricant NOT designed specifically for use with O-ring chains to lubricate the drive chain. Wipe off the excess oil or drive chain lubricant. 3-17 MAINTENANCE SPROCKET INSPECTION Remove the left rear cover (page 2-29). Inspect the drive and driven sprocket teeth Ior wear [1] or damage [2], replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition [3], or new replacement chain will wear rapidly. Check the attaching bolts and nuts on the drive and driven sprockets. ll any are loose, torque them. TORQUE: Drive sprocket bolt [1]: 54 N-m (5.5 kgI-m, 4o lbf-I't) Driven sprocket nul [2]: 103 Mm (11.0 kgI-m, so lbI-l‘t) Install the left rear cover (page 2—29). 3-18 MAINTENANCE Never reuse the old drive chain, master link, master link plate and Orrings. REPLACEMENT This motorcycle uses a drive chain With a staked master link. Fully slacken the drive chain (page 3-17). Remove the drive chain using the special tool. NOTE When using the special tool, icllow the manuiacturer's instruction. TOOL: Drive chain tool set O7HMH-MFI10103 Remove the excess drive chain links Irom a new drive chain with the drive chain tool set. STANDARD LINKS: NC7OOX/XA/S/SA: 114 LINKS NC7OOXD/SD: 112 LINKS REPLACEMENT CHAIN DID: DIDSZDVD RK: RKSZDMKO Insert a new master link [i] with new O-rings [2] train the inside oi the drive chain, and install a new plate [3] and O-rings with the identiiication mark lacing the outside. Assemble the master link, O-rings and plate. TOOL: Drive chain tool set O7HMH-MFI10103 Make sure that the master link pins [1] are installed properly. Measure the master link pin length projected Irom the plate. STANDARD LENGTH: Approx. 1.3 mm (0.05 in) Stake the master link pins. 1 LINK NC7OOX/XA/S/SA: 114 LINKS NC7OOXD/SD: 112 LINKS 3-19 MAINTENANCE Make sure that the pins are staked properly by measuring the diameter at the staked area using a slide caliper[l]. DIAMETER OF THE STAKED AREA: DID: 5.40 — 5.60 mm (0.213 — 0.220 in) RK: 5.25 — 5.65 mm (0.207 — 0.222 in) After staking, check the staked area ol the master link lor cracks. ll there is any cracking, replace the master link, O-rings and plate. DRIVE CHAIN SLIDER Check the drive chain slider lor wear or damage. The drive chain slider must be replaced il it is worn to the wear indicator [1] (page 18-16). 3-20 MAINTENANCE BRAKE FLUID Spilled fluid can damage painted, plastic or rubher parts. Place a rag over these parts whenever the system Is serviced. NOTE ' Do not mix dillerent types ol lluid, as they are not compatible with each other. ' Do not allow loreign material to enter the system when filling the reservoir. ' When the iluid level is low, check the brake pads ior wear (page 3-22). - A low lluid level may be due to wear of the brake pads. ll the brake pads are worn and caliper pistons are pushed out, this accounts lor a low iluid level. It the brake pads are not worn and lluid level is low, check the entire system for leaks (page 3-23). FRONT BRAKE Turn the handlebar to the left so that the reservoir l5 level and check the lront brake "Uld level through the sight glass. ll the level lS near the "LOWER" level line [1], lill the recommended brake iluid. Remove the lollowing: — Screws [2] — Reservoircover[3] — Setplate [4] — Diaphragm [5] [41/15] in Fill the reservoir With DOT 4 brake "Uld lrom a sealed container to the casting ledge [1]. [1] Install the diaphragm, set plate and reservoir cover. Install and tighten the cover screws to the specified torque. TOROUE:1.5 NM (0.2 kgl-m, 1.1 lbl-ft) REAR BRAKE Support the motorcycle on a level surlace, and check the rear brake iluid level. Check the brake fluid level. ll the level lS near the "LOWER" level line [1], lill the recommended brake iluid. V ) [1] 3-21 MAINTENANCE Remove the rear brake reservoir mounting bolt [1] and reservoir [2]. Remove the cover screws [3], reservoir cover [4], set plate [5] and diaphragm [6]. Temporarin install the reservoir and mounting bolt to the reservoir stay lower hole [7] using a 6 mm nut [8]. NOTE Align the reservoir tab [9] With the reservoir stay cutout [10]. Fill the reservoir with DOT 4 brake tluid irom a sealed container to the "UPPER" level line [i 1]. Remove the 6 mm nut, mounting bolt and reservoir. Install the diaphragm, set plate and reservoir cover. Install and tighten the cover screws to the specitied torque. TORQUE:1.5 N-m (0.2 kgf—m, 1.1 lbl-ft) Install the reservoir and rear brake reservoir mounting bolt. NOTE Align the reservoir tab with the reservoir stay upper hole [12]. Tighten the rear brake reservoir mounting bolt to the speciiied torque. TORQUE: 1D N-m (1.0 kgf—m, 7 lbf—I‘t) BRAKE PADS WEAR Aiways replace the brake pads as a se! to assure even disc pressure. Aiways replace the brake pads as a se! to assure even disc pressure. FRONT BRAKE PADS Check the brake pads Ior wear. Replace the brake pads iI either pad is worn to the bottom oI wear limit grooves [1]. For brake pad replacement. — NC700X/S (page 19-16) — NC700XA/XD/SA/SD (page 19-17) REAR BRAKE PADS Check the brake pads Ior wear. Replace the brake pads iI either pad is worn to the bottom oI wear limit grooves [1]. For brake pad replacement (page 19-18). [8] [2] [10] [12] NC7OOX/S: NC700XA/XD/SA/SD: 3-22 BRAKE SYSTEM NC 700XA/XD/SA/ SD: INSPECTION This model is equipped with a Combi Brake System. Check the front and rear brake operation as follows: Support the motorcycle securely and raise the front wheel [1] off the ground. Apply the brake pedal [2]. Make sure the front wheel does not turn while the brake pedal is applied. 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: — NC700X/S (page 19-9) — NC700XA/XD/SA/SD (page 19-12) Inspect the brake hose [1] and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut [1] and turn the push rod [2] until the correct pedal height is obtained. MAINTENANCE MAINTENANCE II the brake pedal [1] is adjusted to the lower position [2], make sure that the clearance between the lower end ol the push rod and the brake pedal does not lall below1 mm (0.04 in). II the brake pedal is adjusted to the higher position [3], make sure that the lower end ol the push rod thread [4] is visible inside the joint. After adjustment, tighten the rear master cylinder push rod lock nut to the speciiied torque. TORQUE: 17 N-m (1.7 kgf—m,13lbf—fl) BRAKE LIGHT SWITCH The Iranlbrake/i'ghl Adjust the brake light switch [1] so that the brake light swilch does no! comes on just prior to the brake actually being require ad/uslmem. engaged. II the light tails to come on, adjust the switch so that the light comes on at the proper time. NOTE Hold the switch body and turn the adjuster [2]. Do not turn the switch body. BRAKE LOCK OPERATION (NC700XD/ SD) INSPECTION Support the motorcycle using a salety stand or hoist, raise the rear wheel oil the ground. Turn the rear wheel With your hands and pull the parking brake lever [1] slowly. Check the parking brake lever "A" mark [2] Within the index lines [3] at the rear wheel stopped. II the parking brake lever "A" mark not within the index lines, adjust the parking brake as iollows (page 3-25). 1 mm (0.04 in) [1] [2] 3-24 MAINTENANCE ADJUSTMENT Parking brake lever position can be adjusted at the upper end ol 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. ll the correct lreeplay cannot be gained lrom 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 ' lelt (brake pads contact With the brake disc). Then turn the adjuster bolt 1/4 turn counterclockwise and tighten the lock nut to the specilied torque while holding the adjuster bolt. TORQUE: 17 N-m (1.7 kgf—m,13lbf—ll) Recheck the parking brake operation. HEADLIGHT AIM Ad/usr the headlight aim as specified by local laws and regulations. Support the motorcycle in an upright position. 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. r 3-25 MAINTENANCE Adjust the headlight aim horizontally by turning the horizontal beam adjusting screw [1]. A clockwise rotation moves the beam toward the right and counterclockwise rotation moves the beam toward the lett. CLUTCH SYSTEM (NC700X/XA/S/SA) Tne adjuster ma y be damaged ii it is positioned too Ia! out, leaving minimai thread engagement. Measure the clutch lever treeplay at the end oi the clutch lever. FFIEEPLAY:10 — 20 mm (3/8 — 13/16 in) Minor adjustment is made with the upper adjuster at the clutch lever. Loosen the lock nut [1] and turn the adjuster [2]. ll the adjuster is threaded but near its limit and the correct treeplay cannot be obtained, turn the adjuster all the way in and back but one turn. Tighten the lock nut while holding the adjuster. Recheck the clutch lever lreeplay. NC7OOX/XA/XD: [1] 3-26 MAINTENANCE 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 lreeplay. Tighten the lock nut while holding the adjusting nut. Ii proper freeplay cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch (page 11-7). SIDESTAND INSPECTION Support the motorcycle using a salety stand or hoist. Check the sidestand spring [1] lor damage or loss of tension. Check the sidestand [2] assembly for lreedom of movement and lubricate the sidestand pivot if necessary. Check the sidestand ignition cut-oil system: — Sit astride the motorcycle and raise the sidestand. — Start the engine with the transmission in neutral, then, with the clutch lever lully squeezed, shift the transmission into gear. — Move the Sidestand lull down. — The engine should stop as the sidestand is lowered. there is a problem with the system, check the sidestand sWitch (page 22-28). REMOVAL/INSTALLATION Support the motorcycle upright on a level surface. Remove the sidestand switch bolt [1] and sidestand switch [2]. 3-27 MAINTENANCE Remove the sidestand springs [1]. Remove the sidestand pivot nut [2], bolt [3] and sidestand [4]. Apply grease to the sidestand pivot bolt sliding surlace. Install the sidestand and sidestand pivot bolt. Tighten the sidestand pivot bolt to the specilied torque. TORQUE: 1D N-m (1.0 kgf—m, 7 Ibf—ft) Loosen the sidestand pivot bolt 45 — 90°. Install and tighten the sidestand pivot nut to the specified torque while holding the pivot bolt. TORQUEKSQ NM (4.0 kgf—m, 29 Ibf—ll) Install the sidestand springs. Install the sidestand switch [1]. NOTE - Align the sidestand switch groove with the Irame pin. A - Align the sidestand sWitch tab with the sidestand —-—!\‘_ hole. i Install and tighten a new sidestand switch bolt [2] to the specified torque. TORQUE: 1o N-m (1.0 kgf—m, 1mm) SUSPENSION FRONT SUSPENSION INSPECTION Check the action ol the forks by operating the Iront brake and compressing the front suspension several times. Check the entire assembly for signs ol leaks. damage or loose Iasteners. Replace damaged components which cannot be repaired. NOTE Loose. worn or damaged suspension parts impair motorcycle stability and control. Tighten all nuts and bolts. For lork sen/ice (page 17-25). 3-28 MAINTENANCE REAR SUSPENSION INSPECTION Check the action ol the rear shock absorber by compressing the rear end several times. Check the entire shock absorber assembly Ior leaks. damage or loose tasteners. Replace damaged components which cannot be repaired. NOTE Loose, worn or damaged suspension parts impair motorcycle stability and control. Tighten all nuts and bolts. For shock absorber service (page 18-14). Support the motorcycle using a satety stand or hoist, raise the rear wheel oil the ground. Check lor worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel side to side. Replace the bearings ii any looseness to noted. For swingarm service (page 18-16). NUTS, BOLTS, FASTENERS Check that all chassis nuts, screws and bolts are tightened to their correct torque values (page 1-15). Check that all cotter pins, satety clips, hose clamps and cable stays are in place and properly secured. WHEELS/TIRES Support the motorcycle using a satety stand or hoist, raise the lront wheel oil the ground. Hold the tram tork leg and move the iront wheel sideways With lorce to see ii the wheel bearings are worn. For lront wheel service (page 17-20). Support the motorcycle using a satety stand or hoist, raise the rear wheel oil the ground. Hold the swingarm and move the rear wheel sideways with lorce to see ii the wheel and driven tlange bearings are worn. For rear wheel service (page 18-6). 3-29 MAINTENANCE Check the tire pressure with a tire pressure gauge when the tires are cold. RECOMMENDED TIRE PRESSURE: DRIVER ONLY: FRONT: 250 kPa (2.5a kgI/cmZ, as psi) REAR: 290 kPa (2.9a kgI/cmZ, 42 psi) DRIVER AND PASSENGER: FRONT: 250 kPa (2.5a kgI/cm’, as psi) REAR: 290 kPa (2.9a kgI/cm’, 42 psi) RECOMMENDED TIRE SIZE: FRONT: 120/7OZR17M/C (58W) REAR: 160/GOZR17M/C(69W) RECOMMENDED TIRE BRAND: BRIDGESTONE FRONT: BTOZSF G REAR: BTOZSR G METZELER FRONT: ROADTEC 28 INTERACT E REAR: ROADTEC 28 INTERACT Check the tires lor cuts, embedded nails, or other damage. Check the iront and rear wheels tor trueness. Measure the tread depth at the center oi the tires. Replace the tires when the tread depth reaches the lollowing limits. MINIMUM TIRE TREAD DEPTH FRONT: 1.5 mm (0.0 ‘n) REAR: 2.0 mm (0.08 in) STEERING HEAD BEARINGS Support the motorcycle using a saiety stand or hoist, raise the lront wheel oil the ground. Check that the handlebar moves lreely irom side to side. Make sure the control cables do not interlere with the handlebar rotation. Check lor steering stem bearings by grabbing the iork legs and attempting to move the lront lork iorward to backward. II the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (page 17-33). 3-30 4. PGM-FI SYSTEM pGMFI SYSTEM LOCATION.......................4_2 DTc TROUBLESHOOTING........................4.21 pGMFI SYSTEM DIAGRAM.........................4_4 MIL TROUBLESHOOTING SERVICE INFORMATION-----------------------------4-6 MIL CIRCUIT TROUBLESHOOTING ---------4-63 PGM-Fl SYMPTOM FUEL CUT TROUBLESHO0T|NG...................................4.7 ECT SENSOR PGM-FI CONNECTOR LOCATIONS ------------4-8 BANK ANGLE 4.55 PGM-FI TROUBLESHOOTING INFORMATION--- ECM (NC700X/XA/S/SA)/ PcM (Nc7ooxp/SD) DTc 02 SENSOR- SENSOR UNIT POWER LINE INSPECTION 4-1 PG M-FI SYSTEM PGM-FI SYSTEM LOCATION NC700X/XA/S/SA: IACV IAT SENSOR SENSOR UNIT: — MAP SENSOR — TP SENSOR INJECTOR IGNITION SWITCH ECT SENSOR FUEL PUMP DLC O2 SENSOR EOP SWITCH CKP SENSOR BANK ANGLE SENSOR VS SENSOR SIDESTAND SWITCH 4-2 PGM-FI SYSTEM NC7DOXD/SD: IACV IAT SENSOR SENSOR UNIT: - MAP SENSOR - TP SENSOR INJECTOR IGNITION SWITCH ECT SENSOR PCM FUEL PUMP DLC O2 SENSOR EOP SWITCH CKP SENSOR BANK ANGLE SENSOR VS SENSOR SIDESTAND SWITCH 4-3 PG M-FI SYSTEM PGM-FI SYSTEM DIAGRAM NC7OOX/XA/S/SA: \GNIT‘ON swncn m MAINFUSE ENssmp 5?, ENG‘NESYOstWCH Eflfkp m a m M m m UNH Fl m a N COMEINAT‘ON METER BATTERV FE Em v2 mum 5qu HORN mss mum/won 75A m mm © (86> M: MD @w 2‘ an M rxu mu m (H) vs SENSOR Va Va 7 vcc w mm \MMOB‘LIZER MDT EB; 25 mom RECE'VE“ “CY 30- w wow 5:: 7 iSENSOR UNH mo (H FUELCUT MAP SENSOR HEW ma ‘ ‘ ‘ 1 am Ev (EM 1 w SENSOR 1 av Em 5 Eu RW © (9) w SENSOR © (7) ECY SENSOR © (37} EDP swncn {21) 01 SENSOR w SENSOR FAN com 3p RELAY mm NM mama @ (12> 38: N02 \NJECYOR © (13) 3g ‘3; \GNWON con SPARK PLUG mcvm w mama m m:va ‘5 m:sz 3 23 SSYAND DTc/ManumbE, B‘ B‘ack P P‘NK Br Brown R Red Bu Ema v mm a gagmzdaesmsmfl (EDDDDDDDDDD G cm W WW whende‘echng DTC‘M‘L DDDDDDDDD G, Gray V Yellow J '1 Lg ngmgveen F ShavHermma‘smr ’ 0 Orange readan DTC/MIL mm 33? CONNECTOR EcM 5mg 0! Hub \evmma‘s PGM-Fl SYSTEM NC7DOXD/SD: 5? am MA‘§D;U9E \GNIT‘ON SW‘TCH ENG STOP S ENG‘NESYOF swm 2%: F a R E‘ 7 5" V UN” EN 5‘ N v F‘ 5‘ COME‘NAY‘ON METER m amERv mum SYOF NORN 7 m H‘SS WDICATOR (54> HANK ANGLE SENSOR mamas“: m) vs SENSOR R UNE 525 555 527 @454) PCM FLR Nu m 1 N mum MAP SENSOR ‘ REW ‘ 5: a W 1 NM N Br (8} 1 w SENSOR 1 © (9) w SENSOR @ a) © (37) EORSWRCR (2‘) o: SENSOR cw aw as; Rw FAN CONT FAN MOTOR an REL/W New; NM mama © (12) X NaZ \NJECYOR @ (13) g ‘3}, \GNWON CON SPARK PLUG EN RONsw CKF SENSOR mcvm aw mcwa ms mcva ms mcvza a: 525 55mm ©¢ )= DTC/M‘L number 5‘ Black R P‘NK Br Brawn H Red Bu Blue v mm a - Engme dues nmstan G Green W WW when de‘edmg DTC‘MIL G, Gray V mow , Lg Ogmgyeen A}: Shanmrmma‘slnr 0 Orange readan DTC/MIL PCM asp (amen CONNECTOR ROM 33F (GRAY) CONNECTOR RcM sue Mma‘e \evmmals RcM sue a! mag \evmmals PG M-FI 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 Iire or explosion. ~ A Iaulty PGM-Fl system is oIten related to poorly connected or corroded connectors. Check those connections beIore proceeding. ~ When disassembling the PGM-Fl system parts, note the location ot the O-rings. Replace them with new ones upon reassembly. ~ Use a digital tester Ior PGM-Fl system inspection. ~ The tollowmg color codes are used throughout this section. BI = Black Bu = Blue Gr = Gray 0 = Orange R = Red w = Whlte Br = Brown G = Green Lg = nght green P = Plnk v = Vlolet Y = Yellow SPECIFICATIONS sensor reslstance at sensor reslstance (at nlector reslstance at " TORQUE VALUES , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgI-m, lbI-ft) REMARKS ECT sensor i 10 12(1.2,9) Bank angle sensor mounting bolt 2 6 10 (1.0, 7) 02 sensor i 12 24.5(2.5,18) PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one ol these symptoms, check the DTC or MIL blinking, reter to the DTC index (page 4-15) and begin the appropriate troubleshooting procedure. It there are no DTC/MIL blinking stored in the ECM/PCM memory, do the diagnostic procedure tor the symptom, in sequence listed below, until you find cause. PGM-Fl SYSTEM Symptom Diagnosis procedure Also check for Engine cranks but won‘t start (No DTC and MIL blinking) 1. Inspect the spark plug condition (page 3- a). . Inspect the ignition system (page 5-6). . Inspect the cylinder compression (page 10-5). 4. Inspect the IACV (page 7-22). mm 5. Inspect the iuel supply system (page 7-10). No tuel to injector — Clogged lueI tilter — Pinched or clogged iuel leed nose — Faulty tuel pump — Faulty tuel pump circuits Intake air leak Contammated/deteriorated luel Faulty iuel injector Engine cranks but won‘t start (No luel pump operation sound when the turning the ignition ON) 1. ECM/PCM power/ground circuits mallunction (page 4-68). 2. Inspect the iuel supply system (page 7-10). Open circuit in the power input and/or ground wire ol the ECM/ PCM Blown main tuse (30 A) Blown sub luse 15 A (FI) Blown sub iuse 7.5 A (ENG STOP) Engine stalls, hard to start, rough idling . Inspect the IACV (page 7-22). . Inspect the lueI supply system (page 7-4). . Inspect the battery charging system (page 21-7). 5. Inspect the ignition system (page 5-6). AmN—t . Inspect the engine idle speed (page 3-15). Restricted luel teed hose Contammated/deteriorated luel Intake air leak Faulty MAP sensor Restricted lueI tank breather hose Alterburn wnen engine braking is used Inspect the ignition system (page 5-6). Backliring or misliring during acceleration Inspect the ignition system (page 5-6). Poor pertormance (driveability) and poor iuel economy . Inspect the lueI supply system (page 7-4). 1 2. Inspect the air cleaner element (page 3-7). 3 . Inspect the ignition system (page 5-6). Faulty pressure regulator (luel pump) Faulty inIector Faulty MAP sensor Idle speed is below specilications orlast idle too low (No DTC and MIL blinking) . Inspect the IACV (page 7-22). . Inspect the ignition system (page 5-6). . Inspect the engine idle speed (page 3-15). Idle speed is above specitications or last idle too high (No DTC and MIL blinking) mound . Inspect the throttle operation and lreeplay (page 3-5). 3. Inspect the IACV (page 7-22). 4 Inspect the ignition system (page 5-6). . Inspect the engine idle speed (page 3-15). Intake air leak Engine top-end problem Air cleaner element condition MIL stays ON but no DTCs set, or MIL never comes ON at all Inspect the MIL circuit (page 4-63). PGM-FI SYSTEM PGM-FI CONNECTOR LOCATIONS NOTE 1: Remove the shroud/side cover (NC700X/XA) (page 2-14). NOTE 1: Remove the side cowl (NC7ODS/SA) (page 2-13). ECM 33F (BLACK) CONNECTOR (NOTE 1) NOTE 2: Remove the luggage box lid/hinge assembly (NC700XD/SD) (page 2-19). PCM 33F (GRAY) CONNECTOR (NOTE 2) PCM 33F (BLACK) CONNECTOR (NOTE 2) , E 4-8 PGM-FI SYSTEM NOTE 3: Remove the ECM box (page 4—65). BANK ANGLE SENSOR 2P (BLACK) CONNECTOR (NOTE 3) NOTE 4: Remove the maintenance lid (page 21 -6). NOTE 5: Remove the center cover (NC7ODX/XA/XD) (page 2-16). NOTE 5: Remove the luggage box (NC7ODS/SA/SD) (page 2-20). if: IAT SENSOR / \ ' 2P (BLACK) CONNECTOR (NOTE 5) ‘ DLC (NOTE 4) NOTE 6: Remove the lower cowl (page 2-28). , l ECT SENSOR ‘ ' 2P CONNECTOR >/ , 541/ ' ’~/ We.» ‘ \V ' , ’. ’ ' l ' I’ " 02 SENSOR ’ 1P (BLACK) CONNECTOR (NOTE 5) I A, EOP SWITCH E9 1P (GRAY) CONNECTOR (NOTE 5) PGM-FI SYSTEM NOTE 7: Remove the air cleaner housing (page 7-14). [{ M'fi IACV 4P (BLACK) CONNECTOR (NOTE 7) SENSOR UNIT 5P (BLACK) CONNECTOR (NOTE 7) 6:035 INJECTOR 2P (GRAY) CONNECTOR NOTE 8: Remove the windscreen (page 2-23). COMBINATION METER 16F (GRAY) CONNECTOR (NOTE 8) / \ x \ / HHHH 4-1 0 PGM-FI SYSTEM PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent iaiIure" means a system may have had a iaIlure, but it checks OK now. II the MIL does not come on, check Ior poor contact or loose pins at all connectors reIated to the circuit that ol the troubleshootIng. II the MIL was on, but then went out, the orIginaI problem may be intermittent. Opens and Shorts "Opens" and "Shorts" are common eIectrical terms. An open Is a break in a wire or at a connection. A short is an achdentaI connection ol a wire to ground or to another wire. In simpIe electronics, this usually means something wiII not work at aII. With ECM/ PCMs thIs can something mean something work, but not the way it‘s supposed to. If the MIL has come on Reier to DTC READOUT (page 4-12). lithe MIL did not stay on It the MIL did not stay on, but there is a driveability probIem, do the SYMPTOM TROUBLESHOOTING (page 4-7). SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM The PGM-FI system is equipped with the seli-diagnostic system. When any abnormality occurs In the system, the ECM/PCM turns on the MIL and stores a DTC in its erasable memory. FAIL-SAFE FUNCTION The PGM-FI system is provided WIth a IaiI-sale iunctIon to secure a minImum running capability even when there Is trouble in the system. When any abnormality Is detected by the seIi-dIagnosis iunctIon, running capabIIity is maintained by pre-programed value in the sImuIated program map. When any abnormality is detected in the injector, the IaiI-sale Iunction stops the engine to protect It irom damage. DTC - The DTC is composed ol a main code and a sub code and it is dispIayed as a hyphenated number when retrieved Irom the ECM/PCM WIth the HDS pocket tester. The digits in Iront ol the hyphen are the maIn code, they indicate the component oi Iunction Iailure. The digits behind the hyphen are the sub code, they detail the speciIIc symptom oi the component or iunction iailure. For example, in the case oi the TP sensor: — DTC 08 —1 = (TP sensor voltage) — (lower than the specilied value) — DTC 08 — 2 = (TP sensor voltage) — (higher than the speciIIed vaIue) - The MAP, ECT, TP and IAT sensor diagnosis WIII be made according to the voItage output oi the aiIected sensor. II a IaiIure occurs, the ECM/PCM determInes the Function FaiIure, compares the sensor voltage output to the standard vaIue, and then outputs the corresponding DTC to the HDS pocket tester. For example: — II the input voItage line (A) on the MAP sensor is opened, the ECM/PCM detects the output voltage is about 5 V, then the DTC 1-2 (MAP sensor circuit high Voltage) will be displayed. — II the input voItage line (B) on the TP sensor Is opened, the ECM/PCM detects the output voltage is 0 V, then the DTC 8-1 (TP sensor circuit Iow voItage) will be displayed. MIL Blink Pattern - II the HDS pocket tester is not avaIlable, DTC can be read Irom the ECM/PCM memory by the MIL [1] blink pattern. - The number oI MIL blinks Is the equivalent the maIn code oi the DTC (the sub code cannot be dispIayed by the MIL). - The MIL will blink the current DTC, in case the ECM/PCM detects the problem at present, when the ignitIon switch ON and engIne stop switch "C" or idIIng WIth the sidestand down. The MIL will stay ON when the engIne speed is over 1,850 min‘ (rpm) or with the sIdestand up. ~ The MIL has two types ol bIInks, along innk and short blink. The long blinking lasts ior 1.3 seconds, the short bIInkIng lasts Ior 0.3 seconds. One long innk is the equivalent oI ten short bIInks. For example, when two Iong bIInks are IoIIowed by iive short blinks, the MIL is 25 (two long blinks = 20 blinks, pIus IIve short blinks). ~ When the ECM/PCM stores more than one DTC, the MIL will IndIcate them by bIInkIng in the order Irom the Iowest number to highest number. MIL Check When the ignitIon switch is turned ON and engIne stop switch "(3" the MIL WIII stay on tor a Iew seconds, then go oli. II the MIL does not come on, troubleshoot the MIL cIrcuIt (page 4-63). 4-11 PG M-FI SYSTEM CURRENT DTC/FREEZE DTC The DTC 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 DTC when the sidestand is lowered. It is possible to readout the MIL blink pattern as the current DTC. ~ 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. II it is necessary to retrieve the past problem, readout the Ireeze DTC by following the DTC readout procedure (page 4- 12). HDS POCKET TESTER INFORMATION ' The HDS pocket tester can readout the DTC, freeze data, current data and other ECM/PCM condition. How to connect the HDS pocket tester Turn the ignition switch OFF. Remove the maintenance lid (page 21-6). Remove the DLC [1] lrom the batter box. Connect the HDS pocket tester to the DLC. Turn the ignition switch ON and engine stop switch "0" check the DTC and Ireeze data. NOTE Freeze data indicates the engine conditions when the Iirst mallunction was detected. EcM/PCM reset The HDS pocket tester can reset the ECM/PCM data including the DTC, Ireeze data and some learning memory. After the ECM/PCM reset, perform the TP sensor reset procedure (page 7—19). DTC READOUT Start the engine and check the MIL [1]. NOTE When the ignition switch is turned ON and engine stop SWitch ":1", the MIL will stay on lor a few seconds, then go olf. If the MIL stays on or blinks, connect the HDS pocket tester to the DLC (page 4-12). Read the DTC, Ireeze data and follow the troubleshooting index (page 4- 15). To read the DTC with the MIL blinking, refer to the following procedure. Reading DTC with the MIL Turn the ignition switch OFF. Remove the maintenance lid (page 21-6). Remove the DLC [1] lrom the batter box. Short the DLC terminals using a special tool. CONNECTION: Brown — Green TOO L: 505 can nector [2] o70PZ-ZY30100 Turn the ignition switch ON and engine stop switch "0", read, note the MIL blinks and reler to the DTC index (page 4-15). NOTE If the ECM/PCM has any DTC in its memory, the MIL Will start blinking. 4-12 PGM-FI SYSTEM ERASING DTC Connect the HDS pocket tester to the DLC (page 4-12). Erase the DTC with the HDS pocket tester while the engine is stopped. To erase the DTC without HDS pocket tester, refer to the tollowing procedure. How to erase the DTC with $65 connector 1. Turn the ignition sWitch OFF. 2. Remove the DLC [1] trom the batter box. Short the DLC terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 3. Turn the ignition sWitch ON and engine stop switch 4. Remove the special tool trom the DLC. 5. The MIL will light tor approximately 5 seconds. While the MIL lights, short the DLC terminals again With a special tool. The sell—diagnostic memory is erased it the MIL goes ott and starts blinking. NOTE. - The DLC must be jumped While the MIL lights. It not, the MIL Will not start blinking. ‘ Note that the sell-diagnostic memory cannot be erased it the ignition switch is turned OFF betore the MIL starts blinking. CIRCUIT INSPECTION INSPECTION AT ECM/POM CONNECTOR ‘ Always clean around and keep any foreign material away from the ECM/ PCM 33F connector(s) betore disconnecting it. - A Iaulty PGM-FI system is olten related to poorly connected or corroded terminals. Check those connections before proceeding. In testing at ECM/POM 33F 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 OTZAJ-FIDJA11D TEST HARNESS CONNECTION (NC7DOX/XA/S/SA) Remove the shroud/side cover (NC700X/XA) (page 2—14). Remove the side coWl (NC7ODS/SA) (page 2-13). Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. 4-13 PG M-FI SYSTEM Connect the ECM test harness [1] between the main wire harness [2] and 2 V ECM [a]. l l [1] TOOL: ECM test harness 33F 070MZ-MCA0100 TEST HARNESS CONNECTION (NCTODXD/SD) Remove the luggage box lid/hinge assembly (page 2—19). Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector [1] and PCM 33F (Gray) connector [2]. Connect the ECM test harness [1] between the main wire harness [2] and PCM [3]. TOOL: ECM test harness 33F 070MZ-MCA0100 TEST HARNESS TERMINAL LAVOUT The ECM/PCM 33F connector [1] terminals are numbered as shown in this 1 illustration. [ 1 The ECM test harness terminals are same layout as for the ECM/PCM 33F connector terminals as shown. 1 11 23 33 4-14 PGM-Fl SYSTEM DTC INDEX DTC Reler (MIL Function Failure Symptom/FaiI-safe lunction to “(13:30 blinks) (DTC) MAP sensorcircuit low voltage (less than - Engine operates normally 1-1 (1) 0.029 V) - Pre-program value: 225 mmHg/ 4-21 O MAP sensor or its circuit mallunction 30 kPa MAP sensor circuit high voltage (more - Engine operates normally 443 than 3.809 V) - Pre-program value: 225 mmHg/ 1-2 (1) O Loose or poor contact ol the sensor 30 kPa 4-22 unit connector O MAP sensor or its circuit mallunction ECT sensor circuit low voltage (less than - Hard start at a low temperature 7_1 (7) 0.049 V) - Pre-program value: 110°C/ $23 O ECT sensor or its circuit maliunction 230°F - Cooling lan turns on ECT sensor circuit high voltage (more - Hard start at a low temperature 4-45 than 4.946 V) - Pre-program value: 110°C/ 7-2 (7) O Loose or poor contact ol the ECT 230°F 4-24 sensor connector - Cooling lan turns on O ECT sensor or its circuit maliunction TP sensor circuit low voltage (less than - Poor engine acceleration 0.122 V) - Pre-program value: 0“ 8-1 (8) O Loose or poor contact ol the sensor 4-26 unit connector 447 O TP sensor or its circuit mallunction TP sensorcircuit high voltage (more than - Poor engine acceleration 8-2 (8) 4.966 V) - Pre-program value: 0“ 4-27 O TP sensor or its circuit mallunction IAT sensor circuit low voltage (less than - Engine operates normally 9-1 (9) 0.049 V) - Pre-program value: 35°C/95°F 4-28 O lAT sensor or its circuit mallunction IAT sensor circuit high voltage (more - Engine operates normally 448 than 4.946 V) - Pre-program value: 35°C/95°F 9-2 (9) O Loose or poor contact ol the IAT 4-29 sensor connector O lAT sensor or its circuit mallunction VS sensor no signal - Engine operates normally O Loose or poor contact ol the VS NC700X/XA/ 11-1 sensor connector 430 S/SA: 4-50 (11 O Open or short circuit in the VS sensor NC700XD/SD: wire 4-51 O Faulty VS sensor No.1 Injector circuit maliunction - Engine does not start 12-1 O Loose or poor contact ol the injector - lnjector, luel pump and ignition 432 463 (12) connector coil shut down O lnjector or its circuit mallunction No.2 Injector circuit maliunction - Engine does not start 13-1 O Loose or poor contact ol the injector - lnjector, luel pump and ignition 433 464 (13) connector coil shut down O lnjector or its circuit mallunction O2 sensor mallunction - Engine operates normally 21 -1 O Loose or poor contact ol the O2 (21) sensor connector 4'34 4'54 O 02 sensor or its circuit mallunction lACV circuit mallunction - Engine stalls, hard to start, rough 29-1 O Loose or poor contact ol the lACV idling [has 466 (29) connector O lACV or its circuit mallunction 33-2 (—) ECM/PCM EEPROM mallunction - Engine operates normally 4-37 — 4-15 PG M-FI SYSTEM DTC Reler Refer m (MIL Function Failure Symptom/Fail-safe lunction to (MIL) blinks) (DTC) Bank angle sensor circuit low voltage - Engine operates normally 54-1 (less than 0.020 V) - Engine stop function does not 437 (54) - Bank angle sensor or its circuit operate mallunctlon Bank angle sensor circuit high voltage - Engine operates normally 468 (more than 4.986 V) - Engine stop function does not 54-2 - Loose or poor Contact ol the bank operate 438 (54) angle sensor connector - Bank angle sensor or its circuit mallunctlon 84-1 CPC in the PCM maltunction - Gearshilt system stops (a4) - Faulty PCM 4'40 4'59 Meter communication mallunction - Engine operates normally 86-1 - Open or short circuit in the TXD/RXD 440 4_60 (86) wire - Faulty combination meter EOP switch high voltage (more than - Engine operates normally 1.001 V) - Oil pressure indicator stays on 87-1 - Loose or poor Contact ol the EOP 442 4_62 (87) SWltch connector - Open circuit in the EOP switch wire - EOP switch or its circuit mallunction 4-16 PGM-FI SYSTEM SENSOR UNIT POWER LINE INSPECTION BEFORE DTC TROUBLESHOOTING NOTE O When the DTC displays 1-1, 1-2, 8-1 and 8-2, check the Iollowing betore DTC troubleshooting. O NC700X/XA/S/SA: Betore starting the inspection, check Ior loose or poor contact on the sensor unit 5P (Black) connector and ECM 33P (Black) connector. O NC700XD/SD: Betore starting the inspection, check Ior loose or poor contact on the sensor unit 5P (Black) connector and PCM 33F connectors. O it the ECM/PCM is replaced, pertorm the iollowing: — Key Registration Procedure (page 23-6) — Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Sensor Unit Power Input Voltage Inspection Turn the ignition switch OFF. [1] Disconnect the sensor unit 5P (Black) connector [1]. T rn the ignition switch ON and engine stop switch Measure the voltage at the wire harness side. Connection: V/R or Y/V G/Y NC7OOX/XA/S/SA: Vellow/red (+) — Green/yellow (—) NC7OOXD/SD: Yellow/violet (1-) — 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 DTC troubleshooting (page 4-21). N0 — GO TO STEP 2. 2. Sensor Unit Input Voltage Line Short Circuit Inspection Turn the ignition switch OFF. [1] Check tor continuity between the sensor unit 5P (Black) connector [1] ot the wire harness side and ground. Connection: J L NC7OOX/XA/S/SA: V/R 0' W Vellow/red — Ground NC7OOXD/SD: @\ Vellow/violet — Ground U Is there continuity? '7 YES — O Short circuit in the Yellow/red Wire O Short circuit in the Yellow/violet wire N0 — GO TO STEP 3. 4-17 PG M-FI SYSTEM 3. Sensor Unit Power Line Open Circuit Inspection Disconnect the ioilowing: — ECM asp (Biack) connector (NC7OOX/XA/S/SA) 1 — PCM 33F (Biack) connector (NC700XD/SD) [2] — PCM 33F (Gray) connector (NC700XD/SD) [3] Check tor continuities between the sensor unit 5P (Biack) connector [4] and ECM/PCM 33F connector. Connection: NC7OOX/XA/S/SA: Yellow/red — Yellow/red Green/yellow — Green/yellow NC7OOXD/SD: Yellow/violet — Yellow/violet Green/yellow — Green/yellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — ~ Open circuitinthe Yellow/red wire ~ Open circuit in the Yellow/Vioiet wire ~ Open circuit in the Green/yeliow wire NC7OOX/XA/S/SA: NC7OOXD/SD: [1] [2] 4-18 BEFORE MIL TROUBLESHOOTING NOTE ' When the MIL blinks l and 8 times, check the tollowing before MlL troubleshooting. ' NC700X/XA/S/SA: Belore starting the inspection, check tor loose or poor contact on the sensor unit 5P (Black) connector and ECM 33P (Black) connector. ' NC700XD/SD: Belore starting the inspection, check tor loose or poor contact on the sensor unit 5P (Black) connector and PCM 33F connectors. ' it the ECM/POM is replaced, pertorm the iollowing: — Key Registration Procedure (page 23-6) —Clutoh initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Sensor Unit Power Input Voltage Inspection 1 Turn the ignition switch OFF. Connect the ECM test harness to the ECM/POM 33F connector(s). — NC700X/XA/S/SA (page 4-13) — NC7OOXD/SD(page4-l4) Turn the ignition switch ON and engine stop switch Measure the voltage at the ECM test harness terminals. Connection: NC7OOX/XA/S/SA: 14 (+) — 22 H NC7OOXD/SD: A8 (+) — 322 (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 2. N0 — GO TO STEP 3. 2. Sensor Unit Power Input Voltage Inspection 2 Turn the ignition switch OFF. Disconnect the sensor unit 5P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the wire harness side. Connection: NC7OOX/XA/S/SA: Vellow/red (+) — Green/yellow (—) NC7OOXD/SD: Yellow/violet (1-) — Green/yellow (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — Turn the ignition switch OFF. Connect the sensor unit 5P (Black) connector and start the MIL troubleshooting (page 4-43). N0 — GO TO STEP 4. PGM-FI SYSTEM NC7OOX/XA/S/SA: NC700XD/SD: [1] V/R or WV (.49 4-19 PG M-FI SYSTEM 3. Sensor Unit Input Voltage Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the sensor unit 5P (Biack) connector [i] at the wire harness side and ground. Connection: NC7OOX/XA/S/SA: Yellow/red — Ground NC7OOXD/SD: Vellow/violet — Ground Is there continuity? YES — ~ Short Circuit in the Yellow/red Wire ~ Short Circuit in the Yellow/vioiet wire N0 — Replace the ECM/POM with a known good one, and recheck. 4. Sensor Unit Input Voltage Line Open Circuit Inspection Check ior continuities between the ECM test harness [i] and sensor Unit SP (Biack) connector [2] at the Wire harness side. Connection: NC7OOX/XA/S/SA: 14 — Vellow/red 22 — Green/yellow NC7OOXD/SD: A8 — Yellow/violet 322 — Green/yellow Is there continuity? YES — Intermittent iailure N0 — ~ Open circuitinthe Yellow/red wire ~ Open circuit in the Yellow/Vioiet wire ~ Open circuit in the Green/yeliow wire Y/R orY/V NC7OOX/XA/S/SA: NC700XD/SD: 4-20 PGM-FI SYSTEM DTC TROUBLESHOOTING DTC1-1 (MAP SENSOR LOW VOLTAGE) NOTE O It the ECM/PCM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) — Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the MAP sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — Intermittent iailure 2. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 4-17). Is the sensor unit power line normal? YES — GO TO STEP 3. N0 — Replace or repair the abnormal circuit. 3. MAP Sensor Output Voltage Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the sensor unit 5P (Black) connector oi the Wire harness side. Connection: Violet/red (+) — Green/yellow (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 5. N0 — GO TO STEP 4. 4. MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the sensor unit 5P (Black) connector [1] oi the wire harness side and ground. Connection: Violet/red — ground V/R Is there continuity? YES — Short circuit in the Violet/red Wire N0 — GO TO STEP 5. 4-21 PG M-FI SYSTEM 5. MAP Sensor Inspection Replace the sensor unit with a known good one (page 7-15). Turn the ignition switch OFF. Connect the sensor unit 5P (Black) connector. Erase the DTCs (page 4-13). Turn the ignition switch ON. Check the MAP sensor with the H08 pocket tester. Is DTC 1-1 indicated? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — Faulty original sensor unit (MAP sensor) DTC 1-2 (MAP SENSOR HIGH VOLTAGE) NOTE ' It the ECM/PCM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) — Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. MAP Sensor System Inspection 1 Turn the ignition switch ON and engine stop switch Check the MAP sensor with the H08 pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — ~ Intermittent iailure ~ 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 4-17). Is the sensor unit power line normal? YES — GO TO STEP 3. N0 — Replace or repair the abnormal circuit. 3. MAP Sensor System Inspection 2 Turn the ignition switch OFF. Disconnect the sensor unit 5P (Black) connector [1]. Connect the sensor unit 5P (Black) connector {Siminals at the wire harness side with ajumper wire Connection: Violet/red — Green/yellow Turn the ignition switch ON. Check the MAP sensor with the H08 pocket tester. Is about 0 V indicated? YES — Faulty sensor unit (MAP sensor) N0 — GO TO STEP 4. [1] V/ R [2] 4-22 4. MAP Sensor Inspection Output Line Open Circuit Turn the ignition switch OFF. Remove the jumper wire. Disconnect the iollowing: — E16M 33F (Black) connector (NC7OOX/XA/S/SA) — PCM 33P (Gray) connector (NC700XD/SD) [1] Check ior continuity between the ECM/PCM 33F connector and sensor unit 5P (Black) connector [2] oi the wire harness side. Connection: Violet/red — Violet/red TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — Open circuit in the Violet/red Wire DTC 7-1 (ECT SENSOR LOW VOLTAGE) NOTE ' It the ECM/PCM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) — Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the ECT sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — Intermittent iailure 2. ECT Sensor Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 2P connector. Turn the ignition switch ON. Check the ECT sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 4. N0 — GO TO STEP 3. PGM-FI SYSTEM [2] [1] 4-23 PG M-FI SYSTEM 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the ECT sensor [1] terminals. Standard: 1.0 — 1.3 kn (40°C/104°F) Is the resistance within 1.0 — 1.3 m (40°C/ 104°F)? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Faulty ECT sensor 4. ECT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the ECT sensor 2P connector [1] oi the Wire harness side and ground. Connection: Pink/white — Ground Is there continuity? YES — Short circuit in the Pink/white wire N0 — Replace the ECM/POM with a known good one, and recheck. DTC 7-2 (ECT SENSOR HIGH VOLTAGE) NOTE ' NC700X/XA/S/SA: Beiore starting the inspection, check tor loose or poor contact on the ECT sensor 2P connector and ECM 33F (Black) connector, then recheck the DTC. ' NC700XD/SD: Beiore starting the inspection, check tor loose or poor contact on the ECT sensor 2P connector and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/POM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the ECT sensor with the H08 pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — Intermittent iailure [1] P/W 4-24 PGM-FI SYSTEM 2. ECT Sensor Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 2P connector [1 ]. Connect the ECT sensor 2P connector terminais at the Wire harness side with a jumper wire [2]. Connect' n: Pink/white — Green/yellow Turn the ignition switch ON. Check the ECT sensor with the H08 pocket tester. Is about 0 vindicated? YES — Inspect the ECT sensor (page 22-19). N0 — GO TO STEP 3. 3. ECT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wire. Disconnect the toiiowing: — E16M 33F (Biack) connector (NC7OOX/XA/S/SA) — PCM 33F (Gray) connector (NC700XD/SD) [1] Check tor continuities between the ECM/PCM 33F connector and ECT sensor 2P connector [2] at the wire harness side. Connection: Pink/white — Pink/white Green/yellow — Green/yellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — ~ Open circuit in the Pink/white wire ~ Open circuit in the Green/yellow wire [2] [1] [2] [1] 4-25 PG M-FI SYSTEM DTC 8-1 (TP SENSOR LOW VOLTAGE) NOTE ' NC700X/XA/S/SA: Betore starting the inspection, check tor loose or poor contact on the sensor unit 5P (Black) connector and ECM 33P (Black) connector, then recheck the DTC. ' NC700XD/SD: Betore starting the inspection, check tor loose or poor contact on the sensor unit 5P (Black) connector and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/POM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester with the throttle tully closed. Is about 0 vindicated? YES — Intermittent tailure N0 — GO TO STEP 2. 2. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 4-17). Is the sensor unit power line normal? YES — GO TO STEP 3. N0 — Replace or repair the abnormal circuit. 3. TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P (Black) connector [1]. Check tor continuity between the sensor unit 5P (Black) connector oi the wire harness side and ground. Connection: Red/yellow — Ground Is there continuity? YES — Short circuit in the Red/yellow wire N0 — GO TO STEP 4. 4-26 4. TP Sensor Output Line Open Circuit Inspection Disconnect the iollowing: — ECM 33F (Black) connector (NC7OOX/XA/S/SA) 1 — PCM 33F (Gray) connector (NC700XD/SD) [1] Check Ior continuity between the ECM/PCM 33F connector and sensor unit 5P (Black) connector [2] oi the wire harness side. Connection: Red/yellow — Red/yellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in the Red/yellow wire 5. TP Sensor Inspection Replace the sensor unit with a known good one (page 7-15). Connect the iollowing: — Sensor unit 5P connector — ECM 33F (Black) connector (NC700X/XA/S/SA) — PCM 33F (Gray) connector (NC700XD/SD) Erase the DTCs (page 4-13). Turn the ignition switch ON. Check the TP sensor With the HDS pocket tester. Is DTC 8-1 indicated? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — Faulty original sensor unit (TP sensor) DTC 8-2 (TP SENSOR HIGH VOLTAGE) NOTE ' It the ECM/PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor With the HDS pocket tester. Is about 5 vindicated? YES — GO TO STEP 3. N0 — GO TO STEP 2. 2. TP Sensor Inspection Check that the TP sensor voltage increases continuously when moving the throttle irom Iully closed to iully opened using the data list menu oi the HDS pocket tester. Is the voltage increase continuously? YES NO — Intermittent Iailure — Replace the TP sensor (sensor unit) With a known good one, and recheck. PGM-FI SYSTEM 4-27 PG M-FI SYSTEM 3. TP Sensor FIesistance Inspection Turn the ignition switch OFF. Disconnect the iollowing: — E10M 33F (Black) connector (NC7OOX/XA/S/SA) [ I — PCM 33F (Gray) connector (NC700XD/SD) [1] Measure the resistance at the ECM/PCM 33F connector oI the Wire harness side. Connection: FIed/yellow — Green/yellow Standard: 0.29 — 0.71 I! (20°C/68°F) Is the resistance within 0.29 — 0.71 to (20°C/ 68°F)? YES — GO TO STEP 4. N0 — Faulty sensor unit (TP sensor) 4. TP Sensor Power Input Voltage Inspection Connect the iollowing: — ECM 33F (Black) connector (NC700X/XA/S/SA) — PCM 33F (Gray) connector (NC700XD/SD) Disconnect the sensor unit 5P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the sensor unit 5P (Black) connector oI the Wire harness side. Connection: Vellow/red (1-) — 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. N0 — ~ Open circuitinthe Green/yellow wire ~ Open circuit in the Yellow/red wire DTC 9-1 (IAT SENSOR LOW VOLTAGE) NOTE ' It the ECM/PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. IAT Sensor System Inspection T rn the ignition switch ON and engine stop switch Check the IAT sensor With the HDS pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 2. IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Black) connector. Turn the ignition switch ON. Check the IAT sensor With the HDS pocket tester. Is about 0 vindicated? YES — GO TO STEP 3. N0 — Faulty IAT sensor 4-28 PGM-FI SYSTEM 3. IAT Sensor Voltage Output Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the IAT sensor 2P (Biack) connector [1] ol the wire harness side and ground. Connection: Gray/blue — Ground Is there continuity? YES — Short circuit in the Gray/blue Wire N0 — Replace the ECM/POM with a known good one, and recheck. 7 DTC 9-2 (IAT SENSOR HIGH VOLTAGE) NOTE ' NC700X/XA/S/SA: Beiore starting the inspection, check lor loose or poor contact on the iAT sensor 2P (Black) connector and ECM 33F (Black) connector, then recheck the DTC. ' NC700XD/SD: Beiore starting the inspection, check lor loose or poor contact on the iAT sensor 2P (Black) connector and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/POM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) —Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the IAT sensor With the HDS pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — Intermittent lailure 2. IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Biack) connector [1]. Connect the IAT sensor 2P (Black) connector terminals at the wire harness side with ajumper wire [21- @- Connect n: Gray/blue— Green/yellow ‘ Gr/Bu G/V Turn the ignition switch ON. Check the IAT sensor With the HDS pocket tester. Is about 0 vindicated? YES — Faulty iAT sensor N0 — GO TO STEP 3. [2] 4-29 PG M-FI SYSTEM 3. IAT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the iollowing: — ECM 33F (Black) connector (NC700X/XA/S/SA) [1] — PCM 33P (Gray) connector (NC700XD/SD) [1] Check tor continuity between the ECM/PCM 33F connector and IAT sensor 2P (Black) connector [2] ot the Wire harness side. Connection: Gray/blue — Gray/blue Green/yellow — Green/yellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — ~ Open circuit in the Gray/blue wire ~ Open circuit in the Green/yellow wire DTC 11-1 (vs SENSOR) NOTE ' NC700X/XA/S/SA: Belore starting the inspection, check tor loose or poor contact on the VS sensor 3P (Black) and combination meter lSP (Gray) connector, then recheck the DTC. NC700XD/SD: Belore starting the inspection, check tor loose or poor contact on the VS sensor 3P (Black) and PCM 33F (Black) connector, then recheck the DTC. It the ECM/PCM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) —Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. VS Sensor System Inspection Erase the DTCs (page 4-13). Test-ride the motorcycle above 2,000 min‘ (rpm). Stop the engine. Turn the ignition switch ON and engine stop switch Check the VS sensor with the HDS pocket tester. Is the DTC 11-1 indicated? YES — ~ NC700X/XA/S/SA: GO TO STEP 2. ~ NC700XD/SD: GO TO STEP 3. N0 — Intermittent tailure 2. Speedometer Inspection Check tor operation ot speedometer. Does the speedometer operate normally? YES — GO TO STEP 3. N0 — Inspect the speedometer (page 22-8). 2] [1] 4-30 PGM-FI SYSTEM 3. VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the VS sensor 3P (Biack) connector ot the Wire harness side. Connection: Pink/blue (4») — Green/red (—) Standard: Batteryvoltage Is there battery voltage? YES — GO TO STEP 4. N0 — ~ Open circuit in the Pink/blue wire ~ Open circuit in the Green/red wire 4. VS Sensor Signal Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the VS sensor 3P (Biack) connector [1] ot the wire harness side and ground. Connection: Pink/green — Ground Is there continuity? YES NO — Short circuit in the Pink/green wire — GO TO STEP 5. 5. VS Sensor Signal Line Open Circuit Inspection NC700X/XA/S/SA: Disconnect the combination meter 16F (Gray) connector [1]. Check tor continuity between the VS sensor 3P (Biack) connector [2] and combination meter iGP (Gray) connector ot the wire harness side. Connection: Pink/green — Pink/green NC700XD/SD: Disconnect the PCM 33F (Gray) connector [3]. Check tor continuity between the VS sensor 3P (Biack) connector [4] and PCM 33F (Gray) connector ot the Wire harness side. Connection: Pink/green — Pink/green TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 6. N0 — Open circuit in the Pink/green wire [1] G/R NC700X/XA/S/SA: [1] [2] WT J. P/G NC700XD/SD: [4] 4-31 PG M-FI SYSTEM 6. VS Sensor Inspection Replace the VS Sensor with a known good one (page 22-18). Connect the iollowing: — Combination meter iGP (Gray) connector (NC700X/XA/S/SA) — PCM 33F (Gray) connector (NC700XD/SD) Erase the DTCs (page 4-13). Test-ride the motorcycle above 2,000 min‘ (rpm). Stop the engine. Turn the ignition switch ON and engine stop switch Check the VS sensor with the HDS pocket tester. Is the DTC 11-1 indicated? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Faulty original VS sensor DTC12-1 (No.1 INJECTOR) NOTE ' NC700X/XA/S/SA: Beiore starting the inspection, check Ior loose or poor contact on the injector 2P (Gray) connector and ECM 33F (Black) connector, then recheck the DTC. ' NC700XD/SD: Beiore starting the inspection, check Ior loose or poor contact on the injector 2P (Gray) connector and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/POM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) —Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Injector System Inspection Erase the DTCs (page 4-13). T rn the ignition switch ON and engine stop switch Check the injector with the HDS pocket tester. Is the DTC 12-1 indicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 2. Injector Input Voltage Inspection Turn the ignition switch OFF. Disconnect the injector 2P (Gray) connector [1]. Turn the ignition switch ON. Measure the voltage between the injector 2P (Gray) connector oI the Wire harness side and ground. Connection: Black (4-) — Ground (—) Standard: Batteryvoltage Does the standard Voltage exist? YES — GO TO STEP 3. N0 — Open or short circuit in the Black wire 4-32 PGM-FI SYSTEM 3. Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the injector 2P (Gray) connector [1] ot Wire harness side and ground. Connection: No.1 : Pink/yellow — Ground No.2: iolet/yellow — Ground Is there continuity? YES — ~ Snort circuit in the Pink/yellow wire ~ Snort circuit in the Violet/yellow wire N0 — GO TO STEP 4. 4. lniector Resistance Inspection Measure the resistance between the in)ector 2P (Gray) connector [1] terminals. Standard: 11 — 13 Q (20°C/68°F) Is the resistance within 11 — 13.0 (217°C/68"F)? YES — GO TO STEP 5. N0 — Faulty in)ector 5. Injector Signal Line Open Circuit Inspection Disconnect the toiiowing: — ECM 33F (Biack) connector (NC7OOX/XA/S/SA) 1 — PCM 33P (Gray) connector (NC700XD/SD) [1] Check lor continuity between the ECM/PCM 33F connector and in)ector 2P (Gray) connector [2] ot the Wire harness side. Connection: No.1 : Pink/yellow — Pink/yellow No.2: Violet/yellow — Violet/yellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — ~ Open circuitinthe Pink/yeiiow Wire ~ Open circuit in the Violet/yellow wire DTC13-1 (No.2 INJECTOR) See page 4-32 4-33 PG M-FI SYSTEM DTC 21 -1 (02 SENSOR) NOTE ' NC700X/XA/S/SA: Betore starting the inspection, check Ior loose or poor contact on the O2 sensor 1P (Black) connector or 02 sensor cap and ECM 33F (Black) connector, then recheck the DTC. ' NC700XD/SD: Betore starting the inspection, check Ior loose or poor contact on the O2 sensor 1P (Black) connector or 02 sensor cap and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/PCM is replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. 02 Sensor System Inspection Turn the ignition switch ON and engine stop switch 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 HDS pocket tester. Is the DTC 21-1 indicated? YES — GO TO STEP 2. N0 — intermittent Iailure 2. 02 Sensor Short Circuit Inspection Turn the ignition switch OFF. Disconnect the 02 sensor 1P (Black) connector [1]. Check Ior continuity between the 02 sensor 1P (Black) connector oi the wire harness side and ground. Connection: White/green — Ground Is there continuity? YES — Short circuit in the White/green wire N0 — GO TO STEP 3. 3. 02 Sensor Line Open Circuit Inspection 1 Disconnect the iollowing: — ECM 33F (Black) connector (NC7OOX/XA/S/SA) 1 [ l — PCM 33F (Gray) connector (NC700XD/SD) [1] Check Ior continuity between the ECM/PCM 33F connector and Oz sensor 1P (Black) connector [2] ot the Wire harness side. Connection: White/green — White/green TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the White/green Wire \mq j) W/G [1] [2] 4-34 PGM-FI SYSTEM 4. 02 Sensor Line Open Circuit Inspection 2 Disconnect the 02 sensor cap [1]. [1] [2] Check tor continuity between the 02 sensor cap and 02 sensor 1P (Black) connector [2] oi the sensor side. Connection: Black — Black Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in the Black wire 5. 02 Sensor Inspection Replace the 02 sensor with a known good one (page 4-69). Connect the tollowing: — Oz sensor i P (Black) connector — ECM 33F (Black) connector (NC700X/XA/S/SA) — PCM 33F (Gray) connector (NC700XD/SD) Erase the DTCs (page 4-13). Start the engine and warm up the engine up to coolant temperature is 80°C (176°C). Test-ride the motorcycle and recheck the O2 sensor with the HDS pocket tester. Is the DTC 21-1 indicated? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Faulty original 02 sensor and/or 02 sensor cord DTC 29-1 (IACV) NOTE ' NC700X/XA/S/SA: Betore starting the inspection, check tor loose or poor contact on the IACV 4P (Black) connector and ECM 33F (Black) connector, then recheck the DTC. ' NC700XD/SD: Betore starting the inspection, check tor loose or poor contact on the IACV 4P (Black) connector and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/POM is replaced, pertorm the lollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Hecheck DTC Erase the DTCs (page 4-13). Turn the ignition switch ON and engine stop switch Check the IACV with the HDS pocket tester. Is the DTC 29-1 indicated? YES — GO TO STEP 2. N0 — ~ Intermittent tailure ~ Loose or poor contact on the IACV 4P (Black) connector 4-35 PG M-FI SYSTEM 2. IACV Short Circuit Inspection Turn the ignition switch OFF. Disconnect the IACV 4P (Black) connector [1 ]. Check ior continuities between the iACV 4P (Biack) connector oi the Wire harness side and ground. Connection: Yellow/green — Ground Gray/red — Ground Violet/white — Ground Pink/black — Ground Is there continuity? YES — ~ Snort circuit in the Yellow/green or Gray/red wire ~ Snort circuit in the Violet/white or Pink/ biackwire N0 — GO TO STEP 3. . IACV Open Circuit Inspection Disconnect the ioilowing: — ECM 33F (Black) connector (NC7OOX/XA/S/SA) 1 — PCM 33F (Gray) connector (NC700XD/SD) [1] Check tor continuities between the ECM/PCM 33F connector and IACV 4P (Black) connector [2] oi the wire harness side. Connection: Vellow/green — Vellow/green Gray/red — Gray/red Violet/whi — inlet/white Pink/black— Pin /b|ack TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — ~ Open circuit in the Yeilow/green or Gray/red wire ~ Open circuit in the Violet/white or Pink/ biackwire . IACV Resistance Inspection Measure the resistance at the IACV 4P (Biack) connector [1] at the motor side. Connection: A — D B — C 110 — 150 n (25°C/77°F) Is the resistance within 110 — 150 0 (25°C/77"F)? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — Faulty iACV Standard: Y/G Y/G Y/G Hi V IP/Bl V @ P/Bl A [1] 1 \‘j \\ <5 4-36 DTC 33-2 (EEPROM) NOTE O It the ECM/POM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) —Clutch Initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Hecheck DTC Erase the DTCs (page 4-13). Turn the ignition switch ON and engine stop switch Recheck the ECM EEPROM. Is the DTC 33-2 indicated? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Intermittent iailure DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE) NOTE O It the ECM/POM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Hecheck DTC Erase the DTCs (page 4-13). Turn the ignition switch ON and engine stop switch Check the bank angle sensor With the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — Intermittent iailure 2. Bank Angle Sensor Power Input Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the bank angle sensor 2P (Black) connector [1]. Check tor continuity between the bank angle sensor P (Black) connector oi the wire harness side and ground. Connection: Black/white — Ground Is there continuity? YES — GO TO STEP 3. N0 — Short circuit in the Black/white wire PGM-FI SYSTEM 4-37 PG M-FI SYSTEM 3. Bank Angle Sensor Output Line Short Circuit Inspection Disconnect the ioilowing: — ECM 33F (Black) connector (NC700X/XA/S/SA) — PCM 33F (Gray) connector (NC700XD/SD) Check tor continuity between the bank angle sensor 2P (Black) connector [1] oi the wire harness side and ground. Connection: Black/blue — Ground Is there continuity? YES — Short circuit in the Black/blue wire N0 — GO TO STEP 4. 4. Bank Angle Sensor Inspection Replace the bank angle sensor With a known good one (page 4-65). Connect the iollowing: — Bank angie sensor 2P (Black) connector — ECM 33F (Black) connector (NC700X/XA/S/SA) — PCM 33F (Gray) connector (NC700XD/SD) Erase the DTCs (page 4-13). Turn the ignition switch ON. Check the bank angie sensor With the HDS pocket tester. Is DTC 54-1 indicated? YES — Replace the ECM/PCM with a knoWn good one, and recheck. N0 — Faulty original bank angie sensor DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE) NOTE ' NC700X/XA/S/SA: Beiore starting the inspection, check lor loose or poor contact on the bank angle sensor 2P (Black) connector and ECM 33F (Black) connector, then recheck the DTC. ' NC700XD/SD: Beiore starting the inspection, check lor loose or poor contact on the bank angle sensor 2P (Black) connector and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/PCM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Flecheck DTC Erase the DTCs (page 4-13). Turn the ignition switch ON and engine stop switch Check the bank angie sensor With the HDS pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — Intermittent lailure [1] n/ Bl/Bu 4-38 PGM-FI SYSTEM 2. Bank Angle Sensor Power Input Voltage Inspection Tum the ignition switch OFF. Disconnect the bank angle sensor 2P (Biack) connector [1]. Tum the ignition switch ON. Measure the voltage at the bank angle sensor connector oi the Wire harness side and ground. Connection: Black/white (+) — Ground (—) Standard: Batteryvoltage Does the standard Voltage exist? YES — GO TO STEP 3. N0 — Open circuit in the Black/white wire 3. Bank Angle Sensor Output Line Short Circuit Inspection Tum the ignition switch OFF. Disconnect the toiiowing: — ECM 33F (Black) connector (NC700X/XA/S/SA) — PCM 33F (Gray) connector (NC700XD/SD) Check tor continuity between the bank angle sensor 2P (Black) connector [1] oi the wire harness side and ground. Connection: Black/blue — Ground Is there continuity? YES — Short circuit in the Black/blue wire N0 — GO TO STEP 4. 4. Bank Angle Sensor Output Line Open Circuit Inspection Check lor continuity between the ECM/PCM 33F connector [1] and bank angle sensor 2P (Biack) connector [2] ot the wire harness side. Connection: Black/blue — Black/blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — ~ Inspect the bank angle sensor (page 4- 66). ~ Repiace the ECM/PCM With a known good one, and recheck. N0 — Open circuit in the Black/blue wire [2] 4-39 PG M-FI SYSTEM DTC 84-1 (CPU IN THE PCM MALFUNCTION) (NC7OOXD/SD) NOTE ' It the PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 4-13). Check the DTC With the HDS pocket tester. Is DTC 84-1 indicated? YES — Replace the PCM With a known good one, and recheck. N0 — Intermittent Iailure DTC 86-1 (METER COMMUNICATION MALFUNCTION) NOTE ' NC700X/XA/S/SA: Beiore starting the inspection, check Ior loose or poor contact on the combination meter lGP (Gray) connector and ECM 33F (Black) connector, then recheck the DTC. ' NC700XD/SD: Beiore starting the inspection, check Ior loose or poor contact on the combination meter lGP (Gray) connector and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Flecheck DTC Erase the DTCs (page 4-13). Turn the ignition switch ON and engine stop switch Check the meter communication with the H08 pocket tester. Is the DTC 85-1 indicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 2. Combination Meter Serial Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the tollowing: — Combination meter lGP (Gray) connector [1] — ECM 33P (Black) connector (NC700X/XA/S/SA) — PCM 33P (Gray) connector (NC700XD/SD) Check tor continuity between the combination meter lGP (Gray) connector oi the wire harness side and ground. Connection: FIed/blue — Ground Is there continuity? YES — Short circuit in the Red/blue wire N0 — GO TO STEP 3. 4-40 3. Combination Meter Serial Line Open Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the combination meter 16F (Gray) connector [1] and ECM/POM 33F connector [2] of the wire harness side. Connection: Fled/blue — Fled/blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in the Red/biue wire 4. Combination Meter Serial Line Output Voltage Inspection Turn the ignition switch OFF. Connect the combination meter 16F (Gray) connector. Turn the ignition switch ON while pushing and holding combination meterA button [1] and B button [2] over 10 seconds. NOTE The combination meter enters the communication diagnostic mode. Measure the voitage at the ECM/POM 33F connector [1] ol the wire harness side and ground. Connection: Fled/blue (4-) — Ground (—) Standard: 8 V or more (Every 5 seconds) TOOL: Test probe 07ZAJ-RDJA110 Does the standard Voltage exist? YES — GO TO STEP 5. NO — inspect the combination meter (page 22- a). 5. ECM Serial Line Output Voltage Inspection Turn the ignition switch OFF. Disconnect the combination meter 1GP (Gray) connector. Connect the tollowing: — ECM 33F (Black) connector (NC7DOX/XA/S/SA) — PCM 33F (Gray) connector (NC7DOXD/SD) Remove the DLC [1] from the battery box. Short the DLC terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 PGM-FI SYSTEM [1] [2] EL PG M-FI SYSTEM Rotate and hold the throttle grip [1] to the hilly open position. Turn the ignition sWitch ON while holding the throttle grip at the tully open position over 10 seconds. NOTE The ECM enters the communication diagnostic mode. Measure the voltage at the combination meter iSP (Gray) connector [1] oi the wire harness side and ground. Connect' n: Red/blue (ad—Ground (—) Standard: 8 V or more (Every 5 seconds) Does the standard Voltage exist? YES — inspect the combination meter (page 22- 8 . N0 — Replace the ECM/POM with a known good one, and recheck. 7 DTC 87-1 (EOP SWITCH MALFUNCTION) NOTE ' NC700X/XA/S/SA: Before starting the inspection, check tor loose or poor contact on the combination meter iGP (Gray) connector, EOP switch iP (Gray) connector and ECM 33F (Black) connector, then recheck the DTC. NC700XD/SD: Before starting the inspection, check tor loose or poor contact on the combination meter iGP (Gray) connector, EOP switch iP (Gray) connector and PCM 33F (Gray) connector, then recheck the DTC. ' It the ECM/POM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23—6) —C|utch initialize Learning Procedure (NC7ODXD/ SD) (page 12-120) 1. EOP Switch System Inspection Erase the DTCs (page 4-13). Turn the ignition switch ON and engine stop switch Check the EOP switch with the HDS. Is the DTC 87-1 indicated? YES — GO TO STEP 2. N0 — Intermittent tailure 4-42 PGM-FI SYSTEM 2. EOP Switch Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the tollowing: — EOP switch 1P (Gray) connector [1] — ECM 33F (Black) connector (NC7OOX/XA/S/SA) 2 — PCM 33P (Gray) connector (NC700XD/SD) [2] Check tor contlnulty between the EOP switch 1P (Gray) connector and ECM/PCM 33P connector oi the we harness side. Connection: Light green — Light green TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 3. N0 — Open circuit in the Light green wire 3. EOP Switch Inspection Replace the EOP switch with a known good one. Connect the ioIIowing: — EOP switch 1P (Gray) connector — ECM 33P (Black) connector (NC700X/XA/S/SA) — PCM 33P (Gray) connector (NC700XD/SD) Erase the DTCs (page 4-13). Turn the ignition switch ON. Check the EOP switch with the HDS. Is the DTC 87-1 indicated? YES — Replace the ECM/PCM with a known good one, and recheck. N0 — Faulty onginal EOP switch MIL TROUBLESHOOTING MIL 1 BLINK (MAP SENSOR) NOTE ' It the ECM/PCM is replaced, periorm the ioIIowing: — Key Reglstration Procedure (page 23-6) — Clutch lnitlalize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Sensor Unit Power Line Inspection Check the sensor unit power llne inspection (page 4-19). Is the sensor unit power line normal? YES — GO TO STEP 2. N0 — Replace or repair the abnormal circult. 4-43 PG M-FI SYSTEM 2. MAP Sensor Output Voltage Inspection 1 T rn the ignition switch ON and engine stop switcn Measure the voltage at the test harness terminals. Connection: NC7OOX/XA/S/SA: 32 (+) — 22 H NC7OOXD/SD: 332 (+) — 322 H Standard: 0.50 — 3.41 V (20°C/68°F) Is the voltage within 0.50— 3.41 V(2l7"C/68°F)? YES — Intermittent lailure N0 — GO TO STEP 3. 3. MAP Sensor Output Voltage Inspection 2 Turn the ignition switch OFF. Disconnect the sensor unit 5P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the sensor Unit SP (Biack) connector ol the Wire harness side. Connection: Violet/red (+) — Green/yellow (—) Standard. 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — Faulty sensor unit (MAP sensor) N0 — GO TO STEP 4. 4. MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the sensor unit 5P (Biack) connector [1] ol the wire harness side and ground. Connection: Violet/red — Ground Is there continuity? YES — Short circuit in the Violet/red Wire N0 — GO TO STEP 5. 32 or B32 I 122 or B22 (E [1] [1] V/R 4-44 PGM-FI SYSTEM 5. MAP Sensor Output Line Open Circuit Inspection Check tor continuity between the ECM test harness and sensor unit 5P (Black) connector [1] oi the wire harness side. Connection: NC7OOX/XA/S/SA: 32 — Violet/red NC7OOXD/SD: 332 — Violet/red Is there continuity? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Open circuit in the Violet/red Wire MIL 7 BLINKS (ECT SENSOR) NOTE ' NC700X/XA/S/SA: Beiore starting the inspection, check lor loose or poor contact on the ECT sensor 2P connector and ECM 33P (Black) connector, then recheck the MIL blinking. NC700XD/SD: Beiore starting the inspection, check lor loose or poor contact on the ECT sensor 2P connector and PCM 33F (Gray) connector, then recheck the MIL blinking. ' It the ECM/POM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) —Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. ECT Sensor Output Voltage Inspection Connect the ECM test harness to the ECM/POM 33F connector(s). — NC700X/XA/S/SA (page 4-13) — NC7OOXD/SD(page4-i4) Turn the ignition switch ON and engine stop switch Measure the voltage at the ECM test harness terminals. Connection: NC7OOX/XA/S/SA: 20 (+) — 22 H NC7OOXD/SD: 320 (+) — 322 H Standard: 2.7 — 3.1 V (20°C/68°F) Is the voltage within 2.7— 3.1 V(2l7"C/58°F)? YES — Intermittent lailure N0 — GO TO STEP 2. 4-45 PG M-FI SYSTEM 2. ECT Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 2P connector [1 ]. Turn the ignition switch ON. Measure the voitage at the ECT sensor 2P connector oi the Wire harness side. Connection: Pink/white (+) — Green/yellow (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 3. N0 — GO TO STEP 4. 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the ECT sensor [1] terminals. Standard: 1.0 —1.3 kn (40°C/104°F) Is the resistance within 1.0 — 1.3 m (40°C/ 104°F)? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Faulty ECT sensor 4. ECT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Check lor continuities between the ECM test harness and ECT sensor 2P connector [1] oi the wire harness side. Connection: NC7OOX/XA/S/SA: 20 — Pink/white 22 — Green/yellow NC7OOXD/SD: BZD — Pink/white 322 — Green/yellow Are there continuities? YES — GO TO STEP 5. N0 — ~ Open circuit in the Pink/white wire ~ Open circuit in the Green/yeliow wire [1] 22 or 522' ' 4-46 5. ECT Sensor Output Line Short Circuit Inspection Check tor continuity between the ECT sensor 2P connector [1] ol the wire harness side and ground. Connection: Pink/white — Ground Is there continuity? YES NO — Short circuit m the Pink/white wwre — Replace the ECM/PCM with a known good one, and recheck. MIL 8 BLINKS (TP SENSOR) 1. Sensor Unit Power Line Inspection Check the sensor unit power Ilne inspection (page 4-19). Is the sensor unit power line normal? YES — GO TO STEP 2. N0 — Replace or repair the abnormal drum. 2. TP Sensor Output Voltage Inspection Turn the ignitlon switch ON and engine stop switch Measure the TP sensor output voltage at the ECM test harness terminals. Connection: NC7OOX/XA/S/SA: 33 (+) — 22 H NC7DOXD/SD: 333 (+) — 322 H Standard: 0.29 — 0.71 V (throttle fully closed) 4.13 — 4.76 V (throttle lully opened) Is there standard voltage? YES — Intermlttent lailure N0 — GO TO STEP 3. 3. TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P (Black) connector [1]. Check tor continuity between the sensor unit 5P (Black) connector oi the wire harness side and ground. Connection: Red/yellow — Ground Is there continuity? YES NO — Short circuit m the Red/yellow wire — GO TO STEP 4. PGM-FI SYSTEM [1] l l 22 or 822 EB 33 or BBS 4-47 PG M-FI SYSTEM 4. TP Sensor Output Line Open Circuit Inspection Check tor continuity between the sensor unit 5P (Black) connector [l] at the wire harness side and ECM test harness. Connection: NC7OOX/XA/S/SA: 33 — Red/yellow NC7OOXD/SD: 333 — Red/yellow Is there continuity? YES — Faulty sensor unit (TP sensor) N0 — Open circuit in the Red/yellow wire MIL 9 BLINKS (IAT SENSOR) NOTE ' NC700X/XA/S/SA: Betore starting the inspection, check tor loose or poor contact on the lAT sensor 2P (Black) connector and ECM 33F (Black) connector, then recheck the MIL blinking. ' NC700XD/SD: Betore starting the inspection, check tor loose or poor contact on the lAT sensor 2P (Black) connector and PCM 33F (Gray) connector, then recheck the MIL blinking. ' It the ECM/POM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. lAT Sensor Output Voltage Inspection Connect the ECM test harness to the ECM/POM 33F connector(s). — NC7OOX/XA/S/SA (page 4-13) — NC7OOXD/SD(page 4-14) Turn the ignition switch ON and engine stop switch Measure the voltage at the ECM test harness terminals. Connection: NC7OOX/XA/S/SA: 9 (+) — 22 (—) NC7OOXD/SD: as (+) — 322 (—) Standard: 2.7 — 3.1 V (20°C/68°F) Is the voltage within 2.7 — 3.1 V(2l7"C/58°F)? YES — Intermittent tailure N0 — GO TO STEP 2. i" «iiwnx 4-48 2. IAT Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Biack) connector [1]. Turn the ignition switch ON. Measure the voltage at the IAT sensor 2P (Biack) connector oi the Wire harness side. Connection: Gray/blue (+) — Green/yellow (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 3. N0 — GO TO STEP 4. . IAT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the iAT sensor terminals. Standard: 2.2 — 2.7 kn (20°C/68°F) Is the resistance within 2.2 — 2.7 k!) (20°C/68"F)? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Faulty iAT sensor . IAT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the IAT sensor 2P (Biack) connector [1] ol the wire harness side and ECM test harness. Connection: NC7OOX/XA/S/SA: 9 — Gray/blue 22 — Green/yellow NC7OOXD/SD: BQ — Gray/blue B22 — Green/yellow Is there continuity? YES — GO TO STEP 5. N0 — ~ Open circuit in the Gray/biue wire ~ Open circuit in the Green/yellow wire PGM-FI SYSTEM [1] 4-49 PG M-FI SYSTEM 5. IAT Sensor Output Line Short Circuit Inspection Check tor continuity between the IAT sensor 2P (Black) connector [1] ot the wire harness side and ground. Connection: Gray/blue — Ground Is there continuity? YES — Short circuit in the Gray/blue Wire N0 — Replace the ECM/PCM with a known good one, and recheck. MIL 11 BLINKS (VS SENSOR) (NC700X/ XA/S/SA) NOTE Belore starting the inspection, check tor loose or poor contact on the VS sensor 3P (Black) connector and combination meter 1GP (Gray) connector, then recheck the MIL blinking. 1. Speedometer Inspection Check tor operation ot speedometer. Does the speedometer operate normally? YES — GO TO STEP 2. N0 — gnspect the combination meter (page 22- . VS Sensor Pulse Inspection Support the motorcycle securely and raise the rear wheel all the ground. Turn the ignition switch ON and engine stop switch Measure the voltage between the combination meter 1GP (Gray) connector [1] and ground while slowly turning the rear wheel by hand. Connection: Pink/green (1-) — Ground ( a) Standard: Repeat 0 to 5 V Is the indicated voltage at the standard Value? YES — inspect the combination meter (page 22- 8 . N0 — GO TO STEP 3. . VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the VS sensor 3P (Black) connector ot the Wire harness side. Connection: Pink/blue (+) — Green/red ( a) Standard: Batteryvoltage Is there battery voltage? YES — GO TO STEP 4. N0 — - Open circuitinthe Pink/blue wire - Open circuit in the Green/red wire [1] La i i ) Gr/Bu [1] P/Bu G/R 4-50 4. VS Sensor Signal Line Open Circuit Inspection PGM-FI SYSTEM Turn the ignition switch OFF. [2] Disconnect the combination meter 1GP (Gray) connector [1]. Check tor continuity between the VS sensor 3P (Black) connector [2] and combination meter iGP (Gray) connector oi the wire harness side. Connection: Pink/green — Pink/green Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in the Pink/green wire 5. VS Sensor Signal Line Short Circuit Inspection Check tor continuity between the VS sensor 3P (Black) connector [1] ot the wire harness side and ground. Connection: Pink/green — Ground Is there continuity? YES — Short circuit in the Pink/green wire N0 — Faulty VS sensor [1] MIL 11 BLINKS (VS SENSOR) (NC700XD/SD) NOTE ' Betore starting the inspection, check tor loose or poor contact on the VS sensor 3P (Black) connector and PCM 33F (Black) connector, then recheck the MIL blinking. ' It the PCM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. VS Sensor Pulse Inspection Support the motorcycle securely and raise the rear wheel ott the ground. Connect the ECM test harness to the PCM 33F connectors (page 4-14). Turn the ignition switch ON with the engine stop switch Measure the voltage at the ECM test harness terminal and ground while slowly turning the rear wheel by hand. Connection: A32 (4») — Ground (—) Standard: Repeat 0 to 5 V Is the indicated voltage at the standard value? YES — Intermittent tailure N0 — GO TO STEP 2. 4-51 PG M-FI SYSTEM 2. VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage at the VS sensor 3P (Black) connector oI the Wire harness side. Connection: Pink/blue (+) — Green/red (—) Standard: Batteryvoltage Is there battery voltage? YES — GO TO STEP 3. N0 — ~ Open circuitinthe Pink/blue wire ~ Open circuit in the Green/red wire 3. VS Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF. Check Ior continuity between the VS sensor 3P (Black) connector [1] oi the wire harness side and ECM test harness. Connection: A32 — Pink/green Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Pink/green wire 4. VS Sensor Signal Line Short Circuit Inspection Check Ior continuity between the VS sensor 3P 1 (Black) connector [1] oi the wire harness side and [ 1 ground. Connection: Pink/green — Ground 1,. r .AE l Is there continuity? YES — Short circuit in the Pink/green wire N0 — GO TO STEP 5. 5. VS Sensor Inspection Replace the VS sensor With a known good one (page 22-18). Erase the DTCs (page 4-13). Test-ride the motorcycle above 2000 min‘ (rpm). Stop the engine and recheck the MIL blinking. Does the MIL blink 11 times? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty original VS sensor 4-52 PGM-FI SYSTEM MIL 12 BLINKS (No.1 INJECTOR) NOTE ' NC700X/XA/S/SA: Betore starting the inspection, check Ior loose or poor contact on the injector 2P (Gray) connector and ECM 33P (Black) connector, then recheck the MIL blinking. ' NC700XD/SD: Betore starting the inspection, check Ior loose or poor contact on the injector 2P (Gray) connector and PCM 33F (Gray) connector, then recheck the MIL blinking. ' It the ECM/POM is replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Injector Input Voltage Inspection Turn the ignition switch OFF. Disconnect the in)ector 2P (Gray) connector [1]. Turn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P (Gray) connector ot the Wire harness side and ground. Connection: Black (1-) — Ground (—) Standard: Batteryvoltage Does the standard Voltage exist? YES — GO TO STEP 2. N0 — Open circuit in the Black wire 2. Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the injector 2P (Gray) connector [1] ot the wire harness side and ground. Connection: No.1 : Pink/yellow — Ground No.2: iolet/yellow — Ground Is there continuity? YES — ~ Short circuit in the Pink/yellow wire ~ Short circuit in the Violet/yellow wire N0 — GO TO STEP 3. 3. lniector Resistance Inspection Measure the resistance at the injector [1] terminals. [1] Standard: 11 — 13 Q (20°C/68°F) Is the resistance within 11 — 13.0 (20°C/68"F)? YES — GO TO STEP 4. N0 — Faulty inyector ‘6 1:1 4-53 PG M-FI SYSTEM 4. Injector Signal Line Open Circuit Inspection Connect the ECM test harness to the ECM/POM 33F connector(s). — NC7OOX/XA/S/SA (page 4-13) — NC7OOXD/SD(page4-i4) Check ior continuity between the ECM test harness and injector 2P (Gray) connector [1] ol the wire harness side. Connection: NC7OOX/XA/S/SA: No.1: 5 — Pink/yellow No.2: 4 — Violet/yellow NC7OOXD/SD: No.1: 35— Pink/yellow No.2: 34 — Violet/yellow Is there continuity? YES — Replace the ECM/POM with a known good one, and recheck. N0 — ~ Open circuitinthe Pink/yeilow wire ~ Open circuit in the Violet/yellow wire MIL 13 BLINKS (No.2 INJECTOR) See page 4-53 MIL 21 BLINKS (Oz SENSOR) NOTE ' NC700X/XA/S/SA: Beiore starting the inspection, check lor loose or poor contact on the O2 sensor 1P (Black) connector or 02 sensor cap and ECM 33F (Biack) connector, then recheck the MIL blinking. NC700XD/SD: Eeiore starting the inspection, check lor loose or poor contact on the O2 sensor 1P (Black) connector or 02 sensor cap and PCM 33F (Gray) connector, then recheck the MIL blinking. ' It the ECM/POM is replaced, perlorm the iollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. 02 Sensor System Inspection Turn the ignition switch ON and engine stop switch Start the engine and warm up the engine up to coolant temperature is 80°C (176°F). Test-ride the motorcycie and recheck the MIL blinking. Does the MIL blink 21 times? YES — GO TO STEP 2. N0 — intermittent lailure 4-54 2. 02 Sensor Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the 02 sensor 1P (Black) connector [1]. Check tor continuity between the 02 sensor 1P (Biack) connector oi the wire harness side and ground. Connection: White/green — Ground Is there continuity? YES — Short circuit in the White/green wire N0 — GO TO STEP 3. 3. 02 Sensor Line Open Circuit Inspection 1 Connect the ECM test harness to the ECM/POM 33F connector(s). — NC700X/XA/S/SA (page 4-13) — NC700XD/SD(page4-i4) Check for continuity between the ECM test harness and 02 sensor 1P (Black) connector [1] oi the wire harness side. Connection: NC7OOX/XA/S/SA: 29 — White/green NC7OOXD/SD: 329 — White/green Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the White/green Wire 4. 02 Sensor Line Open Circuit Inspection 2 Disconnect the 02 sensor cap [1]. Check tor continuity between the 02 sensor cap and 02 sensor 1P (Black) connector [2] oi the sensor side. Connection: Black — Black Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in the Black wire PGM-FI SYSTEM [1] 29 or 529 [1] [2] 4-55 PG M-FI SYSTEM 5. 02 Sensor Inspection Replace the 02 sensor with a known good one (page 4-69). Disconnect the ECM test harness and connect the ECM/POM connector(s). Erase the DTCs (page 4-13). Start the engine and warm up the engine up to coolant temperature l5 80°C (176°F). Test-rlde the motorcycle and recheck tne MIL blinking. Does the MIL blink 21 times? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Faulty onginal Oz sensor MIL 29 BLINKS (IACV) NOTE ' NC700X/XA/S/SA: Beiore starting the inspectlon, check Ior loose or poor contact on the IACV 4P (Black) connector and ECM 33F (Black) connector, then recheck the MIL bllnking. NC700XD/SD: Beiore starting the inspectlon, check Ior loose or poor contact on the IACV 4P (Black) connector and PCM 33F (Gray) connector, tnen recheck tne MIL bllnking. ' It the ECM/POM is replaced, perlorm the Io|lowing: — Key Reglstration Procedure (page 23-6) —Clutch lnitlalize Learning Procedure (NC700XD/ SD) (page 12-120) 1. IACV Resistance Inspection Turn the ignition switch OFF. Disconnect the IACV 4P (Black) connector [1 ]. Measure the reslstance at the IACV 4P (Black) connector at the motor slde. Connection: A — D B — C Standard: 110 — 150 n (25°C/77°F) Is the resistance within 110 — 150 a (25 “C/77"F)? YES — GO TO STEP 2. N0 — Faulty lACV [1] 44/ \‘j my, to 4-56 2. IACV Short Circuit Inspection Check tor contmuwties between the \ACV 4P (Stack) connector [1] ot the wire harness side and ground. Connection: Gray/red — Ground Yellow/green — Ground Violet/white — Ground Pink/black — Ground Is there continuity? YES — ~ Short circuit in the Yetlow/green or Gray/red wire ~ Short circuit in the Violet/white or Pink/ btack wire N0 — GO TO STEP 3. . IACV Open Circuit Inspection Connect the ECM test harness to the ECM/POM 33F connector(s). — NC700X/XA/S/SA (page 4-13) — NC7OOXD/SD (page 4-1 4) Check tor continuitwes between the ECM test harness and IACV 4P (Black) connector [1] oi the wire harness swde. Connection: NC7OOX/XA/S/SA: 17 — Yellow/green 15 — Gray/red 16 — Violet/white 3 — Pink/black NC7OOXD/SD: B17 — Yellow/green B15 — Gray/red B16 — Violet/white B3 — PInk/black Is there continuity? YES — Replace the ECM/POM with a known good one, and recheck. N0 — ~ Open circuit in the Yeltow/green or Gray/red wire ~ Open circuit 1n the Vwolet/white or Pink/ btack wire PGM-FI SYSTEM Y/G 150rB15 1sarB16 [1] 4-57 PG M-FI SYSTEM MIL 54 BLINKS (BANK ANGLE SENSOR) NOTE ' NC700X/XA/S/SA: Betore starting the inspection, check tor loose or poor contact on the bank angle sensor 2P (Black) connector and ECM 33F (Black) connector, then recheck the MIL blinking. ' NC700XD/SD: Betore starting the inspection, check tor loose or poor contact on the bank angle sensor 2P (Black) connector and PCM 33F (Gray) connector, then recheck the MIL blinking. ' ii the ECM/PCM is replaced, pertorm the iollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Bank Angle Sensor Power Input Voltage Inspection Turn the ignition switch OFF. Disconnect the bank angle sensor 2P (Black) connector [1]. Turn the ignition switch ON and engine stop switch Measure the voltage at the bank angle sensor 2P (Black) connector oi the wire harness side and ground. Connection: Black/white (4») — Ground (—) Standard: Batteryvoltage Does the standard Voltage exist? YES — GO TO STEP 2. N0 — Open circuit in the Black/white wire 2. Bank Angle Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the tollowing: — ECM 33P (Black) connector (NC700X/XA/S/SA) — PCM 33P (Gray) connector (NC700XD/SD) Check ior continuity between the bank angle sensor 2P (Black) connector [1] oi the wire harness side and ground. Connection: Black/blue — Ground Is there continuity? YES — Short circuit in the Black/blue wire N0 — GO TO STEP 3. [1] if/ i Bl/Bu 4-58 3. Bank Angle Sensor Output Line Open Circuit Inspection PGM-FI SYSTEM Connect the ECM test harness to the ECM/PCM 1 33F connector(s). [ 1 — NC700X/XA/S/SA (page 4-13) — NC700XD/SD(page4-l4) Check tor continuity between the ECM test harness and bank angle sensor 2P (Black) connector [l] at the wwre harness side. Connection: NC7OOX/XA/S/SA: 21 — Black/blue NC7DOXD/SD: 321 — Black/blue Is there continuity? YES — GO TO STEP 4. N0 — Open circuit ln the Black/blue wire 4. Bank Angle Sensor Inspection lnspect the bank angle sensor (page 4-66). Is the bank angle sensor operation normal? YES — Replace the ECM/PCM with a known good one, and recheck. No — Faulty bank angle sensor MIL 84 BLINKS (CPU IN THE PCM MALFUNCTION) (NC7OOXD/SD) NOTE O It the PCM l5 replaced, pericrm the lollowing: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learnlng Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 4-13). Turn the lgnlticn switch ON with the engine stop swwtch "(7", and check the ML blinking. Does the MIL blink 84 times? YES — Replace the PCM wwth a known good one. and recheck. N0 — Intermlttent lailure 4-59 PG M-FI SYSTEM MIL 86 BLINKS (METER COMMUNICATION MALFUNCTION) NOTE ' NC700X/XA/S/SA: Betore starting the inspection, check Ior loose or poor contact on the combination meter 16F (Gray) connector and ECM 33F (Black) connector, then recheck the MIL blinking. ' NC700XD/SD: Betore starting the inspection, check Ior loose or poor contact on the combination meter 16F (Gray) connector and PCM 33F (Gray) connector, then recheck the MIL blinking. ' it the ECM/POM is replaced, pertorm the iollowing: — Key Registration Procedure (page 23—6) —Clutch lnitialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. Combination Meter Serial Line Output Voltage Inspection Connect the ECM test harness to the ECM/POM 33F connector(s). — NC700X/XA/S/SA (page 4-13) — NC700XD/SD(page4—14) Disconnect the iollowing: — ECM 33F (Black) connector (NC7DOX/XA/S/SA) — PCM 33F (Gray) connector (NC7DOXD/SD) Turn the ignition switch ON and engine stop switch while pushing and holding combination meter A button [1] and B button [2] over 10 seconds. NOTE The combination meter enter the communication diagnostic mode. Measure the voltage at the ECM test harness terminal and ground. Connection: NCTOOX/XA/S/SA: 13 (+) — Ground (—) NCTOOXD/SD: B13 (1-) — Ground (—) if) Standard: 3 V or more (Every 5 seconds) 13 or 313 Does the standard Voltage exist? 77 YES — GO TO STEP 2. NO — inspect the combination meter (page 22- 8 . 2. ECM/POM Serial Line Output Voltage Inspection Turn the ignition switch OFF. Disconnect the combination meter 16F (Gray) connector. Connect the iollowing: — ECM 33F (Black) connector (NC7DOX/XA/S/SA) — PCM 33F (Gray) connector (NC7DOXD/SD) Remove the DLC [1] from the battery box. Short the DLC terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 4-60 PGM-FI SYSTEM Rotate and hoid the throttle grip [1] to the hilly open position. Turn the ignition sWitch ON while holding the throttie grip at the tully open position over 10 seconds. NOTE The ECM/PCM enters the communication diagnostic mode. Measure the voltage at the combination meter 16F (Gray) connector [1] at the wire harness side and ground. Connect' n: Red/blue (4-) — Ground (—) Standard: 8 V or more (Every 5 seconds) Does the standard Voltage exist? YES — inspect the combination meter (page 22- 8 . N0 — Replace the ECM/PCM with a known good one, and recheck. 4-61 PG M-FI SYSTEM MIL 87 BLINKS (EOP SWITCH MALFUNCTION) NOTE ' NC700X/XA/S/SA: Betore starting the inspection, check tor loose or poor contact on the combination meter 1GP (Gray) connector, EOP switch 1P (Gray) connector and ECM 33P (Black) connector, then recheck the MIL blinking. ' NC700XD/SD: Betore starting the inspection, check tor loose or poor contact on the combination meter 1GP (Gray) connector, EOP switch 1P (Gray) connector and PCM 33F (Gray) connector, then recheck the MIL blinking. ' It the ECM/POM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) —C|utch initialize Learning Procedure (NC700XD/ SD) (page 12-120) 1. EOP Switch Output Line Open Circuit Inspection Connect the ECM test harness to the ECM/POM 33F connector(s). — NC7OOX/XA/S/SA (page 4-13) — NC7OOXD/SD(page4-14) Disconnect the EOP switch 1P (Gray) connector [1]. Check tor continuity between the ECM test harness and the EOP switch 1P (Gray) connector ot the Wire harness side. Connection: NC7OOX/XA/S/SA: 31 — Light green NC7OOXD/SD: 331 — Light green TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 2. N0 — Open circuit in the Light green wire 2. EOP Switch Inspection Replace the EOP sWitch With a known good one (page 22-20). Erase the DTCs (page 4-13). Turn the ignition switch ON and engine stop switch Check the ML blinking Does the MIL blink 87 times? YES — Replace the ECM/POM with a known good one, and recheck. N0 — Faulty original EOP switch 31 or BS1 4-62 MIL CIRCUIT TROUBLESHOOTING NC700X/XA/S/SA: NC7DUXD/SD: NOTE ' It the ECM/PCM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) — Clutch initialize Learning Procedure (NC700XD/ SD) (page 12-120) Check that the ML comes on tor 2 seconds and goes oft when the ignition SWitch is turned ON and engine stop switch It the MIL dose not come on at ali, inspect the combination meter (page 22-10). It the MIL [1] and engine oil pressure indicator [2] are stay on, and the tachometer, high cooiant temperature indicator and HISS indicator do not come on, inspect the TXD/RXD line (page 22-11). It the ML [3] and engine oil pressure indicator [4] stay on, the shift indicator "—" [5] is blinking, and the tachometer, high cooiant temperature indicator and HiSS indicator do not come on, inspect the TXD/RXD line (page 22-11). lithe MIL stays on, check as toliows: Turn the ignition switch OFF. Remove the iollowing: — Shroud/side cover (NC700X/XA) (page 2-14) — Side cow| (NC7OOS/SA) (page 2-13) — Luggage box lid/hinge assemny (NC7OOXD/SD) (page 2-19) Disconnect the iollowing: — ECM asp (Black) connector (NC7OOX/XA/S/SA) [1 i — POM 33F (Gray) connector (NC700XD/SD) [1] Check tor continuity between the ECM/PCM 33F connector oi the wire harness side and ground. CONNECTION: Brown — Ground STANDARD: No conti uity TOOL: Test probe 07ZAJ-HDJA110 Ii there is continuity, check ior short circuit in the Brown wire between the DLC and ECM/PCM. Ii there is no continuity, Replace the ECM/PCM with a known good one, and recheck. PGM-FI SYSTEM NC7OOX/XA/S/SA: [1] [3] 4-63 PG M-FI SYSTEM FUEL CUT RELAY INSPECTION Remove the maintenance lid (page 21—6). Open the luse/relay box cover and remove the luel cut relay [1]. Connect a ohmmeter to the luel cut relay [1] terminals. Connect a 12 V battery to the luel cut relay terminals as shown. There should be continuity only when 12 V battery is connected. ll there is no continuity only when the 12 V battery is connected, replace the iuel cut relay. ECT SENSOR REMOVAL/INSTALLATION Drain the coolant (page 8—6). Remove me ECT Disconnect the ECT sensor 2P connector [1]. sensm WW9 me Remove the ECT sensor [2] and O—ring [3]. engine is cold. Install a new O-ring onto the ECT sensor and install them. Tighten the ECT sensor to the speciiied torque. TORQUE: 12 NM (1.2 kgf—m, 9 Ibf—l‘t) Connect the ECT sensor 2P connector. Fill the cooling system with recommended coolant (page 8-6). 4-64 PGM-FI SYSTEM BANK ANGLE SENSOR REMOVAL/INSTALLATION Remove the luggage box (page 2-19). Remove the bolts [1] and ECM box [2] from the frame. Disconnect the bank angle sensor 2P (Black) connector [1]- Remove the bank angle sensor mounting bolts [2] and bank angle sensor [3]. Installation is in the reverse order ol removal. NOTE Install the bank angle sensor With its "UP" mark [1] E lacing up. TORQUE: Bank angle sensor mounting bolt: 10 N-m (1.0 kgf—m, 7 Ibl-ft) 4-65 PG M-FI SYSTEM SYSTEM INSPECTION WITH HDS POCKET TESTER Connect the HDS pocket tester (page 4-12). Remove the bank angle sensor (page 4-65). 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 Read the voltage With the HDS pocket tester. STANDARD: 7.0 — 3.8 V Incline the bank angle sensor approximately 60° to the left or right with keeping the ignition switch ON. Read the voltage With HDS pocket tester. STANDARD: 0.40 — 0.34 V SYSTEM INSPECTION WITH ECM TEST HARNESS Connect the ECM test harness to the ECM/POM 33F connector(s). — NC700X/XA/S/SA (page 4-13) — NC700XD/SD (page 4-14) Remove the bank angle sensor (page 4-65). Connect the bank angle sensor 2P (Black) connector. Place the bank angle sensor horizontal as shown. Turn the ignition switch ON and engine stop switch Measure the output voltage at the ECM test harness [1] terminals. CONN ECTION: NC700X/XA/S/SA: 21 (+) - 5 H NC700XD/SD: 321 (+) — BS (—) STANDARD: 7.0 — 3.8 V Incline the bank angle sensor approximately 60° to the left or right With k ping the ignition sWitch ON and engine stop switch ' " Measure the output voltage at the ECM test harness terminals. CONN ECTION: NC700X/XA/S/SA: 21 (+) - 5 H NC700XD/SD: 321 (+) — BS (—) STANDARD: 0.40 — 0.34 V 60" BANK ANGLE POSITION HORIZONTAL © approximately 60" [1] 21‘or 321 approximately 60" 4-66 PGM-FI SYSTEM ECM (NC700X/XA/S/SA)/PCM (NC700XD/SD) REMOVAL/INSTALLATION (NC7OOX/ XA/S/SA) Remove the shroud/side cover (NC7OOX/XA) (page 2- 14). Remove the side cowl (NC7OOS/SA) (page 2-13). Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector [1]. Release the band [2] lrom the ECM and remove the ECM from the ECM box. Installation is in the reverse order oi removal. NOTE It the ECM is replaced, perform the Key Registration Procedures (page 23-6). REMOVAL/INSTALLATION (NC700XD/ SD) Remove the luggage box lid/hinge assembly (page 2- 19). Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector [1] and PCM 33F (Gray) connector [2]. Release the band [3] from the PCM and remove the PCM from the ECM box. Installation is in the reverse order oi removal. NOTE - If the PCM is replaced, perform the iollowing: — Key Registration Procedure (page 23—6) — Clutch Initialize Learning Procedure (page 12- 120) 4-67 PG M-FI SYSTEM ECM/PCM POWER/G ROUND LINE INSPECTION NOTE ' NC700X/XA/S/SA: Before starting the inspection. check for loose or poor contact on the ECM 33F (Black) connector and recheck the MIL blinking. ' NC700XD/SD: Before starting the inspection. check for loose or poor contact on the PCM 33F (Gray) connector and recheck the MIL blinking. - If the ECM/PCM is replaced, perform the following: — Key Registration Procedure (page 23—6) — Clutch Initialize Learning Procedure (NC700XD/ SD) (page 12-120) ENGINE DOES NOT START (MIL does not blink) 1. ECM/POM Power Input Voltage Inspection Remove the following: — Shroud/side cover (NC7DOX/XA) (page 2-14) — Side cowl (NC7OOS/SA) (page 2-13) — Luggage box lid/hinge assembly (NC700XD/SD) (page 2-19) Disconnect the following: — ECM 33F (Black) connector (NC7ODX/XA/S/SA) [1] — PCM 3GP (Gray) connector (NC7DOXD/SD) [2] T rn the ignition switch ON and engine stop switch Measure the voltage at the ECM/POM 33F connector [1] of the Wire harness side and ground. Connection: Black (+) — Ground (—) Standard. Battery voltage TOOL: Test probe 07ZAJ-RDJA110 Does the standard voltage exist? YES — GO TO STEP 2. N0 — 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 — NC7OOX/XA/S/SA: 4-68 PGM-FI SYSTEM 2. EcM/PCM Ground Line Inspection Turn the ignition switch OFF. Check for continuities between the ECM/PCM 33F connector [1] ol the wire harness side and ground. Connection: Green/orange — Ground Green — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM/PCM with a known good 7 i one, and recheck. N0 — - Open circuit in the Green/orange Wire - Open circuit in the Green wire 02 SENSOR - 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, it dropped NOTE - Handle the 02 sensor With care. - Do not sen/ice the 02 sensor while it is hot. REMOVAL Remove the lower cowl (page 2-28). Release the 02 sensor wire lrom the clamp [1] and radiator reserve tank guide [2]. Remove the radiator reserve tank (page 8-14). Disconnect the 02 sensor cap [3]. Remove the 02 sensor [1]. Do not use an impact wrench while removing or installing the 02 sensor, or it may be damaged. 4-69 PG M-FI SYSTEM INSTALLATION Install and hand tlghten the 02 sensor [1]. Tighten the 02 sensor to the specified torque. TORQUE:24.5 NM (2.5 kgl-m,18|bf‘ft) Connect the 02 sensor cap [1]. - Take care no! to tilt the 02 sensor cap when connecting the cap to the 02 sensor. - Do no! turn [he 02 sensor cap, after oonneoling it. Install the radlator reserve tank (page 8-14). Install the 02 sensor wwre to the clamp [2] and radiator reserve tank guide [3]. Install the lower cowl (page 2-28). 4-70 5. IGNITION SYSTEM SYSTEM LOCATION---- IGNITION SYSTEM INSPECTION ----5-6 SYSTEM D|AGRAm..... |GN|T|0N T|M|NG . SERV|CE |NF0RMAT|0N |GN|T|0N COIL TnouBLESHoonNG...................................5.5 CKp SENSOR IGNITION SYSTEM SYSTEM LOCATION NC700X/XA/S/SA: IGNITION SWITCH ENGINE STOP SWITCH CLUTCH SWITCH FUSE BOX SPARK PLUGS CKP SENSOR BANK ANGLE SENSOR SIDESTAND SWITCH NEUTRAL SWITCH NC700XD/SD: ENGINE STOP SWITCH IGNITION COILS MAIN FUSE 30 A IGNITION SWITCH FUSE BOX SPARK PLUGS CKP SENSOR BANK ANGLE SENSOR SIDESTAND SWITCH NEUTRAL SWITCH 5-2 SYSTEM DIAGRAM IGNITION SYSTEM NC7DOX/XA/S/SA: wfi R M W ECM B BI MAIN FUSE IGNITION Fl 9] A1 30 A SWITCH 15 A l T e e FI/BI EI/w Bl/Bu Er/BI wan G/W v BF . BATTERY Eh (BLUE) J Bl BIA/Y G G/R G/O f —o\— W/Y W/Y —;/2 V ENGINE STOP ENG STOP BANK 2P (RED) SWITCH 7.5 A ANGLE Y My SENSOR — CKP EI/R Bl m, Br/Bl SENSOR Bl: Black Br n 0... Br: Brown y? Bu: Blue FUEL CUT RELAv G: Green Ta NEUTRAL Lg: Ligm green Br Br INDICATOR 0: Orange NEUTFIAL , I’ WW5“ BIA/Y wan G SIDESTAND SWITCH DIODE I Y.YeIIoW i 10pm“: No 1. No 2. 7 (GRAY) L9 IGNITION IGNITION B. a. NEUTRAL COIL COIL [0/0] SWITCH SPARK SPARK CLUTCH PLUG PLUG SWITCH 7 Ncmoxn/sn: mfi n 41/ V POM B. E. MAIN FUSE IGNITION Fl 9] A 30 A SWITCH 15 A l T e 6 FI/BI BI/W BI/Bu BIIBI Y/Bu G/W v BATTERV 8P - (BLUE) J E5 BI Bu/Y G Lg G/o —o\:— W/Y W/Y —;/! SEEK ENGINE STOP ENG STOP ANGLE Ir 2" (RED) SWITCH 7.5 A SENSOR v W/Y — CKP Bl/R BI EWB‘ SENSOR Br '1 0—— _ o FUEL CUT RELAY >1“ Br Br BIA/Y wan / EI: Black Br: Brawn e glyglETSCLAND Le am am N01. Na 2. G: Green IGNITION IGNITION __ NEUTRAL Lg: Light green COIL COIL T SWITCH g: grznge I e SPARK SPARK . W: WhIte PLUG £PLUG ? v: Yellaw 5-3 IGNITION SYSTEM SERVICE INFORMATION GENERAL ’ The ECM/PCM may be damaged il dropped. Also if the connector is disconnected when current is llowmg, the excessive voltage may damage the module. Always turn off the ignition sWItch before servicing. Use spark plug ol the correct heat range. Using a spark plug with an incorrect heat range can damage the engine. When sen/icing the ignition system, always Iollow the steps in the troubleshooting tabIe (page 5-5). Some electrical components may be damaged it terminals or connectors are connected or disconnected while the ignition sWitch is turned to ON position and current is present. A iaulty ignition system is olten related to poorly connected or corroded connections. Check those connections pelore 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 4-67). Reler to ioIIowing components iniormations: — Ignition switch (page 22-24) — Engine stop switch (page 22-25) — Bank angle sensor (page 4-65) — Sidestand switch (page 22-28) — Neutral switch (page 22-27) The iollowmg color codes are used throughout this section. BI = Black Bu = Blue Lg = Light green R = Red Y = Yellow Br = Brown G = Green 0 = Orange W = White SPECIFICATIONS ITEM SPECIFICATIONS Spark plug (Iridium) IFRSG-11K (NGK) Spark plug gap 1.0 — 1.1 mm (0.039 — 0.043 in) Ignition coil peak voltage 100 V minimum CKP sensor peak voltage (at 20°C/68°F) 0.7 V minimum Ignition timing ("F" mark) 12° BTDC at idle TORQUE VALUE , THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Timing hole cap 1 14 10 (1.0, 7) Apply grease to the threads. Right crankcase cover Wire clamp 2 6 12 (1.2, 9) Apply locking agent to the threads. poIt (NC700XD/SD) Coating width; 6.5 11.0 mm (0.26 t 0.04 in) except 2.0 11.0 mm (0.08 i 0.04 in) Irom tip IGNITION SYSTEM TROUBLESHOOTING Inspect the ioIIowing beiore 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 coiI secondary voltage) - II there is no spark at cylinder, temporarily exchange the ignition coil with a knoWn-good one and periorm the spark test. II there is spark, the original ignition coil is IauIty. (The engine is not cranked by the starter motor). No spark at spark plug "Initial voltage" oi the ignition primary coil is the battery voltage with the ignition switch turned ON and engine stop switch Unusual condition Probable cause (Check in numerical order) Ignition coil primary voltage No initial voltage With the ignition switch turned ON and engine stop sWitch "C" (Other electrical components are normal). AmN—A w . Faulty ignition switch . Faulty engine stop switch . Faulty iuel cut relay or its related circuits . An open circuit in Brown wire between the ignition coil and iueI cut relay . Loose or poor connection oi 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). Initial voltage is normal, but it drops by 2 — 4 V while cranking the engine. moo . Incorrect peak voltage adaptor connections (System is normal ii measured voltage is over the speciiications 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/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 (NC700X/XA/S/SA) or neutral switch . Loose or poor connection or an open circuit in No.6 related Wires — Sidestand switch Iine: Green/white and Green — Neutral switch line (NC700X/XA/S/SA): Green/red and Light green — Neutral switch line (NC700XD/SD): Light green . Faulty CKP sensor (Measure peak voltage) . Faulty ECM/PCM (in case When above No. I through 8 are normal). Initial voltage is normal but there is no peak voltage while cranking the engine. AmN—t . Incorrect peak voltage adaptor connections . Faulty peak voltage adaptor . Faulty CKP sensor . Faulty ECM/PCM (in case When above No. I through 3 are normal). Initial voltage is normal but peak voltage is lower than the standard value. {ANA . The multimeter impedance is too low; below 10 MQ/DCV. . Cranking speed is too slow (Battery is undercharged). . The sampling timing oi the tester and measured pulse were not synchronized (System is normal iI measured voltage is over the standard voltage at least once). . Faulty ECM/PCM (in case When above No. I through 3 are normal). Initial and peak voltages are normal but no spark jumps. . Faulty spark plug or leaking ignition coil secondary current am pere . Faulty ignition coil CKP sensor Peak voltage is lower than standard value. mN—‘N . The multimeter impedance is too low; below 10 MQ/DCV. . Cranking speed is too low. (Battery is undercharged.) . The sampling timing oi the tester and measured pulse were not synchronized (System is normal iI measured voltage is over the standard voltage at least once). . Faulty CKP sensor (in case when above No.1 through 3 are normal). No peak voltage . Faulty peak voltage adapter . Faulty CKP sensor IGNITION SYSTEM IGNITION SYSTEM INSPECTION NOTE ' If there is no spark at the plug, check all connections for loose or poor contact belore measuring the peak voltage. ' Use a commercially available digital multimeter with an impedance of 10 Mfl/DCV minimum. - The display value diflers depending upon the internal impedance of the multimeter. - If using the Imrie diagnostic tester (model 625), follow the manufacturer‘s instructions. Connect the peak voltage adaptor [1] to the digital multimeter [2], or use the Imrie diagnostic tester. TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with commercially available gital multimeter (impedance 10 Mn/DCV minimum) IGNITION COIL PRIMARY PEAK VOLTAGE NOTE ' Check all system connections before perlorming 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 3-8). 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. [2] IGNITION SYSTEM Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the side cowl (NC7OOS/SA/SD) (page 2-13) Do nutdiscunnec! With the ignition coil primary Wire connected, connect the ignition coil the peak voltage adaptor or Imrie tester to the ignition primary wire. coil primary terminal [1] and ground. TOOL: lmrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimeter (impedance 10 Mn/DCV m um) CONNECTION: No.1: Blue/yellow (+) — Ground (—) No.2: Yellow/blue (+) — Ground (—) Turn the ignition switch ON and engine stop sWitch Check the initial voltage at this time. The battery voltage should be measured. II the initial voltage cannot be measured, follow the checks described in the troubleshooting table (page 5- 5). Shift the transmission into neutral. Avoidruuchrng the Crank the engine with the starter motor and measure spark plug and the ignition coil primary peak voltage. tester probes to _ , . plevemelecmc PEAK VOLTAGE. 100 V minimum Shad“ II the peak voltage is abnormal, follow the checks described in the troubleshooting table (page 5-5). Install the shroud/side cover (NC7DOX/XA/XD) (page 2— 14). Install the side cowl (NC7ODS/SA/SD) (page 2-13). CKP SENSOR PEAK VOLTAGE (NC700X/XA/S/SA) NOTE Check the cylinder compression and check that the spark plugs are installed correctly in the cylinder head. Disconnect the ECM 33F (Black) connector [1] (page 4- 67). Connect the peak voltage tester or adaptor probes to the ECM 33F (Black) connector terminals of the wire harness side. TOOLS: lmrie diagnostic tester (model 625) or Peak voltage adaptor [2] 07HGJ-0020100 with commercially available digital multimeter (impedance 10 Mn/DCV m um) Test probe 07ZAJ-FIDJA110 CONNECTION: Yellow (4-) — Green/orange (—) Shift the transmission into neutral. Turn the ignition switch ON and engine stop sWitch Crank the engine with the starter motor and measure the CKP sensor peak voltage. PEAK VOLTAGE: 0.7 V minimum II the peak voltage measured at the ECM 33F (Black) connector is abnormal, measure the peak voltage at the CKP sensor connector. 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: Vellow (+) — White/yellow H In the same manner as at the ECM 33F (Black) connector, measure the peak voltage and compare it to the voltage measured at the ECM 33F (Black) connector. — It 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. 3 — It the peak voltage ot the CKP sensor side is lower than standard value, Iollow the checks described in the troubleshooting table (page 5-5). For CKP sensor replacement (page 5-11). Install the removed parts in the reverse order oI removal. CKP SENSOR PEAK VOLTAGE (NC700XD/SD) NOTE Check the cylinder compression and check that the spark plugs are installed correctly in the cylinder head. Disconnect the spark plug caps (page 3-8). Connect the ECM test harness to the PCM 33F connectors (page 4—14). Connect the peak voltage tester or adaptor probes to the ECM test harness [1] terminals. TOOL: lmrie diagnostic tester (model 625) or Peak voltage adaptor [2] 07HGJ-0020100 with commercially available digital multimeter (impedance 10 Mfl/DCV m um) [2] CONNECTION: 811 (+) — BS (—) Shift the transmission into neutral. Turn the ignition switch ON and engine stop switch Crank the engine with the starter motor and measure the CKP sensor peak voltage. PEAK VOLTAGE: 0.7 V minimum II the peak voltage measured at the ECM test harness is abnormal, measure the peak Voltage at the CKP sensor connector. 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 (4-) — White/yellow (—) In the same manner as at the ECM test harness. measure the peak voltage and compare it to the voltage measured at the ECM test harness. — If the peak voltage measured at the ECM test harness 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 ol 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 5-11). Install the removed parts in the reverse order ol 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. NOTE Read the instructions lor timing light operation. Start the engine and let it idle. IDLE SPEED: 1,200 2100 min" (rpm) The ignition timing is correct il the "F" mark [2] on the llywheel aligns with the index notch [3] on the alternator cover. Apply engine oil to a new O—ring [1] and install it to the timing hole cap. Apply grease to the timing hole cap [2] threads. Install and tighten the timing hole cap to the specified torque. TORQUE: 10 MM (1.0 kgf‘m, 1mm) IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION No.1 IGNITION COIL Remove the lollowing: — Lower cowl (page 2-28) — Aircleaner housing (page 7-14) Disconnect the spark plug cap [1]. Release the spark plug Wire [2] from the clamp [3]. Release the clamp [4] lrom the lrame tab. Release the clamp [5] lrom the lan motor stay. Nc7oos/SA/SD: Remove the wire band [1] and spark plug Wire [2] from the main wire harness. Disconnect the primary wire connectors [1] from the ignition COlI. Remove the bolts [2]. spacers [3] and ignition coil [4] Irom the ignition COlI stay. Installation is in the reverse order oI removal. NOTE Route the wire properly (page 1-25). [21/[3] No.2 IGNITION COIL Remove the lollowing: — Lower cowl (page 2-28) — Aircleaner housing (page 7-14) Disconnect the spark plug cap [1]. Release the clamp [2] lrom the lrame tab. 5-10 IGNITION SYSTEM Disconnect the primary wire connectors [1] from the ignition coil. Release the clamp [2] lrom the lrame tab. Remove the bolts [3], spacers [4] and ignition coil [5] lrom the ignition coil stay. Installation is in the reverse order ol removal. NOTE Route the wire properly (page 1-25). CKP SENSOR REMOVAL/INSTALLATION (NC700X/ XA/S/SA) Remove the right crankcase cover (page 11—5). [3] Remove the wire grommet [1] lrom the right crankcase cover. Remove the CKP sensor mounting bolts [2] and CKP sensor [3]. Installation is in the reverse order ol removal. NOTE - Apply locking agent to the CKP sensor mounting bolts threads (page 1-23). - Apply liquid sealant (Three bond 12078 or equivalent) to the CKP sensor Wire grommet sealing surface. EEMOVAL/INSTALLATION (NC700XD/ D) Remove the right crankcase cover (page 12-97). Remove the right crankcase cover wire clamp bolts [1] and wire clamp [2]. 5-11 IGNITION SYSTEM Remove the wire grommet [1] lrom the right crankcase cover. [3] 4% [1] Remove the CKP sensor mounting bolts [2] and CKP / sensor [3]. Installation is in the reverse order ol removal. NOTE - Apply locking agent to the CKP sensor mounting bolt threads (page 1-23). - Apply locking agent to the right crankcase cover wire clamp bolt threads (page 5—4). - 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 lbI-ft) 5-12 6. ELECTRIC STARTER SYSTEM SYSTEM D|AGRAM SERVICE |NFORMAT|0N TnouBLESHOOTING................................... 6-2 6-3 6-4 STARTER MOTOR ..................................... ..5.3 STARTER RELAY swn-CH NEUTRAL DIODE (NC7OOX/XA/S/SA)-------6-12 STARTER RELAY (NC700XD/SD)-------------6-12 6-1 ELECTRIC STARTER SYSTEM LOCATION NC700X/XA/S/SA: ENGINE STOP SWITCH STARTER SWITCH CLUTCH SWITCH MAIN FUSE 30 A STARTER RELAY SWITCH BATTERY IGNITION SWITCH FUSE BOX STARTER MOTOR NEUTRAL SWITCH r SIDESTAND SWITCH NC700XD/SD: ENGINE STOP SWITCH STARTER SWITCH MAIN FUSE 30 A STARTER RELAY SWITCH BATTERY FUSE BOX STARTER MOTOR 6-2 SYSTEM DIAGRAM NC7DOX/XA/S/SA: ELECTRIC STARTER I I Bl Bl Bl Bl STARTER STARTER RELAY SWITCH MOTOR GD (3 L _ , M I, BATTERY (_—1 MAIN FUSE g 30 A I I IGNITION Gm R SWITCH I_O/O__ CLUTCH 1GP ?’ SWITCH (GRAY) W“ “’3' ‘0/0- Bl em I /C* EUR 4‘2» W/Y #1,,— STARTER ENGINE STOP ENG STOP Bl SWITCH SWITCH 7.5 A NEUTRAL G/w DIODE 5 1‘; L /R L 9 9 2:25am” v Bl: Black NEUTRAL G1 Glee" Tu NEUTRAL SWITCH Lg: LIght green INDICATOR Fl: Red —; Y: Yellow w: White Nc7ooxn/sn: I I Bl Bl Bl B rj [j STARTER all Slack MOTOR I reen GD 9 M w R: Red BATTERY MAIN FUSE v: Violet — 30 A w: White Y: Yellow #_ Y/R R c Fl/Bl IGNITION SWITCH G/R a» BI/R ~3\t W/Y fix STARTER ENGINE STOP ENG STOP SWITCH SWITCH 7.5 A o e To PCM < WW 7 m Bl/W ;/: START A RELAY IIlgm ELECTRIC STARTER SERVICE INFORMATION GENERAL II the current is kept Ilovwng through the starter motor turn it while the engine is not cranking over, the starter motor may be damaged. — Ignition switch (page 22-24) — Starter switch (page 22-25) — Engine stop switch (page 22-25) — Neutral switch (NC700X/XA/S/SA) (page 22-27) — Sidestand switch (NC700X/XA/S/SA) (page 22-28) — Clutch switch (NC700X/XA/S/SA) (page 22-26) The starter motor can be serviced with the engine installed in the lrame. Always turn the ignition switch OFF beiore servicing the starter motor. The motor could suddenly start, causing serious iniury. A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. When sen/icing the starter system, always lollow the steps in the troubleshooting llow chart (page 6-5). Reler to the lollowing components iniormation: SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.0 — 13.0 (0.47 — 0.51) 6.5 (0.26) TORQUE VALUE . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Starter motor terminal nut 1 6 10 (1.0, 7) ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn (NC7OOX/XA/S/SA) 1. Fuse Inspection Check ior blown main iuse 30 A or sub iuse 7.5 A (ENG STOP). Is the fuse blown? YES — Replace the iuse. NO — GO TO STEP 2. 2. Battery Inspection Make sure the battery is iully charged and in good condition (page 2i -6). Is the battery in good condition? YES — GO TO STEP 3. N0 — 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 3 "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) N0 — 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 tor continuity: l. 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 — GO TO STEP 6. N0 — Loose or poor contact connector Open circuit in Wire harness Faulty neutral diode (page 6-12) Faulty neutral sWitch (page 22-27) Faulty sidestand SWitch (page 22-28) Faulty clutch switch (page 22-26) 6. Starter Relay Input Voltage Inspection Connect the starter relay switch connector. With the ignition sWitch turned ON and engine stop switch "C" 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 — GO TO STEP 7. N0 — Faulty ignition switch (page 22-24) Faulty starter switch (page 22-25) Faulty engine stop switch (page 22-25) Loose or poor contact connector Open circuit in Wire harness ELECTRIC STARTER 7. Starter Relay Switch Continuity Inspection Remove and check the operation ot the starter relay switch (page 6-11). Is there continuity? YES — Loose or poor contact starter relay switch connector N0 — Faulty starter relay switch Starter motor does not turn (NC7OOXD/SD) ‘I. Fuse Inspection Checktor biown main tuse (30 A), ENG STOP tuse (7.5 A) and Fi luse (15 A). Are the fuses in good condition? YES — GO TO STEP 2. N0 — Replace the blown tuse. . Battery Inspection Make sure the battery is tuliy charged and in good condition (page 21-6). Is the battery in good condition? YES — GO TO STEP 3. N0 — Charge or replace the battery. . 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. N0 — GO TO STEP 5. . Starter Motor Inspection Turn the ignition switch OFF. Apply battery voltage directiy to the starter motor and check the operation. Does the starter motor turn? YES — ~ Pooriy contacted battery positive cable or starter motor cable ~ Fauin starter relay sWitch N0 — Faulty starter motor (page 6-8) . Relay Coil Input Line Inspection Check the relay coil input line at the starter reiay sWitch (page 6-10). Is the input line normal? YES — GO TO STEP 6. N0 — Fauin ignition switch (page 22-24) Fauin starter sWitch (page 22-25) ~ Fauin engine stop switch (page 22-25) ~ Loose or poor connected connector ~ Open circuit in the wire harness . Relay Coil Ground Line Inspection Check the relay coil ground line ot the starter relay switch (page 6-11). Is the ground line normal? YES — GO TO STEP 7. N0 — GO TO STEP 8. . 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 N0 — Faulty starter relay switch 3. Starter Relay Inspection Checktne starter relay (page 6-12). Is the starter relay normal? YES — ~ Loose or poor connected connector ~ Open circuit in the wire harness ~ Fauity neutrai switch or its circuit ~ Fauity PCM N0 — Faulty starter relay ELECTRIC STARTER 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. (NC7DOX/XA/S/SA) 1. St St St Clutch Switch Inspection Checktne ciutch switch operation (page 22-26). Is the clutch switch operation normal? YES — GO TO STEP 2. N0 — Faulty clutch switch . Sidestand Switch Inspection Check the sidestand swrtch operation (page 22-28). Is the sidestand switch operation normal? YES — ~ Loose or poor contact connector ~ Open circuit in Wire harness N0 — Faulty sidestand switch arter motor turns slowly Low battery voltage Pooriy connected battery terminai cable Pooriy connected starter motor cable Faulty starter motor Pooriy connected battery ground cable arter motor turns, but engine does not turn Starter motor is running backwards — Case assembled improperly — Terminals connected improperly Faulty starter clutch Damaged or laulty starter reduction gear/shalt Damaged or laulty starter idle gear/shalt arter relay switch "Clicks", but engine does not turn over Crankshait does not turn due to engine probiems ELECTRIC STARTER STARTER MOTOR REMOVAL/INSTALLATION Disconnect the battery negative cable (page 21—6). 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 O-ring [1]. Installation is in the reverse order ot removal. NOTE ' Apply engine oil to a new O-ring. ' Route the cables properly (page 1-25). TORQUE: Starter motor terminal nut: 10 N-m (1.0 kgt-m, 7 lbt-ft) DISASSEMBLY/ASSEMBLY MOTOR CASE ‘3’ v g SEAL RING FRONT COVER $2" '7' O-RING BOLTS SPRING ARMATURE TERMINAL BOLT ,/ BRUSH HOLDER I1] [21/[31 [41/[51 [1] F15! SEAL RING j O-RING F1! g WASHER INSULATOR TERMINAL STOPPER REAR COVER POSITIVE BRUSHES 6-8 ELECTRIC STARTER INSPECTION FRONT COVER Check the oil seal [1] in the Iront cover for deterioration, wear or damage. Turn the inner race ol bearing [2] in the lront cover with your finger. The bearings should turn smoothly and quietly. Also check that the outer race lits tightly in the front cover. Replace the starter motor as an assembly il necessary. REAR COVER Inspect the brushes lor damage and measure the brush length. SERVICE LIMIT: 6.5 mm (0.26 in) Check for continuity or no continuity lor 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 ofl between commutator bars [1]- Check the commutator bars ol the armature lor discoloration. Check for continuity or no continuity lor 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 il necessary. [2] ELECTRIC STARTER STARTER RELAY SWITCH INSPECTION Remove the maintenance lid (page 21—6). Shift the transmission into neutral. Turn the ignition switch ON and engine stop switc Push the starter swnch. The coil is normal ii the starter relay switch [1] clicks. ll you don't hear the starter relay switch "CLICK", release the starter relay switch/shock rubber from the battery box tabs [2] and inspect the starter relay switch using a procedure below. STARTER RELAV INPUT VOLTAGE Turn the ignition switch ON and engine stop switch Measure the voltage between the Yellow/red (+) wire terminal at the starter relay switch 4P (Red) connector [1] and ground (—). ll the battery voltage appears only when the starter switch is pushed with the ignition switch turned ON and engine stop SWitch "C", the starter relay input voltage is normal. ' GROUND LINE (NC7DOX/XA/S/SA) Disconnect the starter relay switch 4P (Red) connector [1]. Check lor continuity between the Green/red Wire of the wire harness side (ground line) and ground. ll there is continuity when the transmission is in neutral or when the clutch is disengaged and the sidestand is retracted, the ground circuit ol the relay coil is normal. (In neutral, there is a slight resistance due to the diode.) 6-10 ELECTRIC STARTER GROUND LINE (NC7DOXD/SD) Turn the ignition switch ON and engine stop sWitch Measure the voltage between the Yellow/red (+) and Green/red (—) Wire terminals at the starter relay switch 4P (Red) connector [1]. IR Y/R V Ll ll the battery voltage appears only when the starter switch is pushed with the ignition switch turned ON and engine stop sWitch ":1", the starter relay ground line is normal. E<> 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. e e. BATTERY l REMOVAL/INSTALLATION Remove the maintenance lid (page 21—6). Release the starter relay switch/shock rubber from the battery box tabs [1]. Release the rubber cover [2]. Disconnect the starter relay switch 4P (Red) connector [3]- Remove the bolts [4] and cables [5]. Remove the starter relay switch [6] lrom the shock rubber [7]. Installation is in the reverse order ol removal. 6-11 ELECTRIC STARTER NEUTRAL DIODE (NC700X/XA/S/SA) INSPECTION Remove the maintenance lid (page 21—6). Open the luse/relay box cover and remove the neutral diode [1]. Check tor continuity between the neutral diode terminals. When there is continuity, a small resistance value Will register. ll there is continuity, in direction shown by the arrow, the neutral diode is normal. STARTER RELAY (NC700XD/SD) INSPECTION Remove the maintenance lid (page 21—6). Open the luse/relay box cover and remove the START RELAY [1]. Connect an ohmmeter to the START RELAY [1] connector terminals. Connect a 12 V battery to the START RELAY connector terminals as shown. There should be continuity only when 12 V battery is connected. ll there is no continuity only when the 12 V battery is connected, replace the START RELAY. 6-12 7. FUEL SYSTEM COMPONENT LocAT|0N SERVICE |NFORMAT|0N FUEL LINE REPLACEMENT........................ FUEL TANK .................................... .. FUEL pUMP 7-2 7-3 7-4 ........... "7.3 7-10 AIR CLEANER HOUSING THRO‘I'I'LE BODY FUEL SYSTEM COMPONENT LOCATION 7-2 FUEL SYSTEM SERVICE INFORMATION GENERAL - Work in a well ventilated area. Smoking or allowing ilames or sparks in the work area or where gasoline is stored can cause a Iire or explosion. BeIore disconnecting the Iuel teed hose, relieve tuel pressure Irom 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 01 vehicle control. - Do not snap the throttle valve Irom iull open to iull close aIter 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 Irom entering the engine aIter the throttle body or Iuel rail has been removed. - Do not damage the throttle body. It may cause incorrect throttle valve operation. - Prevent dirt and debris Irom entering the throttle bore and air passages aiter the throttle body has been removed. Clean them using a compressed air iI necessary. - Do not loosen or tighten the white painted nut and screw oI the throttle body. Loosening or tightening them can cause throttle valve and idle control Iailure. - The parts oi the throttle body not shown in this manual should not be disassembled. - For Iuel level sensor inspection (page 22-21). - The tollowmg color codes are used throughout this section. G = Green P = Pink R = Red W = White Y = Yellow SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number GQGUA Idle speed 1,200 i 100 min‘ (rpm) Throttle grip ireeplay 2 — 6 mm (1/16 — 1/4 in) Fuel pressure at idle 343 kPa (3.5 kgt/cm , 50 psi) Fuel pump Ilow (at 12 V) 230 cm (7.8 US oz, 8.1 Imp oz) minimum/10 seconds TORQUE VALUES . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbf-II) REMARKS Fuel pump mounting nut 6 6 12 (1.2, 9) For tightening sequence (page 7-14) Air cleaner connecting hose band 1 4 1.5 (0.2, 1.1) screw Insulator band screw 2 5 — See page 7-18 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 following: — Shroud/side cover (NC7ODX/XA/XD) (page 2-14) — Shelter/side cover (NC7ODS/SA/SD) (page 2-15) 3. Disconnect the fuel pump 1P (Black) connector [1]. Turn the ignition switch ON and engine stop switch 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- 6). QUICK CONNECT FITTING REMOVAL NOTE Do not bend or twist fuel leed hose. FUEL PUMP SIDE Refer to fuel tank removal (page 7-8). 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. 3. Squeeze the retainer tabs [2] With the hand to release them from the locking pawls [3]. Pull the fuel feed hose off and remove the retainer. NOTE - Absorb the remaining fuel in the fuel leed 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 tabs pressed down. and alternately pull and push the connector until it comes off easily. FUEL SYSTEM 4. To prevent damage and keep Ioreign matter out, 1 cover the disconnected connector and pipe end with I I the piastic bags [1]. QUICK CONNECT FITTING INSTALLATION FUEL PUMP SIDE ReIer to iuel tank instailation (page 7-8). INJECTOR SIDE NOTE ' Aiways replace the retainer and ioint rubber oi the quick connect Iitting when the iuel teed hose is disconnected. ' Replace the retainer and joint rubber with the same manuiacturer‘s item that was removed. ' Do not bent or tWist Iuei teed hose. 1. Insert a new retainer [1] into the connector [2]. NOTE ' Aiign new retainer locking pawls with the connector grooves. Align [1] 2’? [2] Align 2. Set a new joint rubber [1] as shown. Then press the iuel teed hose into the quick connect iitting untii both retainer pawis [2] look with a "CLICK". NOTE ' Aiign retainer tabs With ioint rubber grooves. Ii it is hard to connect, put a small amount at engine oii on the iniectorioint. FUEL SYSTEM 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]. . Make sure the joint rubber [2] is in place (between the retainer tabs). . Increase the fuel pressure and check that there is no leakage in fuel supply system (page 7-6). FUEL PRESSURE NORMALIZATION 1. Connect the fuel pump 1 P (Black) connector [1]. 2 Connect the battery negative (—) cable (page 21-6). . Turn the ignition switch ON and engine stop switch "N. NOTE Do not start the engine. The fuel pump will run for about 2 seconds, and fuel pressure Wlll rise. . Repeat 2 or 3 times. and check that there is no leakage in the fuel supply system. . Turn the ignition switch OFF. Install the following: Shroud/side cover (NC7ODX/XA/XD) (page 2-14) Shelter/side cover (NC7ODS/SA/SD) (page 2-15) l2] [1] FUEL SYSTEM Wlpe clf spilled cu! gasallne. FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fitting from the injector (page 7-4). Attach the luel pressure gauge, attachments and manifold. TOOLS: Fuel pressure gauge, 0 — 100 psi [1] 07406-0040004 Pressure gauge manifold [2] 07ZAJ-55A0111 Hose attachment, 9 mm/B mm [3] 07ZAJ-55A0120 Hose attachment, 8 mm/B mm [4] 07ZAJ-S7CD100 Attachment joint, 8 mm/B mm [5] 07ZAJ-S7CDZOO Temporarily connect the battery negative (—) cable and luel pump 1P (Black) connector. Turn the ignitlon switch ON and engine stop SWltch Stan the engine and let it ldle. Read the luel pressure. STANDARD: 343 kPa (3.5 kgl/cm’, 50 psi) ll the luel pressure is higher than specilled, replace the luel pump assembly. ll the luel pressure is lower than specllied, inspect the lollowing: — Fuel llne leaking — Pinched or clogged luel leed hose or luel tank breather hose — Fuel pump unit (page 7—10) — Clogged fuel filter (page 7-11) After inspection, relieve the luel pressure (page 7-4). Remove the fuel pressure gauge, attachment and manifold lrom the injector. Connect the quick connect fitting (page 7—5). FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick connect fitting from the injector (page 7-4). Place the end of the hose [1] into an approved gasoline container. Temporarily connect the battery negative (—) cable and luel pump 1P (Black) connector. Turn the ignitlon switch ON and engine stop SWltch Measure the amount ol fuel llow. NOTE ' The luel pump operates for 2 seconds. Repeat 5 times so that the total measuring time. - Return luel to the fuel tank when the llrst fuel ls flowed. Amount of luel flow: 230 cm3 (7.8 US oz, 8.1 Imp oz) minimum/ 10 seconds at 12 V ll fuel llow is less than specilled, inspect the followmg: — Fuel pump unit (page 7—10) — Clogged fuel filter (page 7-11) Connect the quick connect fitting (page 7—5). FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Relieve the luel pressure (page 7-4). l4] [1 l [3] l1 ] [7] Remove the bolts [1], luel cap [2] and luel cap tray [3]. Release the following: — Fuel tank drain hose A [4] — Fuel tank breather hose [5] — Seat lock cable [6] Remove the fuel tank mounting bolts [7], Washers [8], upper mounting rubbers [9], lower mounting rubbers [10] and collars [11]. Lift the rear end of the fuel tank and disconnect the following: — Fuel pump unit 3P (Black) connector [12] — Quick connect fitting (page 7-8) NOTE Do not bend or twist fuel leed hose. Remove the luel tank [13]. Installation is in the reverse order of removal. NOTE - Connect the quick connect fitting (page 7-9). - Route the hose and wire properly (page 1-25). FUEL PUMP SIDE QUICK CONNECT FITI'ING REMOVAL 1. Relieve the fuel pressure (page 7-4). 2. Check the luel quick connect fitting [1] for dirt, and clean if necessary. Place a shop towel over the quick connect fitting. 3. Pull and release the joint rubber [1] from the retainer. 4. Hold the connector with one hand and squeeze the retainer tabs [2] with the other hand to release them from the locking pawls [3]. Pull the connector off and remove the retainer. NOTE - Absorb the remaining fuel in the fuel leed 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 tabs pressed down, and alternately pull and push the connector until it comes off easily. 5. To prevent damage and keep Ioreign matter out, cover the disconnected connector and pipe end with the piastic bags [1]. FUEL PUMP SIDE QUICK CONNECT FITI'ING INSTALLATION NOTE ' Aiways replace the retainer and joint rubber oi the quick connect Iitting when the iuel teed hose is disconnected. ' Replace the retainer and joint rubber with the same manuiacturer‘s item that was removed. ' Do not bent or tWist Iuei teed hose. 1. Insert a new retainer [1] into the connector [2]. NOTE ' Aiign new retainer locking pawls with the connector grooves. 2. Set a new joint rubber [1] as shown. Then press the quick connect Iitting onto the pipe until both retainer pawls [2] lock with a "CLICK". NOTE ' Aiign the quick connect Iitting with the pipe. ' Ii it is hard to connect, put a small amount oI engine oil on the pipe end. FUEL SYSTEM [1] [2] FUEL SYSTEM 3. Make sure the connection is secure and that the pawls are Iirmly 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. Increase the Iuel pressure and check that there is no leakage in Iuel supply system (page 7-6). FUEL PUMP UNIT INSPECTION Turn the ignition switch ON and engine stop switch "C" and confirm that the fuel pump operates Ior 2 seconds. II the fuel pump does not operate, inspect as follows: Turn the ignition switch OFF. Lift and support the fuel tank (page 7-8). NOTE Do not disconnect the quick connect Iitting. Disconnect the Iuel pump unit 3P (Black) connector [1]. Turn the ignition switch ON and engine stop switch Measure the voltage at the Iuel pump unit 3P (Black) connector [1] terminals ol the wire side. CONNECTION: Yellow/red (1-) — Green/red (—) STANDARD: Batteryvoltage There should be standard voltage Ior a few seconds. II there is standard Voltage, replace the Iuel pump unit. II there is no standard Voltage, inspect the following: — Loose or poor contact on the fuel pump 1P (Black) connector — Main fuse 30 A — Sub luse 15 A (Fl) — Sub fuse 7.5 A (ENG STOP) — Ignition switch — Engine stop switch — Fuel cut relay (page 4-64) — Open circuit in Yellow/red or Green/red wire — ECM/PCM (page 4-68) 7-10 FUEL SYSTEM REMOVAL Remove the luel tank (page 7-8). 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 luel pump unit [2] and packing [3]. NOTE Be carelul not to damage the luel level sensor lloat arm. DISASSEMBLY/INSPECTION Remove the screws [1]-and Black wire terminals [2]. [mm [1M2] Dlsconnect the Pink Wire connector [3] and Blue Wire connector [4]. Remove the fuel pump unit assembly [1] and O-ring [2] lrom the luel pump stay [3]. Remove the chamber [1]. [1] Release the tab [2] and remove the fuel level sensor assembly [3] lrom the luel filter [4]. [2] 7-11 FUEL SYSTEM Remove the tuel pump [1] and O-ring [2]. Visually inspect the fuel pump tiller [3] for dirt, debris or any clogging. Replace tuel pump unit as an assembly it necessary. Remove the pressure regulator [1] and O-ring [2] from the fuel filter [3]. [3] ASSEMBLY Replace the hJeI filter [1] with a new one. a [21 Install a new O-ring [2] to the pressure regulator [3]. v Install the pressure regulator. Install a new O-ring [1] to the fuel pump [2]. Install the hiel pump. NOTE Align the Blue wire with the tuel filter groove. 7-12 FUEL SYSTEM Insert the fuel pump filter edge [1] between the fuel 2 4 pump and pressure regulator [2]. I I I I Install the luel level sensor assembly [3]. Install the chamber [4]. Install a new O-ring [1] to the fuel pump stay [2]. Install the fuel pump unit assembly [3] to the luel pump stay. NOTE Align the fuel pump stay with fuel pump assembly grooves. Install the screws [1] and Black wire terminals [2]. Tighten the screws securely. Connect the Pink Wire connector [3] and Blue wire connector [4]. INSTALLATION Install a new packing [1] onto the luel pump unit [2]. NOTE - Always replace the packing with a new one. - Be careful not to pinch the dirt and debris between the luel pump unit and packing. - Align the packing tab with the Iuel pipe. v [1] Align 7-13 FUEL SYSTEM Install the fuel pump unit [1] into the luel tank. NOTE Be careful not to damage the luel level sensor lloat arm [1] [2] Install and tighten the luel pump mounting nuts [1] to the specified torque in the sequence as shown. TORQUE: 12 N-m (1.2 kgt-m, 9 lbt-l‘t) Install the luel tank (page 7-8). AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the air cleaner (page 3-7). Remove the bolts [1] and radiator lower stay [2]. Release the radiator boss lrorn the radiator mounting rubber [3]. Release the fan motor 3P (Gray) connector [1], air cleaner housing drain hose [2] and spark plug ere [3] lrom the radiator. 7-14 FUEL SYSTEM Lower the radiator and disconnect the crankcase breather hose [1]. NOTE Be careful not to damage the radiator lins. Loosen the air cleaner connecting hose band screw [1]. [4] [2] [3] Remove the bolts [2] and collar [3]. Disconnect connecting hose and remove the air cleaner housing [4]. Installation is in the reverse order ol removal. NOTE ' Route the wire harness and hoses properly (page 1- 25). ' Make sure the radiator mounting rubber slits facing down. ' Align radiator lower stay slit with cylinder head tab. TORQUE: Air cleaner connecting hose band screw: 1.5 N-m (0.2 kgf—m, 1.1 mm) THROTTLE BODY REMOVAL Remove the air cleaner housing (page 7-14). Disconnect the sensor unit 5P (Black) connector [1] and IACV 4P (Black) connector [2]. lrom the throttle drum and cable stay. Loosen the throttle cable B lock nut [4] then disconnect the throttle cable B [5] lrom the throttle drum and cable stay. FUEL SYSTEM Loosen the lnsulator band screw [1] and remove the throttle body assembly [2]. DISASSEMBLY Do not remove the sensor unit unless it is replaced. The throttle body/sensor unit is lactory pre-set. Do not disassemble in a way other than shown in this manual. Do not snap the throttle valve from lull open to lull 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] ol the throttle body. Loosening or tightening it can cause throttle valve and idle control lailure. Always clean around the throttle body before each sensor removal to prevent dirt and debris from entering the air passage. NOTE For IACV removal (page 7-22). Remove the sensor umt torx screws [1], sensor unit [2] and O-ring [3]. [3] Cleanlngthealr Clean the alr passage of the throttle body using a passages and compressed air. sensor hole with 5 Check the air passage for clogs. piece of wlre will damage the throttle body. 7-16 FUEL SYSTEM ASSEMBLY NOTE For IACV installation (page 7-23). TORX SCREWS THROTTLE BODY @ O>R|NG N SENSOR UNIT O-RING a N! TORX SCREWS Ilrhe thing is nu! Install a new O-ring [1] to the throttle body properly. mmkdpmpeny' When installing the sensor unit [2] to the throttle body, {held/e allwillleaks a“ "the “New” _ andeng/‘nei'dle 9 9' speed wIIIbe — The TP sensor clip with the throttle valve boss unslable. — The sensor unit tab with the throttle body hole Install and tighten the sensor unit torx screws [1] securely. 7-17 FUEL SYSTEM INSTALLATION Install the throttle body assembly [1] to the cylinder head. NOTE - Align the throttle body tab with the insulator groove. - Align the insulator band hole with the insulator tab. Tighten the insulator band screw to the specified range. 11 — 13 mm (0.4— 0.5 in) H Connect the throttle cables [1] to the throttle drum and throttle cable stay. NOTE Route the cables properly (page 1-25). Tighten the throttle cable B lock nut [2] securely. Tighten the throttle cable A adjuster lock nut [3] securely. Connect the sensor unit 5P (Black) connector [1] and IACV 4P (Black) connector [2]. NOTE Route the wire harness properly (page 1-25). Install the air cleaner housing (page 7—14). Adjust the throttle grip lreeplay (page 3-5). 7-18 FUEL SYSTEM THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE NOTE ll the sensor unit is removed, reset the throttle valve lully closed position as lolloWing. 1. Erase the DTC's (page 4-13). 2. Turn the ignition switch OFF. 3. Short the DLC [1] terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 4. Disconnect the ECT sensorZP connector [1]. Short the ECT sensor 2P connector terminals ol the Wire harness side with a jumper wire [2]. Connection: Pink/while — Green/yellow v 5. Turn the ignition switch ON and engine stop switch _ J "5;", then Mleill start blinking. , . . . \ G/Y P/W Disconnect the iumper Wire while the MIL blinking 7 (Within 10 seconds). [2] 6. After disconnection oi the jumper Wire, the MIL [1] 1 start to short blinking. l 1 a," +‘—,——\ - Q » ’ v ‘ m a l e s w s s 1 r_.__._._._.__._ ,—____ 7-19 FUEL SYSTEM 7. Check ii the MIL blinks. If the MIL begins short blink (0.3 seconds), the throttle valve lully closed position is reset. @ 0.3 seconds M, l “sewnds U 0.1 ‘ seconds MIL ON 7 1-2 1 seconds MIL OFF 7 r ‘ RESET RECEIVING PATTERN SUCCESSFUL PATTERN If the MIL stays lit, the throttle valve lully closed position is not reset, repeat the reset procedure from step 1. 8. Turn the ignition switch OFF. 9. Connect the ECT sensor 2P connector [1]. INJECTOR REMOVAL Relieve the fuel pressure and disconnect the quick connect fitting from the injector side (page 7-4). Remove the battery box (page 2-31). Disconnect the injector 2P (Gray) connectors [1]. Remove the clip [2] from the luel rail. Remove the bolts [3], collars [4] and injector assembly [5]- Remove the retainers [1] lrorn the injector/fuel rail. 7-20 FUEL SYSTEM Remove the injectors [1] Irom the Iuel rail. [ : Remove the O-ring [1], cushion rubber [2] and seal ring [a] Irom the injector [4]. [2] [‘1 Check the removed parts for wear or damage and replace them it necessary. [3] [4] INSTALLATION Apply engine oil to a new O-ring [1] and a new seal ring [3] [4] [1] [21. a E’? Install the cushion rubber [3] until it IS lully seated. NOTE Align the cushion rubber cut out with the injector connector. & Install the seal ring to the injector [4], being caretul not to damage them. Install the O-ring to the injector. __7a yd [2] Align Install the injectors [1] to the fuel rail [2], being carelul [1] [2] not to damage the O-ring. NOTE Align the injector body With the Iuel rail tab [3] as shown. [3] 7-21 FUEL SYSTEM Install the retainers [1] to the injector/luel rail. [1] Install the injector assembly [1], bolts [2] and collars [3]. Tighten the fuel rail mounting bolts securely. Connect the injector 2P (Gray) connectors [4] while aligning their grooves with the fuel rail tabs. Install the clip [5] to the fuel rail. Install the battery box (page 2-31). Connect the quick connect Iitting to the injector side (page 7-5). IACV REMOVAL/INSPECTION Remove the air cleaner housing (page 7-14). The IACV is installed on the throttle body and is operated by the step motor. When the ignition switch is turned ON and engine stop switch the IACV operates Ior a few seconds. Check the step motor operating (beep) sound With the ignition sWitch turned ON and engine stop switch Disconnect the IACV 4P (Black) connector [1]. Remove the IACV setting plate torx screws [2] and setting plate [3]. Remove the IACV [4] and O-ring [5]. 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 check the IACV operation. Disconnect the IACV 4P (Black) connector. 7-22 FUEL SYSTEM INSTALLATION Turn the slide valve [1] clockwise until lightly seated on IACV. I” Install a new O-nng [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] securely. Connect the IACV 4P (Black) connector [5]. Install the air cleaner housing (page 7—14). 7-23 MEMO 8. COOLING SYSTEM SYSTEM FLOW SERVICE |NFORMAT|0N TnouBLESHOOTING................................... SYSTEM COOLANT REPLACEMENT......................... 8-3 3-4 3-6 TH ERMOSTAT/TH ERMOSTAT Housme .................................................... ..3.7 n RADMTOR .................................................. ..3.9 WATER PUMP RADIATOR RESERVE TANK---------------------8-14 FAN c0NT_ RELAY....................................3.15 8-1 COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR CAP RADIATOR RADIATOR RESERVE TANK THERMOSTAT WATER PUMP 8-2 SERVICE INFORMATION GENERAL COOLING SYSTEM AWARNING 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 belore removing the radiator cap. Using coo/an! 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 reiill or drain the system. All cooling system services can be done with the engine installed in the lrame. After servicing the system, check lor leaks with a cooling system tester. - Avoid spilling coolant on painted suriaces. Reler to the ECT sensor inspection (page 22-18). SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1.69 liters (1.79 US qt, 1.49 lmp qt) At draining 1.41 liters (1.49 US qt, 1.24 lmp qt) Reserve tank 0.13 liter (0.14 US qt, 0.11 lmp qt) Radiator cap reliel pressure 108— 137 kPa(1.1—1.4 kgl/cm ,16—20 psi) Thermostat Begin to open so — 84°C (176 — 133m Fully open 95°C (203°F) Valve liit 8 mm (0.3 in) minimum Recommended antilreeze High quality ethylene glycol antitreeze containing silicate-tree corrosion inhibitors Standard coolant concentration 1 :1 (mixture With distilled water) TORQUE VALUES . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgI-m, mm) REMARKS Water hose band screw 6 — — See page 8-9 See page 8-10 See page 8-14 Fan motor shroud mounting bolt 3 6 8.4 (0.9, 6.2) Fan motor mounting screw 3 4 2.7 (0.3, 2.0) Cooling tan mounting nut 1 3 1.0 (0.1, 0.7) Apply locking agent to the threads. COOLING SYSTEM TROUBLESHOOTING Engine temperature too high ~ Fautty high coolant temperature indicator or ECT sensor ~ Thermostat stuck ctosed ~ Fautty radiator cap ~ Insulticient coolant ~ Passage blocked in radiator, hoses or water jacket ~ Air in system ~ Fautty cooling tan motor ~ Fau‘ty FAN CONT. RELAY ~ Fautty water pump Engine temperature too low ~ Fautty high coolant temperature indicator or ECT sensor ~ Thermostat stuck open ~ Fau‘ty FAN CONT. RELAY Coolant leak ~ Fautty water pump mechanical seat ~ Deteriorated O-nngs ~ Fautty radiator cap ~ Damaged or deteriorated cylinder head gasket ~ Loose hose connection or clamp ~ Damaged or deteriorated hose ~ Damaged radiator COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the screw [1] and radiator cap [2]. Test the coolant gravity using a hydrometer (see below lor "Coolant gravity chart"). For maximum corrosion protectlon, a 1:1 solutlon of ethylene glycol and distllled water is recommended (page 8-6). Look for contamlnalion and replace the coolant if necessary. COOLANT GRAVITV CHART Coolant iemperature "0 (°F) 0 5 10 15 20 25 3D 35 40 45 50 (32) (41) (50) (59) (68) (77) (86) (95) (104) (113) (122) 5 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.999 0.997 10 1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005 15 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012 “\0 20 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019 .2 25 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025 g 30 1.053 1.052 1.051 1.049 1.047 1.045 1.043 1.041 1.038 1.035 1.032 g 35 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040 73 40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047 0 45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054 50 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059 55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 8-5). 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 reliel 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/cmz, 16 — 20 psi) Install the tester to the radiator. Pressure the radiator, engine and hoses, and check for leaks. Excessive pressure can damage [he cooling system components. Do not exceed 137 kPa (1.4 kgI/crrF, 20 psi). Repair or replace components if the system Will not hold specified pressure for at least 6 seconds. COOLANT REPLACEMENT PREPARATION ' The effectiveness of coolant [1] decreases with the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant regularly as specified in the maintenance schedule. ' Mix only distilled, low mineral water [2] With the antifreeze [3]. RECOMMENDED ANTIFREEZE: High quality ethylene glycol antiIreeze containing silicate-tree corrosion inhibitors RECOMMENDED MIXTURE: 1:1 (mixture with distilled water) 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 lower cowl (page 2—28). Remove the screw [1] and radiator cap [2]. COOLING SYSTEM 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. Remove the radiator reserve tank (page 8-14). Empty the coolant and rinse the inside of the reserve tank With water. Install the reserve tank (page 8-14). Fill the system With the recommended coolant through the liller 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 lrom the system as follows: 1. Shift the transmission into neutral. Stan the engine and let it idle lor 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 if it is low. After installation, check that there are no coolant leaks. Install the lower cowl (page 2-28). THERMOSTAT/THERMOSTAT HOUSING REMOVAL/INSTALLATION Drain the coolant (page 8—6). Remove the battery box (page 2-31). Disconnect the ECT sensor 2P connector [1]. Loosen the water hose band screw [2] and disconnect r the radiator upper water hose [3]. COOLING SYSTEM Loosen the water hose band screw [1] and disconnect '- the water bypass hose [2]. Remove the bolts [3], stay [4] and thermostat housing [5]. Remove the O-ring [1]. [1] N! Remove the bolts [1] and thermostat housing cover [2]. Remove the thermostat [1] from the housing. 8-8 COOLING SYSTEM Installation is in the reverse order ol removal. NOTE ' Align the thermostat air bleed hole with the rib side \ bolt hole. _ 3 Replace the O—ring with a new one. 1 Align the water bypass hose index mark with the l thermostat housing tab. i l i i Tighten the water hose band screws to the specified J range as shown. ' Route the wire harness and hoses properly (page 1- v 1—. » _ A A A . 25). Fill the recommended coolant mixture to the liller neck and bleed the air (page 8—6). INSPECTION Visually inspect the thermostat [1] lor damage. Check lor damage of the seal ring [2]. Wear insulated gloves and adequate eye protection. Keep llammable materials away lrom the electric heating element. Du not/etlfie Heat the water With an electric heating element to thermostat or operating temperature lor 5 minutes. (he’mume'erm Suspend the thermostat [2] in heated water to check its touch the pan, or Opera‘im you writ get raise reading. Replace the thermostat if the valve stays open at room temperature, or it it responds at temperatures other than those specilied. THERMOSTAT BEGIN TO OPEN: so — 84°C (176 —183°F) VALVE LIFT: 8 mm (0.3 in) minimum at 95°C (203°F) [2] RADIATOR REMOVAL/INSTALLATION Remove the lower cowl (page 2—28). Drain the coolant (page 8—6). Loosen the water hose band screw [1] and disconnect _ ' the radiator lower water hose [2] and radiator upper water hose [3]. Disconnect the siphon hose [4]. COOLING SYSTEM Remove the bolts [1] and radiator lower stay [2]. Release the radiator boss lrom the radiator mounting rubber [3]. Release the fan motor 3P (Gray) connector [1], air cleaner housing drain hose [2] and spark plug Wire [3] lrom the radiator [4]. Disconnect the fan motor 3P (Gray) connector and remove the radiator. NOTE Be careful not to damage the radiator lins. Installation is in the reverse order ol removal. NOTE - Tighten the water hose band screws to the specified range as shown. - Route the wire harness and hoses properly (page 1- 25). - Make sure the radiator mounting rubber slits facing down. - Align radiator lower stay slit with cylinder head tab. Fill the recommended coolant mixture to the tiller neck and bleed the air (page 8-6). 8-10 COOLING SYSTEM DISASSEMBLY/ASSEMBLY Disassemble and assemble the radiator as tollowing the illustration. RADIATOR m FAN MOTOR SHFlOUD 3-4 NW (0-9 kgf-m, 6.2 lbl-lt) NOTE ' Align the cooling tan and tan motor shaft tlat surfaces. ' Apply locking agent to the cooling tan mounting nut threads. TORQUE: Fan motor shroud mounting bolt: 3.4 N-m (0.9 kgf—m, 0.2 mm) Fan motor mounting screw: 2.7 N-m (0.3 kgf—m, 2.0 mm) Cooling tan mounting nut: 1.0 N-m (0.1 kgf—m, 0.7 mm) 8-11 COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Check the bleed hole [1] of the water pump lor signs of coolant leakage. - A small amount 01 coolant weeping from the bleed hole is normal. - Make sure that there are no COHIanOUS coolant leakage lrom the bleed hole while operating the engine. Replace the water pump as an assembly it necessary. REMOVAL/INSTALLATION Remove the lower cowl (page 2-28). Drain the coolant (page 8—6). Loosen the water hose band screw [1] and disconnect the radiator lower water hose [2] and water bypass hose [3]. Remove the lollowing: — 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]. 8-12 COOLING SYSTEM Remove and slide the water pump assembly. Remove the 6 x 35 mm bolts [1]. Reinstall the water pump assembly. Remove the 6 x 32 mm bolt [2] and sealing washer [3]. [2&3] ~a Remove the lollowing: — Waterpumpcoverfi] — Gasket[2] — Plate [3] Remove the gasket [1] and dowel pins [2] from the water pump body. l Remove the water pump body [1] and O-rings [2] from the cylinder head. NOTE Do not disassemble the water pump body. 8-13 COOLING SYSTEM Installation is in the reverse order oi removal. NOTE (6) - Replace the O-rings, gaskets and sealing washer \ With new ones. \ i Apply engine oil to the large O-ring. 1 Align the water pump slit With camshalt tab. 3 i Align the water bypass hose index mark with the 1 i i water pump tab. ,i - Tighten the water hose band screws to the specified range as shown. ' _. - _ A A _ s A - Route the hoses properly (page 1-25). Fill the recommended coolant mixture to the iiller neck and bleed the air (page 8-6). DISASSEMBLY/ASSEMBLY NOTE When engine removed, remove the water pump assembly. Remove the lollowing: — 6 x 32 mm bolts [1] — Sealing washer [2] — Water pump cover [3] — Gasket [4] — Plate [5] — Gasket [6] — Dowel pins [7] — Water pump body [8] Assembly is in the reverse order oi disassembly. NOTE - Do not disassemble the water pump body. - Replace the gasket and sealing washer with new ones RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the lower cowl (page 2-28). Release the 02 sensor wire [1] irom the radiator reserve tank [2]. Release the resenle tank overflow hose [3]. Remove the bolt [4] and radiator reserve tank. 8-14 COOLING SYSTEM Disconnect the siphon hose [1] and drain the coolant lrorn the reserve tank. Installation is in the reverse order ol removal. NOTE ' Align the radiator reserve tank tab with stay hole. ' Route the hoses properly (page 1-25). Fill the radiator reserve tank with the recommended coolant (page 3-15). FAN CONT. RELAY INSPECTION Remove the maintenance lid (page 21—6). Open the luse/relay box cover and remove the FAN CONT. RELAY [1]. Connect an ohmmeter to the FAN CONT. RELAY [1] connector terminals. Connect a 12 V battery to the FAN CONT. RELAY connector terminals as shown. There should be continuity only when 12 V batter is connected. ll there is no continuity only when the 12 V battery is connected, replace the FAN CONT. RELAY. 8-15 MEMO 9. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM SERVICE |NFORMAT|0N TnouBLESHOOTING................................... OIL PRESSURE INSPECTION 9-2 9-4 9-5 9-6 OIL PUMP (NC700X/XA/S/SA) OIL PUMP (NC700XD/SD)------------- OIL STRA|NER . LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM NC700X/XA/S/SA: ROCKER ARM SHAFT CAMSHAFT PISTON EOP SWITCH OIL FILTER CARTRIDGE PRESSURE RELIEF VALVE CRANKSHAFT OIL PUMP OIL STRAINER MAINSHAFT COUNTERSHAFT 9-2 LUBRICATION SYSTEM NC7DOXD/SD: ROCKER ARM SHAFT CAMSHAFT EOP SWITC H OIL FILTER CARTRIDGE PISTON PRESSURE RELIEF VALVES EOP SENSOR CRANKSHAFT CLUTCH OIL PUMP ENGINE OIL PUMP OIL STRAINER MAINSHAFT COUNTERSHAFT LINEAR SOLENOID VALVE LUBRICATION SYSTEM SERVICE INFORMATION GENERAL ACAUTION Used engine oil may cause skin cancer it repeatedly lelt in contact with the skin Ior 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 oi the oil pump and oil strainer. The oil pump and oil strainer can be serviced With the engine installed in the irame. The service procedures in this section must be perlormed with the engine oil drained. When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. ll any portion ot 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. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil NC700X/XA/S/SA Alterdraining 3.1 liters (3.3 US qt, 2.7 Imp qt) — capac‘w a't‘eer'cdlg'ng‘gg/ 3.4 liters (3.6 us qt, 3.0 imp qt) — Sigisembw 3.7 liters (3.9 us qt, 3.3 imp qt) — NC700XD/SD Alter draining 3.2 liters (3.4 US qt, 2.8 Imp qt) — Q't‘eer’fhrgng‘gg’ 3.4 liters (3.6 us qt, 3.0 imp qt) — agggsembw 4.1 liters (4.3 us qt, 3.6 imp qt) — Recommended engine oil Honda "II-stroke motorcycle oil" or an equivalent API service classilication: S6 or higher (except oils labeled as energy conserving — on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA Oil pressure at engine oil tiller 470 kPa (4.8 kgt/cm , 68 psi) at 5,000 min‘ (rpm)/(80°C/176°F) _ Oil pump rotor (NC700X/XA/S/SA) Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 — 0.21 (0.006 — 0.008) 0.35 (0.014) Side clearance 0.04 — 0.09 (0.002 — 0.004) 0.12 (0.005) Engine oil pump rotor (NC700XD/SD) Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 — 0.21 (0.006 — 0.008) 0.35 (0.014) Side clearance 0.04 — 0.09 (0.002 — 0.004) 0.12 (0.005) Clutch oil pump rotor (NC700XD/SD) Tip clearance 0.15 (0.006) — Body clearance 0.15 — 0.21 (0.006 — 0.008) — Side clearance 0.04 — 0.09 (0.002 — 0.004) — TORQUE VALUE . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgI-m, IbI-It) REMARKS Engine oil lilter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads. 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 levei low - Clogged oil strainer - Fauity oil pump - Internai oil leak - Incorrect oi| being used No oil pressure - Oil levei too low - Oil pressure reliei valve stuck open - Damaged oil pump - Internai oil leak High 'l pressure - Oil pressure reliei valve stuck closed - Clogged oil liiter, oii gallery or metering entice - Incorrect oi| being used Oil contamination - Oil or iiiter not changed olten enough - Worn piston rings Oil emulsilication - Blown cylinder head gasket - Leaky coolant passage - Entry ol water LUBRICATION SYSTEM OIL PRESSURE INSPECTION Remove the Iollowing: — Lower cowl (page 2-28) — Engine oil Iilter cartridge (page 3—13) Apply engine oil to the O-ring and install the oil pressure attachment [1] onto the oil Iilter boss. TOOL: Oil pressure gauge attachment 070MJ-0010101 Apply engine oil to the O-ring and install the engine oil Iilter cartridge [2] onto the oil pressure attachment. TOOL: Oil Iilter wrench 07HAA-PJ70101 TOROUE:26 N-m (2.7 kgf—m,19lbt-It) Connect the oil pressure gauge [3] and attachment [4] to the oil pressure gauge attachment. TOOLS: Oil pressure gauge set 0750643000001 or equivalent commercially available Oil pressure gauge attachment 07406-0030000 or equivalent commercially available Fill the engine With the recommended engine oil (page 3-12). Warm the engine to normal operating temperature (approximately 80°C/176°F) and increase the engine speed to 6,000 min‘ (rpm) and read the oil pressure. STAN DARD: 470 kPa (4.8 kgl/cmz, 68 psi) at 5,000 min" (rpm)/ (80°C/176°F) Stop the engine and remove the tools. Install the Iollowmg: — Engine oil Iilter cartridge (page 3—13) — Lower cowl (page 2-28) OIL PUMP (NC700X/XA/S/SA) REMOVAL/INSTALLATION Remove the right crankcase cover (page 11—5). Remove the bolts [1] and oil pump [2]. Remove the O-rings [1] and dowel pins [2]. Installation is in the reverse order ol removal. NOTE - Replace the O-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 [3]- Remove the thrust washer [4], oil pump shaft [5], drive pin [6], outer rotor [7] and inner rotor [B] from the oil pump body [9]. Clean all disassembled parts thoroughly. Assembly is in the reverse order ol disassembly. NOTE Dip all parts in clean engine oil. INSPECTION NOTE It any portion ol the oil pump is worn beyond the service limit, replace the oil pump as an assembly. Temporarily install the outer and inner rotors into the oil pump body. Temporarily install the drive pin and oil pump shaft. Measure the rotor tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) TIP CLEARANCE: LUBRICATION SYSTEM Measure the pump body clearance. SERVICE LIMIT: 0.35 mm (0.014 in) Measure the side clearance using a straight edge and teeler gauge. SERVICE LIMIT: 0.12 mm (0.005 in) OIL PUMP (NC700XD/SD) REMOVAL/INSTALLATION Remove the right crankcase cover (page 12-97). Remove the bolts [1] and oil pump [2]. Remove the O-rings [1] and dowel pins [2]. Installation is in the reverse order ol removal. NOTE - Replace the O-rings with new ones. - Align the oil pump shaIt end with the balanoer shaft groove. BODV CLEARANCE: SIDE CLEARANCE: 9-8 LUBRICATION SYSTEM DISASSEMBLY Remove the bolts [1] and oil pump cover [2]. Remove the Clutch 0“ pump inner rotor [1] and outer 1 2 rotor [2]. l 1 l 1 Remove the drive pin [1], Oil pump plate [2] and dowel pins [31- [a] Remove the oil pump shaft [1], drive pin [2], engine oil pump inner rotor [3] and outer rotor [4]. 9-9 LUBRICATION SYSTEM INSPECTION Engine oil pump: Temporarily install the inner rotor, outer rotor, drive pin and (MI pump shait into the OlI pump body. Clutch oil pump: Temporarily install the inner rotor, outer rotor, drive pin and (MI pump shait into the OlI pump cover. Measure the rotor tip clearance. Engine oil pump SERVICE LIMIT: 0.20 mm (0.003 in) Clutch oil pump STANDARD: 0.15 mm (0.006 in) Measure the pump body clearance. Engine oil pump SERVICE LIMIT: 0.35 mm (0.014 in) Clutch oil pump STANDARD: 0.15 — 0.21 mm (0.006 — 0.003 in) Measure the side clearance using a straight edge and Ieeler gauge. Engine oil pump SERVICE LIMIT: 0.12 mm (0.005 in) Clutch oil pump STANDARD: 0.04 — 0.09 mm (0.002 — 0.004 in) TIP CLEARANCE: BODY CLEARANCE: SIDE CLEARANCE: 9-10 LUBRICATION SYSTEM ASSEMBLY Assembly IS in the reverse order o1 disassembly. NOTE Dip all parts in clean engine oil. CLUTCH OIL PUMP OIL PUMP PLATE INNER ROTOR DRIVE PIN CLUTCH OIL PUMP OUTER ROTOR DOWEL PIN OIL PUMP BODY ENGINE OIL PUMP DOWEL PIN OUTER ROTOR ENGINE OIL PUMP OIL PUMP COVER INNER ROTOR OIL PUMP SHAFT OIL STRAI NER REMOVAL Drain the engine oil (page 3-13). Remove the exhaust pipe/muffler (page 2-32). Loosen the bolts [1] in a crisscross pattern m 2 or 3 steps, and remove the bolts and owl pan [2]. 9-11 LUBRICATION SYSTEM Remove the oil strainer [1] and seal ring [2]. Clean the oil strainer screen and check tor damage, replace it il 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 surlace thoroughly. Apply liquid sealant (Three Bond 12073 or equivalent) to the oil pan mating surface as shown. NOTE Do not apply more liquid sealant than necessary. Install the oil pan [1] and bolts [2]. Tighten the bolts in a crisscross pattern in 2 or 3 steps. Install the exhaust pipe/muffler (page 2-32). Fill the engine With the recommended engine oil and check that there are no oil leaks (page 3-12). 9-12 10. CYLINDER HEADNALVES COMPONENT LOCATION----- -----10-2 ROCKER ARM ----- -- ---10-8 SERVICE INFORMATION -----10-3 CAM CHAIN TENSIONER ------10-11 TnouBLESHoonNG.................................10.4 CAMSHAFT ............................................. "10.13 m CYLINDER COMPREssmN TEST.............10_5 CYLINDER HEAD ................................... "10.15 CYLINDER HEAD COVER..........................10.5 10-1 CYLINDER HEAD/VALVES COMPONENT LOCATION 10 N-m (1.0 kgf-m, 7 mm) 55 N-m (5.7 Kgl-m, 41 mm) 4.0 N-m (0.4 kgf-m, 3.0 mm) 44 N-m (4.5 kgl-m, 32 lbf-ft) 29 N-m (3.0 kgf-m, 21 mm) 1 0-2 CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL - This section covers service ol the cylinder head, valves, camshaft and rocker arm. - The rocker arm services can be done WIth the engine installed In the lrame. The cylinder head, valves and camshalt service requires engine removal. - When disassembling, mark and store the disassembled parts to ensure that they are reinstalled In theiroriginal locations. - Clean all disassembled parts with cleaning solvent and dry them by blowing them oll with compressed air belore inspection. - Camshaft lubricating oil is led through oil passages in the cylinder head. Clean the oil passages before assembling cylinder head. - Be careful not to damage the mating surlaces when removing the clender head cover and clender head. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 470 min ‘(rpm) 1,775 kPa (18.1 kgf/cm , 257 psi) — Valve clearance IN 0.17 t 0.02 (0.007 t 0.001) — EX 0.28 t 0.02 (0.011 t 0.001) — Rocker arm, Rocker arm |.D. 20.012 — 20.030 (0.7879 — 0.7886) 20.041 (0.7890) rocker arm Rocker arm shalt O.D. 19.972 — 19.993 (0.7863 — 0.7871) 19.961 (0.7859) 503“ Rocker arm-to-shalt clearance 0.019 — 0.058 (0.0007 — 0.0023) 0.08 (0.003) Cam chain tensioner wedge B length — 6.0 (0.24) Gamma“ ca’" '0“ “'9” IN 34.7997 — 35.0297 (1.36967 — 1.37912) 34-7697 (1 .36888) 34.9027 EX 34.9227—35.1627 (1.37491 —1.38436) (1.37412) Runout — 0.04 (0.002) Camshaft journal 0.0. 41935—41950 (16510—16516) 41.927 (1.6507) Valve, valve Valve stem CD. IN 4.975 — 4.990 (0.1959 — 0.1965) 4.965 (0.1955) guide EX 4.965 — 4.990 (0.1955 — 0.1961) 4.955 (0.1951) Valve guide |.D. IN/EX 5.000—5.012(01969—01973) 5.04 (0.198) Stem-to-guide IN 0.010 — 0.037 (0.0004 — 0.0015) 0.075 (0.0030) clearance EX 0.020 — 0.047 (0.0008 — 0.0019) 0.085 (0.0033) Valve guide IN 17.7 — 18.0 (0.70 — 0.71) — ro ectIon above ‘C’yIiJnderhead EX 19.6— 19.9 (0.77—0.79) — Valve seat wIdth IN 0.90 — 1.10 (0.035 — 0.043) 1.5 (0.06) EX 1.30 — 1.50 (0.051 — 0.059) 1.9 (0.07) Valve spring free length 49.07 (1.932) 48.1 (1.89) Cylinder head warpage — 0.10 (0.004) Cylinder head camshaft)ournal |.D. 41.995 — 42.019 (1.6533 — 1.6543) 42.027 (1.6546) Cylinder head-to-camshaft clearance 0.045 — 0.084 (0.0018 — 0.0033) 0.10 (0.004) TORQUE VALUES , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbf-It) REMARKS Cylinder head cover socket bolt 3 6 10 (1.0, 7) Breather plate mounting bolt 8 6 12 (1.2, 9) Apply locking agent to the threads. Coating WIdth; 6.5 11.0 mm (0.26 i 0.04 in) except2.0 :1.0 mm (0.08 1 0.04 in) from tip Rocker arm shaft bolt 3 8 29 (3.0, 21) Apply engIne oil to the threads and seatIng surface. Camshaft maintenance cap 1 36 4.0 (0.4, 3.0) See page 10-11 See page 10-28 Cam chain tensioner bolt 2 6 12 (1.2, 9) Cam sprocket bolt 1 10 56 (5.7, 41) Apply engIne oil to the threads and seatIng surface. Water hose band screw 6 — — See page 10-16 Insulator band screw 1 5 — See page 10-25 Cylinder head special bolt 6 9 44 (4.5, 32) Apply molybdenum oil solution to the threads and seatIng surface. 1 0-3 CYLINDER HEAD/VALVES TROUBLESHOOTING ~ Engine top-end problems usually attect engine pertormance. These problems can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rod stethoscope. ~ Ii the pertormance is poor at low speeds, check tor white smoke in the crankcase breather hose. It the hose is smoky, check tor 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 camshatt — 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 1 0-4 CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Remove the Iollowing: — Shroud/side cover (NC700X/XA/XD) (page 2-14) — Shelter/side cover (NC7ODS/SA/SD) (page 2—15) — Lower cowl (page 2-28) Warm the engine to normal operating temperature. Stop the engine and remove the all spark plug caps and spark plugs (page 3-8). Disconnect the Iuel pump 1 P (Black) connector [1]. 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. The maximum reading is usually reached within 4 — 7 seconds. STANDARD: 1,775 kPa (18.1 kgI/cm’, 257 psi) at 470 min“ (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 Remove the bolts [1] and radiator lower stay [2]. Release the radiator boss lrom the radiator mounting rubber [3]. 1 0-5 CYLINDER HEAD/VALVES Release the fan motor 3P (Gray) connector [1], air cleaner housing drain hose [2] and spark plug Wire [3] from the radiator. Lower the radiator and disconnect the crankcase breather hose [1]. NOTE Be careful not to damage the radiator lins. Remove the cylinder head cover socket bolts [1] and mounting rubbers [2]. NOTE Be careful not to damage the radiator lins. [1 l/[2] Remove the cylinder head cover [1] from the cylinder head. NOTE Be careful not to damage the radiator lins. Remove the cylinder head cover packing [2] from the cylinder head cover. 1 0-6 Installation is in the reverse order ot removal. NOTE - Replace the cylinder head cover packing With a new one. - Check the mounting rubbers [1] are in good condition, replace them it necessary. - Install the mounting rubbers with their "UP" mark [2] facing up. - Route the wire harness and hoses properly (page 1- 25). - Make sure the radiator mounting rubber slits facing down. - Align radiator lower stay slit with cylinder head tab. TORQUE: Cylinder head cover socket bolts: 10 Nm (1.0 mm, 7 lbt-l‘t) DISASSEMBLY/ASSEMBLY Remove the breather plate mounting bolts [1]. Remove the breather plate [1] and gasket [2]. Assembly is in the reverse order oi disassembly. NOTE - Replace the breather plate gasket With a new one. - Apply locking agent to the breather plate mounting bolt threads (page 10-3). TORQUE: Breather plate mounting bolt: 12 Nm (1.2 mm, 9 lbt-l‘t) CYLINDER HEAD/VALVES [2] 1 0-7 CYLINDER HEAD/VALVES ROCKER ARM REMOVAL Remove the cylinder head cover (page 10-5). in ' Remove the camshaft maintenance cap [1] and O-ring [2]. Remove the crankshalt hole cap (page 3—10). Turn the crankshaft counterclockwise and align the "A" mark [1] on the cam sprocket with the lower cylinder head index line [2]. Remove the rocker arm shalt bolts [1]. Remove the rocker arm assembly [1]. NOTE Be carelul not to let the dowel pin [2] lall into the crankcase. Remove the dowel pin from the rocker arm shalt. 1 0-8 DISASSEMBLY/ASSEMBLY Remove the washers [1] and rocker arms from the rocker arm shaft [2]. Apply molybdenum oil solution to the rocker arm sliding surlace and rocker arm shaft outer surlace. 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 5 [4] N0 mark: Intake rocker arm P [5] "PWC-B" mark: exhaust rocker arm B [6] CYLINDER HEAD/VALVES 77a [2] INSPECTION Check the sliding surlace ol each rocker arm Ior wear or damage. Check the oil hole Ior clog ol each rocker arm. Measure the rocker arm I.D. SERVICE LIMIT: 20.041 mm (0.7890 in) 1 0-9 CYLINDER HEAD/VALVES Check the sliding surlace ol the rocker arm shalt lor wear or damage. Check the 0“ hole lor clog ol the rocker arm shaft. Measure the rocker arm shalt CD. at the rocker arm sliding area. SERVICE LIMIT: 19.961 mm (0.7859 in) Calculate the rocker arm-to-shalt clearance. SERVICE LIMIT: 0.08 mm (0.003 in) INSTALLATION Make sure the "A" mark [1] on the cam sprocket lacing ' the lower cylinder head index line [2]. II it does not align, turn the crankshaft counterclockwise and align II. Install the dowel pin [1] to the rocker arm shaft. Install the rocker arm assembly [2]. NOTE - Align boss [3] and dowel pin with the cylinder head holes [4]. - Make sure the washers [5] are installed in correct position. - Be carelul not to let the dowel pin laII into the crankcase. Apply engine oil to the rocker arm shalt bolts threads and seating surlace. Install and tighten rocker arm shaft bolts [1] to the specified torque. TORQUE:29 N-m (3.0 kgf‘m, 21 let) 10-10 CYLINDER HEAD/VALVES V Apply engine oil to a new O—ring [1] and install it to the camshaft maintenance cap [2]. Temporarily Install the camshaft maintenance cap to the cylinder head. ll the engine is removed from the frame, tighten the camshaft maintenance cap to the specified torque. TORQUE:4.0 N-m (0.4 kgI-m, 3.0 lbI-ft) ll the engine is installed on the lrame, insert a ieeler gauge (0.1 mm) [1] between the camshaft maintenance cap and cylinder head. Tighten the camshalt maintenance cap securely. Remove the ieeler gauge. Further tighten the camshaft maintenance cap at 30°. NOTE One concave area [2] size is equivalent with 30". Install the lollowmg: — Cylinder head cover (page 10-5) — Crankshaft hole cap (page 3-12) CAM CHAIN TENSIONER CAM CHAIN INSPECTION Remove the cylinder head cover (page 10-5). Measure the cam chain tensionerwedge 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. 6.0 mm (0.24 in) For the cam chain replacement, remove the Iollowmg: — Cam sprocket (page 10-13) — Primary drive gear — NC7DOX/XA/S/SA (page 11—15) — NC7DOXD/SD (page 12-108) RELEASING CAM CHAIN TENSION Remove the cylinder head cover (page 10-5). Install an 0D. 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]. NOTE Be careful not to let the 2 mm pin lall into the crankcase. CYLINDER HEAD/VALVES REMOVAL/INSTALLATION Remove the thermostat housing (page 8-7). [3] Release the cam chain tension (page 10-11). Remove the cam chain tensioner bolts [1] and sealing washers [2]. Remove the cam chain tensioner [3]. a? [1 1/[2] Nd Install the cam chain tensioner [1] while aligning tensioner end With the groove in the crankcase. Install new sealing washers, cam chain tensioner bolts I and tighten the cam chain tensioner bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf‘m, 9 Ith) Apply the cam chain tension (page 10-12). Install the thermostat housing (page 8—7). INSPECTION Remove the cam chain tensioner (page 10-12). Check the cam chain tensioner [1] lor wear or damage. Replace the cam chain tensioner it necessary. Remove the cam chain guide (page 10—16). Check the cam chain guide [2] for wear or damage. Replace the cam chain guide if necessary. 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]. NOTE Be careful not to let the 2 mm pin Iall into the crankcase. Install the cylinder head cover (page 10-5). 10-12 CYLINDER HEAD/VALVES CAMSHAFT REMOVAL Remove the engine. — NC700X/XA/S/SA (page 16—5) — NC700XD/SD (pagelG-S) Loosen the water hose band screw [1] and disconnect the water bypass hose. Remove the bolts [2], water pump [3] and O-rings [4]. Remove the rocker arm (page 10-8). Release the cam chain tension (page 10-11). Loosen the cam sprocket bolt [1] by holding the r flywheel mounting bolt and remove it. Remove the cam sprocket bolt and cam sprocket [2] by I . removing the cam chain [3] trom the cam sprocket. .3‘ ’ H 11 NOTE H“ Attach a piece 01 wire to the cam chain to prevent it ‘ I trom falling into the crankcase. Remove the camshaft [1]. INSPECTION CAMSHAFT Check the cam and journal surlaces of the camshalt tor scoring, scratches or evidence of insuflicient lubrication. Support both sides ol the camshalt (at journals) with V- blocks and check the camshatt runout with a dial gauge. SERVICE LIMIT: 0.04 mm (0.002 in) 10-13 CYLINDER HEAD/VALVES Using a mlcrometer, measure each cam lobe height. SERVICE LIMITS: IN: 34.7697 mm (1.36888 in) ex: 34.9021 mm (1.37412 in) Measure the camshaft journals O.D. SERVICE LIMIT: 41.927 mm (1.6507 in) CYLINDER HEAD Measure the cylinder head camshaIt journal |.D. SERVICE LIMIT: 42.027 mm (1.6546 in) Calculate the cyllnder head-to-camshaft clearance. SERVICE LIMIT: 0.10 mm (0.004 in) CAM SPROCKET Check the cam sprocket teeth tor wear or damage. 10-14 CYLINDER HEAD/VALVES INSTALLATION Apply molybdenum oil solution to the camshaft lobes, journals and thrust surfaces. Install the camshaft [1]. Align the "IT" mark on the flywheel with the index notch on the alternator cover (page 3-10). Align the ' 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 NM (5.1 kngm, 41 let) Apply the cam chain tension (page 10-12). Install the rocker arm (page 10-10). Ti 1 g "}I [1] Align Apply engine oil to a new large O-ring [1] and install it to the water pump [2]. Install a new O-ring [3] to the water pump. Install the water pump to the cylinder head. NOTE Align the water pump shaft groove with camshalt tab. 10-15 CYLINDER HEAD/VALVES Install and tighten the bolts [1]. Connect the water bypass hose [2]. NOTE - Align the water bypass hose index mark with the water pump tab. - Route the hoses properly (page 1-25). Tighten the water hose band screws to the specified range as shown. Install the engine. — NC700X/XA/S/SA (page 16—15) — NC700XD/SD (page 16-21) CYLINDER HEAD REMOVAL Remove the tollowing: — Engine — NC7DOX/XA/S/SA (page 16-5) — NC700XD/SD (page 16-9) — Cylinder head cover (page 10-5) — Right crankcase cover — NC7DOX/XA/S/SA(page 11-5) — NC700XD/SD (page 12-97) Remove the camshaft maintenance cap [1] and O-ring [2]- (o — 0.04 in) 10-16 CYLINDER HEAD/VALVES 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 "A" mark [1] on the cam sprocket tacing ' the lower cylinder head index line [2]. Ii the "A" mark on the cam sprocket is facing the upper ‘ cylinder head index line [3], turn the crankshaft clockwise one tull turn (360°) and realign the "A" mark 1 with the lower cylinder head index line. ‘ Remove the cam chain tensioner (page 10-12). Insert the gear holder [1] between the primary drive gear and driven gear. TOOL: Gear holder, 2.5 07724-0010100 Remove the cam sprocket bolt [2]. Remove the cam sprocket [3] by removing the cam chain [4] lrom the cam sprocket. NOTE Attach a piece 01 wire to the cam chain to prevent it lrom falling into the crankcase. 10-17 CYLINDER HEAD/VALVES Remove the 6 mm bolts [1]. Remove the cylinder head special bolts [1]. NOTE Loosen the cylinder head special bolts in a crisscross pattern in 2 or 3 steps. Remove the cylinder head [2]. NOTE - Attach a piece ol Wire to the cam chain to prevent it from lalling into the crankcase. - Do not strike the cylinder too hard and do not damage the mating surlace With a screwdriver. Remove the gasket [1], dowel pins [2] and cam chain 7 guide [3]. Remove the partition plate [1]. Check the partition plate lor deterioration or damage. 10-18 CYLINDER HEAD/VALVES DISASSEMBLY Remove the lollowing: — Cylinder head (page 10—16) Spark plug (page 3-8) — Injector (page 7-20) — Camshalt (page 10-13) 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 NOTE To prevent loss 01 tension, do not compress the valve springs more than necessary to remove the cotters. Remove the lollowing: — Spring retainer [1] — Valve spring [2] — Valve [3] — Stem seal [4] — Valve spring seat [5] NOTE Mark all parts during disassembly so they can be placed back in theiroriginal locations. INSPECTION CYLINDER HEAD Remove carbon deposits lrorn the combustion chambers [1]. NOTE Avoid damaging the gasket surlace. Check the spark plug hole and valve areas lor cracks. CYLINDER HEAD/VALVES Check the cylinder head lor warpage with a straight edge and leeIer gauge. SERVICE LIMIT: 0.10 mm (0.004 in) VALVE SPRING Measure the lree length ol the valve spring. SERVICE LIMIT: 48.1 mm (1.89 in) Replace the springs il they are shorter than the service 7 limits. g VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide. Inspect each valve Ior bending, burning or abnormal stern wear. Measure and record each valve stem O.D. SERVICE LIMITS: IN: 4.965 mm (0.1955 in) EX: 4.955 mm (0.1951 In) Ream the guides to remove any carbon deposits before checking clearances. Insert the reamer [1] lrorn the combustion chamber side of the cylinder head and always rotate the reamer c|ockwrse. TOOL: Valve guide reamer, 5.010 mm 07984-MA60001 10-20 CYLINDER HEAD/VALVES Fla/ace the valve seals whenever me valve guldes are replaced (page 10. 22). Do not use a torch to heal the cylinder head: it may muse warping. Use cutting oil on the reamer durlrig this aperaiian. Measure and record each valve guide I.D. SERVICE LIMIT: 5.04 mm (0.198 in) Subtract each valve stem O.D. lrom the corresponding guide ID. to obtain the stem—to-guide clearance. SERVICE LIMITS: IN: 0.075 mm (0.0030 in) EX: 0.005 mm (0.0033 In) II the stem-to-guide clearance is out ol standard, determine il a new guide with standard dimensions would bring the clearance within tolerance. If so, replace any guides as necessary and ream to lit. II the stem-to—guide clearance exceeds the sen/ice limit with the new guides. replace the valves and guides. VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section ol a refrigerator for about an hour. Heat the cylinder head to 100 — 150°C (212 — 302°F) with a hot plate or oven. To avoid burns, wear heavy gloves when handling the heated cylinder head. Support the cylinder head and drive out the valve guides from combustion chamber side of the cylinder head. TOOL: Valve guide driver [1] 07942-8920000 Drive in the valve guides to the specilied depth lrorn the top of the cylinder head. SPECIFIED DEPTH: IN: 17.7 — 18.0 mm (0.70 — 0.71 in) ex:19.e —19.9 mm (0.77 — 0.73 in) in , v in, nil/m, TOOL: Valve guide driver [1] 07743-0020000 Let the cylinder head cool to room temperature. Ream new valve guides after installation. Insert the reamer [1] lrorn the combustion chamber side of the cylinder head and always rotate the reamer clocKWise. TOOL: Valve guide reamer, 5.010 mm 07984-MA60001 Clean the cylinder head thoroughly to remove any metal particles. Relace the valve seat (page 10-22). 10-21 CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating oI Prussian Blue to the valve seats. Tap the valves and seats using a rubber hose or other hand-lapping tool [1]. Remove the valve and inspect the valve seat iace. The valve seat contact should be within the speciiied width and even all around the circumlerence. 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 (0.0 ' EX: 1.9 mm (0.0 n) II the seat width is not within specification, reiace the valve seat (page 10-23). Inspect the valve seat iace Ior: ' Uneven seat Width: — Replace the valve and reiace the valve seat. ' Damaged lace: — Replace the valve and reiace the valve seat. The valves cannot be ground. II a valve Iace lS burned or badly worn or it it contacts the seat unevenly, replace the valve. ' Contact area (too high or too low) — Relace the valve seat. [1] I I SEAT WIDTH 10-22 Follow the relacing manulacturer's operating instructions. Helace the seat with a 45° Cutter whenevera valve guide is replaced. VALVE SEAT REFACING Valve seat cutters/grinders or equivalent valve seat reiacing equipment are recommended to correct worn valve seats. It the contact area is too high on the valve, the seat must be lowered using a 32° ilat cutter. It the contact area is too low on the valve, the seat must be raised using a 60° interior cutter. Relinish the seat to specifications, using a 45° linish cutter. Use a 45° cutter to remove any roughness or irregularities lrom the seat. TOOLS: Seat cutter, 27.5 mm (45° IN) Seat cutter, 24 mm (45° EX) Cutter holder, 5.0 mm 07780-0010200 07780-0010600 07781 -0010400 Use a 32° cutter to remove the top 1/4 ol 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 at 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. Relinish it necessary. After cutting the seat, apply lapping compound to the valve iace, and lap the valve using light pressure. - Excessive lapping pressure may deform or damage the seat. - Change the angle 0! lapping tool [1] frequently to prevent uneven seat wear. - Do natal/0w lapping compound to enter the guides. After lapping, wash all residual compound oll the cylinder head and valve. Recheck the seat contact aiter lapping. CYLINDER HEAD/VALVES 10-23 CYLINDER HEAD/VALVES ASSEMBLY @ INSULATOR COTTE RS RETAINER % , VALVE SPFIING / i : STEM SEAL g \, SPRING SEAT VALVE GUIDE 3 INTAKE VALVE EXHAUST VALVE Install the Valve spring seats [1]. Apply engine oil to new stem seals [2] inside and install them. Apply molybdenum oi| solution to the valve stem sliding surlace 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 lacing the combustion chamber. Install the Valve spring retainer [5]. 7i [3] [1] “I I COMBUSTION CHAMBER SIDE 10-24 CYLINDER HEAD/VALVES Install the valve cutters using the special tool as shown. TOOL: Valve spring compressor 07757-0010000 NOTE - 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 shall as shown to seat the cotters tirmly. NOTE Support the cylinder head above the work bench surlace to prevent possible valve damage. Install the insulator [1] while aligning its slit With cylinder head tab. Tighten the band screw [2] to the specified range. Install the IoIIoWing: Camshalt (page 10-15) Injector (page 7-21) Spark plug (page 3-8) — Cylinder head (page 10—25) INSTALLATION Install the partition plate [1] to the No.1 cylinder intake side. NOTE Install the partition plate with its tab [2] side facing inside. 10-25 CYLINDER HEAD/VALVES Install the cam chain guide [1]. NOTE - 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]. 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 [2] special bolts [2] threads and seating surlace. Install and tighten the cylinder head special bolts in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE“ N-m (4.5 kgf‘m, 32 let) Install and tighten the 6 mm bolts [1]. 10-26 CYLINDER HEAD/VALVES Turn the crankshaft clockwise and align the index lines [1] with the crankcase matting surface, while the "TOP" mark [2] is facing down. NC700X/XA/S/SA ’ {21 V 5550/30: v“ Install the cam sprocket to the camshaft while installing cam chain [1] onto the cam sprocket. NOTE - Install the cam sprocket with its "MGS" mark [2] facing out. - Align the cam sprocket slit with camshalt pin. , - Align the cam sprocket "A" mark with cylinder head lower index line. Align' " I 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 TORQUE:56 Nam (5.7 kgl‘m, 41 let) Install the cam chain tensioner (page 10-12). 10-27 CYLINDER HEAD/VALVES Apply engine oil to a new O—ring [1] and install it to the camshaft maintenance cap [2]. Temporarin Install the camshaft maintenance cap to the cylinder head. It 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 lbl-ft) It 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 One concave area [2] size is equivalent with 30". Install the lollowmg: — Cylinder head cover (page 10-5) — Right crankcase cover — NC7DOX/XA/S/SA (page 11-5) — NC7DOXD/SD (page 12-103) — Engine — NC7DOX/XA/S/SA (page 16-15) — NC7DOXD/SD (page 16-21) 10-28 11. CLUTCH/GEARSHIFI' LINKAGE (NC700X/XA/S/SA) COMPONENT LOCATION----- -----11-2 CLUTCH-------- SERVICE INFORMATION -----11-3 PRIMARY DRIVE GEAR/CKP SENSOR ROTOR .................................................... .. 11.15 TROUBLESH00T|NG.................................11.4 GEARSHIFT L|NKAGE ........................... "11.15 RIGHT CRANKCASE COVER n GEARSHIFT PEDAL ............................... "11.19 11-1 CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) COMPONENT LOCATION 23 N-m (2.3 kgf-m,17|bf-ll) 12 N-m (1.2 kgI-m, 9 lbl-h) 11-2 SERVICE INFORMATION GENERAL CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) - This section covers service 01 the clutch and gearshilt linkage. All service can be done with the engine installed in the lrame. - Engine oil viscosity and level have an ellect on clutch disengagement. Oil additives also eilect clutch periormance 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. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch lever treeplay 10 — 20 (3/3 — 13/16) — Clutch Spring tree length 43.2 (1.70) 41.7 (1.64) Disc thickness 2.62 — 2.78 (0.103 — 0.109) 2.3 (0.09) Plate warpage — 0.30 (0.012) Clutch outer guide l D 21.991 — 22.016 (0.3658 — 0.8668) 22.03 (0.867) 6.0. 31.959 — 31.975 (1.2532 — 1.2539) 31.92 (1.257) Mainshatt CD. at clutch outer guide 21.967 — 21.980 (0.8648 — 0.8654) 21.95 (0.364) Clutch outer guide-to-mainshatt clearance 0.011 — 0.049 (0.0004 — 0.0019) 0.08 (0.003) Primary driven gear |.D. 32.000 — 32.025 (1.2598 — 1.2608) 32.09 (1.263) Primary driven gear-to-clutch outer guide clearance 0.025 — 0.066 (0.0010 — 0.0026) 0.10 (0.004) TORQUE VALUES . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgf—m, lbf-It) REMARKS Clutch center lock nut 1 18 128 (13.1, 94) Apply engine oil to the threads and seating surtace. Lock nut; replace with a new one and stake. Clutch lilter plate bolt 4 6 12 (1.2, 9) Primary drive gear mounting bolt 1 10 93 (9.5, 69) Apply engine oil to the threads and seating surface. Shin drum stopper arm pivot bolt 1 6 12 (1.2, 9) Apply locking agent to the threads. Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) except2.0 11.0 mm (0.08 1 0.04 in) irom tip Shin drum center socket bolt 1 8 23 (2.3, 17) Apply locking agent to the threads. Coating Width; 6.5 11.0 mm (0.26 1 0.04 in) except2.0 11.0 mm (0.08 1 0.04 in) irom tip Gearshilt pedal adjuster lock nut 2 6 10 (1.0, 7) Gearshilt pedal pivot bolt 1 8 27 (2.3, 20) 11-3 CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) TROUBLESHOOTING Clutch lever is too hard to pull in ~ Damaged, kinked or dlrty clutch cable ~ Improperly routed clutch cable ~ Damaged clutch lifter mechanism ~ Faulty clutch lifter bearlng ~ Clutch llfter plece installed improperly Clutch slips when accelerating ~ Clutch lifter stlcklng ~ Worn clutch disc ~ Weak clutch sprlngs ~ No clutch lever Ireeplay ~ Englne oi| mixed with molybdenum or graphlte additive Clutch will not disengage or motorcycle creeps with clutch disengaged Excesslve clutch lever Ireeplay Clutch plate warped Englne oil level too high, Improper englne oi| viscoslty or additive used Loose clutch center lock nut Damaged clutch lifter mechanism Clutch lltter rod installed improperly Worn clutch outer slot and clutch center grooves Improper clutch operatlon Hard to shift Misadjusted clutch cable Improper clutch operatlon Improper englne oi| viscoslty Damaged or bent shift Iork Bent shift Iork shalt Bent shift Iork claw Loose shilt drum stopper plate bolt Damaged shllt drum stopper plate Damaged shlltdrum guide grooves Damaged or bent gearshilt spindle Transmission jumps out at gear ~ Worn shift drum stopper arm ~ Weak or broken shilt drum stopper arm return spring ~ Loose shilt drum stopper plate boIt ~ Damaged shllt drum stopper plate ~ Bent shift Iork shalt ~ Damaged or bent shift Iorks ~ Worn gear engagement dogs or slots Gearshitt pedal will not return ~ Weak or broken gearshift splndle return spring ~ Damaged or bent gearshilt spindle 11-4 CLUTCH/GEARSHIFI' LINKAGE (NC700X/XA/S/SA) RIGHT CRANKCASE COVER REMOVAL/INSTALLATION Remove the lollowing: — Right shroud/side cover (NC7ODX/XA) (page 2-14) — Maintenance lid (page 21 -6) Drain the engine oil (page 3-13). Disconnect the CKP sensor 2P (Red) connector [1] and release the CKP sensor harness. Release the reserve tank overflow hose [1] from the stay [2]. Remove the bolt [3] and stay. Remove the bolts [1] and clutch cable guide [2], then disconnect the clutch cable [3] from the clutch lilter arm [4]- Loosen the right crankcase cover bolts [1] in a crisscross pattern in 2 or 3 steps, and remove the bolts . and sealing washer [2]. Remove the right crankcase cover [3]. CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) Remove the dowel pins [1]. Clean 0" any sealant from the right crankcase cover mating surlaces. Installation is in the reverse order ol removal. NOTE - Apply liquid sealant (Three bond 1207B or equivalent) to the right crankcase cover mating surface as shown. Do not apply more liquid sealant than necessary. Apply liquid sealant (Three bond 1207B or equivalent) to the CKP sensor Wire grommet sealing surface. Replace the sealing washer with a new one. Route the cables and wire harness properly (page 1- 25). Adjust the clutch lever treeplay (page 3-26). Fill the engine With the recommended engine oil and check that there are no oil leaks (page 3-12). CLUTCH LIFTER ARM REMOVAL/ INSTALLATION Remove the clutch lifter rod A [1]. Remove the snap ring [2], clutch litter arm [3] and return spring [4] lrorn the right crankcase cover. Check the return spring for fatigue or damage. Check the lifter arm spindle [1] tor wear or damage. Check the litter arm oil seal [2] and needle bearings [3] 3‘ tor wear or damage. 11-6 CLUTCH/GEARSHIFI' LINKAGE (NC700X/XA/S/SA) Install the clutch litter arm [1], return spring [2] and snap ring [3]. NOTE - 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 litter rod A sliding surlace. Install the clutch litter rod A [6]. CLUTCH REMOVAL Remove the right crankcase cover (page 1 1—5). Remove the clutch lifter rod B [1]. Loosen the clutch litter 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]. NOTE 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] D7JMB-MN50302 Remove and discard the lock nut. CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) Remove the lock washer [1] and thrust washer [2]. Remove the clutch assembly [1]. Remove the tollowing: 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]. [51/[6] 11-8 CLUTCH/GEARSHIFI' LINKAGE (NC700X/XA/S/SA) Replace the clutch springs as a set. Remove the clutch outer guide [1]. INSPECTION CLUTCH LIFTER BEARING Turn the inner race 01 the clutch lifter bearing [1] with yourfinger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate. Replace the clutch lifter bearing ii the inner race does not turn smoothly, quietly, or it the outer race fits loosely in the filter plate. CLUTCH SPRING Measure the clutch spring free length. SERVICE LIMIT: 41.7 mm (1.64 in) CLUTCH CENTEFI Check the grooves [1] ol the clutch center for damage or wear caused by the clutch plates. Replace it if necessary. 11-9 CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) Replace me clutch discs and plates as a set. Replace me clutch discs and plates as a set. CLUTCH LIFI’ER FIOD B Check the clutch lifter rod B ior damage or abnormal wear. CLUTCH DISC Replace the clutch discs it they show signs 01 scoring or discoloration. Measure the disc thickness of each disc. SERVICE LIMIT: 2.3 mm (0.09 in) CLUTCH PLATE Check the plates for discoloration. Check the plate warpage on a surIace plate using a Ieeler gauge. SERVICE LIMIT: 0.30 mm (0.012 in) JUDDEFI SPRING/SPRING SEAT Check the judder spring and spring seat tor deformation. warpage or damage. NOTE - A damaged or warped spring seat will cause the judder spring to be pressed unevenly. - A damaged judder spring also causes the weak contact between the discs and plates or uneven disc/plate contact. 11-10 CLUTCH/GEARSHIFI' LINKAGE (NC700X/XA/S/SA) CLUTCH OUTER/PRIMARY DRIVEN GEAR/CLUTCH OUTER GUIDE Check the slots of the clutch outer for damage or wear caused by the clutch discs. Check the primary driven gear for abnormal wear or damage. Measure the ID. 01 the primary driven gear. SERVICE LIMIT: 32.09 mm (1.263 in) Replace the clutch outer assembly it necessary. Measure the OD. and ID. 01 the clutch outer guide. SERVICE LIMITS: O.D.:31.92 mm (1.257 in) I.D.: 22.03 mm (0.351 in) Calculate the primary driven gear-to-clutch outer guide clearance. SERVICE LIMIT: 0.10 mm (0.004 in) MAINSHAI—‘l’ Measure the mainshaft OD. at clutch outer guide sliding suriaces. SERVICE LIMIT: 21.95 mm (0.864 in) Calculate the clutch cuter guide-tc—mainshaft a clearance. SERVICE LIMIT: 0.08 mm (0.003 in) 11-11 CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) INSTALLATION 7i CLUTCH OUTER GUIDE CLUTCH OUTER THRUST WASHER PRESSURE PLATE L CLUTCH DISC A I \ JUDDER SPRING - , «P “13:32:52: ,, 4! CLUTCH PLATE ’ THRUST WASHER /'9" ’ ‘ LOCK WASHER ‘2 N'"‘ (1-2 WWW f 123 Mm (13.1 kglm, 94 lbf-ft) Ii! CLUTCH SPRING CLUTCH LIFTER ROD B CLUTCH LIFTER BEARING LIFTER PLATE Apply molybdenum oil solution to the clutch outer guide sliding surtace. Install the clutch outer guide [1] to the mainshalt. Install the thrust washer [1] to the clutch outer. 11-12 CLUTCH/GEARSHIFI' LINKAGE (NC700X/XA/S/SA) Apply engine oil to the clutch discs entire surIace. 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]. 7" 30' CLUTCH DISC A: Ea CLUTCH DISC B: %3 5.3 — 5.9 mm (0.21 — 0.23 in) CLUTCH DISC C: r. hfiifl \ Install the clutch center assembly [1] to the clutch cuter [2]- NOTE - 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. CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) Install the thrust washer [1]. Install the lock washer [2] with its "OUTSIDE" mark [3] lacing out. Apply engine oil to a new clutch center lock nut threads and seating surlaoe. Install the clutch center lock nut [1] onto the mainshalt. Hold the pressure plate with the special tool and tighten the lock nut to the specified torque. TOOL: Clutch center holder [2] D7JMB-MN50302 TORQUE: 128 Nm (13.1 kgf‘m, 94 let) Stake the clutch center lock nut [1] into the mainshaft groove. NOTE Be careful not to damage the mainshaft threads. Install the clutch springs [1], lilter 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 MM (1.2 kgf‘m, 9 Ith) Apply engine oil to the clutch lilter rod B sliding surlaoe. Install the clutch litter rod B [4]. Install the right crankcase cover (page 11—5). 11-14 CLUTCH/GEARSHIFI' LINKAGE (NC700X/XA/S/SA) PRIMARY DRIVE GEAR/CKP SENSOR ROTOR REMOVAL Remove the right crankcase cover (page 1 1-5). Hold the primary drive gear [1] using a special tool and . remove the primary drive gear mounting bolt [2] and washer[3]. TOOL: Gear holder, 2.5 [4] Remove the gear holder. 07724-0010100 Remove the CKP sensor rotor [5] and primary drive gear INSPECWON Check the primary drive gear [1] for wear or damage. Check the CKP sensor rotor [2] lor wear or damage. INSTALLATION Install the primary drive gear [1] on the crankshaft. NOTE - Align the primary drive gear wide groove with the crankshaft wide tooth. - Install the primary drive gear with its "OUT" mark [2] facing out. 11-15 CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) Install the CKP sensor rotor [1] on the crankshaft. NOTE - 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 D’ threads and seating surface. _ 7| Install the washer [1] and primary drive gear mounting bolt [2]. Hold the primary drive gear using a special tool and '7 tighten the primary drive gear mounting bolt to the specified torque. TOOL: Gear holder, 2.5 [3] 07724-0010100 TORQUE:93 N-m (9.5 kgf‘m, 69 let) Remove the gear holder. Install the right crankcase cover (page 11-5). GEARSHIFT LINKAGE REMOVAL Remove the following: — Left rear cover (page 2-29) — Right crankcase cover (page 11-5) Clean the gearshift spindle [1]. Remove the gearshift spindle [1] and washer [2]. 11-16 CLUTCH/GEARSHIFI' LINKAGE (NC700X/XA/S/SA) Remove the lollowing: — Shift drum stopper arm pivot bolt [1] — Washers [2] — Stopper arm [3] — Return spring [4] Remove the shilt 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 OlI seal [3]. INSPECTION Check the gearshift spindle for bend, wear or damage. Check the return springs for fatigue or damage. INSTALLATION Install the gearshift spindle OlI seal [1] as shown. NOTE - Install the oil seal with its marked side facing out. - Apply grease to the oil seal lips. (0.02 — 0.06 in) L Es inf 11-17 CLUTCH/G EARSHIFT LINKAGE (NC700X/XA/S/SA) Install the setting plate [1] and a new bolt [2]. NOTE Align the setting plate hole with the crankcase boss. Install the following: — Return spring [1] — Stopper arm [2] — Washers [3] — Shift drum stopper arm pivot bolt [4] NOTE - Apply locking agent to the shift drum stopper arm pivot bolt threads (page 11—3). - Align the return spring hook [5] with stopper arm cut— out. - Install the stopper arm with its "MGS" mark [6] facing out. TORQUE: Shift drum stopper arm pivot bolt: 12 Nm (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 11-3). Install and tighten the shift drum oenter socket bolt [1] to the specified torque. TORQUE:23 N-m (2.3 kgf‘m,17let) 11-18 CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) Install the washer [1] and gearshift spindle [2]. . ‘ NOTE Align the return spring ends with the spring pin. Install the lollowmg: — Right crankcase cover (page 11-5) — Left rear cover (page 2-29) GEARSHIFT PEDAL REMOVALNNSTALLAHON Loosen the gearshift pedal adjuster lock nuts [1] and remove the tie-rod [2]. Remove the gearshilt pedal pivot bolt [3] and gearshift pedal [4]. Remove the dust seals [1]. Installation is in the reverse order of removal. ,6 m NOTE - Apply grease to the gearshift pedal pivot and dust seal lips. - Apply grease to the gearshift pedal tie-rod ball joint 8 mm (Em) area. f TORQUE: *—' MW 4/ Gearshift pedal pivot bolt: / 27 Nm (2.3 kgrm, 20 mm) _ 91.1 mm (3.59 in) Adjust the tie-rod length so that the distance between 1] the ball joint ends is standard length as shown. After adjustment tighten the gearshilt pedal adjuster [ lock nut [1] to the specified torque. TORQUE21D N-m (1.0 kgrm, 7 lbl-ft) 11-19 MEMO 12. DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) COMPONENT LocA'n0N ........................ “12.2 SERVICE |NFORMAT|0N ......................... “12.3 DCT SYMPTOM TROUBLESHOOTING -----12-5 DCT ELECTRICAL SYSTEM LOCAT|0N ................................................ ..12.5 Dc'r SVSTEM DIAGRAM .......................... ..12_7 DCT CONNECTOR LOCATIONS 2-8 DCT TROUBLESHOOTING INFORMATION 12-11 DTC |NDEX .............................................. ..12.15 DTC TROUBLESHOOTING -------------------- --12-20 SHIFT INDICATOR TROUBLESHOOTING--- 12-61 MODE/SHIFT INDICATOR CIRCUIT TROUBLESHOQTMGI ............................. ..12.95 AT/MT MODE SWITCH TROUBLESHOQTMGI ............................. ..12.95 RIGHT CRANKCASE COVER ---------------- --12-97 DUAL CLUTCH ..................................... "12.105 PRIMARY DRIVE GEAR/CKP SENSOR ROTOR .................................................. .. 12.103 SHIFT CONTROL MOTOR/REDUCTION GEARS... 42.109 n GEARSHIFT LINKAGE ......................... "12.112 MAINSHAFT SENSOR ......................... "12.115 TR SENSOR- -12-115 SHIFT SPINDLE ANGLE SENSOR ------ --12-116 CLUTCH EOP SENSOR ....................... ..12.117 EOT SENSOR ....................................... "12.113 DCT SHIFT PEDAL (OPTIONAL) --------- --12-118 CLUTCH INITIALIZE LEARNING (pCM) .................................................... .. 12.120 12-1 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) COMPONENT LOCATION 1 2-2 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) SERVICE INFORMATION GENERAL - This section covers service of the electrical and mechanical systems of the Dual Clutch Transmission (DCT). - A faulty DCT system is often related to poorly connected or corroded connectors. Check those connections before proceeding. - Read the "DCT Troubleshooting information" carefully, and inspect and troubleshoot the DCT system according to the DTC. Observe each step of the procedures one by one. Note the DTC 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 22-27). For VS sensor service (page 22-l 8). Description of the system (page l-QO). The follOWing color codes are used throughout this section. Bl = Black Bu = Blue Gr = Gray 0 Orange R = Red w e White Br = Brown a = Green Lg = Light green P = Pink v = Violet Y = Yellow For DCT System Troubleshooting ~ The DCT system is controlled by the PCM. Therefore some detection items are shared in the PGM-FI and DOT 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-Fl system (page 4-12). — Shift indicator blinks or DTC for the DCT system (page l2-l1) — Symptom of the DCT system operation (page l2—5) — TXD/RXD line (page 2241) Refer to the "PGM-FI Troubleshooting Information" for the "CIRCUlT lNSPECTlON" information (page 4-13). The gearshift mechanism included the folloWing items. If the gearshift mechanism is faulty, refer to each component service. — Shift control motor/reduction gears (page 12-109) — Gearshift linkage (page l2-l 12) — Shift drum/shift fork (page 14-l 7) 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 . Connect the HDS pocket tester. . Select the "DRIVE TRAIN MODE MENU". . Select the "FUNCTlON TEST" and then select the "SHIFT CONTROL MOTOR". . Place the motorcycle on its centerstand to raise the rear wheel off the ground. . 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 DCT to shift between gears. cream—n 1 2-3 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Linear Solenoid Valve Function Procedures NOTE ~ II the PCM has a DTC, the iunction test does not work. ~ The tunction test is not lor the quallty check 01 the linear solenoid Valve. ~ Do not open the throttle while testing the linear solenoid valve lunction. Conduct a test 01 the Ilnear solenold valves when the linear solenoid valves have been serviced or replaced. . Connect the HDS pocket tester. . Select the "DRIVE TRAIN MODE MENU". . Select the "FUNCTION TEST" and then select the “Linear Solenoid". . Select the "Linear Solenoid 1" or "Linear Solenoid 2". . Start the engine and let it ldle. . Make sure that the transmission is ln neutral position. . Select the "Drive Linear Solenoid To 0 kPa“, "Drive Linear Solenoid To 400 kPa" or "Drive Llnear Solenoid To 800 kPa" mode. Measure the linear solenoid current at each mode. \imU‘J>c-)i\)—k SPECIFICATIONS Umt: mm (in) ITEM STANDARD SERVICE LIMIT Clutch clearance 0.9 — 1.1 (0.085 — 0.048) 2.0 (0.08) EOT sensor resistance (20°C/68°F) 2.5 — 2.8 M) — TORQUE VALUES , THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Solenoid valve stopper plate bolt 1 6 12 (1.2, 9) Apply locking agent to the threads. Coatlng width: 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 ln) lrorn tip Right crankcase cover We clamp 2 6 12 (1.2, 9) Apply locking agent to the threads. bolt Coatlng width: 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 ln) lrorn tip Linear solenoid valve body 6 6 — For tlghtening sequence (page 12- mounting bolt 101) Shltt spindle angle sensor bolt 1 6 12 (1.2, 9) Prlmary drive gear mounting bolt 1 10 98 (9.5, 69) Apply engine oil to the threads and seating surlace. Reduction gear cover bolt 8 6 14 (1.4, 10) TR sensor bolt 1 6 12 (1.2, 9) Shift control motor bolt 8 6 14(1.4, 10) Shltt drum center bolt 1 8 28 (2.8, 17) Apply locking agent to the threads. Coatlng width: 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 ln) lrorn tip Drum shltter guide plate bolt 2 6 12 (1.2, 9) Apply locking agent to the threads. Coatlng width: 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 ln) lrorn tip Clutch line EOP sensor 8 10 19.6 (2.0, 14) EOT sensor 1 10 14(1.4, 10) Apply engine oil to the threads and seating surlace. 1 2-4 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DCT SYMPTOM TROUBLESHOOTING Check the shift indicator "—" blinking ol the combination meter (page 12-11). it the shilt indicator "—" is blinking, reler to the DTC index (page 12-15) and begin the appropriate troubleshooting procedure. blinking, inspect the engine oil condition and iollow the symptom troubleshooting described below. It there are n CLUTCH SLIPS AND MOTORCYCLE DOES NOT ACCELERATE Check the clutch clearance (page 12-106). EXCESSIVE NOISE OR VIBRATION AROUND THE DCT SYSTEM Inspect the lollowing components: — Clutch clearance — Dual clutch needle bearings lor wear or damage — Primary drive/sub-gear tor wear or damage — Primary driven gear tor wear or damage — Eacn iasteners are tightened to their correct torque values Replace the damaged components il necessary and tighten the loose lasteners to the specilied torque. 1 2-5 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DCT ELECTRICAL SYSTEM LOCATION PCM CKP SENSOR ABS MODULATOR VS SENSOR INNER MAINSHAFT SENSOR EOT SENSOR CLUTCH EOP SENSORS NEUTRAL SWITCH OUTER MAINSHAFT SENSOR SHIFT CONTROL MOTOR TR SENSOR SHIFT SPINDLE ANGLE SENSOR No.1 LINEAR SOLENOID VALVE No.2 LINEAR SOLENOID VALVE 1 2-6 DCT SYSTEM DIAGRAM DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) mum W mm mom ERAKE new swm Fuszvsn m 3‘ m REAR new new swm WNW m 3‘ m 5‘ MmNFusEann R M mam W m 5‘ i ‘ mum ’ “ ENGINE STOPSWITCH swm w mm“ mm H mzm w | vw _ _ gvgmmm swncn m .m m m 3; “mm [W alw ER SWITCH - mlMJxD/Rxg m 5'“ - 152) SW”@ °\ -(amcu 3‘ M a w W m vw :3“ m m -A W IE EM; 525 W W DLC vsssgzia m. m, g, a, - an Egg 5 .55 Lu J.— FRONTWHEEL . VW : magma» a cstENson—(m) = gm mm W - (67) SW» AZ- “ “ smncomm ‘ V5“ MOTOR - (2431) swswm 3; W mm. 25% A’}:_vau m - 42 E c w _ ( ) W W A I {mm 3; mgmwsmgmm _ g ( 5m» Lsoup A9- wharf)“me in W -(55) ’ W W W Naz LINEAR soLENom D m E; m 5M “50sz W.” V WES) M m _ ' “7 mm rm G V | ND ‘ CW DOES Nov “ENGAGE '(53) m . YR NachumHDoEstmsENGAGE .{gvg‘ggflsm@ll .“T W m -(59) I _m ' “' . mmmsmncaumsasnmswsguamo — — — — — — — — — — — — V I VE w W M7112) CLUTCH IVGI VR 5:: 5‘: FNLSAFERELIW - (9,49; Egg)? W J W van: “32) EV mmmw HOLD mm mngaégfiwgga w: VG As '67) Na‘(CL\)JYCHSUPS - 65 -- :4 o (4 >l DTC14 DTC 8 DTC 14 One long blink :10 blinks, Eight short blinks plus lour short blinks > p Paiiem repeated 1 cycle shilt indicator Check When the ignition sWitch is turned ON With the engine stop switch to ":1", the shift indicator will stay on lor a iew seconds, then go oft. CURRENT DTC/STORED DTC The DTC is indicated in two ways according to the tailure status. ~ ll the PCM detects a current problem, the shilt indicator "—" Will come on and begin to blink when the sidestand is lowered. The shiit indicator "—" blink pattern will indicate the current DTC. ~ ll the PCM does not detect any current but has a problem stored in its memory, the shift indicator "—" Will not light and blink. l1 it is necessary to retrieve the past problem, readout the stored DTC by lolloWing the DTC readout procedure (page 12-12). HDS POCKET TESTER INFORMATION Reler to the PGM-Fl system (page 4-12). NOTE The lront wheel speed sensor signal can be disabled with the H05 tor testing. Never ride the motorcycle with the PCM in this mode. DTC READOUT NOTE ~ ll the shilt indicator [1] blinks, check the PGM-Fl DTC (page 4-12). ll there is any problem in the PGM-Fl system, troubleshoot it lirst. Then recheck the DCT system after erasing the PGM-Fl DTC. ~ After perlorming diagnostic troubleshooting, erase the problem code(s) (page 12-13) and test-ride the motorcycle to be sure that the problem(s) have been removed. Read the DTC and stored data with the HDS Pocket Tester, and lollow the troubleshooting index (page 12-15). To read the DTC without the HDS pocket tester, use the lollowing procedure. 12-12 DUAL CLUTCH TRANSMISSION (DCT) (NC7OOXD/SD) Reading DTC with the shill indicator "—" 1. Turn the ignition sWitch OFF. Remove the maintenance lid (page 21—6). 2. Remove the DLC [1] from the batten/ box. Short the DLC terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 3. Make sure the engine stop switch is turned to While pushing the shift switch (+) [1], turn the ign on switch ON. Read, note the shift indicator "—" blinks and refer to the troubleshooting index (page 12-15). NOTE - lithe PCM has no DTC in its memory, the shift indicator "—" will start blinking (page 12-14). 4. Release the shift switch (+). ERASING DTC Connect the HDS pocket tester to the DLC (page 4-12). Erase the DTC with the H08 while the engine is stopped. To erase the DTC without HDS, refer to the folloWing procedure. How to erase the DTC without HDS 1. Turn the ignition sWitch OFF. Remove the maintenance lid (page 21—6). 2. Remove the DLC [1] from the batten/ box. Short the DLC terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 12-13 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Make sure the engine stop switch is turned to [1] While pushing the shift SWitch (+) [1], turn the ignition switch to ON. 4. Push the shift switch {—l [1]. [2] 5. Push the shift switch (+) [2]. 6. The sell-diagnostic memory is erased if the shift indicator "—" goes off and starts blinking as shown. 2 sec. 2 sec. 2 sec. f—D}!—u¢—e OFF \ 3 sec. 3 sec. 3 sec. —> Pattern repeated 1 cycle NOTE Note that the sell-diagnostic memory cannot be erased if the ignition sWitch is turned to "OFF" before the shift indicator "—" starts blinking. 7. Turn the ignition SWitch OFF. 8. Remove the special tool from the DLC. 12-14 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC INDEX S m Iom/Fail-sale Rafe, RSI” Function Failure y pfunmion to to DTC "—" TP sensor abnormal voltage O Gearshift lunction O Loose or poor contact ol the TP sensor connector works normain 8" (a) O TP sensor or its circuit maifunction 12-20 4'47 O Faulty PCM Clutch line EOP sensor low voltage O Gearshift lunction 9-1 (9) O Ciutch line EOP sensor or its circuit maifunction works normally 12-20 O Faulty PCM Clutch line EOP sensor high voltage O Gearshift lunction 1261 O Loose or poor contact of the clutch line EOP works normain 9-2 (9) sensor connector 12-21 O Ciutch line EOP sensor or its circuit maifunction O Faulty PCM CKP sensor no signal O Gearshiftlunction does O Loose or poor contact of the CKP sensor not work (while driving) connector O Engine does not 19" (‘9) O Eiectromagnetic interference at CKP sensor operate 12-22 1262 O CKP sensor or its circuit malfunction O Faulty PCM Shilt spindle angle sensor low voltage O Gearshiftlunction does O Loose or poor contact of the shift spindie angie not work (while driving) 21-1 (21) sensor connector O Only shifted into 1st 12-23 O Shift spindle angle sensor or its circuit mailunction gear O Faulty PCM 12-63 Shilt spindle angle sensor high voitage O Gearshiftlunction does 212 (21) O Shift spindle angle sensor or its circuit mailunction not work (while driving) 1224 O Faulty PCM O Only shifted into 1st gear Shilt spindle operation malfunction (alter operating O Gearshiftlunctiondoes 22" (22) gearshift mechanism) not work (while driving) 1225 O Gearshilt mechanism mallunction O Only shifted into 1st O Shift spindle angie sensor maifunction gear 1264 Shilt spindle operation malfunction (while operating O Gearshiftlunctiondoes 234 (23) gearshift mechanism) not work (while driving) 1226 O Gearshilt mechanism malfunction O Only shifted into 1st O Shift spindle angie sensor maifunction gear Shilt control motor drive circuit O Gearshiftlunction does O Shift control motor or its circuit malfunction not work (while driving) 24-1 (24) O Shift controi motor drive circuit in the PCM O Engine does not 12-27 12-65 mallunction operate O Faulty PCM Shilt drum position malfunction O Gearshiftlunction does O TR sensor maifunction not work (while driving) 27" (27) O Gearshilt mechanism malfunction O Engine does not 12-28 1266 O Faulty PCM operate Shilt control motor low voltage O Gearshiftlunction does O Shift control motor circuit mallunction not work (while driving) O Ignition hold relay circuit in the PCM mallunction O Engine does not 31-1 (31) O Biown PVB fuse (30 A) operate 12-29 12-67 O Loose or poor contact of the PCM 33F (Biack) connector O Faulty PCM Faii safe relay circuit mallunction O Gearshiftlunction does O PCM (DCT drive circuit) power input line not work (while driving) mallunction O Engine does not 32" (32) O Biown PVB fuse (30 A) operate 12-30 12-68 O Fail sale reiay in the PCM malfunction O Faulty PCM Ignition hold relay mallunction O Gearshiftlunction does O PCM (DCT drive circuit) sub power input line not work (while driving) mallunction O Engine does not 37" (37) O Biown SUB PVB luse (7.5 A) operate 12-30 12-68 O Ignition hoid relay in the PCM malfunction O Faulty PCM 12-15 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) . Refer DTC . . S m lom/FaII-sale (.._.. blinks) Function Failure y pfunmion thlzc N-D shift swttch maliunction O N-D shift switch does O Loose or poor Contact of the N-D shift switch not operate 41-1 (41) connector 12-31 12-69 O N-D shilt switch or its circuit mallunction O Faulty PCM Shtlt switch matlunction O Shilt switch does not 424 (42) O Iéaose or poor contact of the shift switch connector operate 1233 1271 O Ift swttch or Its circuit malfunctton O Faulty PCM EOT sensor tow vottage O Gearshift lunction 44-1 (44) O EOT sensor or its circutt malfunction works normatly 12-34 O Faulty PCM EOT sensor high voltage O Gearshift lunction 1273 O Loose or poor contact oi the EOT sensor works normain 44-2 (44) connector 12-35 O EOT sensor or its circutt malfunction O Faulty PCM No.1 ctutch EOP sensor tow vottage O Gearshiftlunctiondoes 47-1 (47) O No.1 clutch EOP sensor or its circuit malfunction not work 12-37 O Faulty PCM No.1 ctutch EOP sensor high voltage O Gearshiftlunctiondoes 12_74 O Loose or poor contact oi the No.1 ctutch EOP not work 47-2 (47) sensor connector 12-38 O No.1 clutch EOP sensor or its circuit malfunction O Faulty PCM No.2 ctutch EOP sensor tow vottage O Gearshiftlunction does 48-1 (48) O No.2 clutch EOP sensor or its circuit malfunctton not work 12-37 O Faulty PCM No.2 ctutch EOP sensor high voltage O Gearshiftlunction does 12_74 O Loose or poor contact oi the No.2 ctutch EOP not work 48-2 (48) sensor connector 12-38 O No.2 clutch EOP sensor or its circuit malfunctton O Faulty PCM Clutch tine low oil pressure (when clutch engage) O Engine does not O Engine oil tevet low operate O Faulty OtI pump 49" (49) O Faulty ctutch oi| ctrcuit O Ctutch line EOP sensor matiunction O Faulty PCM Clutch tine low OtI pressure (when engtne running) O Engine does not 12 39 12 76 O Engine oil levet low operate O Faulty OtI pump 49'2 (49) O Faulty ctutch oi| ctrcuit O Ctutch line EOP sensor matiunction O Faulty PCM TR sensor low voltage O Gearshiftlunction does 514 (51) O Loose or poor Contact ol the TR sensor connector not work (whtle drivtng) 1240 O TR sensor or its ctrcuit mallunction O Engine does not O Faulty PCM operate 1277 TR sensor high voltage O Gearshiftlunction does O TR sensor or its ctrcuit mallunction not work (whtle drivtng) 51'2 (51) O Faulty PCM O Engine does not 1241 operate Neutral switch stuck OFF O Operates normally O Loose or poor Contact oi the neutrat switch O Shilt indicator bttnktng 52-1 (52) connector 12-42 O Neutral swttch or tts circuit maliunctton O Faulty PCM 12-78 Neutral switch stuck ON O Gearshiftlunction does O Neutral swttch or tts circuit maliunctton not work (whtle driving) 522 (52) O Faulty PCM O Engine does not 1243 operate 12-16 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) . Refer Reler DTC . . S m lom/FaII-sale (.._..blinks) Function Failure y flunc‘ion 3%: i Inner mainshait sensor speed low O Gearsniitlunction does O Loose or poor contact oi the inner mainshait not work sensor connector 53" (53) O Inner mainshait sensor or its circuit maiiunction 12-43 1279 O Eiectromagneticinterierence O Faulty PCM Outer mainsnalt sensor speed low O Gearshiitlunction does O Loose or poor contact oi the outer mainshait not work sensor connector 54" (54) O Outer mainshait sensor or its circuit maliunction 12-46 1282 O Eiectromagneticinterierence O Faulty PCM No.1 linear solenoid valve current lailure O Gearshiitlunction does O Loose or poor contact oi the No.1 linear solenoid not work valve connector 55-1 (55) O No.1 linear solenoid vaive or its circuit maiiunction O No.1 linear solenoid valve drive circuit in the PCM mallunction O Faulty PCM No.1 linear solenoid valve driver in the PCM iaiiure O Gearshiitlunction does 12-48 12-84 O Loose or poor contact oi the No.1 linear solenoid not work valve connector 552 (55) O Loose or poor contact oi the PCM 33F connector O No.1 linear solenoid vaive or its circuit mallunction O No.1 linear solenoid valve drive circuit in the PCM mallunction O Faulty PCM No.2 linear solenoid valve current lailure O Gearshiitlunction does O Loose or poor contact oi the No.1 linear soienoid not work valve connector 56-1 (56) O No.2 linear solenoid vaive or its circuit mallunction O No.2 linear solenoid valve drive circuit in the PCM mallunction O Faulty PCM No.2 linear solenoid valve driver in the PCM iaiiure O Gearshiitlunction does 12-49 12-85 O Loose or poor contact oi the No.2 linear soienoid not work valve connector 562 (56) O Loose or poor contact oi the PCM 33F connector O No.2 linear solenoid vaive or its circuit mallunction O No.2 linear solenoid valve drive circuit in the PCM mallunction O Faulty PCM Gearshift mechanism mailunction O Gearshiitlunction does 574 (57) O Gearshilt mechanism maliunction not work (while driving) 1260 O TR sensor or its circuit mallunction O Engine does not O Faulty PCM operate 1286 Gear position maliunction (iumps out oi gear) O Gearshiitlunctiondoes 57_2 (57) O Gearshilt mechanism maliunction not work (while driving) 1260 O TR sensor or its circuit mallunction O Engine does not O Faulty PCM operate No.1 clutcn does not disengage (when shilting gear) O Engine does not 58-1 (58) O No.1 clutch sticking operate 12-51 12-86 O Faulty ciutcn oil circuit No.2 clutcn does not disengage (when shilling gear) O Engine does not 59-1 (59) O No.2 clutch sticking operate 12-51 12-86 O Faulty ciutcn oil circuit 12-17 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) . Refer DTC . . Symptom/FaIl-sale (.._..blinks) Function Failure func‘ion [#6 No.1 clutch oil pressure mallunction (at clutch initial O Gearsniitlunction does diagnosis) not work 61-1 (61) O No.1 clutch EOP sensor maliunction O Faulty clutch oil circuit O Faulty PCM No.1 clutch no oil pressure O Gearsniitlunction does O No.1 clutch EOP sensor maliunction not work 61-2 (61) O Faulty clutch oil circuit O No.1 linear solenoid valve or its circuit mallunction O Faulty PCM No.1 clutch oil pressure degradation O Gearsniitlunction does 1261 12436 O No.1 clutch EOP sensor maliunction not work 61-3 (61) O Faulty clutch oil circuit O No.1 linear solenoid valve mallunction O Faulty PCM No.1 clutch oil pressure canceling mallunction O Engine does not O No.1 clutch EOP sensor maliunction operate O Faulty clutch oil circuit 61-4 (61) O Loose or poor Contact ol the linear solenoid valve and No.1 clutch EOP sensor connectors O No.1 linear solenoid valve mallunction O Faulty PCM No.1 clutch oil pressure high O Gearsnittlunctiondoes O No.1 clutch EOP sensor maliunction not work (while driving) 62-1 (62) O Faulty clutch oil circuit O Engine does not O No.1 linear solenoid valve mallunction operate O Faulty PCM No.1 clutch OlI pressure high (Prevention oi O Gearsnittlunctiondoes 12-51 12-86 motorcycle creeps) not work (while driving) 622 (62) O No.1 clutch EOP sensor maliunction O Engine does not O Faulty clutch oil circuit operate O No.1 linear solenoid valve mallunction O Faulty PCM No.2 clutch oil pressure mallunction (at clutch initial O Gearsnittlunctiondoes diagnosis) not work 63-1 (63) O No.2 clutch EOP sensor maliunction O Faulty clutch oil circuit O Faulty PCM No.2 clutch no oil pressure O Gearsnittlunctiondoes O No.2 clutch EOP sensor maliunction not work 63-2 (63) O Faulty clutch oil circuit O No.2 linear solenoid valve or its circuit mallunction O Faulty PCM No.2 clutch OlI pressure degradation O Gearsnittlunction does 1262 12437 O No.2 clutch EOP sensor maliunction not work 63-3 (63) O Faulty clutch oil circuit O No.2 linear solenoid valve mallunction O Faulty PCM No.2 clutch OlI pressure canceling mallunction O Engine does not O No.2 clutch EOP sensor maliunction operate O Faulty clutch oil circuit 63-4 (63) O Loose or poor Contact oi the linear solenoid valve and No.2 clutch EOP sensor connectors O No.2 linear solenoid valve or its circuit mallunction O Faulty PCM 12-18 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) . Refer Reler DTC . . S m tom/FaII-sale (.._..blinks) Function Failure y flunc‘ion lfi’xc t No.2 clutch oil pressure high O Gearshiftlunction does O No.2 clutch EOP sensor malfunction not work (whlle driving) 64-1 (64) O Faulty clutch oil circuit O Engine does not O No.2 linear solenoid valve malfunction operate O Faulty PCM No.2 clutch oil pressure high (Preventlon ol O Engine does not 12-52 12-87 motorcycle creeps) operate O No.2 clutch EOP sensor malfunction 64'2 (64) O Faulty clutch oil circuit O No.2 linear solenoid valve malfunction O Faulty PCM Front and rear wheel speed signal malfunctlon O Gearshiftlunction does O Front wheel speed sensor or its clrcuit mallunction not work 65-1 (65) O VS sensor or lts clrcuit mallunction 12-53 12-88 O Faulty ABS modulator O Faulty PCM VS sensor no signal O Gearshiftlunction does O VS sensor or lts clrcuit mallunction not work 66-1 (66) O Loose or poor contact of the VS sensor connector 12-54 12-89 O Electromagnetic lnterference at VS sensor O Faulty PCM Front wheel speed sensor no signal O Gearshiftlunction does O Front wheel speed sensor or its clrcuit mallunction not work O Loose or poor Contact of the lront wheel speed sensor connector 67-1 (67) O Electromagnetic interference at frontwheel speed 12-55 12-90 sensor O Faulty ABS modulator O Faulty pulser rlng O Faulty PCM No.1 clutch operation malfunction (clutch slips) O Gearshiftlunctiondoes 684 (68) O \gfus‘elnngaogllltjcflrcuit mallunction not work 1266 129‘ O Faulty PCM No.2 clutch operation malfunction (clutch slips) O Gearshiftlunctiondoes 69" (69) . gius‘elnngrzogllltjcflrcuit mallunction not work 1267 1292 O Faulty PCM Inner mainshaft / countershalt speed ratio fallure O Gearshiftlunctiondoes 714 (71) O VS sensor or its clrcuit mallunction not work O lnner mainshalt sensor or its circuit mallunction O Faulty PCM 1267 1292 Outer malnshalt / countershaft speed ratio lailure O Gearshiftlunction does 72" (72) O VS sensor or its clrcuit mallunction not work O Outer mainshaft sensor or lts circuit malfunction O Faulty PCM 844 (84) CngéflltlywigaM malfunctlon O Gearshift system stops 1268 1293 Shilt pedal angle sensor (Optlonal) malfunction O DCT shift pedal O Shift pedal angle sensor or its circuit malfunction (Optlonal) lunction O DCT shilt pedal (Optional) mechanism does not work 1-1 (1) malfunctlon 12-58 12-93 O Loose or poor contact of the shift pedal angle sensor connector O Faulty PCM 12-19 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC TROUBLESHOOTING DTC 8-1 (TP SENSOR ABNORMAL VOLTAGE) 1. TP Sensor System Inspection Check the TP sensor with the HDS pocket tester when the throttle is iully closed. Is Low voltage (about I7 V) or High voltage (about 5 V) indicated? YES — ~ AboutO V: See DTC 8-1 (page 4-26) ~ About 5 V: See DTC 8-2 (page 4-27) N0 — Intermittent Iailure DTC 9-1 (CLUTCH LINE EOP SENSOR LOW VOLTAGE) NOTE O lithe PCM IS replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Clutch Line EOP Sensor System Inspection Connect the H08 pocket tester and start the engine. Check the clutch line EOP sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 2. Clutch Line EOP Sensor Inspection Stop the engine. Disconnect the clutch line EOP sensor 3P (Black) connector. Turn the ignition switch ON. Check the clutch line EOP sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 3. N0 — 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: Vellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 4. N0 — Open circuit in the Yellow/red wire G/Y 12-20 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Clutch Line EOP Sensor Output Line Short Circuit Inspection Check ior continuity between the wire harness side clutch line EOP sensor 3P (Black) connector [1] terminal and ground. Connection: Violet/green — Ground Is there continuity? YES — Short circuit in the Vioiet/green wire N0 — Replace the PCM with a known good one, and recheck. DTC 9-2 (CLUTCH LINE EOP SENSOR HIGH VOLTAGE) NOTE O Beiore starting the inspection, check lor loose or poor contact on the clutch line EOP sensor 3P (Biack) and PCM 33P connectors, and recheck the DTC. O lithe PCM is replaced, periorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Clutch Line EOP Sensor System Inspection Check the clutch iine EOP sensor with the HDS pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — Intermittent lailure 2. Clutch Line EOP Sensor Inspection Turn the ignition switch OFF. Disconnect the clutch iine EOP sensor 3P (Biack) [II connector. Connect the Wire harness side ciutch line EOP sensor 3P (Black) connector [1] terminals with a jumper wire [2]. Connection: Violet/green — Green/yellow Turn the ignition switch ON. G/Y V/G Check the clutch line EOP sensor with the HDS pocket tester. Is the 0 V indicated? YES — Faulty clutch line EOP sensor N0 — GO TO STEP 3. I2] 12-21 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Clutch Line EOP Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Gray) connector. Check tor continuity between the wire harness side clutch line EOP sensor 3P (Black) connector [1] and PCM 33F (Gray) connector [2] terminais. Connection: Green/yellow — 322 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in the Green/yellow wire . Clutch Line EOP Sensor Output Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector. Check tor continuity between the wire harness side clutch line EOP sensor 3P (Black) connector [1] and PCM 33F (Black) connector [2] terminais. Connection: Violet/green — A17 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the PCM with a known good one, and recheck. NO — Open circuit in the Violet/green wire DTC 19-1 (CKP SENSOR NO SIGNAL) NOTE ' Beiore starting the inspection, check lor ioose or poor contact on the CKP sensor 2P (Red) and PCM 33F (Gray) connectors, then recheck the DTC. It the PCM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) . CKP sensor Peak Voltage Inspection Disconnect the CKP sensor 2P (Red) connector. Turn the ignition switch ON With the engine stop switch Crank the engine with the starter motor, and measure the CKP sensor peak voitage at the CKP sensor 2P (Red) connector [1] terminais ol the CKP sensor side. Connection: Vellow (+) — White/yellow (—) TOOL: lmrie diagnostic tester (model 625) or Peak voltage adaptor [2] 07HGJ—OOZD1DO with commercially available digital multimeter (impedance 1!) MQ/DCV minimum) Is the voltage more than ‘7. 7 V? YES — GO TO STEP 2. NO — Faulty CKP sensor [1] B22 I2] [2] [1] A17 [2] 12-22 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. CKP sensor Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Gray) connector. Check tor continuity between the CKP sensor 2P (Red) connector [1] and PCM 33F (Gray) connector [2] terminals. Connection: Yellow — B11 Green/orange — Be B11 [1] TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Short circuit 1n the Yellow ere N0 — ~ Open clrcult in the Yellow wire [2] ~ Open clrcult in the Green/orange ere DTC 21-1 (SHIFT SPINDLE ANGLE SENSOR LOW VOLTAGE) NOTE O Betore starting the inspectlon, check Ior loose or poor contact on the shift spindle angle sensor 3P (Gray) and PCM 33F connectors, and recheck the DTC. O It the PCM lS replaced, pertorm the Iollowing: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learnlng Procedure (page 12-120) 1. Shift Spindle Angle Sensor System Inspection Check the shift splndle angle sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — lntermlttent Iailure 2. Shift Spindle Angle Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the shltt splndle angle sensor 3P (Gray) connector. Turn the ignition switch ON. Measure the voltage between the wire harness side shltt spindle angle sensor 3P (Gray) connector [1] terminals. Connection: Yellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 3. N0 — Open circuit 1n the Yellow/red wire 12-23 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Shift Spindle Angle Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector. [2] Check tor continuity between the wire harness side shift spindle angle sensor 3P (Gray) connector [1] and PCM 33F (Black) connector [2] terminals. TOOL: Test probe 07ZAJ-RDJA110 Connection: Violet/red — A16 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Violet/red Wire [1] A16 4. Shift Spindle Angle Sensor Output Line Short Circuit Inspection Check tor continuity between the wire harness side 1 shift spindle angie sensor 3P (Gray) connector [1] [ 1 terminal and ground. Connection: Violet/red — ground Is there continuity? YES — Short circuit in the Violet/red Wire N0 — GO TO STEP 5. 5. Shift Spindle Angle Sensor Inspection Replace the shift spindle angle sensor with a known good one (page 12-116). Connect the shift spindle angle sensor 3P (Gray) connector and PCM 33F (Black) connector. Turn the ignition switch ON. Check the shift spindle angie sensor with the HDS pocket tester. Is about 0 V indicated? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty original shilt spindle angle sensor DTC 21-2 (SHIFT SPINDLE ANGLE SENSOR HIGH VOLTAGE) NOTE ' It the PCM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Shift Spindle Angle Sensor System Inspection Check the shift spindle angie sensor with the HDS pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — Intermittent lailure 12-24 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Spindle Angle Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the shift spindie angle sensor 3P (Gray) [1] connector. Turn the ignition switch ON. Measure the voltage between the wire harness side shift spindle angle sensor 3P (Gray) connector [1] terminals. Connection: Yellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 3. N0 — 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 12-116). Connect the shift spindle angle sensor 3P (Gray) connector. Turn the ignition switch ON. Check the shift spindie angie sensor with the H08 pocket tester. Is about 5 vindicated? YES — Replace the PCM With a known good one. and recheck. N0 — 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 spindie angie sensor with the H08 pocket tester. Is Low voltage (about I7 V) or High voltage (about 5 V) indicated? YES — ~ AboutOV: See DTC 21-1 (page 12-23). ~ About 5 V: See DTC 21-2 (page 12-24). N0 — GO TO STEP 2. 2. Shift Control Motor/Reduction Gear Condition Check the shift control motor and reduction gears are instailed properly and are not damaged. Are the shift control motor and reduction gears in normal condition? YES — GO TO STEP 3. N0 — Instali the shift control motor and reduction gears properly or repiace faulty parts. 12-25 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Shift Control Motor Condition Inspection Remove the shift control motor (page 12-109). 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. N0 — Faulty shift controi motor 4. Shift Spindle Angle Sensor System Inspection Remove the shift spindle angle sensor With the connector connected (page 12-116). Turn the ignition switch ON. While turning the shift spindle angie sensor shalt, check the shift spindle angle sensor voitage with the HDS pocket tester. 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. N0 — Faulty shift spindle angle sensor 5. Shift Spindle Angle Sensor Condition Inspection Check that the shift spindie angle sensor is instailed properly. Is the shift spindle angle sensor in normal condition? YES — GO TO STEP 6. N0 — Install the shift spindle angie sensor properly. 6. DTC Recheck Recheck the DTC with the HDS pocket tester. ls DTC 22-1 indicated? YES — Replace the PCM With a known good one. and recheck. N0 — Intermittent lailure DTC 23-1 (SHIFT SPINDLE OPERATION MALFUNCTION: WHILE OPERATING GEARSHIFT MECHANISM) Refer to DTC 22-1 (page 12-25) 12-26 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 24-1 (SHIFT CONTROL MOTOR DRIVE CIRCUIT) NOTE ' It the PCM is replaced, perform the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Shift Control Motor Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector and shift control motor 2P (Black) connector. Check Ior continuity between the wire harness side shift control motor 2P (Black) connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Pink/blue — A1 Pink/blue — A2 Yellow/blue — A4 Yellow/blue — A15 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 2. N0 — ~ Open circuitinthe Pink/blue wire ~ Open circuit in the Yellow/blue wire 2. Shift Control Motor Line Short Circuit Inspection Check Ior continuity between the wire harness side shift control motor 2P (Black) connector [1] terminals and ground. Connection: Pink/blue — Ground Yellow/blue — Ground Is there continuity? YES — ~ Short circuit in the Pink/blue wire ~ Short circuit in the Yellow/blue Wire NO — GO TO STEP 3. 3. Shift Control Motor Inspection Remove the shift control motor (page 12-109). Connect a Iully 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 NO — Faulty shift control motor — Replace the PCM with a known good one. A15 )1 P/Bu @jI/T [1] \ Y/Bu i7? 12-27 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 27-1 (SHIFT DRUM POSITION MALFUNCTION) NOTE ' It the PCM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. TR Sensor System Inspection Check the TR sensor With the HDS pocket tester. ls Low voltage (about I] V) or High voltage (about 5 V) indicated? YES — ~ About 0 V: See DTC 51-1 (page 12-40). ~ About 5 V: See DTC 51-2 (page 12-41). N0 — GO TO STEP 2. 2. Shift Control Motor/Reduction gear condition Check the shilt 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. N0 — Install the shilt control motor and reduction gears properly or replace taulty parts. 3. Shift Control Motor Condition Inspection Remove the shift control motor (page 12-109). Connect a Iully 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. N0 — Faulty shift control motor 4. TR Sensor System Inspection Remove the TR sensor with the connector connected (page 12-115). Turn the ignition switch ON. While turning the TR sensor shalt, check the TR sensor voltage with the HDS pocket tester. 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. N0 — Faulty TR sensor 12-28 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. TR Sensor Condition Inspection Check that the TR sensor is installed properly and is not damaged. Is the TH sensor in normal condition? YES — GO TO STEP 6. N0 — Install the TR sensor properly. 6. DTC Recneck Recheck the DTC with the HDS pocket tester. Is DTC 27-1 indicated? YES — Replace the PCM With a known good one. and recheck. N0 — Intermittent Iailure DTC 31 -1 (SHIFT CONTROL MOTOR LOW VOLTAGE) NOTE ' Betore starting the inspection, check Ior loose or poor contact on the shiIt control motor 2P (Black) and PCM 33F (Black) connectors, and recheck the DTC. ' It the PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recneck Erase the DTCs (page 12-13). Check the DTC With the HDS pocket tester. Is DTC 32-1 or 37-1 indicated? YES — ~ DTC 32-1 indicated (page 12-30). ~ DTC 37-1 indicated (page 12-30). NO — GO TO STEP 2. 2. Shift Control Motor Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector and shift control motor 2P (Black) connector. Check Ior continuity between the wire harness side shift control motor 2P (Black) connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Pink/blue — A1 Pink/blue — A2 Vellow/blue — A4 Vellow/blue — A15 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the PCM with a known good one, and recheck. N0 — ~ Open circuitinthe Pink/blue wire ~ Open circuit in the Yellow/blue wire 12-29 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 32-1 (FAIL SAFE RELAY CIRCUIT MALFUNCTION) NOTE Beiore starting the inspection, check Ior loose or poor contact on the PCM 33F (Black) connector and recheck the DTC. It the PCM is replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) . Shift Control Motor Power Supply Voltage Inspection Check the shiIt control motor power supply voltage with the HDS pocket tester. Is there battery voltage? YES — GO TO STEP 2. N0 — ~ Open circuit in the Yellow/red wire between the PCM 33F (Black) connector and iuse/relay box ~ Open circuit in the Red Wire between the Iuse/relay box and starter relay switch 4P (Red) connector ~ Blown PVBiuse(30 A) . DTC Recheck Recheck the DTC with the HDS pocket tester. Is DTC 32-1 indicated? YES — Replace the PCM With a knoWn good one. and recheck. N0 — Intermittent Iailure DTC 37-1 (IGNITION HOLD RELAY MALFUNCTION) NOTE Beiore starting the inspection, check Ior loose or poor contact on the PCM 33F (Black) connector and recheck the DTC. It the PCM is replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) . POM (DOT Drive Circuit) Sub Power Voltage Inspection Check the PCM sub power voltage with the H08 pocket tester. Is the battery Voltage indicated? YES — GO TO STEP 2. N0 — ~ Open circuit in the EroWn/red wire between the PCM 33F (Black) connector and iuse/relay box ~ Open circuit in the Red Wire betWeen the Iuse/relay box and starter relay switch 4P (Red) connector ~ Blown SUB PVB iuse (7.5 A) 12-30 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. DTC Recheck Recheck the DTC with the HDS pocket tester. Is DTC 37-1 indicated? YES — Replace the PCM With a known good one, and recheck. N0 — Intermittent Iailure DTC 41 -1 (N-D SHIFT SWITCH MALFUNCTION) NOTE ' Beiore starting the inspection, check Ior loose or poor contact on the right handlebar switch and PCM 33F connectors, and recheck the DTC. ' It the PCM is replaced, perform the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. N-D Shilt Switch Power Input Voltage Inspection Disconnect the iollowing: NC700XD: NC7OOSD: — Right handlebar switch 6P (Black) connector [1] [2] (NC700XD) [1] — Right handlebar switch 7P (Green) connector (NC7OOSD) [2] Tum the ignition switch ON With the engine stop switch Measure the voltage between the wire harness side right handlebar switch connector terminal and ground. Connection: Yellow/red (1-) — Ground (—) Is the voltage within 4.75 — 5.25 V? ' W YES — GO TO STEP 2. N0 — Open circuit in the Yellow/red wire 2. N-D Shilt Switch Inspection Tum the ignition switch OFF. V Check ior continuity between the switch side right Ncmoxn' handlebar switch connector [1] terminals in each [1] switch position. 0 Connectl n: Ft N switch: Light green/blue — Fted . _ o. D swflch. Lg/Bu Black/yellow — Red BW Is there continuity with the switch pushed and no continuity with the switch released? YES — GO TO STEP 3. N0 — Faulty N-D shiIt switch “C7003” [1] 12-31 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. N-D Shitt Switch Input Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector. Check tor continuity between the wire harness side right handlebar switch connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Light green/black — A18 Black/yellow — A29 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — ~ Open circuit in the Light green/black wire ~ Open circuit in the Black/yellow wire . N-D Shitt Switch Input Line Short Circuit Inspection Check tor continuity between the wire harness side PCM 33F (Black) connector [1] terminals and ground. Connection: A18 — Ground A29—Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — ~ Short circuit in the Light green/black wire ~ Short circuit in the Black/yellow wire N0 — Replace the PCM with a known good one, and recheck. NC7OOXD: NC7OOSD: [1] A18 A18 [i] 12-32 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 42-1 (SHIFT SWITCH MALFUNCTION) NOTE ' Before starting the inspection, check Ior loose or poor contact on the IeIt handlebar switch and PCM 33F connectors, then recheck the DTC. ' It the PCM is replaced, perform the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Shift Switch Power Input Voltage Inspection Disconnect the following: NC700XD: NC7OOSD: — Left handlebar switch 3P (Black) connector [1] [2] (NC700XD) [1] — Left handlebar switch 7P (Green) connector (NC7OOSD) [2] Turn the ignition switch ON With the engine stop switch' , Measure the voltage between the wire harness side IeIt handlebar switch connector terminal and ground. Connection: Yellow/red (1-) — Ground (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 2. N0 — Open circuit in the Yellow/red wire 2. Shift Switch Inspection Turn the ignition switch OFF. V Check Ior continuity between the switch side left Ncmoxn' handlebar switch connector [1] terminals in each [1] switch position. Y/R Connection: "+" switc : Green/blue — Yellow/red ' switch: Lg/R Light green/red — Yellow/red . G/Bu Is there continuity with the switch pushed and no continuity with the switch released? YES — GO TO STEP 3. N0 — Faulty shift switch NC7OOSD: 12-33 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Shift Switch Input Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector. Check ior continuity between the wire harness side Ieit handlebar switch connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Blue/yellow — A7 Light green/red — A30 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. NO — ~ Open circuit in the Blue/yellow Wire ~ Open circuit in the Light green/red wire 4. Shift Switch Input Line Short Circuit Inspection Check ior continuity between the wire harness side PCM 33F (Black) connector [1] terminals and ground. Connection: A7 — Ground A30 — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — ~ Short circuit in the Blue/yellow wire ~ Short circuit in the Light green/red wire NO — Replace the PCM with a known good one, and recheck. DTC 44-1 (EOT SENSOR Low VOLTAGE) NOTE ' It the PCM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. EOT Sensor System Inspection Check the EOT sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. NO — Intermittent iailure NC700XD: [1] Bu/Y Lg/Ft @ NC7OOSD: [1] @ A30 [2] A30 12-34 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. EOT Sensor Inspection Turn the ignition switch OFF. Disconnect the EOT sensor 2P (Black) connector. Turn the ignition switch ON. Check the EOT sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 4. N0 — GO TO STEP 3. 3. EOT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the EOT sensor [1] terminals. Is the resistance within 2.5 — 2.8 k9 (ZINE/63°F)? YES — Replace the PCM with a known good one, and recheck. N0 — 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 Is there continuity? YES — Short circuit in the Blue/green wire N0 — Replace the PCM with a known good one, and recheck. DTC 44-2 (EOT SENSOR HIGH VOLTAGE) NOTE O Betore starting the inspection, check tor loose or poor contact on the EOT sensor 2P (Black) and PCM 33F connectors, and recheck the DTC. O it the PCM is replaced, periorm the iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. EOT Sensor System Inspection Check the EOT sensor with the H08 pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — Intermittent iailure 12-35 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. EOT Sensor Inspection Turn the ignition switch OFF. Disconnect the EOT sensor 2P (Black) connector. Short the wire harness side EOT sensor 2P (Black) connector [1] terminals with a jumper wire [2]. Connection: Blue/green — Green/yellow Turn the ignition switch ON. Check the EOT sensor with the HDS pocket tester. Is about 0 vindicated? YES — Faulty EOT sensor. N0 — GO TO STEP 3. 3. EOT Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector. Check tor continuity between the wire harness side EOT sensor 2P (Black) connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Blue/green — A19 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Blue/green wire 4. EOT Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33F (Gray) connector. Check tor continuity between the wire harness side EOT sensor 2P (Black) connector [1] and PCM 33F (Gray) connector [2] terminals. Connection: Green/yellow — 322 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the PCM with a known good one, and recheck. N0 — Open circuit in the Green/yellow wires l1] [1] A19 [2] [1] B22 12-36 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 47-1 or 48-1 (No.1 or No.2 CLUTCH EOP SENSOR LOW VOLTAGE) NOTE O It the PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Clutch EOP Sensor System Inspection Connect the H08 pocket tester and start the engine. Check the clutch EOP sensor with the HDS pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 2. Clutch EOP Sensor Inspection Stop the engine. Disconnect the clutch EOP sensor 3P (Gray) connector. Turn the ignition switch ON. Check the clutch EOP sensor with the HDS pocket tester. Is about 0 vindicated? YES — GO TO STEP 3. N0 — Faulty clutch EOP sensor 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 (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 4. N0 — Open circuit in the Yellow/red wire 4. Clutch EOP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] terminal and ground. Connection: No.1 clutch EOP sensor: ' ' Vellow/green — Ground We or BUG No.2 clutch EOP sensor: Black/green — Ground Is there continuity? YES — ~ Short circuitin the Yellow/green wire ~ Short circuit in the Black/green wire N0 — Replace the PCM with a known good one, and recheck. 12-37 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 47-2 or 48-2 (No.1 or No.2 CLUTCH EOP SENSOR HIGH VOLTAGE) NOTE O Betore starting the inspection, check Ior loose or poor contact on the clutch EOP sensor 3P (Gray) and PCM 33F connectors, and recheck the DTC. O It the PCM l5 replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Clutch EOP Sensor System Inspection Check the clutch EOP sensor with the H05 pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 2. Clutch EOP Sensor Inspection Turn the ignition switch OFF. Disconnect the clutch EOP sensor 3P (Gray) connector. Short the wire harness side clutch EOP sensor 3P (Gray) connector [1] terminals with a jumper wire [2]- Connection: No.1 clutch EOP sensor: Yellow/green — Green/yellow No.2 clutch EOP sensor: Black/green — Green/yellow Turn the ignition switch ON. Check the clutch EOP sensor with the HDS pocket tester. Is about 0 vindicated? YES — Faulty clutcn EOP sensor N0 — GO TO STEP 3. 3. Clutch EOP Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM ESP (Gray) connector. Check tor continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] and PCM 33F (Gray) connector [2] terminals. Connection: Green/yellow — 322 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Green/yellow wire [2] l V/G or BI/G [1] [1] [2] 12-38 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Clutch EOP Sensor Output Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector. Check tor continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] and PCM 33F (Black) connector [2] terminais. Connection: No.1 clutch EOP sensor: Yellow/green — A6 No.2 clutch EOP sensor: Black/green — A5 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the PCM with a known good one, and recheck. N0 — ~ Open circuit in the Yellow/green wire ~ Open circuit in the Black/green wire DTC 49-1, 49-2 (CLUTCH LINE LOW OIL PRESSURE) NOTE O It the PCM is replaced, periorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Clutch Line EOP Sensor System Inspection Check the clutch iine EOP sensor with the H08 pocket tester. Is Low voltage (about I] V) or High voltage (about 5 V) indicated? YES — ~ About 0 V (while engine running): See DTC 9-1 (page 12-20). ~ About 5 V: See DTC 9-2 (page 12-21). N0 — GO TO STEP 2. 2. Engine Oil Level Inspection Check the engine oil ievel (page 3-12). Is the engine oil level correct? YES — GO TO STEP 3. N0 — Add the recommended oii to the upper ievel. 3. Clutch Line Oil Filter Condition Inspection Check the clutch oil lilter (page 3-14). Is the oil filter in good condition? YES — GO TO STEP 4. N0 — Replace the clutch oi| iilter. 12-39 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Clutch Line EOP Sensor Inspection Replace the clutch line EOP sensor with a known good one (page 12-117). Erase the DTCs (page 12-13). Test-ride the motorcycle above 2,000 min‘ (rpm) and stop the engine. Check the clutch iine EOP sensor with the H08 pocket tester. Is DTC 49-1 or 49-2 indicated? YES — GO TO STEP 5. N0 — Faulty original clutch iine EOP sensor 5. POM Inspection Replace the PCM With a known good one (page 4- s7). Test-ride the motorcycle above 2,000 min‘ (rpm) and stop the engine. Check the clutch iine EOP sensor with the H08 pocket tester. Is DTC 49-1 or 49-2 indicated? YES — - Oil pressure relieivalve stuck open - Damaged oil pump - Internal oil leak in the ciutch oil line N0 — Faulty original PCM DTC 51 -1 (TR SENSOR Low VOLTAGE) NOTE ' Beiore starting the inspection, check lor ioose or poor contact on the TR sensor 3P (Biack) and PCM 33F connectors, and recheck the DTC. ' It the PCM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. TR Sensor System Inspection Check the TR sensor With the HDS pocket tester. Is the voltage about 0 V? YES — GO TO STEP 2. N0 — Intermittent lailure 2. TR Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the TR sensor 3P (Biack) connector. Turn the ignition switch ON. Measure the voltage between the wire harness side TR sensor 3P (Black) connector [1] terminals. Connection: Vellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 3. N0 — Open circuit in the Yellow/red wire 1 2-40 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. TR Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector. [1] Check tor continuity between the wire harness side TR sensor 3P (Black) connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Black/pink — A23 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the BIack/pinkwire [2] A28 4. TR Sensor Output Line Short Circuit Inspection Check tor continuity between the wire harness side TR sensor 3P (Black) connector [1] terminal and ground. Connection: Black/pink — Ground Is there continuity? YES — Short circuit in the Black/pinKWire N0 — GO TO STEP 5. [l] 5. TR Sensor Inspection Replace the TR sensor With a known good one (page 12415). Connect the TR sensor 3P (Black) connector and PCM 33F (Black) connector. Turn the ignition switch ON. Check the TR sensor With the HDS pocket tester. Is the voltage about 0 V? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty original TR sensor DTC 51-2 (TR SENSOR HIGH VOLTAGE) NOTE ' It the PCM is replaced, periorm the IolloWing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. TR Sensor System Inspection Check the TR sensor With the HDS pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 12-41 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. TR Sensor Ground Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the TR sensor 3P (Black) connector. Turn the ignition switch ON. Measure the voltage between the wire harness side TR sensor 3P (Black) connector [1] terminals. Connection: Vellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 3. N0 — Open circuit in the Green/yellow wire 3. TR Sensor Inspection Replace the TR sensor with a known good one (page 12-115). Connect the TR sensor 3P (Black) connector. Turn the ignition switch ON. Check the TR sensor Wllh the HDS pocket tester. Is about 5 vindicated? YES — Replace the PCM with a known good one. and recheck. N0 — Faulty onginal TR sensor DTC 52-1 (NEUTRAL SWITCH STUCK OFF) NOTE ' Betore starting the inspection, check tor loose or poor contact on the neutral switch and PCM 33F (Gray) connectors, and recheck the DTC. ' It the PCM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Recheck the DTC with the HDS pocket tester. Is DTC 52-1 indicated? YES — GO TO STEP 2. N0 — Intermittent tailure 2. Neutral Switch Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Gray) connector and neutral switch connector. Check tor continuity between the wire harness side PCM 33F (Gray) connector [1] and neutral switch connector [2] terminals. Connection: 330 — Light green TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 3. N0 — Open circuit in the Light green wire [1] l2] 1 2-42 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Neutral Switch Inspection Replace the neutral switch With a knoWn good one (page 22-28). Connect the PCM 33F (Gray) connector and neutral switch connector. Turn the ignition switch ON. Recheck the DTC with the HDS pocket tester. Is DTC 52-1 indicated? YES — Replace the PCM With a known good one, and recheck. N0 — Faulty original neutrai switch 3m 52-2 (NEUTRAL SWITCH STUCK N) NOTE O It the PCM is replaced, pertorm the IoIIoWing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Neutral Switch Line Short Circuit Inspection Disconnect the neutral switch connector. Check tor continuity between the neutral switch connector terminai and ground. Connection: Light green — Ground Is there continuity? YES — Short circuit in the Light green wire. N0 — GO TO STEP 2. 2. Neutral Switch Inspection Replace the neutral switch With a knoWn good one (page 22-28). Connect the neutral switch connector. Check the DTC With the HDS pocket tester. Is DTC 52-2 indicated? YES — Replace the PCM With a known good one, and recheck. N0 — Faulty original neutrai switch DTC 53-1 (INNER MAINSHAFT SENSOR SPEED LOW) NOTE O Betore starting the inspection, check Ior loose or poor contact on the inner mainshalt sensor 3P (Biack) and PCM 33P connectors, and recheck the DTC. O It the PCM is replaced, pertorm the IoIIoWing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Check the DTC With the HDS pocket tester. Is DTC 53-1 indicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 12-43 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Inner Mainshafl Sensor Input Voltage Inspection Tum the ignition switch OFF. Disconnect the inner mainshatt sensor 3P (Biack) connector. Tum the ignition switch ON. Measure the voltage between the wire harness side inner mainshait sensor 3P (Black) connector [1] terminals. Connection: Brown/yellow (+) — Green/yellow (—) Is there about battery voltage? YES — GO TO STEP 3. N0 — GO TO STEP 4. 3. Inner Mainshafl Sensor Output Line Inspection Measure the voitage between the wire harness side 1 SP (Biack) connector [1] terminal and ground. I I Connection: Gray/yellow (4») — Ground (—) \FJA'fi Is the voltage within 4.75 — 5.25 V? Gr/Y YES — GO TO STEP 3. ' N0 — GO TO STEP 6. 4. Inner Mainshalt Sensor Input Line Open Circuit Inspection Tum the ignition switch OFF. Disconnect the PCM 33F (Black) connector. [ Check tor continuity between the wire harness side inner mainshait sensor 3P (Black) connector [1] and PCM 33F (Black) connector [2] terminais. Connection: Brown/yellow — A14 1] A14 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in the Brown/yellow wire 1 2-44 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. Inner Mainshatt Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33F (Gray) connector. Check tor continuity between the Wire harness side inner mainshait sensor 3P (Black) connector [1] and PCM 33F (Gray) connector [2] terminals. Connection: Green/yellow — 322 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the PCM with a known good one, and recheck. NO — Open circuit in the Green/yellow wire . Inner Mainshaft Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector. Check tor continuity between the wire harness side inner mainshait sensor 3P (Black) connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Gray/yellow — A20 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 7. NO — Open circuit in the Gray/yellow wire . Inner Mainshatt Sensor Output Line Short Circuit Inspection Check tor continuity between the wire harness side inner mainshait sensor 3P (Black) connector [1] terminal and ground Connection: Gray/yellow — Ground Is there continuity? YES — Short circuit in the Gray/yellow wire N0 — GO TO STEP 8. . Inner Mainshaft Sensor Inspection Turn the ignition switch OFF. Replace the inner mainshait sensor With a knoWn good one (page 12-115). Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Check the DTC With the HDS pocket tester. Is DTC 53-1 indicated? YES — Replace the PCM With a known good one, and recheck. NO — Faulty original inner mainshatt sensor [2] B22 A20 [1] [1] 12-45 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 54-1 (OUTER MAINSHAFT SENSOR SPEED LOW) NOTE O Betore starting the inspection, check tor loose or poor contact on the outer mainshatt sensor 3P (Black) and PCM 33F connectors, and recheck the DTC. O It the PCM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Check the DTC With the HDS pocket tester. Is DTC 54-1 indicated? YES — GO TO STEP 2. N0 — Intermittent tailure 2. Outer Mainshaft Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the outer mainshatt sensor 3P (Black) connector. Turn the ignition switch ON. Measure the voltage between the wire harness side outer mainshatt sensor 3P (Black) connector [1] terminals. Connection: White/blue (1-) — Green/yellow (—) Is there about battery voltage? YES — GO TO STEP 3. N0 — 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. Connection: Pink/yellow (+) — Ground (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 8. N0 — GO TO STEP 6. 1 2-46 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Outer Mainshatt Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector. Check tor continuity between the wire harness side outer mainshatt sensor 3P (Biack) connector [1] and PCM 33F (Black) connector [2] terminais. Connection: White/blue — A25 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 5. NO — Open circuit in the White/blue wire 5. Outer Mainshaft Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33F (Gray) connector. Check tor continuity between the Wire harness side outer mainshatt sensor 3P (Biack) connector [1] and PCM 33F (Gray) connector [2] terminais. Connection: Green/yellow — 322 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the PCM with a known good one, and recheck. NO — Open circuit in the Green/yellow wire 6. Outer Mainshatt Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector. Check ior continuity between the wire harness side outer mainsnait sensor 3P (Biack) connector [1] and PCM 33F (Black) connector [2] terminais. Connection: Pink/yellow — A21 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 7. NO — Open circuit in the Pink/yellow wire A25 [2] 12-47 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 7. Outer Mainshaft Sensor Output Line Short Circuit Inspection Check ior continuity between the wire harness side outer mainshalt sensor 3P (Black) connector [1] terminal and ground Connection: Pink/yellow — Ground Is there continuity? YES — Short circuit in the Pink/yellow wire N0 — GO TO STEP 8. 3. Outer Mainshaft Sensor Condition Inspection Turn the ignition switch OFF. Replace the outer mainshait sensor with a known good one (page 12-115). Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Check the DTC With the HDS pocket tester. Is DTC 54-1 indicated? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty original outer mainshait sensor DTC 55-1, 55-2 (No.1 LINEAR SOLENOID VALVE) NOTE O Beiore starting the inspection, check Ior loose or poor contact on the linear solenoid valve 4P (Green) and PCM 33F (Black) connectors, and recheck the DTC. O lithe PCM is replaced, perlorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Recheck the DTC with the HDS pocket tester. Is DTC 55-1 or 55-2 indicated? YES — GO TO STEP 2. N0 — Intermittent lailure 2. No.1 Linear Solenoid Valve Inspection Turn the ignition switch OFF. Disconnect the linear solenoid valve 4P (Green) connector. Measure the resistance between the linear solenoid valve side 4P (Green) connector [1] terminals. Connection: Blue — Gray Standard: 5.0 — 5.6 fl (20°C/68°F) Is the resistance within standard range? YES — GO TO STEP 3. N0 — Faulty linear solenoid valve 1 2-48 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. No.1 Linear Solenoid Valve Input/ground Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector. Check tor continuity between the wire harness side linear solenoid valve 4P (Green) connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Gray/white — A9 Blue/white — A10 TOOL: Test probe 07ZAJ-RDJA110 Is the continuity normal? YES — GO TO STEP 4. N0 — ~ Open circuit in the Gray/white Wire ~ Open circuit in the Blue/white wire A10 4. No.1 Linear Solenoid Valve Input/ground Line Short Circuit Inspection Check tor continuity between the wire harness side linear solenoid valve 4P (Green) connector [1] terminals and ground. Connection: Gray/white — Ground Blue/white — Ground Is there continuity? YES — ~ Snort circuit in the Gray/white wire ~ Snort circuit in the Blue/white wire N0 — Replace the PCM with a known good one, and recheck. DTC 56-1, 56-2 (No.2 LINEAR SOLENOID VALVE) NOTE ' Beiore starting the inspection, check Ior loose or poor contact on the linear solenoid valve 4P (Green) and PCM 33F (Black) connectors, and recheck the DTC. ' lithe PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Recheck the DTC with the HDS pocket tester. Is DTC 56-1 or 56-2 indicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 12-49 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. No.2 Linear Solenoid Valve Inspection Turn the ignition switch OFF. Disconnect the linear solenoid valve 4P (Green) [I] connector. Measure the resistance between the linear solenoid valve side 4P (Green) connector [1] terminals. Connection: Yellow — White/red Standard: 5.0 — 5.6 (I (20°C/68°F) Is the resistance within standard range? YES — GO TO STEP 3. N0 — Faulty linear solenoid valve 3. No.2 Linear Solenoid Valve Input/ground Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector. Check tor contlnuity between the wire harness side [1] linear solenoid valve 4P (Green) connector [1] and PCM 33F (Black) connector [2] termlnals. Connection: Pink/white — A11 Brown/white — A22 A11 TOOL: Test probe 07ZAJ-RDJA110 Is the continuity normal? YES — GO TO STEP 4. N0 — ~ Open clrcultin the Plnk/whlte wire ~ Open CerUlI in the Brown/whlte wire 4. No.2 Linear Solenoid Valve Input/ground Line Short Circuit Inspection Check tor contlnuity between the wire harness side linear solenoid valve 4P (Green) connector [1] terminals and ground. Connection: Pink/white — Ground Brown/white — Ground Is there continuity? YES — ~ Short CerUIIIH the Pink/white wwre ~ Short CerUII in the Brown/whlte wire N0 — Replace the PCM with a known good one, and recheck. DTC 57-1 (GEARSHIFT MECHANISM MALFUNCTION) See page 12-28 DTC 57-2 (GEAR POSITION MALFUNCTION; JUMPS OUT OF GEAR) See page 12-28 12-50 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 58-1 (No.1 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR) NOTE O It the PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Clutch Condition Inspection Remove the dual clutch assembly and inspect the clutch tor sticking (page 12-105). Is the No.1 clutch stuck? YES — Faulty clutch NO — GO TO STEP 2. 2. Clutch Oil Line Inspection Check the clutch oil passages in the right crankcase cover and mainshait tor clogging. Is the oil passage clogged? YES — Clean the oil passage. N0 — Replace the PCM With a known good one. and recheck. DTC 59-1 (No.2 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR) See page 12-51 DTC 61-1, 61-2, 61-3, 61-4, 62-1, 62-2 (No.1 CLUTCH OIL PRESSURE MALFUNCTION) NOTE O It the PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Recheck the DTC with the HDS pocket tester. Is DTC 47-1, 47-2, 55-1 or 55-2 indicated? YES — ~ DTC 47-1 is indicated (page 12-37). ~ DTC 47-2 is indicated (page 12-38). ~ DTC 55-1 is indicated (page 12-48). ~ DTC 55-2 is indicated (page 12-48). NO — GO TO STEP 2. 2. No.1 Clutch EOP Sensor Inspection Replace the No.1 clutch EOP sensor with a known good one (page 12-117). Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Check the No.1 clutch EOP sensor with the H08 pocket tester. Is DTC 81-1, 61-2, 61-3, 51-4, 82-1 or 62-2 indicated? YES — GO TO STEP 3. N0 — Faulty original No.1 clutch EOP sensor 12-51 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. POM Inspection Replace the PCM wrth a known good one (page 4- s7). Test-nde the motorcycle and stop the engine. Check the No.1 clutch EOP sensor with the H08 pocket tester. Is DTC 81-1, 61-2, 61-3, 51-4, 82-1 or 62-2 indicated? YES — ~ Faulty No.1 linear solenold valve ~ Clogged No.1 clutch oil line ~ Internal oil leak in the No.1 clutch Oll line N0 — Faulty onginal PCM DTC 63-1, 63-2, 63-3, 63-4, 64-1, 64-2 (No.2 CLUTCH OIL PRESSURE MALFUNCTION) NOTE O It the PCM l5 replaced, perlorm the lollowing: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learmng Procedure (page 12-120) 1. DTC Recheck Recheck the DTC with the HDS pocket tester. Is DTC 43-1, 48-2, 56-1 or 55-2 indicated? YES — DTC 48-1 l5 indicated (page 12-37). DTC 48-2 l5 indicated (page 12-38). DTC 56-1 l5 indicated (page 12-49). DTC 56-2 l5 indicated (page 12-49). N0 — GO TO STEP 2. 2. No.2 Clutch EOP Sensor Inspection Replace the No.2 clutch EOP sensor with a known good one (page 12-117). Erase the DTCs (page 12-13). Test-nde the motorcycle and stop the engine. Check the No.2 clutch EOP sensor with the H08 pocket tester. Is DTC 83-1, 63-2, 63-3, 53-4, 84-1 or 64-2 indicated? YES — GO TO STEP 3. N0 — Faulty onginal No.2 clutch EOP sensor 3. POM Inspection Replace the PCM wrth a known good one (page 4- s7). Test-nde the motorcycle and stop the engine. Check the No.2 clutch EOP sensor with the H08 pocket tester. Is DTC 83-1, 63-2, 63-3, 53-4, 84-1 or 64-2 indicated? YES — ~ Faulty No.2 linear solenold valve ~ Clogged No.2 clutch oil line ~ Internal oil leak in the No.2 clutch Oll line N0 — Faulty onginal PCM 12-52 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 65-1 (FRONT AND REAR WHEEL SPEED SIGNAL MALFUNCTION) NOTE O Betore starting the inspection, check that the tire sizes are correct, and the drive and driven sprockets are the speciiied ones. O It the PCM is replaced, pertorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph) tor more than 30 seconds. Stop the engine. Check the DTC With the HDS pocket tester. Is DTC 56-1 or 57-1 indicated? YES — ~ DTC 66-1 is indicated (page 12-54). ~ DTC 67-1 is indicated (page 12-55). NO — GO TO STEP 2. 2. Front Wheel Speed Sensor Air Gap Inspection Measure the Iront wheel speed sensor air gap (page 20-24). Is the air gap correct? YES — GO TO STEP 3. N0 —Check each part Ior deIormation and looseness and correct accordingly. Recheck the air gap. 3. Front Wheel Speed Sensor Condition Inspection inspect the area around the iront 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 ior obstructions. Check installation condition oI the pulser ring or wheel speed sensor Ior looseness. Check the pulser ring and sensor tip tor detormation or damage. Are the sensor and pulser ring in good condition? YES — GO TO STEP 4. N0 — Remove any deposits. Install properly or replace iaulty part. 4. VS Sensor Condition Inspection Remove the VS sensor (page 22-18). Check the VS sensor tor damage or contaminated. Is the VS sensor in good condition? YES — Replace the PCM With a known good one. and recheck. N0 — Replace the VS sensor with a known good one, and recheck. 12-53 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 66-1 (VS SENSOR N0 SIGNAL) NOTE O Betore starting the inspection, check Ior loose or poor contact on the VS sensor 3P (Black) and PCM ESP (Black) connectors, and recheck the DTC. O It the PCM is replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph) tor more than 30 seconds. Stop the engine. Check the DTC With the HDS pocket tester. Is DTC 56—1 indicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 2. VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector. [I] 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 (—) Is there battery voltage? YES — GO TO STEP 3. N0 — ~ Open circuitinthe Pink/blue wire ~ Open circuit in the Green/red wire 3. VS Sensor Output Line Inspection Measure the voltage between the wire harness side 1 SP (Black) connector [1] terminal and ground. [ 1 Connection: Pink/green (1-) — Ground (—) \PAvi Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 6. N0 — GO TO STEP 4. 12-54 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. VS Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector. Check tor continuity between the wire harness side VS sensor 3P (Black) connector [1] and PCM 33F (Black) connector [2] terminals. Connection: Pink/green — A32 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in the Pink/green wire 5. VS Sensor Output Line Short Circuit Inspection Check tor continuity between the wire harness side VS sensor 3P (Black) connector [1] terminal and ground Connection: Pink/green — Ground Is there continuity? YES NO — Short circuit in the Pink/green wire — GO TO STEP 6. 6. VS Sensor Inspection Turn the ignition switch OFF. Replace the VS sensor With a knoWn good one (page 22-18). Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Check the DTC With the HDS pocket tester. Is DTC 66—1 indicated? YES — Replace the PCM With a knoWn good one, and recheck. N0 — Faulty original VS sensor DTC 67-1 (FRONT WHEEL SPEED SENSOR N0 SIGNAL) NOTE ' Betore starting the inspection, check Ior loose or poor contact on the Iront wheel speed sensor 2P (Blue), ABS modulator 25F and PCM 33F (Black) connectors, and recheck the DTC. ' It the PCM is replaced, pertorm the IolloWing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Check the DTC With the HDS pocket tester. Is DTC 67-1 indicated? YES — GO TO STEP 2. N0 — Intermittent Iailure [1] P/G 12-55 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. ABS Problem Code Inspection Check the ABS probiem code (page 20-8). Does the ABS modulator have any problem code? YES — Foilow the problem code index (page 20- 10). N0 — GO TO STEP 3. 3. Front Wheel Speed Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 25F connector and PCM 33F (Black) connector. Check lor continuth between the ABS modulator 25P connector [1] and PCM 33F (Biack) connector [2] terminals. Connection: Violet/red — A33 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Violet/red wire 4. Front Wheel Speed Sensor Line Short Circuit Inspection Check tor contmuity between the wire harness side PCM 33F (Black) connector [1] and ground. Connection: A33 — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Short circuit in the Violet/red wwre N0 — Replace the PCM with a known good one, and recheck. DTC 68-1 (No.1 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS) NOTE ' It the PCM 15 replaced, perlorm the lollowing: — Key Regwstration Procedure (page 23-6) — Clutch Initialize Learmng Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-nde the motorcycle above 18 km/h (11 mph). Stop the engine. Check the DTC wwth the HDS pocket tester. Is DTC 66—1 indicated? YES — Reler to DTC 66-1 troubiesnooting (page 12-54). N0 — GO TO STEP 2. [1] A33 12-56 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Clutch Clearance Inspection Remove the No.1 cIutch assembly and measure the clutch clearance (page 12-105). Is the clearance within the standard range? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty No.1 clutch assembly DTC 69-1 (No.2 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS) NOTE O It the PCM is replaced, pertorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Check the DTC With the HDS pocket tester. Is DTC 56—1 indicated? YES — Reler to DTC 66-1 troubIeshooting (page 12-54). N0 — GO TO STEP 2. 2. Clutch Condition Inspection Remove the No.2 cIutch assemny and measure the clutch clearance (page 12-105). Is the clearance within the standard range? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty No.2 clutch assembly. DTC 71-1, 72-1 (INNER, OUTER MAINSHAFT/COUNTERSHAFT SPEED RATIO FAILURE) NOTE O It the PCM is replaced, pertorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck 1 Check the DTC With the HDS pocket tester. Is DTC 53-1, 54-1 or 65-1 indicated? YES — ~ DTC 53-1 is indicated (page 12-43). ~ DTC 54-1 is indicated (page 12-46). ~ DTC 66-1 is indicated (page 12-54). N0 — GO TO STEP 2. 12-57 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. DTC Recheck 2 Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Check the DTC With the HDS pocket tester. Is DTC 71-1 or 72-1 indicated? YES — Replace the PCM With a known good one, and recheck. N0 — Intermittent Iailure DTC 84-1 (CPU IN THE PCM MALFUNCTION) NOTE O It the PCM is replaced, perIorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Check the DTC With the HDS pocket tester. Is DTC 84-1 indicated? YES — Replace the PCM With a known good one, and recheck. N0 — Intermittent Iailure DTC1-1 (SHIFT PEDAL ANGLE SENSOR (OPTIONAL) MALFUNCTION) NOTE O Betore starting this inspection, check Ior loose or poor contact on the shilt pedal angle sensor 3P (Black) connector and PCM 33F connectors, and recheck the DTC. O It the PCM is replaced, perIorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) — DCT Shiit Pedal (Optional) Registration (page 12- 118) O It the DCT shift pedal (optional) is removed irom the vehicle, pertorm the DCT Shift Pedal Registration Cancellation (page 12-119). 1. Recheck the DTC Erase the DTCs (page 12-13). Turn the ignition switch ON and engine stop switch dperate the DCT shift pedal up and down several times with the engine stopped. Recheck the DTC with the HDS pocket tester. Is the DTC 1-1 indicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 12-58 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Pedal Inspection Angle Sensor Input Voltage Tum the ignition switch OFF. Disconnect the shilt pedal angie sensor 3P (Black) connector [1]. Tum the ignition switch ON and engine stop switch Measure the voitage between the wire harness side shift pedal angie sensor 3P (Biack) connector terminals. Connection: Yellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 4. N0 — GO TO STEP 3. 3. Shift Pedal Inspection Angle Sensor Open Circuit Tum the ignition switch OFF. Disconnect the PCM 33F (Gray) connector [1]. Check lor continuity between the Wire harness side shift pedal angie sensor 3P (Biack) connector [2] and PCM 33F (Gray) connector terminais. Connection: Green/yellow — 322 Vellow/red — B14 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the PCM with a known good one, and recheck. N0 — ~ Open circuitin Green/yellowwire ~ Open circuit in Yellow/red wire 4. Shift Pedal Angle Sensor Output Line Open Circuit Inspection Tum the ignition switch OFF. Disconnect the PCM 33F (Gray) connector [1]. Check lor continuity between the Wire harness side shift pedal angie sensor 3P (Biack) connector [2] and PCM 33F (Gray) connector terminais. Connection: Vellow/violet — B19 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in Yeliow/violet wire Y/R‘ 7 (EN [2] 822 12-59 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. Shift Pedal Angle Sensor Output Line Short Circuit Inspection Check ior continuity between the wire harness side shift pedal angie sensor 3P (Biack) connector [1] and ground. Connection: Yellow/violet — Ground Is there continuity? YES — Short circuit in Yeliow/violet wire. N0 — GO TO STEP 6. 6. Shift Pedal Angle Sensor Resistance Inspection Measure the resistance at the sensor side shift 1 pedai angle sensor 3P (Black) connector [1] [ 1 terminals. Connection: Vellow/red — Blue/green Standard: 4 — 6 kfl (20°C/68°F) Operate the DCT shiit pedal to check that the resistance changes in accordance with the pedal operation. Connection: Vellow/blue — Blue/green When moving the pedal up: Resistance increases When moving the pedal down: Resistance decreases Are the resistance inspections normal? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty shilt pedal angie sensor, replace the DCT shilt pedal as an assembly. 12-60 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) SHIFT INDICATOR TROUBLESHOOTING DTC 9 (CLUTCH LINE EOP SENSOR) NOTE O Beiore starting the inspection, check Ior loose or poor contact on the clutch line EOP sensor 3P (Black) and PCM 33F connectors, and recheck the DTC. O It the PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Clutch Line EOP Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the clutch line EOP sensor 3P (Black) connector. Turn th nition switch ON With the engine stop Measure the voltage between the wire harness side clutch line EOP sensor 3P (Black) connector [1] terminal and ground. Connection: Yellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 2. NO — GO TO STEP 5. 2. Clutch Line EOP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Connect the ECM test harness to the PCM [II connectors (page 4-14). Check tor continuity between the wire harness side clutch line EOP sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: Violet/green — A17 Is there continuity? 1 YES — GO TO STEP 3. I N0 — Open circuit in the Violet/green wire [2] A17 3. Clutch Line EOP Sensor Output Line Short Circuit Inspection Check tor continuity between the wire harness side clutch line EOP sensor 3P (Black) connector [1] terminal and ground. Connection: Violet/green — Ground Is there continuity? YES — Short circuit in the Violet/green wire NO — GO TO STEP 4. 12-61 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Clutch Line EOP Sensor Inspection Replace the clutch line EOP sensor with a knoWn good one (page 12-117). Connect the clutch line EOP sensor 3P (Black) connector. Turn the ignition switch ON with the engine stop switch ":1", lower the sidestand and check the shilt indicator. Is DTC 9 indicated? YES — Replace the PCM With a known good one and recheck. N0 — Faulty original clutch iine EOP sensor. . Clutch Line EOP Sensor Power/Ground Line Open Circuit Inspection Turn the ignition switch OFF. Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side clutch line EOP sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: Yellow/red — B14 Green/yellow — 322 Is there continuity? YES — Replace the PCM With a knoWn good one and recheck. N0 — ~ Open circuitinthe Yellow/red wire - Open circuit in the Green/yelioW wire DTC 19 (CKP SENSOR) NOTE ' Beiore starting the inspection, check lor ioose or poor contact on the CKP sensor 2P (Red) and PCM 33F connectors, and recheck the DTC. It the PCM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) . CKP Sensor Peak Voltage Inspection at PCM Connect the ECM test harness to the PCM connectors (page 4-14). Turn the ignition switch ON with the engine stop switch Crank the engine and measure the CKP sensor peak voltage between the test harness [1] terminal and ground. Connection: B11 (+)—BG(—) TOOL: lmrie diagnostic tester (model 625) or Peak voltage adaptor [2] O7HGJ-0020100 with commercially available digital multimeter (impedance 1!) MQ/DCV minimum) Is the voltage more than ‘7. 7 V? YES — Replace the PCM With a known good one and recheck. N0 — GO TO STEP 2. [1] B14 [2] 822 12-62 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. CKP Sensor Peak Voltage Inspection Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector. Turn the ignition switch ON. Crank the engine and measure the CKP sensor peak voltage between the CKP sensor 2P (Red) connector [1] terminais. Connection: Yellow (4-) — White/yellow (—) Is the voltage more than I]. 7 V? YES — ~ Open or short circuit in the Yellow wire ~ Open circuit in the White/yellow wire N0 — Faulty CKP sensor DTC 21 (SHIFT SPINDLE ANGLE SENSOR) NOTE ' Betore starting the inspection, check lor loose or poor contact on the shift spindle angie sensor 3P (Gray) and PCM 33F connectors, and recheck the DTC. ' It the PCM is replaced, pertorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Shift Spindle Angle Sensor Inspection Input Voltage Turn the ignition switch OFF. Disconnect the shift spindie angle sensor 3P (Gray) connector. Turn the ignition switch ON With the engine stop switch Measure the voltage between the wire harness side shitt spindle angie sensor 3P (Blue) connector [1] terminals. Connection: Yellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 2. N0 — GO TO STEP 5. 2. Shift Spindle Angle Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side shitt spindle angle sensor 3P (Gray) connector [1] and test harness [2] terminals. Connection: Violet/red — A16 Is there continuity? YES — GO TO STEP 3. N0 — Open circuit in the Vioiet/red Wire [2] [1] A16 12-63 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Shift Spindle Angle Sensor Output Line Short Circuit Inspection Check tor contmuity between the wire harness side 1 shwtt spindle angle sensor 3P (Gray) connector [1] [ 1 terminal and ground. Connection: Violet/red — Ground Is there continuity? YES — Short circuit in the Violet/red wwre N0 — GO TO STEP 4. 4. Shift Spindle Angle Sensor Inspection Replace the shilt spindle angle sensor with a known good one (page 12-116). Connect the shm spindle angle sensor 3P (Gray) connector and PCM 33F (Black) connector. Turn the lgmlion switch ON with the engine stop switch lower the sldestand and check the shit indicator. Is DTC 21 indicated? YES — Replace the PCM wwth a known good one. and recheck. N0 — Faulty onginal shilt spindle angle sensor 5. Shift Spindle Angle Sensor Power/Ground Line Open Circuit Inspection Turn the ignition switch OFF. 1 B14 2 Connect the ECM test harness to the PCM [ 1 [ ] connectors (page 4-14). Check tor contmuity between the wire harness side shwtt spindle angle sensor 3P (Gray) connector [1] and test harness [2] terminals. Connection: Vellow/red — B14 Green/yellow — 322 Is there continuity? YES — Replace the PCM wwth a known good one and recheck. N0 — ~ Open cwrcuwtinthe Yellow/red wire - Open cwrcuwt in the Green/yellow wire B22 DTC 22, 23 (SHIFT SPINDLE OPERATION MALFUNCTION) 1. Shift Control Motor/Reduction gear condition Check the shilt control motor and reductwon gears are installed properly and are not damaged. Are the shift control motor and reduction gears in normal condition? YES — GO TO STEP 2. N0 — Install the shilt control motor and reduction gears properly or replace taulty parts. 12-64 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Control Motor Condition Inspection Remove the shilt control motor (page 12-109). Connect a lully 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 3. N0 — Faulty shift control motor 3. Shift Spindle Angle Sensor Condition Inspection Check that the shift spindie angle sensor is instailed properly. Is the shift spindle angle sensor in normal condition? YES — Faulty shift spindle angle sensor N0 —|nsta|| the shilt spindle angle sensor properly. DTC 24 (SHIFT CONTROL MOTOR DRIVE CIRCUIT) NOTE ' If the PCM is replaced, perform the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Shift Control Motor Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Disconnect the shilt control motor 2P (Black) connector. Check lor continuity between the wire harness side shift control motor 2P (Black) connector [1] and test harness [2] terminals. Connection: Pink/blue — A1 Pink/blue — A2 Yellow/blue — A4 Yellow/blue — A15 Is there continuity? YES — GO TO STEP 2. [1] A15 N0 — ~ Open circuitinthe Pink/blue wire ~ Open circuit in the Yellow/blue wire 12-65 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Control Motor Line Short Circuit Inspection Check tor continuity between the wire harness side shift control motor 2P (Black) connector [1] and ground. Connection: Pink/blue — Ground Yellow/blue — Ground p/Bu “U \ Y/BU Is there continuity? \> / YES — ~ Short circuit in the Pink/blue wire ‘ ' / Q ~ Short circuit in the Yellow/blue Wire N0 — GO TO STEP 3. i 7 l1] 3. Shift Control Motor Inspection Remove the shift control motor (page 12-109). Connect a lully 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. N0 — Faulty shift controi motor DTC 27 (SHIFT DRUM POSITION) NOTE ' It the PCM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Shift Control Motor/Reduction gear condition Check the shilt control motor and reduction gears are instailed properly and are not damaged. Are the shift control motor and reduction gears normal condition ? YES — GO TO STEP 2. N0 — Install the shift control motor and reduction gears properly or repiace iaulty parts. 2. Shift Control Motor Condition Inspection Remove the shift control motor (page 12-109). Connect a lully 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 3. N0 — Faulty shift controi motor 1 2-66 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. TR Sensor Condition Inspection Check that the TR sensor is installed properly and is not damage. Is the TH sensor normal condition? YES — GO TO STEP 4. N0 — Install the TR sensor properly. 4. DTC Recneck Replace the TR sensor With a known good one (page 12-115). Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Read the DTC with the shitt indicator (page 12-13). Is DTC 27 indicated? YES — Replace the PCM With a known good one, and recheck. N0 — Faulty original TR sensor DTC 31 (SHIFT CONTROL MOTOR) NOTE ' Beiore starting the inspection, check tor loose or poor contact on the shitt control motor 2P (Black) and PCM 33P connectors, and recheck the DTC. ' It the PCM is replaced, periorm the tollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. PVB Fuse Inspection Check the PVB iuse (30 A). Is the PVB fuse in good condition? YES — GO TO STEP 2. N0 — Faulty PVB tuse (30 A) 2. Shift Control Motor Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Disconnect the shitt control motor 2P (Black) connector. Check tor continuity between the wire harness side shift control motor 2P (Black) connector [1] and test harness [2] terminals. Connection: Pink/blue — A1 Pink/blue — A2 Vellow/blue — A4 Vellow/blue — A15 Is there continuity? YES — Replace the PCM with a known good one, [1] A15 and recheck. N0 — ~ Open circuitinthe Pink/blue wire ~ Open circuit in the Yellow/blue wire 12-67 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 32 (FAIL SAFE RELAY) NOTE Betore starting the inspection, check Ior loose or poor contact on the PCM 33F (Black) connector and recheck the DTC. It the PCM is replaced, perlorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) . PVB Fuse Inspection Check the PVB iuse (30 A). Is the PVB Iuse in good condition? YES — GO TO STEP 2. N0 — Faulty PVB Iuse (30 A) . Shift Control Motor Power Supply Voltage Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Measure the voltage between the test harness [1] terminals and ground. Connection: A12 (4») — Ground (—) A13 (4-) — Ground (—) Is there battery voltage? YES — Replace the PCM With a known good one and recheck. N0 — ~ Open circuit in the Yellow/red Wire between the PCM 33P (Black) connector and iuse/relay box ~ Open circuit in the Red wire between the iuse/relay box and starter relay switch 4P (Red) connector DTC 37 (IGNITION HOLD RELAY) NOTE Betore starting the inspection, check Ior loose or poor contact on the PCM 33F (Black) connector and recheck the DTC. It the PCM is replaced, perlorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) . SUB PVB Fuse Inspection Check the SUB PVB tuse (7.5 A). Is the SUE PVB Iuse in good condition? YES — GO TO STEP 2. N0 — Faulty SUB PVB Iuse (7.5 A) A12 A13 [1] 12-68 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. POM (DOT Drive Circuit) Sub Power Voltage Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Measure the voltage between the test harness [1] terminals and ground. Connection: A3 (+) — Ground (—) Is there battery voltage? YES — Replace the PCM with a known good one and recheck. NO — ~ Open circuit ln the Brown/red wire between the PCM 33F connector and iuse/relay box ~ Open circuit in the Red wire between the iuse/relay box and starter relay switch 4P (Red) connector (Black) DTC 41 (N-D SHIFT SWITCH) NOTE ' Beiore starting the inspectlon, check Ior loose or poor contact on the right handlebar switch and PCM 33F (Black) connectors, and recheck the DTC. ' It the PCM l5 replaced, periorm the Iollowing: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learnlng Procedure (page 12-120) 1. N-D Shitt Switch Power Input Voltage Inspection Turn the ignition switch OFF. Disconnect the tollowing: — Right handlebar switch 6P (Black) connector (NC700XD) [1] — Right handlebar switch 7P (Green) connector (NC7OOSD) [2] Turn the ignitlon switch ON WlIh the engine stop switch Measure the voltage between the wire harness side right handlebar switch connector terminal and ground. Connection: Yellow/red (1-) — Ground (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 2. NO — Open circuit ln the Yellow/red wire A3 [1] NC700XD: [1] NC7OOSD: [2] 12-69 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. N-D Shitt Switch Inspection Turn the ignition switch OFF. Check tor continuity between the switch slde right Ncmoxnz handlebar switch connector [1] terminals ln each [1] switch positlon. [) Connection: R N switch: Light green/blue — Red 0 D switch: 0' Lg/Bu Black/yellow — Red 5W 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 NC7OOSD: [1] Lg/Bu 3. N-D Shitt Switch Input Line Open Circuit Inspection Connect the ECM test harness to the PCM NCNOXD: A18 connectors (page 4-14). Check tor continuity between the wire harness side [1] right handlebar switch connector [1] and test harness [2] terminals. Connection: Light green/black — A18 Black/yellow — A29 Is there continuity? YES — GO TO STEP 4. NO — ~ Open circult in the nght green/black wire ~ Open clrcuit in the Black/yellow wire NC7OOSD: A18 [1] [2] 1 2-70 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. N-D ShiIt Switch Inspection Input Line Short Circuit Check tor continuity between the test harness [1] terminals and ground. Connection: A18 — Ground A29 — Ground Is there continuity? YES — ~ Short circult in the Light green/black me ~ Short clrcult in the Black/yellow wire N0 — Replace the PCM with a known good one, and recheck. DTC 42 (SHIFT SWITCH) NOTE ' Betore starting the inspectlon, check Ior loose or poor contact on the IeIt handlebar switch and PCM 33F (Black) connectors, and recheck the DTC. ' It the PCM l5 replaced, periorm the Iollowing: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learnlng Procedure (page 12-120) 1. Shift Switch Power Input Voltage Inspection Turn the ignition switch OFF. Disconnect the tollowing: — Left handlebar switch 3P (Black) connector (NC700XD) [1] — Left handlebar switch 7P (Green) connector (NC7OOSD) [2] ' nitlon switch ON Wlth the engine stop Measure the voltage between the wire harness side IeIt handlebar switch connector termlnal and ground. Connection: Yellow/red (1-) — Ground (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 2. N0 — Open circuit m the Yellow/red wire A18 A20 [1] NC700XD: [1] NC700SD: 12-71 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Shift Switch Inspection Turn the ignition switch OFF. Check ior continuity between the switch slde left handlebar switch connector [1] terminals in each switch positlon. Connectio "4-" 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? YES — GO TO STEP 3. N0 — Faulty shift switch 3. Shift Switch Input Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side Ieit handlebar switch connector [1] and test harness [2] terminals. Connection: Blue/yellow — A7 Light green/red — A30 Is there continuity? YES — GO TO STEP 4. N0 — ~ Open clrcult in the Blue/yellow wwe ~ Open clrcult in the Light green/red wire NC7OOXD: G/Bu V/R NC7OOSD: NC700XD: [1] NC7OOSD: [1] [2] A30 1 2-72 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Shift Switch Input Line Short Circuit Inspection Check for continuity between the test harness [1] terminals and ground. Connection: A7 — Ground A30 — Ground Is there continuity? YES — ~ Short clrcult in the Blue/yellow wire ~ Short clrcult in the nght green/red wire N0 — Replace the PCM with a known good one, and recheck. DTC 44 (EOT SENSOR) NOTE ' Betore starting the inspectlon, check ior loose or poor contact on the EOT sensor 2P (Black) and PCM 33F connectors, and recheck the DTC. ' lt the PCM l5 replaced, periorm the iollowing: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learnlng Procedure (page 12-120) 1. EOT Sensor Input Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Disconnect the EOT sensor 2P (Black) connector. Check tor continuity between the wire harness side EOT sensor 2P (Black) connector [1] and test harness [2] terminals. Connection: Blue/green — A19 Is there continuity? YES — GO TO STEP 2. N0 — Open circuit in the Blue/green wire 2. EOT Sensor Input Line Short Circuit Inspection Check the continuity between the wire harness side EOT sensor 2P (Black) connector [1] terminal and ground. Connection: Blue/green — Ground Is there continuity? YES — Short circuit ln the Blue/green wire N0 — GO TO STEP 3. A30 Bu/G [1] [2] A19 12-73 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. EOT Sensor Ground Line Open Circuit Inspection Check tor contlnuity between the wire harness side EOT sensor 2P (Black) connector [1] and test harness [2] terminals. Connection: Green/yellow — 322 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Green/yellow wire [2] [1] 822 4. EOT Sensor Resistance Inspection Measure the resistance between the EOT sensor [1] connector termlnals. Is the resistance within 2.5 — 2.8 k9 (ZINE/63°F)? YES — Replace the PCM with a known good one, and recheck. N0 — Faulty EOT sensor DTC 47 or 48 (No.1 or No.2 CLUTCH EOP SENSOR) NOTE ' Betore starting the inspectlon, check ior loose or poor contact on the clutch EOP sensor 3P (Gray) and PCM 33F connectors, and recheck the DTC. ' It the PCM l5 replaced, periorm the iollowing: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learnlng Procedure (page 12-120) 1. Clutch EOP Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the clutch EOP sensor 3P (Gray) connector. Turn the ignitlon switch ON wwth the engine stop switch Measure the voltage between the wire harness side clutch EOP sensor 3P (Gray) connector [1] terminals. Connection: Vellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 2. N0 — GO TO STEP 5. 1 2-74 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Clutch EOP Sensor Output Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] and test harness [2] terminals. Connection: No.1 clutch EOP sensor: Vellow/green — A6 No.2 clutch EOP sensor: Black/green — A5 Is there continuity? YES — GO TO STEP 3. N0 — ~ Open circuit in the Yellow/green wire ~ Open circuit in the Black/green wire . Clutch EOP Sensor Output Line Short Circuit Inspection Check tor continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] terminal and ground. Connection: No.1 clutch EOP sensor: Vellow/green — Ground No.2 clutch EOP sensor: Black/green — Ground Is there continuity? YES — ~ Short circuit in the Yellow/green wire ~ Short circuit in the Biack/green wire N0 — GO TO STEP 4. . Clutch EOP Sensor Inspection Replace the clutch EOP sensor with a known good one (page 12-117). Connect the clutch EOP sensor 3P connector. Turn the ignition switch ON with the engine stop switch lower the sidestand and check the shilt indicator. Is DTC 47 or 43 indicated? (G ray) YES — Replace the PCM With a known good one and recheck. N0 — Faulty original clutch EOP sensor . Clutch EOP Sensor Power/Ground Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side clutch EOP sensor 3P (Gray) connector [1] and test harness [2] terminals. Connection: Yellow/red — B14 Green/yellow — 322 Is there continuity? YES — Replace the PCM with a known good one and recheck. N0 — ~ Open circuit in the Yellow/red wire ~ Open circuit in the Green/yellow wire [1] A6 [2] [1] ,#7 Y/G or Bl/G 12-75 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 49 (CLUTCH LINE LOW OIL PRESSURE) NOTE O It the PCM is replaced, perIorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Engine Oil Level Inspection Check the engine oil level (page 3-12). Is the engine oil level correct? YES — GO TO STEP 2. N0 — Add the recommended oil to the upper level. 2. Clutch Line Oil Filter Condition Inspection Check the clutch oil Iilter (page 3-14). Is the oil filter in good condition? YES — GO TO STEP 3. N0 — Replace the clutch oil tilter 3. Clutch Line EOP Sensor Inspection Replace the clutch line EOP sensor with a known good one (page 12-117). Erase the DTCs (page 12-13). Test-ride the motorcycle above 2000 min‘ (rpm) and stop the engine. Read the DTC with the shiIt indicator (page 12-13). Is DTC 49 indicated? YES — GO TO STEP 4. N0 — Faulty original clutch line EOP sensor 4. POM Inspection Replace the PCM With a known good one (page 4- e7). Test-ride the motorcycle above 2000 min‘ (rpm) and stop the engine. Read the DTC with the shiIt indicator (page 12-13). Is DTC 49 indicated? YES — - Oil pressure relietvalve stuck open - Damaged oil pump - Internal oil leak in the clutch oil line N0 — Faulty original PCM 1 2-76 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 51 (TR SENSOR) NOTE ' Beiore starting the inspection, check tor loose or poor contact on the TR sensor 3P (Black) and PCM 33F connectors and recheck the DTC. ' It the PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. TR Sensor Input Voltage Inspection Tum the ignition switch OFF. Disconnect the TR sensor 3P (Black) connector. Tum the ignition switch ON With the engine stop switch ' Measuredthe voltage between the wire harness side TR sensor 3P (Black) connector [1] terminals. Connection: Yellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 2. N0 — GO TO STEP 5. 2. TR Sensor Output Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side TR sensor 3P (Black) connector [1] and test harness [2] terminals Connection: Black/pink — A23 Is there continuity? YES — GO TO STEP 3. N0 — Open circuit in the BIack/pinkwire 3. TR Sensor Output Line Short Circuit Inspection Check tor continuity between the wire harness side TR sensor 3P (Black) connector [1] terminal and ground. Connection: Black/pink — Ground Is there continuity? YES — Short circuit in the Black/pinKWire N0 — GO TO STEP 4. [1] A28 [l] 12-77 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. TR Sensor Inspection Replace the TR sensor with a known good one (page 12-115). Connect the TR sensor 3P (Black) connector. Turn the lgnltion switch ON with the engine stop switch ":1", lower the sldestand and check the shlit indicator. Is DTC 51 indicated? YES — Replace the PCM wrth a known good one, and recheck. NO — Faulty onginal TR sensor 5. TR Sensor Power/Ground Line Open Circuit Inspection Connect the ECM test harness to the PCM 1 2 connectors (page 4-14). [ 1 [ 1 Check tor contlnuity between the wire harness side TR sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: Vellow/red — B14 Green/yellow — 322 Is there continuity? YES — Replace the PCM wrth a known good one and recheck. NO — ~ Open clrcultinthe Yellow/red wire - Open clrcult in the Green/yellow wire B22 DTC 52 (NEUTRAL SWITCH) NOTE ' Beiore starting the inspectlon, check ior loose or poor contact on the neutral switch and PCM 33F (Gray) connectors, and recheck the DTC. ' It the PCM l5 replaced, periorm the iollowing: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learnlng Procedure (page 12-120) 1. DTC Recneck Turn the lgnltion switch ON with the engine stop switch ":7", lower the sldestand and check the shlit indicator. Is DTC 52 indicated? YES — GO TO STEP 2. NO — Intermittent iailure 2. Neutral Switch Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Disconnect the neutral switch connector. Check ior contlnulty between the neutral switch connector [1] and test harness [2] terminals. Connection: Light green — BSD Is there continuity? YES — GO TO STEP 3. NO — Open circuit in the Light green wire 1 2-78 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Neutral Switch Line Short Circuit Inspection Disconnect the neutral switch connector [1]. 1 Check lor continuity between the neutral switch I I connector terminal and ground. Connection: Light green — Ground ‘ Is there continuity? YES — Short circuit in the Light green wire N0 — GO TO STEP 4. Q 4. Neutral Switch Inspection Replace the neutral switch with a know good one (page 22-28). Connect the neutral switch connector. Turn the ignition switch ON with the engine stop switch lower the sidestand and check the shilt indicator. Is DTC 52 indicated? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty original neutral switch DTC 53 (INNER MAINSHAFT SENSOR SPEED LOW) NOTE O Belore starting the inspection, check lor loose or poor contact on the inner mainshalt sensor 3P (Black) and PCM 33F connectors, and recheck the DTC. O It the PCM is replaced, perlorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Inner Mainshaft Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the inner mainshatt sensor 3P (Black) connector. Turn th nition switch ON With the engine stop Measure the voltage between the wire harness side inner mainshalt sensor 3P (Black) connector [1] terminals. Connection: Brown/yellow (+) — Green/yellow (—) Is there about battery Voltage? YES — GO TO STEP 2. N0 — GO TO STEP 3. 12-79 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Inner Mainshaft Sensor Output Line Inspection Measure the voitage between the wire harness side inner mamshatt sensor 3P (Black) connector [1] terminal and ground. Connection: Gray/yellow (4») — Ground (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 7. N0 — GO TO STEP 5. . Inner Mainstiatt Sensor Input Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor contmuity between the wire harness side inner mamshatt sensor 3P (Black) connector [1] and test harness [2] termmais. Connection: Brown/yellow — A14 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Brown/yellow wire . Inner Mainshatt Sensor Ground Line Open Circuit Inspection Check tor contmuity between the wire harness side inner mamshatt sensor 3P (Black) connector [1] and test harness [2] termwnais. Connection: Green/yellow — 322 Is there continuity? YES — Replace the PCM with a known good one, and recheck. N0 — Open circuit in the Green/yellow wire A14 [1] B22 1 2-80 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. Inner Mainshalt Output Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check ior continuity between the wire harness side inner mainshalt sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: Gray/yellow — A20 Is there continuity? YES — GO TO STEP 6. N0 — Open circuit in the Gray/yellow wire . Inner Mainshalt Sensor Output Line Short Circuit Inspection Check ior continuity between the wire harness side inner mainshalt sensor 3P (Black) connector [1] terminal and ground. Connection: Gray/yellow — Ground Is there continuity? YES NO — Short circuit in the Gray/yellow wire — GO TO STEP 7. . Inner Mainshafl Sensor Inspection Replace the inner mainshalt sensor With a known good one (page 12-115). Erase the DTCs (page 12-13). Test-ride the motorcycle and read the DTC with the shift indicator (page 12-13). Is DTC 53 indicated? YES — Replace the PCM With a new one, and recheck. N0 — Faulty original inner mainshatt sensor [2] A20 [1] l1] Gr/Y 12-81 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 54 (OUTER MAINSHAFT SENSOR SPEED LOW) NOTE O Beiore starting the inspection, check Ior loose or poor contact on the outer mainshatt sensor 3P (Black) and PCM 33F connectors, and recheck the DTC. O It the PCM is replaced, perIorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Outer Mainshaft Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the outer mainsnaIt sensor 3P (Black) [I] connector. Turn the ignition switch ON With the engine stop switch Measure the voltage between the wire harness side outer mainshaIt sensor 3P (Black) connector [1] terminals. Connection: White/blue (1-) — Green/yellow (—) Is there about battery voltage? YES — GO TO STEP 2. NO — GO TO STEP 3. 2. Outer Mainshaft Sensor Output Line Inspection Measure the voltage between the wire harness side outer mainsnaIt sensor 3P (Black) connector [1] terminal and ground. Connection: Pink/yellow (+) — Ground (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 7. NO — GO TO STEP 5. 3. Outer Mainshatt Sensor Input Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side outer mainsnatt sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: White/blue — A25 [1] A25 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in the White/blue wire 1 2-82 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Outer Mainshaft Sensor Ground Line Open Circuit Inspection Check tor continuity between the wire harness side outer malnshait sensor 3P (Black) connector [1] and test harness [2] termlnals. Connection: Green/yellow — 322 Is there continuity? YES — Replace the PCM with a known good one, and recheck. N0 — Open circuit in the Green/yellow wire 5. Outer Mainshaft Output Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side outer malnshait sensor 3P (Black) connector [1] and test harness [2] termlnals. Connection: Pink/yellow — A21 Is there continuity? YES — GO TO STEP 6. N0 — Open circuit in the Pink/yellow wire 6. Outer Mainshaft Sensor Output Line Short Circuit Inspection Check tor continuity between the wire harness side outer malnshait sensor 3P (Black) connector [1] terminal and ground. Connection: Pink/yellow — Ground Is there continuity? YES — Short circuit in the Pink/yellow wire N0 — GO TO STEP 7. 7. Outer Mainshaft Sensor Inspection Replace the outer mainshatt sensor with a known good one (page 12-115). Erase the DTCS (page 12-13). Test-nde the motorcycle and read the DTC with the shlft indicator (page 12-13). Is DTC 54 indicated? YES — Replace the PCM sensor wwth a new one. and recheck. N0 — Faulty original outer mainshatt sensor [1] 822 [2] A21 [1] [1] 12-83 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 55 (No.1 LINEAR SOLENOID VALVE) NOTE ' Beiore starting the inspection, check tor loose or poor contact on the linear solenoid valve 4P (Green) and PCM 33F (Black) connectors, and recheck the DTC. ' It the PCM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. No.1 Linear Solenoid Valve Inspection Turn the ignition switch OFF. Disconnect the linear solenoid valve 4P (Green) connector. Measure the resistance between the linear solenoid valve side 4P (Green) connector [1] terminals. Connection: Blue — Gray Standard: 5.0 — 5.6 fl (20°C/68°F) Is the resistance within standard range? YES — GO TO STEP 2. N0 — Faulty linear solenoid valve 2. No.1 Linear Solenoid Valve Input/ground Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side linear solenoid valve 4P (Green) connector [1] and test harness [2] terminals. Connection: Gray/white — A9 Blue/white — A10 Is there continuity? YES — GO TO STEP 3. N0 — ~ Open circuitinthe Gray/White Wire ~ Open circuit in the Blue/White Wire 3. No.1 Linear Solenoid Valve Input/ground Line Short Circuit Inspection Check tor continuity between the wire harness side linear solenoid valve 4P (Green) connector [1] terminals and ground. Connection: Gray/white — Ground Blue/white — Ground Is there continuity? YES — ~ Snort circuitinthe Gray/White Wire ~ Snort circuit in the Blue/white wire N0 — Replace the PCM with a known good one, and recheck. l2] A9 [1] [1] 1 2-84 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 56 (No.2 LINEAR SOLENOID VALVE) NOTE ' Beiore starting the inspection, check tor loose or poor contact on the linear solenoid valve 4P (Green) and PCM 33F (Black) connectors, and recheck the DTC. ' It the PCM is replaced, periorm the tollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. No.2 Linear Solenoid Valve Inspection Turn the ignition switch OFF. Disconnect the linear solenoid valve 4P (Green) connector. Measure the resistance between the linear solenoid valve side 4P (Green) connector [1] terminals. Connection: Yellow — White/red Standard: 5.0 — 5.6 n (20°C/68°F) Is the resistance within standard range? YES — GO TO STEP 2. N0 — Faulty linear solenoid valve 2. No.2 Linear Solenoid Valve Input/ground Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side linear solenoid valve 4P (Green) connector [1] and test harness [2] terminals. Connection: Pink/white — A11 Brown/white — A22 Is there continuity? YES — GO TO STEP 3. N0 — ~ Open circuit in the Pink/white wire ~ Open circuit in the Brown/white wire 3. No.2 Linear Solenoid Valve Input/ground Line Short Circuit Inspection Check tor continuity between the wire harness side linear solenoid valve 4P (Green) connector [1] terminals and ground. Connection: Pink/white — Ground Brown/white — Ground Is there continuity? YES — ~ Snort circuit in the Pink/white wire ~ Snort circuit in the Brown/white wire N0 — Replace the PCM with a known good one, and recheck. W/R [1] [2] A11 A22 12-85 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 57 (GEARSHIFT MECHANISM/ GEAR POSITION MALFUNCTION) See page 12-66 DTC 58 (No.1 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR) NOTE O It the PCM is replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. Clutch Condition Inspection Remove the dual clutch assembly and inspect the clutch tor sticking (page 12-105). Is the No.1 clutch stuck? YES — Faulty clutch assembly N0 — GO TO STEP 2. 2. Clutch Oil Line Inspection Check the clutch oil passages in the right crankcase cover and mainshatt Ior clogging. Is the oil passage clogged? YES — Clean the oil passage. N0 — Replace the PCM With a known good one. and recheck. DTC 59 (No.2 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR) See page 12-86 DTC 61, 62 (No.1 CLUTCH OIL PRESSURE MALFUNCTION) NOTE O It the PCM is replaced, perIorm the IoIIowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Turn the ignition switch ON with the engine stop switch lower the sidestand and check the shiIt indicator. Is DTC 47 or 55 indicated? YES — ~ DTC 47 indicated (page12—74). ~ DTC 55 indicated (page 12-84). N0 — GO TO STEP 2. 2. No.1 Clutch EOP Sensor Inspection Replace the No.1 clutch EOP sensor with a known good one (page 12-117). Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Read the DTC with the shiIt indicator (page 12-13). Is DTC 51 or 52 indicated? YES — GO TO STEP 3. N0 — Faulty original No.1 clutch EOP sensor 1 2-86 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. POM Inspection Replace the PCM Wlih a known good one (page 4- s7). Test-nde the motorcycle and stop the engine. Read the DTC with the shiIt indicator (page 12-13). Is DTC 51 or 52 indicated? YES — ~ Faulty No.1 linear solenoid valve ~ Clogged No.1 clutch oil line ~ Internal 0“ leak in the No.1 clutch Oll line N0 — Faulty onginal PCM DTC G3, 64 (No.2 CLUTCH OIL PRESSURE MALFUNCTION) NOTE O It the PCM is replaced, periorm the Iollowmg: — Key Reglstration Procedure (page 23-6) — Clutch Initialize Learnlng Procedure (page 12-120) 1. DTC Recheck Turn the lgmtion switch ON with the engine stop switch lower the sldestand and check the SW“ indicator. Is DTC 4B or 56 indicated? YES — ~ DTC 48 indicated (page12—74). ~ DTC 56 indicated (page 12-85). N0 — GO TO STEP 2. 2. No.2 Clutch EOP Sensor Inspection Replace the No.2 clutch EOP sensor with a known good one (page 12-117). Erase the DTCs (page 12-13). Test-nde the motorcycle and stop the engine. Read the DTC with the shiIt indicator (page 12-13). Is DTC 53 or 54 indicated? YES — GO TO STEP 3. N0 — Faulty onginal No.2 clutch EOP sensor 3. POM Inspection Replace the PCM Wlih a known good one (page 4- s7). Test-nde the motorcycle and stop the engine. Read the DTC with the shiIt indicator (page 12-13). Is DTC 53 or 54 indicated? YES — ~ Faulty No.2 linear solenoid valve ~ Clogged No.2 clutch oil line ~ Internal 0“ leak in the No.2 clutch Oll line N0 — Faulty onginal PCM 12-87 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 65 (FRONT AND REAR WHEEL SPEED SENSOR SIGNAL MALFUNCTION) NOTE O Betore starting the inspection, check that the tire sizes are correct, and the drive and driven sprockets are the speciiied ones. O It the PCM is replaced, perIorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Read the DTC with the shiIt indicator (page 12-13). Is DTC 56 or 57 indicated? YES — ~ DTC 66 indicated (page12—89). ~ DTC 67 indicated (page 12-90). N0 — GO TO STEP 2. 2. Speed Sensor Air Gap Inspection Measure the Iront wheel speed sensor air gap (page 20-24). Is the air gap correct? YES — GO TO STEP 3. N0 —Check each part Ior deIormation and looseness and correct accordingly. Recheck the air gap. 3. Speed Sensor Condition Inspection inspect the area around the iront 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 ior obstructions. Check installation condition oI the pulser ring or wheel speed sensor Ior looseness. Check the pulser ring and sensor tip tordetormation or damage. Are the sensor and pulser ring in good condition? YES — GO TO STEP 4. N0 — Remove any deposits. Install properly or replace Iaulty part. 4. VS Sensor Condition Inspection Remove the VS sensor (page 22-18). Check the VS sensor tor damage or contaminated. Is the VS sensor in good condition? YES — Replace the PCM With a known good one. and recheck. N0 — Replace the VS sensor with a known good one, and recheck. 1 2-88 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DTC 66 (VS SENSOR NO SIGNAL) NOTE O Beiore starting the inspection, check tor loose or poor contact on the VS sensor 3P (Black) and PCM 33F connectors, and recheck the DTC. O It the PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Read the DTC with the shitt indicator (page 12-13). Is DTC 56 indicated? YES — GO TO STEP 2. N0 — Intermittent Iailure 2. VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector. 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 (—) Is there battery voltage? YES — GO TO STEP 3. N0 — ~ Open circuitin the Pink/blue wire ~ Open circuit in the Green/red wire 3. VS Sensor Output Line Inspection Measure the voltage between the wire harness side 1 SP (Black) connector [1] terminal and ground. I I Connection: Pink/green (+) — Ground (—) \PAvi Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 6. N0 — GO TO STEP 4. 12-89 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. VS Sensor Output Line Open Circuit Inspection Connect the ECM test harness to the PCM connectors (page 4-14). Check tor continuity between the wire harness side VS sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: Pink/green — A32 Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in the Pink/green wire 5. VS Sensor Output Line Short Circuit Inspection Check tor 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 N0 — GO TO STEP 6. 6. VS Sensor Inspection Replace the VS sensor With a known good one (page 22-18). Erase the DTCs (page 12-13). Test-ride the motorcycle and stop the engine. Read the DTC with the shitt indicator (page 12-13). Is DTC 66 indicated? YES — Replace the PCM With a known good one, and recheck. N0 — Faulty original VS sensor DTC 67 (FRONT WHEEL SPEED SENSOR N0 SIGNAL) NOTE ' Betore starting the inspection, check tor loose or poor contact on the tront wheel speed sensor 2P (Blue), ABS modulator 25F and PCM 33F connectors, and recheck the DTC. ' It the PCM is replaced, pertorm the tollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Read the DTC with the shitt indicator (page 12-13). Is DTC 67 indicated? YES — GO TO STEP 2. N0 — Intermittent tailure [2] A32 [1] [1] PK; 12-90 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. ABS Problem Code Inspection Check the ABS probiem code (page 20-8). Does the ABS modulator have any problem code? YES — Foilow the probiem code index (page 20- 10). N0 — GO TO STEP 3. 3. Front Wheel Speed Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS moduiator 25F connector. Connect the ECM test harness to the PCM connectors (page 4-14). Check lor continuity between the ABS modulator 25F connector [1] and test harness [2] terminals. Connection: Violet/red — A33 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Vioiet/red Wire [2] [1] 4. Front Wheel Speed Sensor Line Short Circuit Inspection Check tor continuity between the test harness [1] 1 terminal and ground. [ 1 Connection: A33 — Ground A33 Is there continuity? YES — Short circuit in the Vioiet/red Wire N0 — Replace the PCM with a known good one, and recheck. DTC 63 (No.1 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS) NOTE ' It the PCM is replaced, pertorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Ftecheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Read the DTC with the shilt indicator (page 12-13). Is DTC 66 indicated? YES — Reler to DTC 66 troubleshooting (page 12- 39). N0 — GO TO STEP 2. 12-91 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Clutch Condition Inspection Remove the No.1 ciutch assembly and measure the clutch clearance (page 12-105). Is the clearance within the standard range? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty No.1 clutch assembly DTC 69 (No.2 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS) NOTE O It the PCM is replaced, perlorm the lollowirig: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Test-ride the motorcycle above 18 km/h (11 mph). Stop the engine. Read the DTC with the shilt indicator (page 12-13). Is DTC 56 indicated? YES — Reler to DTC 66 troubieshooting (page 12- 39). N0 — GO TO STEP 2. 2. Clutch Condition Inspection Remove the No.2 ciutch assembly and measure the clutch clearance (page 12-105). Is the clearance within the standard range? YES — Replace the PCM With a known good one. and recheck. N0 — Faulty No.2 clutch assembiy DTC 71, 72 (INNER, OUTER MAINSHAFT/COUNTERSHAFT SPEED RATIO FAILURE) NOTE O It the PCM is replaced, perlorm the lollowirig: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck 1 Turn the ignition switch ON with the engine stop switch lower the sidestarid and check the shilt indicator. Is DTC 53, 54 or 65 indicated? YES — ~ Reier to DTC 53 troubieshooting (page 12-79). ~ Reier to DTC 54 troubieshooting (page 12-82). ~ Reier to DTC 66 troubieshooting (page 12-89). N0 — GO TO STEP 2. 12-92 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. DTC Recheck 2 Erase the DTCs (page 12-13). Test-ride the motorcycie above 18 km/h (11 mph) tor more than 30 seconds. Stop the engine. Read the DTC with the shilt indicator (page 12-13). Is DTC 71 or 72 indicated? YES — Replace the PCM With a known good one. and recheck. N0 — Intermittent laiIure DTC 84 (CPU IN THE PCM MALFUNCTION) NOTE O ll the PCM is replaced, pertorm the lollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. DTC Recheck Erase the DTCs (page 12-13). Read the DTC with the shilt indicator (page 12-13). Is DTC 84 indicated? YES — Replace the PCM With a known good one. and recheck. N0 — Intermittent laiIure DTC1 (SHIFT PEDAL ANGLE SENSOR (OPTIONAL) MALFUNCTION) NOTE O Betore starting this inspection, check lor loose or poor contact on the shilt pedal angle sensor 3P (Biack) connector and PCM 33F (Gray) connector and recheck the MIL. O ll the PCM is replaced, perlorm the loIIowing procedure. — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) — DCT Shilt Pedal (Optional) Registration (page 12- 118) O ll the DCT shift pedaI (optional) is removed lrom the vehicIe, pertorm the DCT Shilt PedaI Registration Cancellation (page 12-119). 1. DTC Recheck Erase the DTC's (page 12-13). T rn the ignition switch ON and engine stop switch Operate the DCT shilt pedal up and down severai times with the engine stopped. Recheck the DTC with the shilt indicator (page 12- is). Is the DTC 1 indicated? YES — GO TO STEP 2. N0 — Intermittent laiIure 12-93 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Sh ift Pedal Angle Sensor Input Voltage Inspection Tum the ignition switch OFF. Disconnect the shilt pedal angie sensor 3P (Black) connector [1]. Tum the ignition switch ON and engine stop switch Measure the voitage between the wire harness side shift pedal angie sensor 3P (Biack) connector terminals. Connection: Vellow/red (1-) — Green/yellow (—) Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 4. N0 — GO TO STEP 3. . Shift Pedal Angle Sensor Open Circuit Inspection Tum the ignition switch OFF. Connect the ECM test harness to the PCM connectors (page 4-14). Check lor continuity between the shilt pedai angie sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: Green/yellow — 322 Vellow/red — B14 Is there continuity? YES — Replace the PCM with a known good one, and recheck. N0 — ~ Open circuit in Green/yellow wire ~ Open circuit in Yellow/red wire . Shift Pedal Angle Sensor Output Line Open Circuit Inspection Tum the ignition switch OFF. Connect the ECM test harness to the PCM connectors (page 4-14). Check lor continuity between the shilt pedai angie sensor 3P (Black) connector [1] and test harness [2] terminals. Connection: Vellow/violet — B19 Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in Yeiiow/violet wire Y/R A 59 N) 9 B14 [2] 322 [2] B19 12-94 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 5. Shift Pedal Angle Sensor Output Line Short Circuit Inspection Check lor continuity between the Wire harness side shift pedal angie sensor 3P (Biack) connector [1] and ground. Connectlon: Vellow/violet — Ground Is there continuity? YES — Short circuit in Yeiiow/violet wire NO — GO TO STEP 6. 6. Shift Pedal Angle Sensor Resistance Inspection Measure the resistance at the sensor side shift pedai angle sensor 3P (Black) connector [1] terminals. Connection: Yellow/red — Blue/green Standard: 4 — 6 k0 (20°C/68°F) Operate the DCT shiit pedal to check that the resistance changes in accordance with the pedal operation. Connection: Vellow/blue — Blue/green When moving the pedal up: Resistance increases When moving the pedal down: Resistance decreases Are the resistance inspections normal? YES — Replace the PCM With a known good one, and recheck. N0 — Faulty shilt pedal angie sensor, replace the DCT shilt pedai as an assembly. MODE/SHIFT INDICATOR CIRCUIT TROUBLESHOOTING II the mode indicator does not operate, check that the combination meter shows lollowing when the ignition switch is turned ON with the engine stop switch — MIL [1] and engine oil pressure indicator [2] stay on. — Shin indicator "—" [3] is biinking. — Tachometer, high coolant temperature indicator and HISS indicator do not come on. It so, check the TXD/RXD line (page 22-11). It not so, repiace the combination meter. 12-95 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) AT/MT MODE SWITCH TROUBLESHOOTING II the engine can be started but AT/MT mode cannot be changed, periorm this troubleshooting. NOTE ' Beiore starting the inspection, check Ior loose or poor contact on the right handlebar switch and PCM 33F connectors, and recheck the AT/MT mode switch operation. ' It the PCM is replaced, perIorm the Iollowing: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 12-120) 1. AT/MT mode switch Power Input Voltage Inspection Disconnect the tollowing: NC700XD: NC7OOSD: [1] — Right handlebar switch 6P (Black) connector (NC700XD) [1] — Right handlebar switch 7P (Green) connector (NC7OOSD) [2] Turn the ignition switch ON with the engine stop switch ' , . Measure the voltage between the wire harness side right handlebar switch connector terminal and ground. Connection: Black/white (+) — Ground (—) Is there battery voltage? YES — GO TO STEP 2. N0 — Open circuit in the Black/white wire between the right handlebar switch connector and Iuse/relay box (Fl Iuse) 2. AT/MT mode switch Inspection Turn the ignition switch OFF. Check tor continuity between the switch side right handlebar switch connector [1] terminals in each switch position. 8le Connection: Black/white — Blue/black NC700XD: Is there continuity with the switch pushed and no continuity with the switch released? @ YES — GO TO STEP 3. N0 — Faulty AT/MT mode switch Bu/BI III NC7OOSD: Bl/W \53 £33 \ , Bu/BI [1] 12-96 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. AT/MT mode switch Input Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector. _ Check lor continuity between the wire harness side Ncmoxn' right handlebar swwtch connector [1] and PCM ESP [1] [2] (Black) connector [2] terminals. Connection: White/yellow — A27 TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the PCM with a known good one, and recheck. N0 — Open circuit in the White/yellow wire A27 NC7OOSD: [1] You. A27 RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-13). Remove the Iollowing: — Maintenance lid (page 21 -6) — Shroud/side cover (NC700XD) (page 2-14) — Shelter/side cover (NC7OOSD) (page 2-15) — Right engine side cover (page 2-30) Disconnect the linear solenoid valve 4P (Green) connector [1] and remove it from the ABS modulator stay. Disconnect the CKP sensor 2P (Red) connector [1] and release the CKP sensor harness. 12-97 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Disconnect the clutch EOP sensor 3P connectors [1]. Remove the tollowing: — Bolt and shilt spindle angle sensor [2] — Bolt [3] and wire clip stay [4] — Bolts [5] and Wire clamps [6] sensor wire from the right crankcase cover. Du nu! allow duster Remove the bolts [1] and hose clamp [2]. d'” ’0 am” the 0” Remove the right crankcase cover [3]. passages. Remove the oil joint pipe [1] and dowel pins [2]. Remove the O-rings from the joint pipe. Remove the seal rings [3] from the mainshatt end. LINEAR SOLENOID VALVE BODY DISASSEMBLY NOTE - Keep dust and dirt away from all the parts. - Be careful not to damage the mating surlaces of the valve body components. Remove the right crankcase cover (page 12—97). Remove the right crankcase cover Wire clamp bolt [1] and wire olamp [2]. Remove the Wire grommets [3] from the right crankcase cover. 12-98 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 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] lrom the valve body cover. Remove the bolt [1], linear solenoid valves [2] and stopper plate [3] from the valve body. Remove the stopper plate from the linear solenoid valves. 12-99 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Wash all the parts with a high Ilash point or non- m flammable solvent and blow through all oil passages . with compressed air to clean completely. v » / § 0 Check the linear solenoid valves [1] and valve body [2] N? " tor scratches, scoring or damage. o . » .3 \ \ [2] 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 COVER VALVE BODY LINEAR SOLENOID VALVES I i' l CKP SENSOR MOUNTING BOLTS 1—“ 12 N-m (1.2 Kgl-m, 9 lbl-lt) I‘m STOPPER PLATE 1—W12 N-m (1.2 mm, 9 lbf-ft) SEPARATE PLATE W|RE CLAMP Coat linear solenoid valves [1] with engine oil. Set the stopper plate [2] into the grooves in the solenoid valves. 12-100 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the linear solenoid valves [1] and stopper plate . [2] into the valve body. L“ [3] Apply locking agent to the threads 01 the stopper plate bolt [3] (page 12-4). Install the stopper plate bolt and tighten it. TORQUE: 12 NM (1.2 kgl‘m, 9 lel) 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] tor damage and replace them it 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. 12-101 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Apply liquid sealant (Three bond 12073 or equivalent) to the CKP sensor wire grommet and linear solenoid Jim! [1]/I2] valve Wire grommet sealing surIace. 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 12-4). Install the wire clamp [4] and tighten bolts. TORQUE: 12 N-m (1.2 kgf‘m, 9 Ibf‘fl) Install the right crankcase cover (page 12—103). OIL GUIDE COLLAR REMOVAL/ INSTALLATION Remove the right crankcase cover (page 12—97). Remove the snap ring [1] Irom the right crankcase cover. Remove the oil guide collar [1] from the right crankcase cover with the special tool. TOOL: Bearing remover, 20 mm [2] 07931-MA70000 Remove the O-rings from the oil guide collar. Coat new O-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. 12-102 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the snap ring [1] into the right crankcase cover groove with the chamfered edge facing in. Install the right crankcase cover (page 12—103). INSTALLATION Do hula/low duster Coat new O-rings [1] with engine oil and install them din to enter the all onto the oil joint pipe [2]. passages 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 mainshalt grooves. Push in the seal rings to seat them into the grooves. Clean the right crankcase cover mating surlaces thoroughly. Apply liquid sealant (Three Bond 12073 or equivalent) to the right crankcase cover mating surface as shown. 12-103 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the right crankcase cover [1]. Install the bolts [2] With the hose clamp [3] and tighten them in a crisscross pattern in 2 or 3 steps. Route the wire harness and shift spindle angle sensor wire on the right crankcase cover properly (page 1—25). Goat a new O-ring [1] With engine oil and install it onto the shilt spindle angle sensor [2]. Install the shift spindle angle sensor by aligning the flat surlaces ol the sensor and spindle. Install the lollowmg: — Wire clamps [1] and bolts [2] — Wire clip stay [3] and bolt [4] Install the shilt 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 CKP sensor 2P (Red) connector [1]. 12-1 04 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Connect the linear solenoid valve 4P (Green) connector [1] and install it to the ABS modulator stay. Install the lollowmg: Maintenance lid (page 21 -6) Shroud/side cover (NC700XD) (page 2-14) Shelter/side cover (NC7OOSD) (page 2-15) Right engine side cover (page 2-30) Fill the engine With the recommended engine oil and check that there are no oil leaks (page 3-12). DUAL CLUTCH REMOVAL Remove the right crankcase cover (page 12—97). Align the gear teeth of the primary drive gear and sub- - gear [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 mainshalt grooves. DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) DISASSEMBLY Remove clutch guide 1 [1], clutch guide 2 [2] and washers [3] Irom the clutches. Remove the clutch assemblies [1] and O-rings [2] lrorn the primary driven gear. NOTE - 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. CLUTCH CLEARANCE INSPECTION Set a dial indicator on the end plate [1] with the plate bottomed. Measure the clearance by lilting the end plate against the snap ring and record it. Perlorm this inspection at three points in 120° apart. SERVICE LIMIT: 2.0 mm (0.08 in) II the measured value exceeds the service limit, replace the clutch assembly. ASSEMBLY Coat new O-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 12-106 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Apply engine oil to the needle hearings in the primary driven gear. NOTE 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. Tum over the dual clutch assembly while holding clutch guide 1. Apply engine oil to the needle hearings 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 mainshalt grooves. Push in the seal rings to seat them into the grooves. Install the dual clutch assembly [1] onto the mainshalt, being careful not to damage the seal rings. Install the ball bearing [2] onto clutch guide 1 with the marked side lacing out. [3] 12-107 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Remove the 6 mm socket bolt [1] to tree the primary drive gear and sub-gear [2]. Install the right crankcase cover (page 12-103). PRIMARY DRIVE GEAR/CKP SENSOR ROTOR Do no! separate the subgear [mm the primary drive gear unless necessary. R EMOVA L Remove the right crankcase cover (page 12-97). Hold the primary drive gear and sub-gear with a 6 mm socket bolt (page 12-105). Install the special tool between the primary drive and driven gears, and loosen the primary drive gear bolt [1]. TOOL: ' Gear holder, M2.5 [2] 07724-0010100 \' \ _ <- \ Remove the primary drive gear bolt, washer [3], CKP s sensor rotor [4] and primary drive gear/sub-gear [5] ’ I'- trom the crankshatt. 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 r” and seating surlace. 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: Gear holder, M2.5 [3] 07724-0010100 TORQUE: 93 NM (9.5 kgf‘m, 69 Hair“) Remove the 6 mm socket bolt [4] to tree the primary . - drive gear and sub-gear. Install the right crankcase cover (page 12-103). 12-108 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) SHIFT CONTROL MOTOR/REDUCTION GEARS REMOVAL Remove the lollowing: — Guard plpe (page 2-30) — Left rear cover (page 2-30) Disconnect the shift control motor 2P (Black) connector Remove the bolts [2] and shift control motor [3]. Remove the bolt [1], wire clip stay [2] and TR sensor [3]. Remove the bolts [1] and reductlon gear cover [2]. Remove the dowel pins [1] and gasket [2]. Remove the reductlon gears [3]. DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) INSTALLATION @ "1 REDUCTION GEAR v O-RING CASE COVER TR SENSOR 14 N-m (1.4 Kgl-m,10lbI-ft) 14 N-m (1.4 mm, 101nm) Apply 2 — 4 g (0.07 — 0.14 oz) ol specilied grease to the reduction gearjournals and teeth. SPECIFIED GREASE: Templex N3 grease (ESSO) InstaII reduction gear B [1] and align the gear ends with the ribs ol the crankcase. Then install reduction gear C [2] so 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]. 12-110 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the reduction gear cover [1] and bolts [2], and I ‘ > / tighten the bolts. TORQUE:14 N-m (1.4 kgrm, 10 mm) Goat a new O—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 surlaoes of the sensor and shilt drum end. Install the wire clip stay [1] and TR sensor bolt [2], and tighten the bolt. TORQUE: 12 MM (1.2 kgf‘m, 9 let) Goat a new O—ring [1] with engine Oil and install it into the groove in the shift control motor [2]. 12-111 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Install the shift control motor [1] and bolts [2], and tighten the bolts. TORQUE:14 N-m (1.4 kgf-m, 10 Ihl-fl) Connect the shift control motor 2P (Black) connector [3]. Install the following: — Guard pipe (page 2-30) — Left rear cover (page 2-30) GEARSHIFT LINKAGE REMOVAL Remove the following: — Shift control motor/reduction gears (page 12—109) — Dual clutch (page 12—105) — 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] 12-112 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 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 Check the gearshift spindle [1] and gearshift arm [2] for wear or damage. Check the return spring [3] for fatigue or damage. [2] [1] Check the drum shifter guide plate [1], drum shifter [2], 3 4 5 ratchet pawls [3] and plungers [4] for wear or damage. I I I I I 1 Check the plunger springs [5] for fatigue or damage. \‘ / ‘ é \ y [1] [2] 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] 12-113 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 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 12—4). Install the shift drum center bolt and tighten it. TORQUE:23 N-m (2.3 kgf-m, 17 lhl-ft) 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 shifter guide plate/drum shifter assembly [1]. Apply locking agent to the threads of the guide plate bolts [2] (page 12—4). Install the guide plate bolts and tighten them. TORQUE: 12 NM (1.2 kgf-m, 5 Ibf-fl) Install the drum shifter collar [3] onto the drum shifter. 12-114 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 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 shitter collar. Install the lollowmg: — Dual clutch (page 12-107) — Reduction gears/shift control motor (page 12-110) MAINSHAFT SENSOR Inner malnshaf! sensor: REMOVAL/INSTALLATION NOTE The mainshalt sensors and VS sensor are the same parts. Remove the luggage box (page 2-19). Disconnect the outer mainshaft sensor 3P (Black) connector [1] from the outer mainshaft sensor [2]. Disconnect the inner mainshaft sensor 3P (Black) connector [3] from the inner mainshatt sensor [4]. Remove the bolt [5] and mainshaft sensor. Remove the O-ring [6] from the mainshaft sensor. Installation is in the reverse order oi removal. NOTE - Replace the O—ring with a new one. - Apply engine oil to a new O-ring. TR SENSOR REMOVAL/INSTALLATION Remove the lollowing: — Center cross plate (page 2—32) — Left rear cover (page 2-30) Disconnect the TR sensor 3P (Black) connector [1] and remove it lrom the ABS modulator stay. 12-115 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Remove the wire band [1] and release the Wires and hose from the stay [2]. Remove the bolt [1], wire clip stay [2] and TR sensor [3]. Remove the O-ring [4] from the TR sensor. Installation is in the reverse order of removal. NOTE - Replace the O—ring with a new one. - Apply engine oil to a new O-ring. - Align the flat surfaces of the TR sensor and shift drum end. TORQUE: TR sensor bolt: 12 Nm (1.2 kgf-m, 9 lbf-ft) SHIFT SPINDLE ANGLE SENSOR REMOVAL/INSTALLATION Remove the following: — Shroud/side cover (NC700XD) (page 2-14) — Side cowl (NC7OOSD) (page 2—13) — Right engine side cover (page 2-30) Disconnect the shift spindle angle sensor 3P (Gray) connector [1] and remove it from 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]. 12-116 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) Remove the O—ring [1] from the shilt spindle angle sensor [2]. Installation is in the reverse order ol removal. NOTE - Replace the O—ring with a new one. - Apply engine oil to a new O—ring. - Align the flat surfaces of the shift spindle angle sensor and gearshift spindle end. - Route the wire harness properly (page 1-25). TORQUE: sum spindle angle sensor bolt: 12 Nm (1.2 kgf‘m, 9 lbl-l‘t) CLUTCH EOP SENSOR REMOVAL/INSTALLATION Remove the lower cowl (page 2-29). The No.15lutch Disconnect the 3P connector [4] from the clutch EOP EOPsensor[1]. sensor. “MGM” EOP Remove the clutch EOP sensor and O-rings from the sensor [2] and No.2 clutch EOP sense, right crankcase cover. [3] are the same parts. Goat a new O—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 kgl-m,14lbf‘l‘t) Connect the 3P connector to the proper sensor. NOTE Each sensor wires has the lollowmg 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 lower oowl (page 2—29). 12-117 DUAL CLUTCH TRANSMISSION (DCT) (NC7OOXD/SD) EOT SENSOR REMOVAL/INSTALLATION Disconnect the EOT sensor 2P (Black) connector [1]. Remove the EOT sensor [2] and sealing washer [3] Irom 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. TOROUE:14 N-m (1.4 kgt-m,10lbf—Il) b Connect the EOT sensor 2P (Black) connector. \ / gia’ DCT SHIFT PEDAL (OPTIONAL) REGISTRATION (TO ENABLE THE PEDAL) NOTE ' The following registration procedure must be performed in order to enable the optional shilt pedal. ' Make sure that the CLUTCH INITIALIZE LEARNING (PCM) (page 12—120) is complete before starting the registration. ' The registration WlII lail il 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 shilt pedal angle sensor 3P (black) connector is disconnected. 1. Install the shilt pedal to the vehicle and connect the shift pedal angle sensor 3P (black) connector. 2. Turn the ignition switch ON. , . . I , Indicators start blinking Alter 2 seconds, "S" [1] and "D" [2] 'ndlcalors W'" simultaneously. start short blinking (0.5 seconds) simultaneously. NOTE ' The short blinking lasts 5 seconds. \\ 1/ Within 5 seconds after blinking starts, move the shift ‘ ' pedal [3] up and hold for1 second. ’ ‘\ Within 5 seconds after moving the shift pedal up. move it down and hold for 1 second. [2] II] 1: UP Ior1 second. ’i'r \ \ 2: DOWN for 1 second. 12-118 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. It the "S" and "D" indicators start short blinking (0.5 seconds) alternately, registration is successiul. Turn the ignition SWitch OFF. NOTE ' It the "S" and "D" indicators go OFF during the procedure, registration is unsuccessiul. Turn the ignition switch OFF and periorm the registration procedure Irom step 2 again. REGISTRATION CANCELLATION (TO DISABLE THE PEDAL) NOTE ' The registration must be cancelled after removing the optional shiIt pedal Irom the vehicle. II the registration is not cancelled, DTC 1-1 (DTC 1 blink) "SHIFT PEDAL ANGLE SENSOR MALFUNCTION" will be indicated. ' The cancellation will iail iI any oi the iollowing condition presents during the procedure. — The vehicle is moved. — The engine is started. — The transmission is in gear. — The shift SWitch (+l/(—) is operated incorrectly. — The shiIt pedal angle sensor 3P (black) connector is connected. 1. Remove the shiIt pedal trom the Vehicle and disconnect the shiIt pedal angle sensor 3P (black) connector. 2. While pressing down and holding the shiIt switch (+) [1] and shift sWitch (—l [2], turn the ignition switch ON. The ' " [3] and "D" [4] indicators Will start short blinking (0.5 seconds) simultaneously. NOTE ' Do not release the shift switch (+) and shift switch (—) until the successiul pattern described in the next step is indicated. Successful: Indicators blink alternately. Unsuccessful: Both go OFF [4] DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 3. Alter 5 seconds, the "S" and "D" indicators will start short blinking (0.5 seconds) alternately. ll so, cancellation is successlul. Turn the ignition switch OFF. NOTE ll the "S" and "D" indicators go OFF during the procedure, cancellation is unsuccesslul. Turn the ignition switch OFF and perlorm the cancellation procedure lrom step 1 again. CLUTCH INITIALIZE LEARNING (PCM) NOTE ll the PCM and/or clutch assembly are replaced, perlorm this procedure. Belore starting this procedure, check the lollowing: — PGM-Fl system and DOT system have no DTC. — Engine idle speed is normal. — Transmission is in neutral and cooling lan stops. Do not operate the throttle during clutch initialize learning . Warm up the engine to the normal operating temperature (engine oil temperature: 50 — 110°C/ 122 — 230°F) and stop it. NOTE II the PCM is replaced with a new one, the "D" and "S" indicators [i] come on to indicate that the clutch initialize learning is necessary when the ignition switch is turned ON. Further the large "L" [2] (extremely low oil temperature) or small "L" [3] (low oil temperature) is displayed on the shilt indicator to indicate that the engine warming up is necessary it it is not warmed. Successful: \l \l r \ ,S:<—>‘D I\I Indicators blink alternately. Unsuccessful: Both go OFF Extremely low Oll lem erature: p iii [11 x10 or/mln 5 Low oil temperature: x : or/mln E 12-120 DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 2. Turn the ignition switch ON with the engine stop switch 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 oil. ' 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. 3. Operate the N-D snift sWitch [1] in the sequence as follows: — Push the D sWitch — Push the D sWitch — Push the N sWitch — Push the D sWitch — Push the N sWitch ' When only the dual clutch assembly is replaced: The PCM is ready to clutcn initialize learning when the "D" and "S" indicators [2] lights, and the "—" [3] is displayed on the shilt indicator and blinks at interval of 2 seconds. ' When the PCM is replaced: The PCM is ready to clutcn 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 di layed on the shilt indicator. If so, warm up it until the "L" on the shilt indicator goes off. Stop the engine and perform the steps 2 and 3 again. [3] xmaor/mln 7 1 D5 F- I I'm/n '- E- [ i! 4] x1aoor/mln E DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) 4. Start the engine and let it idle. The "—" [i] on the shift indicator starts blinking at interval oi 2 seconds. The Clutch initialize Learning is successtul, when the "D" and "S" indicators [2] go oil. Stop the engine. NOTE The clutcn initialize learning is unsuccesstul, ii the "—" starts blinking at interval oi 0.5 second or it goes olt, and the "D" and "S" indicators stay on. Perform the initialize learning procedure lrorn step 2 again. 5. Stop the engine. 6. Restart the engine, push the D switch ol the N-D shift switch and check that the "D" indicator comes on. Oar/min E x1000r/mln 7 12-122 13. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION----- -----13-2 FLYWHEEL-------- ---13-7 SERVICE lNFORMATION------ -----13-4 STARTER CLUTCH---- ------13—10 TnouBLESHoonNG.................................13.4 STA-[OR .................................................. ..13.13 ALTERNATOR COVER...............................13.5 13-1 ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION NC700X/XA/S/SA: 157 N-m (16.0 Kgl-m,116|bf-ft) 1 3-2 ALTERNATOR/STARTER CLUTCH NC7DOXD/SD: 157 N-m (15.0 kgf-m, 116 mm) 1 3-3 ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL ~ This section covers service oI the alternator and starter clutch. All sen/ice can be done with the engine installed in the Irame. ~ For alternator inspection (page 21 -9). ~ For CKP sensor inspection (page 5-6). ~ For starter motor service (page 6-8). SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear boss O.D. 57.749 — 57.768 (2.2786 — 2.2743) 57.78 (2.273) Starter clutch outer |.D. 74.412 — 74.442 (2.9296 — 2.9308) 74.46 (2.931) TORQUE VALUES , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgI-m, lbI-ft) REMARKS Flywheel mounting bolt 1 12 157 (16.0, 116) Le“ hand thread Apply engine oil to the threads and seating surIace. Starter clutch socket bolt 6 B 80 (3.1, 22) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) Irom tip Alternator stator mounting bolt 4 6 10 (1.0, 7) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) Irom tip Alternator Wire clamp bolt 1 6 10 (1.0, 7) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) Irom tip TROUBLESHOOTING Starter motor turns, but engine does not turn ~ Faulty starter clutch Damaged starter reduction gear/shaft Damaged starter idle gear/shait Damaged or Iaulty starter motor pinion gear Damaged starter driven gear 1 3-4 ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL/INSTALLATION Remove the iollowing: — Shroud/side cover (NC700X/XA/XD) (page 2-14) — Shelter/side cover (NC7ODS/SA/SD) (page 2-15) — Left rear cover (page 2-29) — Guard pipe (NC700XD/SD) (page 2-30) Remove the bolt [1] and rear brake reservoir stay/ resen/oir [2]. Remove the socket bolts [3]. Lower the rear lender B [1]. Disconnect the alternator 3P (Black) connector [2]. Release the sidestand switch Wire harness clamp [1]. Release the alternator wire harness [2]. 1 3-5 ALTERNATOR/STARTER CLUTCH Release the battery box drain hose (NC7ODX/XA/S/SA) [1] trom 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 llywheel, be careful during removal. Remove the dowel pins [1], oil orifice [2] and O—ring [3]. Clean oil any sealant from the alternator cover mating surlaces. Do not loosen the alternator cover sealing bolt [1]. 1 3-6 ALTERNATOR/STARTER CLUTCH Installation is in the reverse order of removal. NOTE - Apply liquid sealant (Three bond 1207B or equivalent) to the alternator cover mating surface as shown. - Apply liquid sealant (Three bond 1207B or equivalent) to the alternator wire grommet sealing surface. Do not apply more liquid sealant than necessary. Replace the O-ring with a new one. Route the cables and wire harness properly (page 1- 25). - Align the rear brake reservoir stay with the frame tab. Fill the engine with the recommended engine oil and check that there are no oil leaks (page 3-12). FLYWH EEL REMOVAL Remove the alternator cover (page 13-5). 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: Flywheel holder [3] NOTE The flywheel mounting bolt has left hand threads. 07725-0040001 Remove the flywheel mounting bolt and washer [4]. Remove the flywheel [1] using the special tool. TOOL: Rotor puller [2] 07933-3290001 Jim! {31 ALTERNATOR/STARTER CLUTCH Remove the washer [1] and needle bearing [2]. Remove the woodrufl key [3]. NOTE Be carelul not to damage the key groove and crankshatt. INSPECTION STARTER REDUCTION GEAR/STARTER IDLE GEAR Check the starter reduction gear [1] and shalt [2] tor 1 wear or damage and replace it il necessary. I 1 Check the starter idle gear [3] and shaft [4] for wear or damage and replace it if necessary. NEEDLE BEARING Check the needle bearing [1] lor abnormal wear or 1 damage. [ ] Replace it if necessary. STARTER CLUTCH OPERATION Check the operation 01 the one-way clutch by turning the starter driven gear [1]. [1] You should be able to turn the starter driven gear counterclockwise smoothly. but the gear should not turn clockwise. For starter clutch service (page 13-10). 1 3-8 ALTERNATOR/STARTER CLUTCH INSTALLATION Install the woodrufl key [1]. NOTE 5 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]. Clean any oil from the crankshaft tapered area and flywheel thoroughly. Install the flywheel [1] to the crankshaft. N OT E Alig n the woodruff key with flywheel keyway. Apply engine oil to the flywheel mounting bolt threads and seating surface. Install the washer [1] and llywheel mounting bolt [2]. Hold the flywheel [3] using the special tool and tighten the flywheel mounting bolt to the specified torque. TOOL: Flywheel holder [4] 07725-0040001 TORQUE: 157 Mm (16.0 kgf-m,116let) 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]. NOTE Install the starter reduction gear with its "OUT" mark [5] facing out. Install the alternator cover (page 13-5). 1 3-9 ALTERNATOR/STARTER CLUTCH STARTER CLUTCH REMOVAL Remove the flywheel (page 13-7). [1] Remove the starter driven gear [1] while turning the starter driven gear counterclockwise. Hold the flywheel [1] using the special tool and remove 1 the starter clutch socket bolt [2]. I 1 [3] TOOL: Flywheel holder [3] 07725-0040001 Remove the starter clutch assembly [1]. I 1] Remove the starter one-way clutch [1] from the starter 2 clutch outer [2]. [ ] 13-10 ALTERNATOR/STARTER CLUTCH INSPECTION Check the starter driven gear lor abnormal wear or damage. Measure the starter drlven gear boss O.D. SERVICE LIMIT: 57.73 mm (2.273 in) Check the starter clutch outer [1] lnner surIace lor abnormal wear or damage and replace them if necessary. Measure the clutch outer l.D. SERVICE LIMIT: 74.46 mm (2.931 in) Check the starter one-way clutch [2] for abnormal wear or damage and replace them if necessary. [1] [2] INSTALLATION STARTER DRIVEN GEAR %%\ . FLVWHEEL 1—“ 30 N-m (3.1 Kgl-m, 22 lbf-ft) 13-11 ALTERNATOR/STARTER CLUTCH Apply engine oil to the starter one-way clutch [1] sliding surlace. Install the starter one-way clutch to the starter olutoh outer [2]. Install the starter clutch assembly [1]. Hold the flywheel [1] using the special tool. TOOL: Flywheel holder [2] 07725-0040001 Apply locking agent to the starter clutch socket bolt threads (page 13-4). Install and tighten the starter clutch socket bolt [3] to the specified torque. TORQUE:3D N-m (3.1 kgf‘m, 22 flats“) Install the starter driven gear [1] into the starter clutch outer while turning the starter driven gear counterclockwise. Reoheck the one—way clutch operation (page 13—8). Install the Ilywheel (page 13-9). [1] 13-12 ALTERNATOR/STARTER CLUTCH STATOR REMOVAL Remove the alternator cover (page 13—5). [5] Remove the alternator Wire clamp bolt [1], wire clamp [2] and grommet [3] from the alternator cover. Remove the alternator stator mounting bolts [4] and stator [5]. [21 ‘53 [4] INSTALLATION Lu 10 N-m (1.0 KgI-m, 7 IbI-ft) 10 N-m (1.0 kgI-m, 7 lbf-ft) WIRE CLAMP STATOFI 4m ALTERNATOR COVER Install the stator [1] to the alternator cover. Apply locking agent to the alternator stator mounting bolt threads (page 13-4). Tighten the alternator stator mounting bolts [2] to the specified torque. TORQUE: 10 MM (1.0 kgf‘m, 1mm) Apply liquid sealant (Three bond 12073 or equivalent) to the alternator Wire grommet [3] sealing surlace, then install it into the alternator cover groove securely. Apply locking agent to the alternator wire clamp bolt threads (page 13-4). Install the wire clamp [4] and alternator wire clamp bolt [5]- Tighten the bolt to the specilied torque. TORQUE: 10 NM (1.0 kgf‘m, 1mm) Install the alternator cover (page 13-5). 13-13 MEMO 14. CRANKCASE/TRANSMISSION/BALANCER COMPONENT LOCATION----- -----14-2 TRANSMISSION (NC700X/XA/S/SA)---------14-8 SERVICE lNFORMATION------ -----14-4 TRANSMISSION (NC700XD/SD) ------------ --14-17 TnouBLESHoonNG.................................14.5 BALANCER ............................................. ..14.25 CRANKCASE SEPARATION......................14.7 CRANKCASE ASSEMBLY ..................... “14.23 14-1 CRANKCASE/TRANSMISSION/BALANCER COMPONENT LOCATION NC700X/XA/S/SA: 39 N-m (4.0 kgf-m, 29 lbl-ft 24 N-m (2.4 kgf-m,1albf-fl) 12 Nm 12 mm“ 9 W“ ) ( ) 20 N-m (2.0 kgf-m, 151111-11)», 150° I 24 N-m (2.4 kgf-m, 18 mm) 12 N-m (1.2 kgl-m, 9 lbf-ft) 12 N-m (1.2 kgf-m, 9 1111-11) 12 N-m (1.2 Kgl-m, 9 1111-11) 24 N-m (2.4 kgf-m, 18 1111-11) 14-2 CRANKCASE/TRANSMISSION/BALANCER Ncmoxn/sn: 24 N-m (2.4 kgl-m, 1a lbf-ft) 211 Mm (2.0 kgl-m, 15lbf-fl)+150“ 39 N-m (4.0 kgf-m, 29 lbf-ft) 12 N-m (1.2 kgl-m, 9 lbf-fl) 24 N-m (2.4 Kgl-m,18|bf-fl) 12 N-m (1.2 kgf-m, 9 lbf-ft) E/ \ 12 N-m (1.2 kgf-m, 9 mun 12 N-m (1.2 Kgl-m, 9 1mm 24 N-m (2.4 kgf-m,18|le) 14-3 CRANKCASE/TRANSMISSION/BALANCER SERVICE INFORMATION GENERAL (NC7OOX/XA/S/SA) ~ The crankcase must be separated to service the following: — Transmission — Balancer — Crankshaft (page 15-5) — Piston/cylinder (page 15-14) ~ The foIIOWing components must be removed belore separating the crankcase: — Engine (page 16-5) — Clutch (page 11-7) — Primary drive gear/CKP sensor rotor (page 11-15) — Gearshilt linkage (page 11-16) — Flywheel (page 13-7) — Cylinder head (page 10-16) — Oil strainer (page 9-11) — Oil pump (page 9-6) — Engine Oil lilter (page 3-13) — Starter motor (page 6-8) — EOP switch (page 22-20) — VS sensor (page 22-18) — Neutral switch (page 22-28) ~ Be careful not to damage the crankcase mating surfaces when servicing. ~ Prior to assembling the crankcase halves, apply sealant to their mating surlaces. Wipe off excess sealant thoroughly. GENERAL (NC7OOXD/SD) ~ The crankcase must be separated to service the following: — Transmission — Balancer — Crankshaft (page 15-5) — Piston/cylinder (page 15-14) ~ The foIIOWing components must be removed belore separating the crankcase: — Engine (page 16-9) — Engine Oil lilter (page 3-13) — EOP switch (page 22-20) — Starter motor (page 6-8) — Cylinder head (page 10-16) — Flywheel (page 13-7) — Shift control motor/reduction gears (page 12-109) — Neutral switch (page 22-28) — Dual clutch (page 12-105) — Primary drive gear/CKP sensor rotor (page 12-108) — Gearshilt linkage (page 12-112) — Oil pump (page 9-8) — Mainshalt sensors (page 12-115) — VS sensor (page 22-18) — EOT sensor (page 12-118) — 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 surlaces. Wipe off excess sealant thoroughly. 1 4-4 CRAN KCASE/TRANSMISSION/BALANCER SPECIFICATIONS (NC700X/XA/S/SA) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear I.0. M5, M8, 01 28.000 — 28.021 (1.1024 —1.1032) 23.04 (1.104) 02, c3, 04 31000—31025 (1.2205— 1.2215) 31.04 (1.222) Gear bushing M5, M8 27.959 — 27.980 (1.1007 — 1.1018) 27.94 (1.100) 0.0. 02 30955—30980 (1.2137— 1.2197) 30.93 (1.213) 03, 04 30950—30975 (1.2135— 1.2195) 30.93 (1.218) Gear-lo-busning M5, M8 0.020 — 0.082 (0.0008 — 0.0024) 0.08 (0.003) clearance 02 0.020 — 0.070 (0.0008 — 0.0028) 0.10 (0.004) 03, 04 0.025 — 0.075 (0.0010 — 0.0030) 0.11 (0.004) Gear bushing I.0. M5 25.000 — 25.021 (0.9843 — 0.9351) 25.04 (0.938) 02 27985—28008(11013—11028) 28.02 (1.103) MalnshaII 0.0. A1 M5 bushing 24.972 — 24.993 (0.9831 — 0.9340) 24.95 (0.932) Counlersnail 00. Al 02 busning 27.987 — 27.930 (1.1011 — 1.1018) 27.95 (1.100) Bushing-lo-shan M5 0.007 — 0.049 (0.0003 — 0.0020) 0.09 (0.004) clearance 02 0.005 — 0.039 (0.0002 — 0.0015) 0.06 (0.002) sniil Iork, Fork I.0. 12.000 — 12.018 (0.4724 — 0.4731) 12.03 (0.474) iork snaI1 Claw Inickness 5.93 — 8.00 (0.233 — 0.238) 5.9 (0.23) snill iork snaI10.0. 11.957 — 11.988 (0.4707 — 0.4712) 11.95 (0.470) SPECIFICATIONS (NC700XD/SD) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear I.0. M5 33.000 — 33.025 (1.2992 — 1.3002) 33.04 (1.301) M8 43.000 — 43.025 (1.8929 — 1.8939) 43.04 (1.894) 01 31.010—31.035(1.2209—1.2213) 31.08 (1.223) 02 25.000 — 25.021 (0.9343 — 0.9851) 25.03 (0.935) 03,04 31.000—31.025(1.2205—1.2215) 31.04 (1.222) Gear bushing M5 32.955 — 32.980 (1.2974 — 1.2934) 32.93 (1.298) 0.0. Ms 42.950 — 42.975 (1.8909 — 1.8919) 42.93 (1.890) 01 30.970 — 30.995 (1.2193 — 1.2203) 30.94 (1.213) 02 24.959 — 24.980 (0.9328 — 0.9835) 24.94 (0.932) 03, 04 30.950 — 30.975 (1.2185 — 1.2195) 30.93 (1.218) Gear-lo-busning M5 0.020 — 0.070 (0.0003 — 0.0028) 0.10 (0.004) clearance M8 0.025 — 0.075 (0.0010 — 0.0030) 0.11 (0.004) 01 0.015 — 0.085 (0.0008 — 0.0028) 0.10 (0.004) 02 0.020 — 0.082 (0.0003 — 0.0024) 0.09 (0.004) 03, 04 0.025 — 0.075 (0.0010 — 0.0030) 0.11 (0.004) Gear bushing l.0. M5 29935—30008 (1.1805— 1.1313) 30.03 (1.182) M8 40.007 — 40.028 (1.5751 — 1.5759) 40.038 (1.5783) 01 28000—28021 (1.1024— 1.1032) 23.04 (1.104) 02 21.985 — 22.008 (0.3855 — 0.8884) 22.02 (0.387) '""e’ mamsm" A1 M5 bushing 29.957 — 29.970 (1.1794 — 1.1799) 29.93 (1.178) guts” “We” A1 M8 bushing 39.975 — 39.991 (1.5738 — 1.5744) 39.985 (1.5734) CounlersnaI100. A1 c1 bushing 27.987 — 27.980 (1.1011 — 1.1018) 27.95 (1.100) A102 bushing 21.952 — 21.985 (0.3843 — 0.8843) 21.94 (0.384) Bushing-lo-snall M5 0.015 — 0.049 (0.0008 — 0.0019) 0.09 (0.004) clearance M8 0.018 — 0.053 (0.0008 — 0.0021) 0.10 (0.004) 01 0.020 — 0.054 (0.0003 — 0.0021) 0.08 (0.003) 02 0.020 — 0.054 (0.0003 — 0.0021) 0.08 (0.003) snm Iork, Fork I.0. 12.000 —12.018(0.4724 — 0.4731) 12.03 (0.474) Iork snail Claw thickness 5.93 — 8.00 (0.233 — 0.238) 5.9 (0.23) ShlIt Iork shah O.D. 11.957 —11.968(0.4707 — 0.4712) 11.95 (0.470) 14-5 CRANKCASE/TRANSMISSION/BALANCER TORQUE VALUES THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, lbl-ft) REMARKS Mainshalt bearing set plate bolt 8 6 12 (1.2, 9) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) lrorn tip Shift drum bearing set plate bolt 2 6 2 (1.2, 9) Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) lrorn tip Balanoer shaft bearing set plate 8 6 2 (1.2, 9) Apply locking agent to the threads. bolt Coating width; 6.5 11.0 mm (0.26 1 0.04 in) except 2.0 11.0 mm (0.08 1 0.04 in) lrorn tip Crankcase main journal bolt (new) 6 9 20 (2.0, 15) + 150” See page 14-30 Replace with a new one. Crankcase 10 mm bolt 1 10 89 (4.0, 29) Crankcase 8 mm bolt 8 8 24 (2.4, 18) Crankcase 8 x 45 mm bolt 1 8 24 (2.4 18 Apply locking agent to the threads. Coating width; 6.5 11.0 mm (0.26 1 0.04 in) lrorn tip Crankcase 6 mm bolt 8 6 (1.2, 9) TROUBLESHOOTING Hard to shift ~ Improper clutch operation ~ Incorrect engine oil weight ~ Bent shift lork ~ Bent shift lork shalt ~ Bent shift lork claw ~ Damaged shilt drum groove ~ Bent gearshilt spindle — NC700X/XA/S/SA (page 11-16) — NC700XD/SD (page 12-112) Transmission jumps out at gear ~ Worn gear dogs Worn gear shifter groove Bent shift lork shalt Worn or bent shift lorks Broken shift drum stopper arm — NC700X/XA/S/SA (page 11-16) — NC700XD/SD (page 12112) ~ Broken shilt drum stopper arm return spring — NC700X/XA/S/SA (page 11-16) — NC700XD/SD (page 12112) ~ Broken gearshilt spindle return spring — NC700X/XA/S/SA (page 11-16) — NC700XD/SD (page 12-112) Excessive engine noise ~ Worn or damaged transmission gear ~ Worn or damaged transmission bearings 1 4-6 CRANKCASE/TRANSMISSION/BALANCER CRANKCASE SEPARATION For Service Intcrmation lor removal 01 necessary parts ‘ before separating the crankcase (page 144). Remove the cam chain [1] from the crankshaft. Remove the crankcase 8 mm bolts [1] and sealing washer[2]. [1]/[2] ._ ;_ Place the engine upside down. 3] 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 1 crisscross pattern in 2 or 3 steps, and remove them. I 1 Separate the lower crankcase [2] lrom the upper crankcase. NOTE Do not ply the crankcase halves with a screwdriver. [2] 14-7 CRANKCASE/TRANSMISSION/BALANCER Remove the dowel pins [1] and oil oritices [2]. Ncmox/XNs/SA, I [1] Clean any sealant off from the crankcase mating surlace. Clean the oil orilices in solvent thoroughly. Check the oil oritices for clogs, and replace them if necessary. [1] [2] NC700XD/SD: l1] [2] [1] TRANSMISSION (NC700X/XA/S/SA) REMOVAL/DISASSEMBLY MAINSHAFI'ICOUNTEFISHAFI’ Separate the crankcase halves (page 14-7). Remove the oountershatt assembly [1]. Remove the dowel pin [2] and countershatt bearing set ring [3]. Disassemble the countershalt assembly. Clean all disassembled parts in solvent thoroughly. NOTE - Keep track ol the disassembled parts (gears, bushings, washers, and snap rings) by sliding them onto a tool or a piece ol 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 mainshalt bearing set plate bolts [1] and set plate [2]. 14-8 CRANKCASE/TRANSMISSION/BALANCER Remove the right mainshaft bearing [1] from the upper V .* crankcase. . Remove the mainshaft assembly [1]. Disassemble the mainshalt assembly. Clean all disassembled parts in solvent thoroughly. NOTE - Keep track of the disassembled parts (gears, bushings, washers, and snap rings) by sliding them onto a tool or a piece ol 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. SHIFI' 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]. 14-9 CRANKCASE/TRANSMISSION/BALANCER Remove the shitt drum [1] and shift drum bearing [2]. INSPECTION SHIFI' DRUM/SHIFT FORK Check the shift fork guide pin for abnormal wear or damage. Measure the shift Iork I.D. SERVICE LIMIT: 12.03 mm (0.474 in) Measure the shift Iork claw thickness. SERVICE LIMIT: 5.9 mm (0.23 in) i l Measure the shill Iork shaft O.D. SERVICE LIMIT: 11.95 mm (0.470 in) Inspect the shift drum guide grooves for abnormal wear or damage. Turn the outer race ol the shift drum bearing with your Iinger. The bearing should turn smoothly and quietly. Also check that the inner race ol the bearing fits tightly on the shilt drum. Replace the bearing lI the inner race does not turn smoothly, quietly, or if the inner race Iits loosely on the shiIt drum. 14-10 CRANKCASE/TRANSMISSION/BALANCER TRANSMISSION Check the gear shifter groove [1] and gear dogs [2] lor abnormal wear or damage. Check the dog holes and teeth for abnormal wear or damage. Measure the ID. oI each gear. SERVICE LIMITS: M5, M6, C1: 28.04 mm (1.104 in) 02, C3, C4: 31.04 mm (1.222 in) Measure the OD. cI each gear bushing. SERVICE LIMITS: M5, M6: 27.94 mm (1.100 in) CZ, C3, C4: 30.93 mm (1.218 in) Measure the ID. oI each gear bushlng. SERVICE LIMITS: M5: 25.04 mm (0.986 in) 02: 28.02 mm (1.103 in) Calculate the gear-to-bushing clearance. SERVICE LIMITS: M5, M6: 0.08 mm (0.003 in) 02: 0.10 mm (0.004 in) C3, C4: 0.11 mm (0.004 in) Check the mainshafl and countershafl Ior abnormal wear or damage. M5 Measure the malnshaIt CD. at the M5 bushlng. SERVICE LIMIT: 24.95 mm (0.982 in) ¢ Measure the countershalt CD. at the c2 bushing. fl SERVICE LIMIT: 27.95 mm (1.100 in) $ T Calculate the gear bushing-to-shalt clearance. SERVICE LIMITS: M5: 0.09 mm (0.004 in) c2: 0.03 mm (0.002 in) 02 14-11 CRANKCASE/TRANSMISSION/BALANCER MAINSHAFI' BEARING Temporarily install the right mainshalt bearing [1] onto the mainshatt. Turn the outer race of the right mainshatt bearing with yourfinger. The bearing should turn smoothly and quietly. Also check that the inner race ol the bearing fits tightly on the mainshafl. Replace the bearing ii the inner race does not turn smoothly, quietly, or ii the inner race fits loosely on the mainshafl. Turn the inner race ol the left mainshafl bearing [1] with your finger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the upper crankcase. Replace the bearing (page 14—12) ii the inner race does not turn smoothly, quietly, or it the outer race fits loosely in the crankcase. COUNTERSHAFI' BEARING Turn the outer race of countershaft bearing [1] with your linger. The bearing should turn smoothly and quietly. Also check that the bearing inner race tits tightly on the countershaft. Replace the countershalt, collar, and bearing as an assembly, if the race does not turn smoothly, quietly, or ii the inner race lits loosely on the countershaft. NOTE The countershatt bearing cannot be replaced. If the countershaft bearing is laulty, replace the countershaft as an assembly. LEFT MAINSHAFT BEARING REPLACEMENT Remove the tollowing: — Crankshaft (page15-5) — Piston (page 15-14) — Countershaft/mainshaft (page 14—8) To avoid burns, wear heavy gloves when handling the . heated upper crankcase. Du nut use a torch Heat the upper crankcase to 80°C (176"F) evenly using to heat the upper a heat gun. crankcase;i!may T . . ap the upper crankcase lightly and remove the left “"59 WWW mainshaft bearing [1]. 14-12 CRANKCASE/TRANSMISSION/BALANCER Apply englne oil to a new Ielt mainshaft bearlng [1]. Dn'ver'nanew Drive the left mainshaft bearlng into the upper bearing squarely crankcase until it is lully seated using the special tools. with me mamng . . TOOLS: .|. s'izgigggflfg Driver,15x280L[2] 07949-3710001 t-_.‘_ I Hankcasa Attachment, 42x47 mm [3] 07746-0010300 Pilot, 20 mm [4] mus-0040500 [3144] Install the removed parts m the reverse order of removal. “I TRANSMISSION ASSEMBLY Clean all parts in solvent. and dry them thoroughly. Apply engine Oll to the gear teeth, rotatlng surface and bearing. Apply molybdenum oil solution to the spllne bushlng outer surface. bushing lnner and outer surlace, shilt lork grooves. Assemble the mainshaft and countershaft. MAINSHAFI' MAINSHAFT/M1 GEAR (16T) THRUST WASHER M5 GEAR BUSHING M5 GEAR (SOT) SPLINE WASHER SNAP RING SNAP RING SPLINE WASHER 14-13 CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT NEEDLE BEARING CAP NEEDLE BEARING THRUST WASHER NEEDLE BEARING SNAP RING SPLINE WASHER SNAP RING SPLINE WASHER Assemble the transmission gears and shafts. NOTE CORRECT INCORRECT - Coat each gear with clean engine oil and check lor smooth movement. - Align the look washer tabs with the spline washer grooves. - Always install the thrust washers and snap rings with the chamlered (rolled) edge lacing away from the thrust load. - Install the snap rings [1] so that the end gap aligns with the groove ol the splines. - Make sure that the snap rings are lully seated in the shaft groove alter installing them. 14-14 CRANKCASE/TRANSMISSION/BALANCER INSTALLATION MAINSHAFI'ICOUNTEFISHAFI’ Install the mainshalt assembly [1] into the upper . crankcase. Apply engine oil to the right mainshaft bearing [1]. Install the right mainshalt bearing into the upper ‘ crankcase. NOTE Install the bearing into the crankcase with the marked side facing out. Apply locking agent to the mainshatt bearing set plate bolts threads (page 14-6). Install the mainshaft bearing set plate [1] with its "OUT ) SIDE" mark [2] facing out. Install and tighten the mainshaft bearing set plate bolts 1 [3] to the specified torque. TORQUE: 12 NM (1.2 kgf‘m, 9 let) Install the dowel pin [1] onto the upper crankcase hole. Install the countershatt bearing set ring [2] to the countershaft bearing groove. Install the countershalt assembly [3]. NOTE - Align the needle bearing cap hole with the dowel pin. - Align the set ring with the upper crankcase groove. Install the shilt drum/shift tork (page 14—16). Assemble the crankcase (page 14-28). 14-15 CRANKCASE/TRANSMISSION/BALANCER SHIFI' 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 mark [2]: center shift fork — "R" mark [3]: right shift fork Apply molybdenum oil solution to the shift fork guide area and guide pin. 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 14-6). 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 Ibf‘ft) Install the mainshafI/countershaft (page 14-15). Assemble the crankcase (page 14-28). 14-16 CRANKCASE/TRANSMISSION/BALANCER TRANSMISSION (NC700XD/SD) REMOVAL/DISASSEMBLY MAINSHAFI'ICOUNTEFISHAFI’ Separate the crankcase halves (page 14-7). Remove the countershaft assembly [1]. Remove the dowel pin [2] and countershalt bearing set ring [3]. Disassemble the countershalt assembly. Clean all disassembled parts in solvent thoroughly. NOTE - Keep track ol the disassembled parts (gears, bushings, washers, and snap rings) by sliding them ’ onto a tool or a piece ol 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 mainshalt bearing set plate bolts [1] and set plate [2]. Remove the right mainshaft bearing [1] from the upper crankcase. Remove the mainshalt assembly [1]. Disassemble the mainshalt assembly. Clean all disassembled parts in solvent thoroughly. NOTE - Keep track ol the disassembled parts (gears, bushings, washers, and snap rings) by sliding them onto a tool or a piece ol 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. CRANKCASE/TRANSMISSION/BALANCER SHIFI' DRUM/SHIFT FORK Remove the shift drum bearing set plate bolts [1] and set plate [2]. Remove the fork shafts [1] and shilt forks [2]. Remove the shift drum [1] and shift drum bearing [2]. INSPECTION SHIFI' DRUM/SHIFT FORK Check the shift fork guide pin for abnormal wear or damage. Measure the shift fork I.D. SERVICE LIMIT: 12.03 mm (0.474 in) Measure the shift fork claw thickness. SERVICE LIMIT: 5.9 mm (0.23 in) Q»: 14-18 CRANKCASE/TRANSMISSION/BALANCER Measure the shllt lork shaft O.D. SERVICE LIMIT: 11.95 mm (0.470 in) Inspect the shilt drum guide grooves for abnormal wear or damage. Turn the outer race ol the shift drum bearing with your Ilnger. The bearing should turn smoothly and quietly. Replace the bearing il the outer race does not tum smoothly or quietly. TRANSMISSION Check the gear shlfter groove and gear dogs Ior abnormal wear or damage. Check the dog holes and gear teeth Ior abnormal wear or damage. 14-19 CRANKCASE/TRANSMISSION/BALANCER Measure Ihe |.D. ol each gear. SERVICE LIMITS: M5: 33.04 mm (1.301 in) M6: 43.04 mm (1.694 in) 01: 31.06 mm (1.223 in) 02: 25.03 mm (0.935 in) (a, ca, c4: 31.04 mm (1.222 in) . ' fi ‘ ' - Measure Ihe O.D. ol each gear bushing. ‘ SERVICE LIMITS: M5: 32.93 mm (1.295 in) M6 42.93 mm (1.590 in) 01: 30.94 mm (1.218 in) 02: 24.94 mm (0.932 in) ca, c4: 30.93 mm (1.213 in) Calculate the gear-Io-bushing clearance. SERVICE LIMITS: ‘—’ M5: 0.10 mm (0.004 in) M6: 0.11 mm (0.004 in) 01: 0.10 mm (0.004 in) 02: 0.09 mm (0.004 in) ca, c4: 0.11 mm (0.004 in) Measure Ihe ID. at each gear bushIng. SERVICE LIMITS: M5: 30.03 mm (1.182 in) M6: 40.033 mm (1.5703 in) 01: 23.04 mm (1.104 in) 02: 22.02 mm (0.307 in) l l Check the mainshafts and countershatt for abnormal M5 wear or damage. I Measure Ihe Inner mainshafl CD. at he M5 bushing. SERVICE LIMIT: 29.93 mm (1.178 in) BI ¢ M5 Measure Ihe ouIer maInshait CD. at he M6 bushIng. SERVICE LIMIT: 39.965 mm (1.5734 in) Measure the countershaft CD. a the 01 and Oz l f I bushing. SERVICE LIMITS: 01: 27.95 mm (1.100 in) 02: 21.94 mm (0.354 in) c1 c2 Calculate the gear bushing-Io-shalt clearance. SERVICE LIMITS: M5: 0.09 mm (0.004 in) M6: 0.10 mm (0.004 in) 01: 0.03 mm (0.003 in) 02: 0.03 mm (0.003 in) 14-20 CRANKCASE/TRANSMISSION/BALANCER MAINSHAFI' BEARING Turn the inner race of the left mainshalt bearing [1] with your finger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the upper crankcase. Replace the bearing (page 14—21) ii the inner race does not turn smoothly, quietly, or it the outer race fits loosely in the crankcase. COUNTERSHAFT BEARING Turn the outer race of countershaft bearing [1] with your finger. The bearing should turn smoothly and quietly. Also check that the bearing inner race tits tightly on the ccuntershaft. Replace the countershaft, collar, and bearing as an assembly, if the outer race does not turn smoothly, quietly, or if the inner race fits loosely on the ccuntershaft. LEFT MAINSHAFT BEARING REPLACEMENT Remove the following: — Crankshaft (page 15-5) — Pistons/connecting rods (page 15—14) To avoid bums, wear heavy gloves when handling the heated upper crankcase. Do not usea torch Heat the upper crankcase to 80°C (176°F) evenly using ' to heal the Upper a heat gun. crankcase;irmay Ta . . p the upper crankcase llghtly and remove the left “"59 “’9’” mainshaft bearing [1]. Apply engine oil to a new left mainshaft bearing [1]. Driveinanew Drive the left mainshaft bearing into the upper bearing squarely crankcase until it is lully seated using the special tools. with the mammg v . TOOLS: d I r rd 5' £25231??? Driver, 15 x 280L [2] 07949.3710001 crankcase. Attachment. 42 x 47 mm [3] 07746-0010300 Pilot, 20 mm [4] mus-0040500 Install the following: — Pistons/connecting rods (page 15—20) — Crankshaft (page15-6) CRANKCASE/TRANSMISSION/BALANCER TRANSMISSION ASSEMBLY Clean all parts in solvent, and dry them thoroughly. Apply engine ml to the gear teeth, rotating surface and bearing. Apply molybdenum oil solution to the spllne bushlng outer surfaces, bushing lnner and outer surfaces, and gear shifter grooves. Assemble the mainshaft and countershalt. MAINSHAFI' INNER MAINSHAFT/M1 GEAR (WET) M4 GEAFI (25T) SNAP RING SPLINE WASHEFI M6 GEAR (377) vd SEAL RINGS NEEDLE BEARING I! : Gear teethe, rataIing surfaces and bearing r7i : Bushing surfaces and gear shiller grooves 14-22 CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT El OIL SEAL COUNTERSHAFT BEARING SET RING COUNTERSHAFT C1 GEAR BUSHING C1 GEAR (ADT) SPLINE WASHER 02 GEAR (40T) SNAP RING THRUST WASHER Ge GEAR (31T) NEEDLE BEARING NEEDLE BEARING CAP I. : Gear teethe, rataling surlaces and hearing In :Busmng surfaces and gear smfler grooves 14-23 CRANKCASE/TRANSMISSION/BALANCER NOTE - Coat each gear with clean engine oil and check tor smooth movement. - Align the lock washer tabs with the spline washer grooves. - Always install the thrust Washers and snap rings with the chamlered (rolled) edge lacing away from the thrust load. - Install the snap rings [1] so that the end gap aligns with the groove oi the splines. - Make sure that the snap rings are tully seated in the shaft groove alter installing them. INSTALLATION MAINSHAFI'ICOUNTEFISHAFI’ Install the mainshalt assembly [1] into the upper _ crankcase. Apply engine oil to the right mainshaft bearing [1]. Install the right mainshalt bearing into the upper crankcase. NOTE Install the bearing into the crankcase with the marked side facing out. Apply locking agent to the mainshalt bearing set plate bolts threads (page 14-6). Install the mainshalt bearing set plate [1] with its "OUT SIDE" mark [2] lacing out. Install and tighten the mainshaft bearing set plate bolts " [3] to the specified torque. TORQUE: 12 MM (1.2 kgf‘m, 9 IbH'l) CORRECT INCORRECT 14-24 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 countershalt assembly [3]. NOTE - 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—25). Assemble the crankcase (page 14-28). SHIFI' 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 — "D20 L" mark [3]: Countershaft left shift fork — "D2C R" mark [4]: Countershaft right shift fork Apply molybdenum 0“ solution to the shift fork shalt 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]. Install the mainshalt 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. 1 4-25 CRANKCASE/TRANSMISSION/BALANCER Apply locking agent to the shift drum bearing set plate I . bolt threads (page 14-6). Install the shift drum bearing set plate [1] and bolts [2]. Tighten the bolts to the specified torque. TORQUE: 12 Nam (1.2 kgf‘m, 9 Ile) Install the mainshafl/countershalt (page 14-24). Assemble the crankcase (page 14-28). BALANCER REMOVAL Separate the crankcase halves (page 14-7). 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 Check the balancer shaft [1] and balancer driven gear [2] for excessive wear or damage. Replace the balancer shaft if necessary. 14-26 CRANKCASE/TRANSMISSION/BALANCER Turn the inner race ol the Ielt balancer shalt bearing [1] with your linger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the lower crankcase. Replace the bearing (page 14—27) il the inner race does not turn smoothly, quietly, or il the outer race fits loosely in the lower crankcase. Temporarily install the right balancer shaft bearing onto the balancer shaft. Turn the outer race of the right balancer shaft bearing with your linger. The bearing should turn smoothly and quietly. Also check that the inner race ol the bearing lits tightly on the balancer shaft. Replace the bearing if the inner race does not turn smoothly, quietly, or il the inner race lits loosely on the balancer shalt. LEFT BALANCER SHAFT BEARING REPLACEMENT Drive out the Ielt balancer shall bearing [1] from the lower crankcase. Apply engine oil to a new Ielt balancer shaft bearing [1]. Drivelnanew Drive the left balancer shalt bearing into the lower bearing squarely crankcase until it is lully seated using the special tools. with me manqng v v TOOLS: s'iie’iigger‘lufinr: Driver, 15 x 280L [2] 07949-3710001 cranks” Attachment, 42 x 47 mm [3] 07746-0010300 Pilol, 20 mm [4] 07745-004050.) 1 4-27 CRANKCASE/TRANSMISSION/BALANCER 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. NOTE Install the bearing into the crankcase with the marked side facing out. Apply locking agent to the balancer shalt beanng set plate bolts threads (page 14-6). Install the balancer shaft bearing set plate [1] with its . "OUT SIDE" mark [2] facing but. Install and tighten the balancer shaft bearing set plate . bolts [3] to the specified torque. TORQUE: 12 N-m (1.2 kgf‘m, 9 lbf‘ft) CRANKCASE ASSEMBLY Apply liquid sealant (Three Bond 12073 or equivalent) to the crankcase mating surface as shown. NOTE - 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. 14-28 CRANKCASE/TRANSMISSION/BALANCER Install the oil orillces [1] onto the upper crankcase [2]. NOTE Install the oil onfices Wlth its narrow hole slde facing upper crankcase. l NC700X/XA/S/SA: 7 Install the dowel pins [1] onto the upper crankcase [2]. NC700XD/SD: [1] 14-29 CRANKCASE/TRANSMISSION/BALANCER Align the balancer driven gear [1] and balancer driven 1 2 sub gear [2] teeth then install a 6 x 14 mm socket bolt [ M 1 [3] to the balancer driven gear and balancer driven sub gear holes at the lower crankcase inspection hole [4]. Apply molybdenum oi| solution to the main journal bearing sliding surlaces on the lower crankcase. [4] Align the index line [1] on balancer drive gear with upper crankcase top surlace while the "/\" mark [2] is lacing up. Install the lower crankcase onto the upper crankcase. [3 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 trom 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 kgt‘m,15lbf‘lt)+ 150” 14-30 CRANKCASE/TRANSMISSION/BALANCER Apply locking agent to the crankcase 8 x 45 mm bolt [4] threads (page 14-6)- Install and tighten the crankcase bolts to the specified [3] torque in a crisscross pattern in 2 or 3 steps. 'l. . g TORQUE: )Mfl' fl: Crankcase 10 mm bolt [1]: 39 Nm (4.0 mm, 29 mm) [21 Crankcase 8 mm bolt [2]: 24 Nm (2.4 mm, 18 mm) Crankcase 8 x 45 mm bolt [3]: 24 Nm (2.4 mm, 18 mm) Crankcase 6 mm bolt [4] 12 Nm (1.2 mm, 9 lbt-I‘t) Place the engine With the lower side down. Install the crankcase 8 mm bolts [1] and a new sealing washer [2]. NOTE The sealing washer location is indicated on the upper crankcase by the "A" mark. Tighten the crankcase 8 mm bolts to the specified torque. TORQUE:24 N-m (2.4 kgrm, 18 mm) on? [1] v. 7_ [1]/[2] N! Install the cam chain [1] to the crankshalt. Install the removed parts in the reverse order of removal (page 14-4). 14-31 MEMO 15. CRANKSHAFr/PISTON/CYLINDER COMPONENT LOCATION----- -----15-2 MAIN JOURNAL BEARING------ ---15-8 SERVICE INFORMATION------ -----15-3 CRANKPIN BEARING -------- -- ----15-11 TROUBLESH00T|NG.................................15.4 p|3TON/CVL|NDER ................................ "15.14 CRANKSHAFT .......................................... ..15.5 15-1 CRANKSHAFr/PISTON/CYLINDER COMPONENT LOCATION 1o N-m (1.0 kgl-m, 7 lbf-ft) + 90° 1 5-2 SERVICE INFORMATION GENERAL CRANKSHAFT/PlSTON/CYLINDER This motorcycle provides cracking connecting rods. Be sure to Install each part in Its original posItion, as noted during removal. Do not reuse the improperly Installed connecting rod and bearing cap, because their mating surfaces are damaged. ~ The crankcase must be separated to service the tolloWing: — Crankshth (page 15-5) — Piston/cylinder (page 15-14) Mark and store the connecting rods, bearing caps and bearing inserts to be sure 01 their correct locations lor reassembly. The crankpin and main )ournal bearing inserts are select tit and are identitied by color codes. Select replacement bearings lrom the code tables. After selecting new bearings, recheck the oil clearance with a plastigauge. Incorrect oil clearance can cause ma)or engine damage. ~ Clean the oil passages in the upper crankcase with compressed air betore installing the pistons. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshth Connecting rod side clearance 0.15 — 0.35 (0.006 — 0.014) 0.45 (0.018) Runout Right side — 0.03 (0.001) Lelt side — 0.03 (0.001) Main )ournal bearing 0" clearance 0.019 — 0.037 (0.0007 — 0.0015) 0.05 (0.002) Cylinder |.D. 73.000 — 73.015 (2.0740 — 2.3746) 73.07 (2.077) Out-ol-round — 0.10 (0.004) Taper — 0.10 (0.004) Warpage — 0.10 (0.004) Piston, iston Piston CD. at 13 mm 0.5 in irom rings 9 bomm ( l 72.976 — 72.990 (2.8731 — 2.8736) 72.970 (2.0720) Piston pin bore |.D. 18.010 — 18.013 (0.7091 — 0.7092) 18.023 (0.7096) Piston pin 0.0. 17990 — 18.000 (0.7005 — 0.7007) 17.900 (0.7002) Piston-to-piston pin clearance 0.010 — 0.017 (0.0004 — 0.0007) 0.035 (0.0014) Piston ring end Top 0.15 — 0.30 (0.000 — 0.012) 0.0 (0.02) 93p Second 0.30 — 0.42 (0.012 — 0.017) 0.6 (0.02) on (side rail) 0.20 — 0.70 (0.000 — 0.020) 0.8 (0.03) Piston ring-to-ring Top 0.035 — 0.080 (0.0014 — 0.0032) 0.15 (0.006) groove clearance Second 0.030 — 0.055 (0.0012 — 0.0022) 0.13 (0.005) Cylinder-to-piston clearance 0.010 — 0.039 (0.0004 — 0.0015) 0.05 (0.002) Connecting rod small end |.D. 17.964 — 17.977 (0.7072 — 0.7078) 17.935 (0.7081) Crankpin bearing oil clearance 0.026 — 0.044 (0.0010 — 0.0017) 0.05 (0.002) TORQUE VALUES . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgt-m, lbt-It) REMARKS Crankpin bearing cap bolt 4 6 10 (1.0, 7) + 90" See page 15-7 Replace with a new one. Apply engine oil to the threads and seating surface. Crankcase main )ournal bolt 6 9 20 (2.0, 15) + 120° See page 15-9 (retightening) Apply engine oil to the threads and seating surface. 1 5-3 CRANKSHAFT/PlSTON/CYLINDER TROUBLESHOOTING Cylinder compression is too low, hard to starting or poor perlormance 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, plston or plston nng ~ Improper installation at piston rings ~ Scored or scratched plston or cylinder wall Abnormal noise ~ Worn plston pin or piston pin hole ~ Worn connecting rod small end ~ Worn cylinder, plston or plston nngs ~ Worn main journal bearings ~ Worn crankpin beanngs Engine vibration ~ Excesslve crankshalt runout 1 5-4 CRANKSHAFWPBTOWCYUNDER CRANKSHAFT Separate the crankcase halves (page 14-7). SIDE CLEARANCE INSPECTION Measure the connecting rod side clearance. SERVICE LIMIT: 0.45 mm (0.018 in) ll the clearance exceeds the sen/ice limit, replace the \ connecting rod. (9 Recheck and if still out ol limit, replace the crankshaft. REMOVAL 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 crankshalt [3]. 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. 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. 1 5-5 CRANKSHAFI'IPISTON/CYLINDER The bearmg labs should be aligned with the gum 1/55 in the crankcase. 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: Right side [1]: 0.03 mm (0.001 in) Left side [2]: 0.03 mm (0.001 in) Check the balanoer drive gear [3] teeth lor abnormal wear or damage. INSTALLATION Install the main journal bearings [1] and orankpin bearings [2] into the original locations. 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 surlaces on the upper crankcase and orankpin bearing sliding surlaces on the connecting rods. Apply molybdenum oil solution to the thrust surfaces of the crankshalt as shown. Install the crankshalt [1] onto the upper crankcase. Set the connecting rods [2] to the orankpins. 1 5-6 CRANKSHAFT/PISTON/CYLINDER Clean the mating surface of the connecting rods and orankpin bearing caps with cleaning solvent and blow them With compressed air. Apply molybdenum 0“ solution to the crankpin bearing ' sliding surlaces on the crankpin bearing caps [1]. Install the crankpin bearing caps. Be sure to install each part in its original position, as v, noted during removal. Do not reuse the improperly installed connecting rod and bearing cap, because their mating surfaces are damaged. NOTE Align the ID. code number on the connecting rods. The clankpin Apply engine oil to new crankpin bearing cap bolt bearing cap bolts threads and seating surfaces. cannot be reused. Once Me bolls have Install and tighten new crankpln bearing cap bolts [1] to the specilied torque in 2 or 3 steps alternately. been looser“? Further tighten the bolts 90°. replace them mm new ones. TORQUE: 10 MM (1.0 kgf‘m, 7 Ibf-ft) + 90° Assemble the crankcase halves (page 14-28). 1 5-7 CRANKSHAFr/PlSTON/CYLINDER MAIN JOURNAL BEARING Do not interchange the bearing inserts. They must be installed in [heir original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshalt (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 oll any oil Irom the bearing inserts and [Ham journals. Install the crankshalt [1] onto the upper crankcase. Put a strlp ol plastigauge [1] lengthwise on each mall’l journal avoiding the oil hole. NOTE Do not rotate the crankshaft durlng inspection. 1 5-8 CRANKSHAFT/PISTON/CYLINDER Install the dowel pins [1] and oil orifices [2] onto the upper crankcase [3]. NOTE Install the oil orifices with its narrow hole side facing upper crankcase. Install the lower crankcase [1] onto the upper crankcase. Apply engine oil to the crankcase main journal bolt (reuse) threads and seating surlaces. 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,15lbf‘fl)+ 120” 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) II the oil clearance exceeds the service limit, select a replacement bearing. BEARING SELECTION Lel‘Iers (A. Bo! C) Record the crankcase bearing support |.D. code letters on [he Ielt side 0/ [1] Irom Ielt side of the upper crankcase as shown. upper crankcase are bearmg suppon I.D. codes 1mm left to right. 1 5-9 CRANKSHAFr/PISTON/CYLINDER Numbers (1, 2 or 3) an the crank weigh! are main journal 0. D. codes Imrn (an to right. ll you are replacing the crankshalt, record the corresponding main journal O.D. code numbers [1] from the crank welght. ll you are reusing the crankshaft, measure the crankpln O.D. Wlth a micrometer. Cross-reference the main journal and bearing support codes to determine the replacement bearing color code [1]. MAIN JOURNAL BEARING THICKNESS: A: Blue: Thickest Black Brown: I E: Yellow: Thinnest MAIN JOURNAL BEARING SELECTION TABLE: BEARING SUPPORT |.D. CODE B 37.000 — 3A7.006 mm 37.006 — 37.012 mm 37.012 — 307.018 mm (1.4567 — 1.4569 in) (1.4569 — 1.4572 in) (1.4572 — 1 .4574 in) ggflé’gggmfl 1 ffigggfigggzmi’n'; E (Yellow) D (Green) c (Brown) 2 ffgggffigggéfi'n'; D (Green) c (Brown) B (Black) 3 fffagggs‘figggflrn'; c (Brown) B (Black) A (Blue) Alt 9 new bearings, recheck the clearance With a plastlgauge. Incorrect clearance can cause severe engine damage. BEARING INSTALLATION Clean the bearan outer surfaces and crankcase 7 bearing supports. Install the main journal bearing inserts [1] onto the ‘V crankcase bearing supports, aligning each tab with each groove. 15-10 CRANKSHAFT/PISTON/CYLINDER CRANKPIN BEARING Do not interchange Ihe bearing insens. They must be installed in their original locations or [he correct bearing oil clearance may no! be obtained, resulling in engine damage. Remove the crankshaft (page 15-5). BEARING INSPECTION Check the bearing insens for unusual wear or peeling. Check the bearing tabs for damage. OIL CLEARANCE INSPECTION Clean the mating surface ol the connecting rod and orankpin bearing cap With cleaning solvent and blow ' them With compressed air. Clean all any oil lrom the bearing inserts and crankpins. «1‘ Carefully install the crankshaft onto the upper crankcase. Set the connecting rods onto the crankpins. Put a strip ol plastigauge [1] lengthwise on each orankpin avoiding the oil hole. NOTE Do not rotate the crankshaft during inspection. 15-11 CRANKSHAFI'IPISTON/CYLINDER Install the crankpln bearing caps [1]. Be sure to install each part in its original position, as noted during removal. Do not reuse the improperly , installed connecting rod and bearing cap, because their V mating surfaces are damaged. ' NOTE Align the ID. code number on the connecting rods. Use the removed Apply engine OII to the crankpin bearing cap bolt (reuse) crankpin bearmg threads and seating surfaces. 5:” :0“ 2m”; Install and tlghten the crankpin bearing cap bolts [1] to c an 'Ingr e 0' the specified torque in 2 or 3 steps alternately. “Emma Further tighten the bolts 90°. TORQUE: 10 Nm (1.0 kgf‘m, 7 lbl-l‘t) + 90” Remove the bearlng caps and measure the compressed plastigauge at its widest polnt on the crankpln to determine the oil clearance. SERVICE LIMIT: 0.05 mm (0.002 in) II the oil clearance exceeds the servtce limit, select the correct replacement bearings. BEARING SELECTION Numbers (1, 2.30! Record the connectlng rod |.D. code number [1] or 4) on the measure the ID. with the crankpin bearing cap Installed connecting rods are without bearing inserts. the connecting rod I.D. codes. 15-12 CRANKSHAFT/PISTON/CYLINDER Letters (A, 300/ ll you are replacing the crankshaft, record the D) an the crank corresponding crankpin O.D. code letter [1]. weigh! ale me ll you are reusing the crankshalt, measure the crankpln crankpl'n 0.11 cades [mm [Mm O.D. Wlth a mlcrometer. right. Cross-reference the connecting rod and crankpln codes 1 to determine the replacement bearing color code [1]. I I CRANKPIN BEARING THICKNESS: 8: Black: Thickest ‘\ - I i . Iii 1" H: White: Thinnest CRANKPIN BEARING SELECTION TABLE: CONNECTING ROD |.D. CODE 1 2 3 4 43.000 — 43.006 mm 43.006 — 43.012 mm 43.012 — 43.01 8 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) CRANKPIN 39994—40000 mm . OD CODE A (15746 _1_5748in) H (WhlIe) G (Red) F (Plnk) E (Yellow) .9 8 — .9 4 B $35?“ fgsg‘ufln'; G (Red) F (Plnk) E (Yellow) D (Green) .9 2 — .9 B c 5?“ f?_5$43mirn'; F (Plnk) E (Yellow) D (Green) c (Brown) D ??_-§77§9‘_3?:g$§1mi$ E (Yellow) D (Green) c (Brown) B (Black) After selecting new bearings, recheck the clearance With a plastlgauge. Incorrect clearance can cause severe englne damage. BEARING INSTALLATION Clean the bearing cuter surlaces, crankpin bearing cap 1 and connecting red. I I Install the crankpin bearings [1] onto the bearlng cap and connecting rod, aligning each tab with each groove. Align CRANKSHAFI'IPISTON/CYLINDER PISTON/CYLINDER Be care/til not to damage the piston ring by spreading the ends too Iar. PISTON/CONNECTING ROD REMOVAL - Belore 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 crankshatt [3]. Remove the countershatt. — NC700X/XA/S/SA (page 14-8) — NC700XD/SD (page 14-17) Remove the piston/connecting rod assembly [1] from the top of the cylinder. 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 Spread each piston ring ends and remove them by lilting up at a point opposite the gap. 15-14 Never use a wire orush: it will warm the groove. Clean carbon deposits trom the piston ring grooves with a ring that will be discarded. PISTON REMOVAL Assemble the special tools as shown. TOOLS: Piston pin tool set — Piston base head [1] - Piston pin pilot [2] - Piston base spring [3] - Piston base [4] 07PAF-0010000 07PAF-0010400 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]. TOOLS: Piston pin tool set — Piston base head insert — Pilot collar, 18 mm 07PAF-0010000 07PAF-0010500 07PAF-0010640 Remove the pilot collar. Assemble and adiust the length 0! the insert pin [1] and insert adjuster [2] to 44.0 mm (1.73 in). TOOLS: Piston pin tool set 07PAF-0010000 - Insert pin 07PAF-0010700 — Insert adiuster 07PAF-0010800 CRAN KSHAFT/PISTON/CYLINDER 1.0 mm (0.04 in) 44.0 mm (1.73 in) [1] [2] 15-15 CRANKSHAFT/PISTON/CYLINDER Push the rings into me cylinder with me top 0/ the piston m be sure they are squarely in the cylinder. Place the piston assembly [1] on the special tools [2]. NOTE Be sure to position the piston Ilat area against the piston base head inserts as shown. Place the pilot collar [3] and insert pin/insert adjuster [4] on the piston assembly. Press the piston pin [1] out With the insert pin [2], insert adjuster [3], pilot collar [4] and a hydraulic press. PISTON INSPECTION Inspect the piston rings Ior iree movement by rotating them in their grooves. The rings should be able to move Ireely grooves Without catching. Push the ring until the outer surIace oI the piston ring is nearly ilush with the piston and measure the ring-to—ring groove clearance. SERVICE LIMITS: Top: 0.15 mm (0.006 in) Second: 0.13 mm (0.005 in) Insert the piston ring squarely into the top oI the cylinder and measure the ring end gap. SERVICE LIMITS: Top: 0.6 mm (0.02 in) Second: 0.6 mm (0.02 in) Oil (side rail): 0.8 mm (0.03 in) /Ori 15-16 Measure the piston pin bore |.D. SERVICE LIMIT: 18.023 mm (0.7096 in) Measure the CD. at the piston pin. SERVICE LIMIT: 17.988 mm (0.7032 in) Calculate the piston-to-pistpn pin clearance. SERVICE LIMIT: 0.035 mm (0.0014 in) Measure the diameter at the piston at 13 mm (0.5 in) Irpm the bottom and 90" to the piston pin hole. SERVICE LIMIT: 72.970 mm (2.8728 in) CONNECTING ROD INSPECTION Measure the connecting rod small end l.D. SERVICE LIMIT: 17.985 mm (0.7031 in) CRAN KSHAFT/PISTON/CYLINDER 15-17 CRANKSHAFI'IPISTON/CYLINDER CYLINDER INSPECTION Inspect the cylinder bore Ior wear or damage. Measure the cylinder ID. in X and Y axis at three levels. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 73.07 mm (2.877 in) Calculate the cylinder-to-piston clearance. Take a maximum reading to determine the clearance. For piston O.D. measurement (page 15-17). SERVICE LIMIT: 0.05 mm (0.002 in) Calculate the taper and out-ol-round at three levels in X and Y axis. Take the maximum reading to determine them. SERVICE LIMITS: Taper: 0.10 mm (0.004 in) Out-of-round: 0.10 mm (0.004 in) Inspect the top of the cylinder for warpage. SERVICE LIMIT: 0.10 mm (0.004 in) PISTON INSTALLATION Face the connecting rod oil jet [1] to the piston "IN" mark [2] side. Temporarily install the pilot collar [1] to the piston pin pilot. and adjust the piston base head insens [2] as shown, then tighten the screws [3]. TOOLS: Pi on pin tool set 07PAF-0010000 — on base head insert 07PAF-0010500 - Pilot collar, 18 mm 07PAF-0010640 Remove the pilot collar. [1] 1] [2] [3] 1.0 mm (0.04 in) 15-18 CRANKSHAFT/PISTON/CYLINDER Apply engine oil to the piston pin outer suriace. Adjust the length oi the insert pin [1] and insert adjuster [2] to 44.0 mm (1.73 in). TOOLS: Piston pin tool set 07PAF-0010000 — Insert pin 07PAF-0010700 — Insert adiuster 07PAF-0010800 Insert the pilot collar [3] into the piston [4] and connecting rod [5]. TOOL: Piston pin tool set - Pilot collar, 18 mm 07PAF-0010000 07PAF-0010640 Place the piston, connecting rod and pilot collar on the special tools. TOOLS: Piston pin tool set [6] — Piston base head insert — Piston base head — Piston pin pilot — Piston base spring - Piston base 07PAF-0010000 07PAF-0010500 07PAF-0010400 07PAF-0010300 07973-6570600 07973-6570500 NOTE Be sure to position the piston ilat 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] and special tools on the hydraulic press. Press the piston pin until special tools tully seated. [4] [5] [6] [Wm (1.73 in) [44.0 mm 15-19 CRANKSHAFT/PISTON/CYLINDER Install the piston/ connecting rod assembly Wllh the "W" mam [3] facing the Intake side. Make sure the piston ring compressor tool sits [lush on the top surface ol the cylinder. PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings. ' 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. 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 surlace. Install the piston/connecting rod assemblies [1] into the cylinders using a commercially available piston ring compressor tool [2]. When reusing the connecting rods, they must be installed in their original locations. - 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 at a plastic hammer or equivalent tool to tap the piston into the cylinder. Install the IolloWing: — Countershaft — NC7DOX/XA/S/SA (page 14—15) — NC7DOXD/SD (page 14-24) — Crankshaft (page 15-6) 20 mm (0.8 in) OR MORE ‘ .3 3 iii [5] '7' 15-20 16. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION SERVICE INFORMATION ENGINE REMOVAL (Nc7oox/XA/s/5A)...................................... .....16.2 .....16.4 1 6-5 ENGINE REMOVAL (Nc7ooxo/5D) .......................................... ..15.9 ENGINE INSTALLATION (Nc7oox/XA/s/SA) ................................. "15.15 ENGINE INSTALLATION (Ncmoxo/SD) ........................................ "15.21 16-1 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION NC700X/XA/S/SA: 32 N-m (3.3 kgf-m, 24 lbf-fl) 54 N-m (5.5 kgl-m, 40 mm) 32 N-m (3.3 kgl-m, 24 mm) / W 1o N-m (1.0 kgl-m, 7 lel) 1 6-2 ENGINE REMOVAL/INSTALLATION NC7DOXD/SD: 32 N-m (3.3 Kgl-m, 24 lbf-ft) 54 N-m (5.5 kgf-m, 40 lel) 54 N-m (5.5 kgf-m, 4o lbf-ft) 54 N-m (5.5 Kgl-m, 4o lbf-ft) 59 N-m (9.0 kgf-m, 44 lel) 54 N-m (5.5 kgf-m, 40 lel) f 32 N-m (3.3 kgl-m, 24 lbf-ft) 54 N-m (5.5 Kgl-m, 4o lbf-ft) 1o N-m (1.0 kgf-m, 7 lel) 1 6-3 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 lrame around the engine belorehand Ior lrame protection. ~ When installing the engine, be sure to tighten the engine mounting Iasteners to the specilied torque in the specilied sequence. ll you mistake the torque or sequence, loosen all mounting lasteners, then tighten them again to the specilied torque in the correct sequence. ~ The lollowmg components can be serviced with the engine installed in the Irame. — Starter motor (page 6-3) — Throttle body (page 7-15) — Water pump (page 8-12) — Oil pump (NC700X/XA/S/SA) (page 9-6) — Oil pump (NC700XD/SD) (page 9-8) — Rocker arm (page 10-3) — Clutch (NC700X/XA/S/SA) (page 11-7) — Gearshilt linkage (NC700X/XA/S/SA) (page 11-16) — Primary drive gear/CKP sensor rotor (NC700X/XA/S/SA) (page 11-15) — Dual clutch (NC700XD/SD) (page 12-105) — Gearshilt linkage (NC700XD/SD) (page 12-112) — Primary drive gear/CKP sensor rotor (NC700XD/SD) (page 12-103) — CKP sensor (page 5-11) — Flywheel (page 13-7) — Stator (page 13-13) ~ The lollowmg components require engine removal Ior service. — Camshalt (page 10-13) — Cylinder head/Valves (page 10-16) — Transmission (NC700X/XA/S/SA) (page 14-3) — Transmission (NC700XD/SD) (page 14-17) — Balancer (page 14-26) — Crankshaft (page 15-5) — Piston/cylinder (page 15-14) SPECIFICATIONS ITEM SPECIFICATIONS Enginedry NC700X/XA/S/SA 60.5 kg (1334 lbs) weight NC700XD/SD 67.3 kg (148.4 lbs) Engine oil NC700X/XA/S/SA Aiterdraining 3.1 liters (3.3 US qt, 2.7 lmp qt) “paw jgfnrgga'"'"9”'”er 3.4 liters (3.6 us qt, 3.0 lmp qt) Aiter disassembly 3.7 liters (3.9 US qt, 3.3 lmp qt) NC700XD/SD Aiter draining 3.2 liters (3.4 US qt, 2.8 lmp qt) jgfnrgga'"'"9”“‘er 3.4 liters (3.6 us qt, 3.0 lmp qt) Aiter disassemny 4.1 liters (4.3 US qt, 3.6 lmp qt) Coolant Radiator and engine 1.69 liters (1.79 US qt, 1.49 Imp qt) GaPaClIV At draining 1.41 liters (1.49 US qt, 1.24 Imp qt) Reserve tank 0.13 liter (0.14 US qt, 0.11 lmp qt) TORQUE VALUES . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgl-m, IbI-It) REMARKS Rear lower engine hunger nut 1 12 59 (6.0, 44) Front lower engine hunger bolt 2 12 54 (5.5, 40) Upper engine hunger bolt 2 12 54 (5.5, 40) Rear upper engine hunger nut 1 12 54 (5.5, 40) Step holder mounting socket bolt 4 8 32 (3.3, 24) Drive sprocket bolt 1 10 54 (5.5, 40) Starter motor terminal nut 1 6 10 (1.0, 7) Water hose band screw 2 — — See page 16-18 See page 16-19 See page 16-24 See page 16-25 1 6-4 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL (NC700X/XA/S/SA) Drain the engine oil (page 3-13). Drain the coolant (page 8—6). Fully slacken the drive chain (page 3-17). Relieve the fuel pressure and disconnect the quick connect fitting from the fuel injector side (page 7-4). Remove the lollowing: — Left rear cover (page 2-29) — Exhaust pipe/mulller (page 2-32) — Radiator (page 8-9) — Radiator reserve tank (page 8-14) — Throttle body (page 7-15) Disconnect the CKP sensor 2P (Red) connector [1] and . < ' release the CKP sensor harness. Remove the bolt [1] and rear brake reservoir stay/ resen/oir [2]. Remove the socket bolts [3]. Lower the rear lender B [1]. Disconnect the alternator 3P (Black) connector [2]. Release the sidestand switch wwre harness clamp [1]. [1] Release the alternator wire harness [2]. 1 6-5 ENGINE REMOVAL/INSTALLATION Disconnect the neutral switch connector [1]. Remove the wire band [2], bolt [3] and setting plate [4]. Release the lollowing: — Neutral switch wire [5] — Sidestand switch wire [6] — Fuel tank drain hose B [7] Disconnect the VS sensor 3P (Black) connector [1]. Disconnect the injector 2P (Gray) connectors [1]. Release the clip [2] lrorn the luel rail. Loosen the band screw [1] and disconnect the water hose [2] from the water pump. Disconnect the spark plug cap [3]. Release the spark plug wire clamp [4] from the lrame. 1 6-6 ENGINE REMOVAL/INSTALLATION Disconnect the spark plug cap [1]. Release the spark plug Wire clamp [2] from the lrame. Remove the bolts [1] and stay [2] from the frame. Disconnect the EOP switch 1P (Gray) connector [3]. Disconnect the ECT sensor 2P connector [1]. Loosen the band screw and disconnect the water hose [2] trom the thermostat cover. Release the main wire harness [3] lrom the stay [4] and trame [5]. Remove the bolts [1] and clutch cable guide [2], then disconnect the clutch cable [3] from the clutch litter arm [4]- 1 6-7 ENGINE REMOVAL/INSTALLATION Release the rubber cap [1]. Remove the starter motor terminal nut [2] and disconnect the starter motor cable [3]. Remove the starter motor mounting bolt [4] and disconnect the ground cable [5]. Release the luel teed hose [6] trom the clamp [7]. Remove the drive sprocket bolt [1], washer [2] and drive sprocket [3]. Remove the step holder mounting socket bolts [1] and E left step holder [2]. ‘ K \ Remove the step holder mounting socket bolts [1] and right step holder [2]. NOTE Do not tWist the brake hose. 1 6-8 ENGINE REMOVAL/INSTALLATION Thefack height Suppon the engine using a jack or other adjustable must be contlliually support to ease of engine hanger bolts removal. adjusted in relieve stress [or ease 0/ DUI! removal. Left side: Remove the upper engine hunger bolts [1] and collar [2]- Remove the front lower hunger bolts [1] and collars [2]. Remove the rear engine hunger nuts [1], collars [2] and bolts [3]. Carefully maneuver the engine and remove it out of the frame to the right. NOTE During engine removal, hold the engine securely and be careful not to damage the frame and engine. ENGINE REMOVAL (NC700XD/SD) Drain the engine oil (page 3-13). Drain the coolant (page 8—6). Fully slacken the drive chain (page 3-17). Relieve the fuel pressure and disconnect the quick connect fitting from the fuel injector side (page 7-4). Remove the following: — Left rear cover (page 2-30) — Guard pipe (page 2-30) — Center cross plate (page 2—32) — Exhaust pipe/muffler (page 2-32) — Radiator (page 8-9) — Radiator reserve tank (page 8-14) — Throttle body (page 7-15) Disconnect the CKP sensor 2P (Red) connector [1] and release the CKP sensor harness. 1 6-9 ENGINE REMOVAL/INSTALLATION Remove the bolt [1] and rear brake resenloir stay/ resen/oir [2]. Remove the socket bolts [3]. Lower the rear lender B [1]. Disconnect the alternator 3P (Black) connector [2]. Release the sidestand switch Wire harness clamp [1]. Release the alternator wire harness [2]. Remove the wire band [1] and release the Wires and hose from the stay [2]. Remove the sidestand switch Wire clamp [3] from the stay. [4] and neutral switch connector [5]. 16-10 ENGINE REMOVAL/INSTALLATION Disconnect the VS sensor 3P (Black) connector [1] and EOT sensor 2P (Black) connector [2]. Disconnect the injector 2P (Gray) connectors [1]. Release the clip [2] lrorn the luel rail. Disconnect the TR sensor 3P (Black) connector [1] and remove it lrom the ABS modulator stay. Loosen the band screw [1] and disconnect the water hose [2] from the water pump. Disconnect the spark plug cap [3]. Release the spark plug wtre clamp [4] from the lrame. 16-11 ENGINE REMOVAL/INSTALLATION Disconnect the spark plug cap [1]. Release the spark plug wire clamp [2] from the lrame. Remove the bolts [1] and stay [2] trom the trame. Disconnect the EOP switch 1P (Gray) connector [3]. Disconnect the clutch EOP sensor 3P connectors [1]. Remove the bolts [2] and clamps [3]. Disconnect the ECT sensor 2P connector [1]. Loosen the band screw and disconnect the water hose [2] trom the thermostat cover. Release the main wire harness [3] lrom the stay [4] and trame [5]. 16-12 ENGINE REMOVAL/INSTALLATION Disconnect the linear solenoid valve 4P (Green) ' ' V connector [1] and shift spindle angle sensor 3P (Gray) connector [2] and remove them from the ABS modulator stay. Release the luel teed hose [3] lrom the clamp [4]. Disconnect the lollowing: — Inner mainshaft sensor 3P (Black) connector [1] — Outer mainshaft sensor 3P (Black) connector [2] Release the rubber cap [1]. Remove the starter motor terminal nut [2] and disconnect the starter motor cable [3]. Remove the starter motor mounting bolt [4] and disconnect the ground cable [5]. Release the luel teed hose [6] lrom the clamp [7]. Remove the drive sprocket bolt [1], washer [2] and drive sprocket [3]. 16-13 ENGINE REMOVAL/INSTALLATION Remove the step holder mountlng socket bolts [1] and left step holder [2]. Remove the step holder mountlng socket bolts [1] and rlght step holder [2]. NOTE Do not thst the brake hose. The/ackheigh! Support the engine uslng a jack or other adjustable must be canllnually support to ease of englne hanger bolts removal. adjusted ru relieve . stress [grease u, {Remove the upper englne hunger bolts [1] and collar bolt rema val. Remove the tront lower hunger bolts [1] and collars [2]. VLen side: 16-14 ENGINE REMOVAL/INSTALLATION Remove the rear engine hunger nuts [1], collars [2] and bolts [3]. Carefully maneuver the engine and remove it out 01 the trame to the right. NOTE During engine removal, hold the engine securely and ‘ be careful not to damage the frame and engine. ENGINE INSTALLATION (NC7OOX/XA/S/ SA) 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 01 the engine hanger bolts. — Front lower right side [1]: 12 x 55 mm bolt and 20 mm collar — Front lower left side [2]: 12 x 80 mm bolt and 41 mm collar — Upper right side [3]: 12 x 45 mm bolt and 10 mm collar — Upper left side [4]: 12 x 35 mm bolt — Rear upper side: 12 x 276 mm bolt, 37 mm collar (right side) [5] and 47 mm collar (left side) [6] — Rear lower side: 12 x 168 mm bolt and 10 mm collar (right side) [7] - Place the jack or other adjustable support under the engine. - The jack height must be continually adjusted to relieve stress tor ease bolt installation. - Carefully align the mounting points with the jack to prevent damage to engine, trame, water hose, wires and cables. - Route the hoses, wires and cables properly (page 1- 25). During engine Place the engine in the frame, then loosely install all the installation, hold the bolts, nuts and collars. engine securely . . andbecaremmw Tighten the rear lower engine hunger nut [1] to the specified torque. Ia damage the [lame and engine- TORQUE:59 NM (6.0 kgf‘m, 44 IN“) 16-15 ENGINE REMOVAL/INSTALLATION Tighten the left front lower engine hunger bolt [1] to the specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 let) Tighten the right front lower engine hunger bolt [2] to the specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 let) [1] Left side‘ we ‘7 Right side: Tighten the lelt upper engine hunger bolt [1] to the specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 let) Tighten the right upper engine hunger bolt [2] to the specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 let) Tighten the rear upper engine hunger nut [1] to the specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 let) Install the right step holder [1] and step holder mounting socket bolts [2]. Tighten the step holder mounting socket bolts to the specified torque. TORQUE:32 N-m (3.3 kgf‘m, 24 let) 16-16 ENGINE REMOVAL/INSTALLATION | t Ilth I It t h Ider [1] and step holder mounting I. sliijetbgugziep 0 ll” Tighten the step holder mounting socket bolts to the specified torque. TORQUEKSZ N-m (3.3 kgf‘m, 24 let) Install the drive sprocket [1], washer [2] and drive sprocket bolt [3]. Tighten the drive sprocket bolt to the specified torque. TORQUE:54 NM (5.5 kgf‘m, 40 mm) 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 MM (1.0 kgrm, 1mm) Reposition the rubber cap [5] properly on the starter motor terminal. Install the Iuel feed hose [6] to the clamp [7]. NOTE Align the Iuel feed hose White paint with clamp. Connect the clutch cable [1] to the clutch lifter arm [2]. Install olutoh cable guide [3] and bolts [4]. Tighten the bolts securely. 16-17 ENGINE REMOVAL/INSTALLATION Connect the ECT sensor 2P connector [1]. Connect the water hose [2] to the thermostat cover. NOTE Align the water hose paint mark with the thermostat cover tab. Install the main Wire harness [3] to the stay [4] and trame [5]. Tighten the water hose band screw to the specified range. Connect the EOP switch 1P (Gray) connector [1]. Install the stay [2] and bolts [3] to the lrame. Tighten the bolts securely. Install the spark plug Wire clamp [1] to the frame. Connect the spark plug cap [2]. 16-18 ENGINE REMOVAL/INSTALLATION Install the spark plug wire clamp [1] to the frame. Connect the spark plug cap [2]. Connect the water hose [3] to the water pump. Tighten the water hose band screw to the specified range. Install the clip [1] to the fuel rail. Connect the injector 2P (Gray) connectors [2]. Connect the VS sensor 3P (Black) connector [1]. 16-19 ENGINE REMOVAL/INSTALLATION Install the loIIoWing: — Fuel tankdrain hose B [1] — Sidestand switch wire [2] — Neutral switch wire [3] Install the setting plate [4] and a new bolt [5]. NOTE Align the setting plate hole With the crankcase boss. Install the wire band [6]. Connect the neutral switch connector [7]. Route the alternator Wire harness [1]. Install the sidestand switch wire harness clamp [2]. Connect the alternator 3P (Black) connector [1]. Install the rear fender B [1] and socket bolts [2]. Tighten the socket bolts securely. Install the rear brake reservoir stay/resenloir [3] and bolt [4]. NOTE Align the rear brake reservoir stay with the frame tab. Tighten the bolt securely. 16-20 ENGINE REMOVAL/INSTALLATION Connect the CKP sensor 2P (Red) connector [1]. Install the lollowmg: — Throttle body (page 7-18) — Radiator (page 8-9) — Radiator reserve tank (page 8-14) — Exhaust pipe/mulller (page 2-32) — Left rear cover (page 2-29) Inspect the following: — Throttle grip freeplay (page 3-5) — Clutch lever freeplay (page 3-26) Adjust the drive chain slack (page 3-16). Fill the engine with the recommended engine oil (page . 3-12). 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—6). Check the exhaust system and cooling system for leaks. ENGINE INSTALLATION (NC700XD/SD) 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 ol the engine hanger bolts. — Front lower right side [1]: 12 x 55 mm bolt and 20 mm collar — Front lower lelt side [2]: 12 x 80 mm bolt and 41 mm collar — Upper right side [3]: 12 x 45 mm bolt and 10 mm collar — Upper left side [4]: 12 x 35 mm bolt — Rear upper side: 12 x 276 mm bolt, 37 mm collar (right side) [5] and 47 mm collar (left side) [6] — Rear lower side: 12 x 168 mm bolt and 10 mm collar (right side) [7] - Place the jack or other adjustable support under the engine. - The jack height must be continually adjusted to relieve stress lor ease bolt installation. Carelully align the mounting points with the jack to prevent damage to engine, lrame, water hose, wires and cables. - Route the water hose, wires and cables properly (page 1-25). During engine Place the engine in the frame, then loosely install all the installation, hold the bolts, nuts and collars. engine securely . . andbecaremmm Tighten the rear lower engine hunger nut [1] to the m damage me specified torque. frame and engine. TORQUE:59 NM (6.0 kgf—m, 44 IBM!) ENGINE REMOVAL/INSTALLATION Tighten the left front lower engine hunger bolt [1] to the VLen side: Rigm side: specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 Ith) Tighten the right front lower engine hunger bolt [2] to the specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 let) [1] Tighten the lelt upper engine hunger bolt [1] to the |—' . IT specified torque. Leftslde. ‘24 TORQUE:54 N-m (5.5 kgf‘m, 40 let) Tighten the right upper engine hunger bolt [2] to the specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 let) Tighten the rear upper engine hunger nut [1] to the specified torque. TORQUE:54 N-m (5.5 kgf‘m, 40 let) Install the right step holder [1] and step holder mounting socket bolts [2]. Tighten the step holder mounting socket bolts to the specified torque. TORQUE:32 N-m (3.3 kgf‘m, 24 lbf‘ft) 16-22 ENGINE REMOVAL/INSTALLATION Install the left step holder [1] and step holder mounting socket bolts [2]. Tighten the step holder mounting socket bolts to the specified torque. TORQUEKSZ N-m (3.3 kgf‘m, 24 let) Install the dI'IVe sprocket [1], washer [2] and drive sprocket bolt [3]. Tighten the drive sprocket bolt to the specified torque. TORQUE:54 NM (5.5 kgf‘m, 40 mm) 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 MM (1.0 kgf‘m, 7 lbf‘fl) Reposition the rubber cap [5] properly on the starter motor terminal. Install the Iuel feed hose [6] to the clamp [7]. NOTE _ V [1]/[2] [6] Align the Iuel feed hose White paint with clamp. Connect the Iollowing: — Inner mainshaft sensor 3P (Black) connector [1] — Outer mainshaft sensor 3P (Black) connector [2] 16-23 ENGINE REMOVAL/INSTALLATION Install the IueI feed hose [1] to the clamp [2]. Connect the linear solenoid valve 4P (Green) connector [3] and shift spindle angle sensor 3P (Gray) connector [4] and install them to the ABS modulator stay. Connect the ECT sensor 2P connector [1]. Connect the water hose [2] to the thermostat cover. NOTE Align the water hose paint mark with the thermostat cover tab. Install the main Wire harness [3] to the stay [4] and trame [5]. Tighten the water hose band screw to the specified range. Connect the clutch EOP sensor 3P connectors [1]. Install the clamps [2] and bolts [3]. Tighten the bolts securely. 16-24 ENGINE REMOVAL/INSTALLATION Connect the EOP switch 1P (Gray) connector [1]. Install the stay [2] and bolts [3] to the Irame. Tighten the bolts securely. Install the spark plug wire clamp [1] to the frame. Connect the spark plug cap [2]. Install the spark plug wire clamp [1] to the frame. Connect the spark plug cap [2]. Connect the water hose [3] to the water pump. Tighten the water hose band screw to the specified range. . 16-25 ENGINE REMOVAL/INSTALLATION Connect the TR sensor 3P (Black) connector [1] and install ll to the ABS modulator stay. Install the clip [1] to the fuel rail. Connect the lnjector 2P (Gray) connectors [2]. Connect the VS sensor 3P (Black) connector [1] and EOT sensor 2P (Black) connector [2]. Route the wires and hose properly. control motor 2P (Black) connector [2]. Install the sldestand swwtch wire clamp [3] onto the stay. Set the hose and wires lnto the stay [4] and install the wire band [5] 16-26 ENGINE REMOVAL/INSTALLATION Route the alternator Wire harness [1]. [2] Install the sidestand switch wire harness clamp [2]. Connect the alternator 3P (Black) connector [1]. Install the rear fender B [1] and socket bolts [2]. Tighten the socket bolts securely. Install the rear brake reservoir stay/reservoir [3] and bolt [4]. N OT E Align the rear brake reservoir stay with the frame tab. Tighten the bolt securely. Connect the CKP sensor 2P (Red) connector [1]. Install the Iollowmg: — Throttle body (page 7-18) — Radiator (page 8-9) — Radiator reserve tank (page 8-14) — Exhaust pipe/mulller (page 2-32) — Center cross plate (page 2—32) — Guard pipe (page 2-30) — Left rear cover (page 2-30) Inspect the throttle grip freeplay (page 3-5). Adjust the drive chain slack (page 3-16). Fill the engine with the recommended engine oil (page 3-12). Connect the quick connect fitting to the fuel injector side (page 7-5). Fill the recommended coolant mixture to the IilIer neck and bleed the air (page 8—6). Check the exhaust system and cooling system for leaks. 16-27 MEMO 17. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION----- -----17-2 FRONT WHEEL ------17-20 SERWCE INFORMATION“... .....17.s FORK .................... .. 17.25 TnouBLESHoonNG.................................17.9 STEEmNG STEM ................................... ..17.33 HANDLEBAR CLUTCH LEVER (Nc7oox/XA/s/5A).......17.42 17-1 FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION NC700X: 103 Mm (10.5 kgf-m, 76 lel) 39 N-m (4.0 kgf-m, 29 lbl-fl) 22 N-m (2.2 kgf-m,16|bl-fl) so N-m (3.1 Kgl-m, 22 lbf-ft) 22 N-m (2.2 kgf-m,16|le) 74 N-m (7.5 kgl-m, 55 lbf-ft) 1 7-2 FRONT WHEEL/SUSPENSION/STEERING NC700XA: 103 N-m (10.5 Kgl-m, 76 mm) 39 N-m (4.0 kgl-m, 29 lbf-ft) 22 N-m (2.2 kgf-m, 16 mm) 30 N-m (3.1 Kgl-m, 22 lbf-ft) 22 N-m (2.2 kgl-m,1elbf-ft) 74 N-m (7.5 kgl-m, 55 mm) 1 7-3 FRONT WHEEL/SUSPENSION/STEERING NC700XD: 103 Mm (10.5 kgf-m, 76 lel) 39 N-m (4.0 kgl-m, 29 mm) 22 N-m (2.2 kgf-m, 16 lel) 30 N-m (3.1 Kgl-m, 22 lbf-ft) 22 N-m (2.2 kgf-m, 1e lbf-ft) 74 N-m (7.5 kgl-m, 55 lbf-ft) 1 7-4 FRONT WHEEL/SUSPENSION/STEERING N07005: 22 N-m (2.2 kgf-m,16|bl-fl) 103 N-m (10.5 kgl-m, 7s lbf-ft) 22 N-m (2.2 kgl-m,1elbf-ft) so N-m (3.1 kgl-m, 22 mm) 22 N-m (2.2 kgl-m, 16 mm) 74 N-m (7.5 kgf-m, 55 lbf-fl) 1 7-5 FRONT WHEEL/SUSPENSION/STEERING NCTOOSA: 103 N-m (10.5 kgf-m, 76 lel) / 4 " 1‘ ‘ 22 N-m (2.2 Kgl-m, 16 mm) x 74 N-m (7.5 kgf-m, 55 lel) 1 7-6 FRONT WHEEL/SUSPENSION/STEERING NCTOOSD: 103 N-m (10.5 kgl-m, 7s lbf-ft) 22 N-m (2.2 kgf-m, 16 mm) 30 N-m (3.1 Kgl-m, 22 mm) 22 N-m (2.2 kgl-m, 16 mm) 74 N-m (7.5 kgf-m, 55 lbl-fl) 1 7-7 FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL ~ When sen/icing the tront wheel, tork or steering stem, support the motorcycle using a satety 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 alter removing the caliper and tront wheel. Alter the iront 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 inlormation (page 19-5). SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 1.5 (0.06) Gold tire Driver only 250 kPa (2.50 kgi/cm , 86 psi) — pressure Driver and passenger 250 kPa (2.50 kgi/cm , 86 psi) — Axle runout — 0.2 (0.01) Wheel rim runout Radial — 2.0 (0.08) Axial — 2.0 (0.08) Wheel balance weight _ 60 g (2.1 oz) max. Fork Spring lree NC700X/XA/XD 304.0 (15.55) 387.0 (15.24) length NC700S/SA/SD 357.0 (14.06) 349.9 (13.78) Tube runout — 0.20 (0.008) Recommended lork tluid Honda ULTRA CUSHION OIL 10W or _ equivalent Fluid level NC700X/XA/XD 104 (4.1) — NC700S/SA/SD 103 (4.1) — Fluid ca acit 514 i 2.5 cm 17.4 i 0.08 US 02, 18.1 t p y NC700X/XA/XD (mg Imp OZ) ( — 518 i 2.5 cm 17.5 i 0.08 US 02, 18.2 t NC700S/SA/SD (mg Imp OZ) ( — TORQUE VALUES , THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgI-m, lbl-ft) REMARKS Handlebar holder bolt 4 B 22 (2.2, 16) Handlebar switch housing screw 4 5 2.5 (0.8, 1.8) Front master cylinder holder bolt 2 6 12 (1.2, 9) Handlebar weight mounting screw 2 6 10 (1.0, 7) ALOC screw; replace With a new one. Front brake disc mounting bolt 5 B 42 (4.8, 31) ALOC bolt; replace with a new one. Front axle 1 18 74 (7.5, 55) Apply grease to the sliding surtace. Front axle pinch bolt 1 B 22 (2.2, 16) Fork socket bolt 2 B 20 (2.0, 15) Apply locking agent to the threads. Bottom bridge pinch bolt 2 10 89 (4.0, 29) Fork cap 2 87 22 (2.2, 16) Top bridge pinch bolt 2 B 22 (2.2, 16) Front brake caliper mounting bolt 2 B 80 (8.1, 22) ALOC bolt; replace with a new one. Steering stem ad)usting nut 1 26 23 (2.8, 17) See page 17-38 Apply engine oil to the threads. Steering stem ad)usting lock nut 1 26 — See page 17-38 Steering stem nut 1 24 108 (10.5, 76) See page 17-38 Clutch lever pivot bolt 1 6 1.0 (0.1 , 0.7) Apply grease to the sliding surtace. (NC700X/XA/S/SA) Clutch lever pivot nut 1 6 6.0 (0.6, 4.4) (NC700X/XA/S/SA) 1 7-8 TROUBLESHOOTING Hard steering - Steering stem adjusting nut too tight - Damaged steering head bearings - Insutticienttire pressure - Faulty tire Steers to one side or does not track straight - Bent iork pipe - Bent axle - Worn wheel bearing - Unequal Iork fluid quantity in each Iork pipe - Faulty steering head bearing - Bent irame - Faulty wheel bearing - Weak Iront tork - Loose steering stern adjusting nut Front wheel wobbling - Bent rim - Worm wheel bearing - Faulty tire - Insutticienttire pressure - Axle not tightened properly - Unbalanced tire and wheel Wheel hard to turn - Faultywheelbearing - Bent axle - Brake drag Soll suspension - Weaklorkspring - Insuflicientiorklluid - Insutticienttire pressure - Incorrect Iork tluid viscosity Stilt suspension - Incorrect Iork tluid viscosity - Bent iork pipe - Clogged Iork Iluid passage - Damaged Iork pipe and/or iork slider - Fork pipe binds - High tire pressure Front suspension noisy - Insufficient iork IIuid - Loose Iork tasteners - Bent iork pipe FRONT WHEEL/SUSPENSION/STEERING 1 7-9 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL (NC700X/XA/S/SA) Remove the rearview mirrors [1] and wire bands [2]. [1] Hold the handlebar weight [1] and remove the handlebar weight mounting screw [2], then remove both handlebar weights. Disconnect the clutch switch connectors [1]. Remove the bolts [2], holder [3] and clutch lever bracket [4]- Remove the screws [1] and separate the lelt handlebar ; switch housing [2]. Remove the left handlebar grip rubber [3]. 17-10 FRONT WHEEL/SUSPENSION/STEERING Disconnect the brake light switch connectors [1]. Remove the bolts [2], holder [3] and master cylinder [4]. NOTE Keep the brake master cylinder upright to prevent air lrom entering the hydraulic system. [4] pm. 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] lrom the throttle pipe [4], then remove the throttle pipe [5]. Hold the handlebar [1] and remove the bolts [2] and holder [3]. 17-11 FRONT WHEEL/SUSPENSION/STEERING REMOVAL (NCTOOXD/SD) Remove the rearview mirrors [1] and wire bands [2]. [1] Hold the handlebar weight [1] and remove the handlebar weight mounting screw [2], then remove both handlebar weights. 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]. Remove the left handlebar grip rubber [3]. 17-12 FRONT WHEEL/SUSPENSION/STEERING Disconnect the brake light switch connectors [1]. Remove the bolts [2], holder [3] and master cylinder [4]. NOTE Keep the brake master cylinder upright to prevent air lrom 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. Hold the handlebar [1] and remove the bolts [2] and holder [3]. 17-13 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION (NC700X/XA/S/SA) NOTE Route the wires, hoses and cables properly (page 1- 25). Clean the inside surface ol the handlebar grip and outside surface of the handlebar and throttle pipe. Apply Honda Bond A, Cemedine #540 or equivalent to the inside surlace 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. [a dry rm 1 hour Rotate the grips lor even application of the adhesive. belure using. Install the handlebar [1] onto the top bridge. NOTE Align the handlebar punch mark with the top bridge top surlace. Hold the handlebar and install the holder [2] and handlebar holder bolts [3] as shown. Tighten the upper bolts lirst, then the lower bolts to the specified torque. TOROUE:22 NM (2.2 kgf—m,16lbf—ll) Apply grease to the throttle cable end and throttle pipe llange groove. Install the throttle pipe [1] to the handlebar. Connect the throttle cable [2] end to the throttle pipe. Install the throttle housing [3] and screws [4]. NOTE Align throttle housing locating pin with the handlebar hole. Tighten the screws securely. Install the right handlebar sWitch housing [1]. NOTE Align the SWitch housing locating pin With the handlebar hole. 17-14 FRONT WHEEL/SUSPENSION/STEERING Install the screws [1] and tighten the upper screw first, 1 then tighten the lower screw to the specilied torque. [ l / TORQUE:2.5 NM (0.3 kgl-m, 1.8 lbl-ft) Install the master cylinder [1], holder [2] ("UP" mark [3] lacing up) and bolts [4]. [1] Alla" [2] 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 NM (1.2 kgf—m, 9 Ibt-ft) Connect the brake light switch connectors [5]. Install the left handlebar switch housing [1]. NOTE Align the sWitch housing locating pin With the handlebar hole. Install the screws [1] and tighten the upper screw first, i then tighten the lower screw to the specilied torque. TORQUE:2.5 NM (0.3 kgl-m, 1.8 lbl-ft) 17-15 FRONT WHEEL/SUSPENSION/STEERING {31522215Sgtgmegsgbmcket [1], holder [2] ("UP" mark [2] [1] Align [5] Align the end oi the clutch lever bracket with the punch mark on the handlebar, and tighten the upper bolt first, then the lower bolt. Connect the clutch SWIICh connectors [5]. Install the handlebar weight [1] to both handlebars aligning each cutout. Hold the handlebar weight [1]. Install and tighten a new handlebar weight mounting screw [2] to the specified torque. TORQUE: 10 MM (1.0 kgt-m, 7 lbt-I‘t) Install the rearview mirrors [1] and wire bands [2]. [1] Adjust the tollowmg: — Clutch lever treeplay (page 3-26) — Throttle grip treeplay (page 3-5) 17-16 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION (NC700XD/SD) NOTE Route the wires, hoses and cables properly (page 1— 25). Clean the inside surface of the handlebar grip and outside surface of the handlebar and throttle pipe. Apply Honda Bond A, Cemedine #540 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. [a dry for 1 hour Rotate the grips for even application of the adhesive. bra/ore using. Install the handlebar [1] onto the top bridge. NOTE Align the handlebar punch mark With the top bridge top surlace. Hold the handlebar and install the holder [2] and handlebar holder bolts [3] as shown. Tighten the upper bolts lirst. then the lower bolts to the specified torque. TORQUE:22 N-m (2.2 kgf—m, 16 lbf—fl) 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]. NOTE 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 specilied torque. TORQUE:2.5 NM (0.3 kgf-m, 1.8 lbf-ft) 17-17 FRONT WHEEL/SUSPENSION/STEERING Install the master cylinder [1], holder [2] ("UP" mark [3] lacing up) and bolts [4]. Align the end ol 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 kgrm, 9 lbfAl‘t) Connect the brake light switch connectors [5]. [1] Align [2] Install the left handlebar switch housing [1]. NOTE 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 specilied torque. TORQUE:2.5 N-m (0.3 kgf‘m, 1.8 lbl-ft) Install the parking brake lever bracket [1]. NOTE Align the parking brake lever bracket locating pin With the handlebar hole. 17-18 FRONT WHEEL/SUSPENSION/STEERING Install the holder [1] and socket bolts [2]. [2] Tighten the socket bolts securely. Connect the parking brake switch connectors [3]. Install the handlebar weight [1] to both handlebars aligning each cutout. Hold the handlebar weight [1]. Install and tighten a new handlebar weight mounting screw [2] to the specified torque. TORQUE: 10 MM (1.0 kgrm, 1mm) Install the rearview mirrors [1] and wire bands [2]. Adjust the throttle grip lreeplay (page 3-5). Check the parking brake lock operation (page 3-24). 17-19 FRONT WHEEL/SUSPENSION/STEERING INNER WEIGHT REPLACEMENT Remove the throttle pipe or grip rubber Irom the handlebar. — NC700X/XA/S/SA (page 17-10) — NC700XD/SD (page 17-12; Straighten the retainer ring tab [1] by the screwdriver or punch. Apply iubnmn! Temporarily install the handlebar weight [2] and screw, spraylhrough the then remove the inner weight assembly [3] by turning tab locking hole [4] the handlebar weight. to the rubber cushions [5] la, easy removal. « x; \ [3] [2] Remove the screw [1], handlebar weight [2], retainer ring [3] and rubber cushions [4] irom the inner weight [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 ol the inner weight and handlebar weight. Install and tighten the handlebar weight screw. Install the inner weight assembly [1] into the handlebar. 2 3 Turn the inner weight and hook the weight retainer tab [ 1;L [2] With the tab locking hole [3] in the handlebar. Remove the screw and handlebar weight. Install the throttle pipe and grip rubber to the handlebar. — NC700X/XA/S/SA (page 17-14) — NC700XD/SD (page 17-17; FRONT WHEEL REMOVAL N0700X/S: Remove the trout brake caliper mounting bolts [1] and slide the brake caliper/bracket assembly [2]. NOTE Do not suspend the brake caliper/bracket assembly Irom the brake hose. Do not twist the brake hose. NC7OOX/S: 17-20 FRONT WHEEL/SUSPENSION/STEERING NC7DoXA/XD/SA/ Remove the brake pads (page 19-17). SD: Remove the bolts [1] and front wheel speed sensor [2] Irom the caliper bracket. 1; “£16 “ 6‘ Check that there is no iron or other magnetic deposits between the pulser ring and iront wheel speed sensor. Remove any deposits. Check the sensor tip for delormation or damage (e.g., chipped pulser ring teeth). Replace the front wheel speed sensor if necessary (page 20-25). Loosen the iront axle pinch bolt [1] and iront axle [2]. Support the motorcycle using a salety stand or hoist, raise the Iront wheel oil the ground. Remove the Iront axle and front wheel. NOTE Do not operate the brake lever after removing the lront wheel. Remove the side collars [1]. INSPECTION WHEEL RIM Check the wheel rim runout by placing the wheel in a truing stand. Spin the wheel by hand and measure the runout using a dial indicator. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) AXLE Place the axle on V—blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 ol the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) 17-21 FRONT WHEEL/SUSPENSION/STEERING WHEEL BEARING Turn the inner race of each bearing With your finger. The bearings should turn smoothly and quietly. Also check that the outer race fits tightly in the wheel hub. Remove and discard the bearings it the races do not turn smoothly, quietly, or it they lit loosely in the wheel hub. Replace the wheel bearings. it necessaw (page 17-22). NOTE Replace the bearings in pairs. WHEEL BALANCE NOTE - Carelully check balance belore 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 it necessary. Note the rotating direction marks [1] on the tire, and upon tire installation. always lit the tire so the marks lace 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 ol the wheel with chalk. Do this 2 or 3 times to verify the heaViest area. ll 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. DISASSEMBLY/ASSEMBLY Loosen the lront brake disc mounting bolts [1] in a crisscross pattern in 2 or 3 steps, and remove the bolts, pulser ring (NC700XA/XD/SA/SD) [2] and brake disc [3]- Remove the lront wheel dust seal [4] from the right wheel hub. [2] 17-22 FRONT WHEEL/SUSPENSION/STEERING Remove the Iront wheel dust seal [1] from the left wheel hub. Assembly l5 in the reverse order oi disassembly. NOTE - Replace the Iront wheel dust seals and Iront brake disc mounting bolts with new ones. - Apply grease to the Irontwheel dust seal lips. - Install the Iront wheel dust seal until it is flush with the wheel hub surface. - Install the Iront brake disc with the marked side facing out. TORQUE: Front brake disc mounting bolt: 42 N-m (4.3 kgf—m, 31 Ibf—ll) a, 42 N-m (4.3 mm, 31 lbl-It) v BRAKE DISC «5‘7 N! BEARING (6204UU) PULSEFI RING (NC700XA/XD/SA/SD) DISTANCE COLLAR g ,6 DUST SEAL my ~fl ,6 DUST SEAL @ @ BEARING (6204UU) 1 7-23 FRONT WHEEL/SUSPENSION/STEERING 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 hearing from the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover head, 20 mm 07746-0050600 Bearing remover shaft 07GGD-0010100 Nevermstallthe aid Drive in a new right side bearing [1] squarely With its bearing, once the marked side facing up until it is fully seated. bearlng has been removed the bearing mustbe Drive in a new left side bearing squarely with its marked replaced with new side facing up until it is seated on the distance collar. ones. Install the distance collar. TOOLS: Driver [2] 07749-0010000 Attachment, 42 x 47 mm [3] 07746-0010300 Pilot, 20 mm [4] 07745-0040500 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 kngm, 55 lel) 17-24 FRONT WHEEL/SUSPENSION/STEERING NC7OOXA/XD/SA/SD N0700XA/XD/SA/ Install the lront wheel speed sensor [1] and bolts [2]. SD: Tighten the bolts securely. Check the air gap between the front wheel speed sensor and pulser ring (page 20-24). Install the brake pads (page 19-17). NC700X/s: Install the front brake caliper/bracket assembly [1] and tighten new brake caliper mounting bolts [2] to the specified torque. TORQUEKSD NM (3.1 kgf—m, 22 IBM!) With the front brake applied, pump the lorks up and down several times to seat the axle and check brake operation. Tighten the lront axle pinch bolt [1] to the specified torque. TORQUE:22 NM (2.2 kgf—m, 16 IBM!) FORK REMOVAL Remove the following: — Front wheel (page 17-20) — Front lender (page 2—28) Do natsuspendthe Remove the brake caliper mounting bolts [1] and brake brake caliper/ caliper/bracket assembly [2]. bracket assembly from the brake hase. Du nu! twist the brake hose. L‘s-‘7 NC7OOX/S: 1 7-25 FRONT WHEEL/SUSPENSION/STEERING Loosen the top bridge pinch bolts [1]. When the fork is ready to be disassembled, loosen the lork cap [2]. Hold the lork legs [3] and loosen the bottom bridge pinch bolts [4] and lower the fork legs, then remove it. DISASSEMBLY Be care/ulna! to Remove the dust seal [1] and stopper ring [2]. scratch the lurk P379- Remove the lollowing: Fork cap [1] O-ring [2] Spring collar [3] Spring seat [4] Remove the lork spring [1]. Drain the lork lluid by pumping the fork pipe several times. 17-26 FRONT WHEEL/SUSPENSION/STEERING Do notoverrtlghten Set the iork slider [1] in a vise with a piece oi wood or the visa an the [ark soft jaws to avoid damage. sllder. [1] l! the lam piston Remove the iork socket bolt [2] and sealing washer [3]. turns WIIh the socket balt, temporarily install the talk spring, spring seat, sprlrlg collar and lam mp. Du natremove the Remove the fork piston [1] and rebound spring [2] lrorn lam piston ring [4], the lork pipe [3]. unless ll ls necessary ta replace with a new ane. Using quick successive motions, pull the fork pipe out of the lork slider. Remove the oil lock piece [1] from the fork slider [2]. 1 7-27 FRONT WHEEL/SUSPENSION/STEERING Removethelollowing: [1] [2] [3] — Oilseal[1] — Back—up ring [2] — Guide bushing [3] INSPECTION FORK SPRING Check the fork spring lor latigue or damage. Measure the lork spring tree length. SERVICE LIMITS: NC700X/XA/XD: 387.0 mm (15.24 in) NC7DOS/SA/SD: 349.9 mm (13.78 in) WWWWVWV FORK PlPE/SLIDER Check the fork pipe [1] and slider [2] tor score marks, 1 scratches, or excessive or abnormal wear. I I [2] Place the lork pipe on V-blocks. Turn the tprk pipe and measure the runout using a dial indicator. Actual runout is 1/2 ol the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) 17-28 FRONT WHEEL/SUSPENSION/STEERING Do not damage the slider bushing. especially the sliding suriace. To prevent loss ul tension do no! open the bushing more than necessary. FORK PISTON/REBOUND SPRING/OIL LOCK PIECE Check the icrk piston [1], piston ring [2] and oil lock piece [3] tor wear or damage. Check the rebound spring [4] tor iatigue or damage. Replace any components that are worn or damage. GUIDE BUSHING/SLIDER BUSHING/BACK-UP RING Visually inspect the slider and guide bushings [1]. Replace the bushings it there is excessive scoring or scratching, or ii the tetlpn is worn so the copper surtace appears [2] on more than 3/4 at the entire suriace. Check the back-up ring [3]; replace it it there is any distortion at the points shown. It the slider bushing [1] Will be removed, caretully remove the slider bushing by prying the bushing gap with a screwdriver until the bushing can be pulled oft by hand. NOTE Do not remove the slider bushing, unless it is necessary to replace with a new one. [2] [1 l [4] [3] [3] CHECK POINTS i ‘ earl [1] 1 7-29 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY FORK PISTON RING 22 N-m (2.2 kgf-m, 16 IbI-II) P(/)RK PISTON a I ‘ é STOPPER RING O-RING 4‘} a @ OIL SEAL SPRING COLLAR BACK-UP RING r GUIDE BUSHING SPRING SEAT SLIDER BUSHING FORK SPRING FORK SLIDER REBOUND SPRING l FORK PIPE l_ ,/ 4 gm LI CW OIL LOCK PIECE 20 N-m (2.0 kgf-m,15|bl-ll) SEALING WASHER V De rm! open the Install the slider bushing [1] being careful not to damage a 2 1 bushings/itmure the coating ol the bushing, il it has been removed. I I I I I I mannemssa’y‘ Remove the burrs lmm the bushing mating surface, being carelul not to peel off the coating. Install the ailseal Apply lork IIUlCI lo a new oil seal lips. wuhr'ts markedside Inslall the guide bushing [2], back-up ring [3] and oil facing up. seal [4] onto the fork pipe. % v [4] Install the rebound spring [I] to the Vork piston [2] and install them into the fork pipe [3]. III [2] I3I 17-30 Do not overrtlghten the visa on the [ark sllder. II the lurk plston turns WIIh the socket bait. temporarily install the folk spn'ng, spn'ng seat. sprlng collar and 1er mp. FRONT WHEEL/SUSPENSION/STEERING Install the oil lock piece [1] onto the fork plston [2] end. Install the fork plpe [3] into the fork slider [4]. [3] [2] [1 l [4] 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 locktng agent to the fork socket bolt threads and install ll. Tighten the fork socket bolt [1] to the specified torque. TORQUEZD NM (2.0 kgf—m, 15 IBM!) Drive the oil seal [1] until the stopper ring groove [2] ls VlSibIe using the special tools. TOOLS: Fork seal driver [3] Fork seal driver attachment [4] 07947-KA50100 07947-KF00100 17-31 FRONT WHEEL/SUSPENSION/STEERING Tighten the fork cap after installing the [ark pipe into the fork bridges. Install the stopper ring [1] into the groove of the fork slider securely. Apply lork fluid to a new dust seal lips. Install the dust seal [2]. Pour the specified amount of recommended lork fluid into the fork pipe. RECOMMENDED FORK FLUID: Honda ULTFIA CUSHION OIL 10W or equivalent FORK FLUID CAPACITY: NC700X/XA/XD: 514 t 2.5 cm3 (17.4 t 0.08 US OZ, 18.1 t 0.09 Imp oz) NC700$lSAlSD: 51B 2 2.5 cm“ (17.5 t 0.08 US oz, 18.1 t 0.09 Imp oz) Slowly pump the fork pipe several times to remove any trapped air from the lower portion of the fork pipe. EE EE vm Do 05 X0) 22 5@ X0) Do Do M» oo 22 Compress the fork pipe fully and measure the fluid level from the top of the fork pipe. FLUID LEVEL: NC700X/XA/XD: 104 mm (4.1 in) NC7DOSISA/SD: 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]. U 0 E z WNWWWWWVVW Apply lork fluid to a new O—ring [1] and install it onto the fork cap [2]. [2] D I \ Loosely install the fork cap by pushing it to the fork pipe [3]- [3] 17-32 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Hamel/19 wires and Install the fork leg through the bottom bridge and top cables properly bridge while aligning top surface of Iork pipe with the {page 1725). top surface of top bridge. Tighten the bottom bridge pinch bolts [1] to the specified torque. TORQUEKSQ N-m (4.0 kgf—m, 29 IBM!) If the fork cap [2] is loosened, tighten the fork cap to the specified torque. TORQUE:22 N-m (2.2 kgf—m, 16 IBM!) Tighten the top bridge pinch bolts [3] to the specified torque. TORQUE:22 N-m (2.2 kgf—m, 16 IBM!) N0700XA/XD/SA/ Install the front brake caliper/bracket assembly [1] and SD: tighten new brake caliper mounting bolts [2] to the specified torque. TORQUEKSD N-m (3.1 kgf—m, 22 IBM!) NC7OOXA/XD/SA/SD: Install the Iollowmg: — Front fender (page 2—28) — Front wheel (page 17-24) STEERING STEM REMOVAL NC700X/XA/XD: Remove the following: — Shroud/side cover (page 2-14) — Handlebar — NC7DOX/XA (page 17—10) — NC7DOXD (page 17-12) Disconnect the ignition swuch 2P (Brown) connector [1] and immobilizer receiver 4P (Black) connector [2]. NC7OOX/XA: Release the each wire harness from the clamps [3]. FRONT WHEEL/SUSPENSION/STEERING NC700X/XA/XD: Remove the ignition switch wire harness clamp [1] and , immobiiizer receiver Wire harness ciamp [2]. Ncmox/XNXD' NC7ODX: Remove the bolt [1] and brake hose clamp [2] from the bottom bridge. Nc7oos/SA/sn: Remove the iollowing: — Headlight/headlight stay (page 2—27) — Handiebar — NC7DOS/SA (page 17-10) — NC7DOSD (page 17-12) Disconnect the ignition switch 2P (Brown) connector [1] and immobilizer receiver 4P (Black) connector [2]. [2] Nc7oos/SA/sn: Remove the headlight cover (page 2-27). Disconnect the combination meter 1GP (Gray) connector [1]. Remove the socket boits [2], brake hose guide [3] and combination meter/stay [4]. NC7OOS/SA/SD: [11 17-34 FRONT WHEEL/SUSPENSION/STEERING Remove the cap. Remove the steering stem nut [1]. Remove the lork legs (page 17-25). NC700X/XA/XD: Release the lollowing: Clutch cable (NC7ODX/XA) [1] Parking brake cable (NC700XD) [1] Left handlebar sWitch Wire harness clamp [2] Throttle cables [3] Right handlebar switch wire harness clamp [4] Brake hose [5] Remove the top bridge [6]. NC7DoXA/XD/SA/ Remove the bolt [1], lront wheel speed sensor wire SD: guide [2] and brake hose joints [3]. Straighten the lock washer tabs [1]. Remove the steering stem adjusting lock nut [2] and lock washer. 1 7-35 FRONT WHEEL/SUSPENSION/STEERING Loosen the steering stern adjusting nut [1] using a special tool. TOOL: Steering stern socket [2] 07916-3710101 Hold the steering stern and remove the steering stem adjusting nut. Remove the tollowing: — 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 using a special tool. nearing, outer and inner races as a TOOLS: 59,. Ball race remover set 07953-MJ10000 Remover attachment [1] 07953-MJ10100 Remover handle [2] 07953-MJ10200 Remove the lower bearing outer race using the special tool and suitable shaft. TOOL: Bearing remover [1] 0794643710500 17-36 FRONT WHEEL/SUSPENSION/STEERING Temporarily install the steering stern nut [1] onto the steering stem [2] to prevent the threads from being damaged when removing the lower inner race [3] from the steering stem. [2] [3] Remove the lower inner race with a chisel or equivalent tools, being careiul not to damage the steering stern. Remove the steering head bearing dust seal [4]. Apply specified grease to a new steering head bearing dust seal lips (page 1-23). 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: Attachment, 30 mm LB. [3] 07746-0030300 Drive in a new upper outer race [1] using the special tools. TOOLS: Driver [2] 07749-0010000 Attachment, 42 x 47 mm [3] 07746-0010300 Drive in a new lower outer race [1] using the special tools. TOOLS: Driver [2] 07749-0010000 Attachment, 52 x 55 mm [3] 07746-0010400 1 7-37 FRONT WHEEL/SUSPENSION/STEERING LOWER BEARING LOWER INNER RACE LOWER DUST SEAL STEERING STEM : DUST SEALS INSTALLATION LOCK NUT LOCK WASHER ‘3‘ ADJUSTING NUT UPPER DUST SEAL R_ B UPPER INNER RACE UPPER BEARING UPPER OUTER RACE Q LOWER OUTER RACE l NC7OOXA/XD/SA/SD: 39 N-m (4.0 kgr-m, 29 lbf-ft) Apply 3 — 5 g (0.1 — 0.2 oz) of specified grease to each steering head bearing inner races and outer races , sliding surlace (page 1—23). Apply specilied grease to a new steering head bearing dust seal lips (page 1-23). 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]. Apply engine oil to the steering stern adjusting nut [1] threads. Install and tighten the steering stern adiusting nut to the specified torque using a special tool. TOOL: Steering stern socket [2] 07916-3710101 TOROUE:23 N-m (2.3 kgf—m,17lbf-Il) 17-38 FRONT WHEEL/SUSPENSION/STEERING NC 700XA/XD/SA/ SD: Move the steering stern lelt and right, look-to-Iock five ’ ‘ times to seat the bearings. ‘ Retighten the adjusting nut [1] to the specified torque using a special tool. TOOL: Steering stern socket [2] 07916-3710101 TORQUE:23 N-m (2.3 kgf—m, 17 lbf—ll) Install a new look washer [1], aligning its short bent tabs with the grooves in the steering stern adjusting nut. Install the look nut [2] until it contacts with the look washer. Further tighten the lock nut, within 90°, to align its grooves With the tabs of the lock washer. Bend up the long look washer tabs [3] into the grooves of the lock nut. Install the brake hose joints [1], front wheel speed sensor wire guide [2] and bolt [3]. NOTE - Ftoute the wires, hose and cable properly (page 1- 25). - Note the installation position of the brake hose joints. — Right side: Brake sub hose C (white painted [4] hose) — Left side: Front brake hose D Tighten the bolt securely. 1 7-39 FRONT WHEEL/SUSPENSION/STEERING NC700X/XA/XD: NC7ODX: NC700X/XA/XD: Install the top bridge [1]. Install the lollowmg: — Brake hose [2] — Right handlebar switch wire harness clamp [3] — Throttle cables [4] — Left handlebar sWitch Wire harness clamp [5] — Clutch cable (NC7ODX/XA) [6] — Parking brake cable (NC700XD) [6] NOTE Route the wires, hose and cable properly (page 1-25). Install the steering stem nut [1], but do not tighten the steering stem nut yet. Install the lork legs (page 17-33). Tighten the steering stem nut to the specified torque. TORQUE: 103 N-m (10.5 kgf—m, 76 Ibf—ll) Turn the steering stern left and right, lock-to—lock several times to make sure the steering stem moves (] smoothly without play or binding. Install the cap to the steering stem nut. Install the brake hose clamp [1] and bolt [2] to the bottom bridge. NOTE Be sure to rest the brake hose clamp against the bottom bridge tab [3]. Install the ignition switch wire harness clamp [1] and immobilizer receiver Wire harness clamp [2]. 1 7-40 FRONT WHEEL/SUSPENSION/STEERING NC700X/XA/XD: Install the wire harness from the clamps [1]. Connect the ignition sWitch 2P (Brown) connector [2] and immobilizer receiver 4P (Black) connector [3]. Install the Iollowmg: — Shroud/side cover (page 2-14) — Handlebar — NC7DOX/XA (page 17—14) — NC7DOXD (page 17-17) NC7005/SA/SD: Install the combination meter/stay [1], brake hose guide [2] and socket bolts [3]. NOTE - Route the wires, hose and cable properly (page 1- 25). - Install the brake hose guide against the combination meter stay. Connect the combination meter 16F (Gray) connector [4]- NC7oos/SA/SD: Install the headlight cover (page 2-27). Connect the ignition sWitch 2P (Brown) connector [1] and immobilizer receiver 4P (Black) connector [2]. Install the Iollowmg: — Headlight/headlight stay (page 2—27) — Handlebar — NC7DOS/SA (page 17—14) — NC7DOSD (page 17-17) Perlorm the digital clock set procedure (page 22-14). 17-41 FRONT WHEEL/SUSPENSION/STEERING CLUTCH LEVER (NC700X/XA/S/SA) REMOVAL/INSTALLATION Remove the clutch lever pivot nut [1] and bolt [2]. Remove the clutch lever [3] and disconnect the clutch ’6" cable [4]. [2] [4] [1] [3] Connect the clutch cable [1] to the clutch lever [2]. Install the clutch lever to the clutch lever bracket. Apply grease to the clutch lever pivot bolt sliding surlace. Install and tighten the clutch lever pivot bolt to the specified torque. TORQUE21JJ NM (0.1 kgf—m, 0.7 lbl-ft) Install and tighten the clutch lever pivot nut to the speciiied torque while holding the clutch lever pivot bolt. TORQUE26JJ NM (0.6 kgf—m, 4.4 lbl-ft) 1 7-42 18. REAR WHEEL/SUSPENSION COMPONENT LOCATION----- -----18-2 SHOCK LINKAGE ----- -- ----18-13 SERVICE lNFORMATION------ -----18-4 SHOCK ABSORBER ----- -- ----18-14 TnouBLESHoonNG.................................13.5 5w|NGARM ............................................ "13.15 REAR 18-1 REAR WHEEL/SUSPENSION COMPONENT LOCATION NC700X/XA/S/SA: NC700XA/SA shown: 44 N-m (4.5 kgf-m, 32 lbf-ft) 93 N-m (10.0 Kgl-m, 72 lbf-ft) 44 N-m (4.5 Kgl-m, 32 lbf-ft) 12 N-m (1.2 kgf-m, 9 lbf-fl) 1 8-2 REAR WHEEL/SUSPENSION NC7DOXD/SD: 44 N-m (4.5 mm, 32 mm) 93 N-m (10.0 kgI-m, 72 lbf-ft) 44 N-m (4.5 kgf-m, 32 lbf-fl) $ Qfijmflmflbm) g 9/ \ . ) 4,7/ 10.0 kgf-m, 72 lbl-fl) / l A 1 a 4 ‘\\_ ‘ 98 N-m( / ,/ L\ <®\ 5 1 8-3 REAR WHEEL/SUSPENSION SERVICE INFORMATION GENERAL ~ When servicing the rear wheel and suspension, support the motorcycle using a satety 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 genuine Honda replacement bolts and nuts tor all suspension pivot and mounting point. For brake system inlormation (page 19-5). SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread deotn — 2.0 (0.08) Gold tire pressure Driver only 290 kPa (2.90 kgi/cm , 42 psi) — Driver and passenger 290 kPa (2.90 kgi/cm , 42 psi) — Axle runout — 0.2 (0.01) wheel rim runout Radial — 2.0 (0.08) Axial — 2.0 (0.08) Wneel balance weight _ 60 g (2.1 oz) max. Drive Size/link NC700X/ DID D|D520V0-114LE — Chain XA/S/SA RK RK520MKO-114LE - NC700XD DID D|D520V0-112LE — /SD RK RK520MKO-112LE — Slack NC700X/XA/XD 30 — 40 (1.2 — 1.6) — NC7OOS/SA/SD 25 — 35 (1.0 — 1.4) — TORQUE VALUES . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgI-m, lbl-ft) REMARKS Driven sprocket nut 5 12 108 (11.0, 80) U-nut Rear brake disc mounting bolt 5 8 42 (4.3, 31) ALOC bolt; replace with a new one. Rear axle nut 1 18 98 (10.0, 72) U-nut Shock absorber mounting nut 2 10 44 (4.5, 32) U-nut Shock arm nut 1 10 44 (4.5, 32) U-nut Shock link nut 2 10 44 (4.5, 32) U-nut Drive chain slider mounting screw 2 5 5.9 (0.6, 4.4) Swingarm pivot nut 1 18 98 (10.0, 72) U-nut Step nolder mounting socket bolt 4 B 32 (3.3, 24) Gearshilt arm pinch bolt 1 6 12 (1.2, 9) ALOC bolt; replace with a new one. (NC700X/XA/S/SA) 1 8-4 REAR WHEEL/SUSPENSION TROUBLESHOOTING Steers to one side or does not track straight - Drive chain adjusters not adjusted equally - Bent axle - Bent irame - Worn swingarm pivot components Rear wheel wobbling Bent rim Worn wheel bearing Worn driven llange bearing Faulty tire Bent irame or swingarm Axle not tightened properly Unbalanced tire and wheel Insufficient tire pressure Wheel hard to turn - Brake drag - Faulty wheel bearing - Faulty driven llange bearing - Bent axle - Drive chain too tight (page 3-16) Solt suspension - Weak shock absorber spring - Oil leakage lrom damper unit - Insuflicienttire pressure Stilt suspension - Bent shock absorber damper rod - Damaged suspension or swmgarm pivot bearing - Bent swingarm pivot or irame Rear suspension noisy - Loose suspension lasteners - Faulty shock absorber 1 8-5 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle using a salety stand or hoist, raise the rear wheel oil the ground. NC7DoXA/XD/SA/ Remove the bolts [1] and rear wheel speed sensor [2]. SD: Loosen the lock nut [1], drive chain adjusting nut [2] and axle nut [3]. Push the rear wheel fonNard. Derail the drive chain [4] lrom the driven sprocket. Remove the axle nut, washer [5] and adjusting plate [6]. Do humps/are the Remove the axle [7], adjusting plate and rear wheel. brake pedal alter removing the rear wheel. Remove the side collars [1]. 1 8-6 REAR WHEEL/SUSPENSION Replace the bearings as a set. INSPECTION WHEEL RIM Check the rim runout by placing the wheel in a truing stand. Spin the wheel by hand, and measure the runout using a dial indicator. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) AXLE Place the axle on V—blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 ol the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) WHEEL AND DRIVEN FLANGE BEARINGS Turn the inner race oi each bearing WlIh your tinger. The bearings should turn smoothly and quietly. Also check that the outer race tits tightly in the wheel hub and driven Ilange. Remove and discard the bearings H the races do not turn smoothly, quietly, or it they Ilt loosely in the wheel hub and driven Ilange. WHEEL BALANCE For wheel balance servicing (page 17-22). DRIVEN SPROCKET For driven sprocket inspection (page 3-18). DISASSEMBLY Loosen the rear brake disc mounting bolts [1] in a crisscross pattern in 2 or 3 steps. Remove the rear brake disc mounting bolts, brake disc [2] and pulser ring (NC7DOXA/XD/SA/SD) [3]. Remove the dust seal [4] Irom the right wheel hub. NC7OOXA/XD/SA/SD shown: 1 8-7 REAR WHEEL/SUSPENSION Remove the dust seal [1] lrom the driven llange [2]. llyau erI Remove the driven llange assembly. disassemble the rim/en flange, Iausen the driven sprocket nuts [3] in a crisscross pattern In 2 a! 3 steps belore remaw‘ng me When flange from me lei! wheel hub. Remove the damper rubbers [1] and O-ring [2]. Remove the driven sprocket nuts [1] and driven 1 sprocket[2]. [ ] Drive out the rear wheel distance collar B [1]. TOOLS: Driver [2] 07749-0010000 Attachment, 22 x 24 mm [3] 07746-0010300 Pilot, 20 mm [4] 07745-0040500 [31/ [4] 1 8-8 REAR WHEEL/SUSPENSION Drive out the driven flange bearing [1]. Install the bearing remover head [1] into the bearing. From the opposite side, install the bearing remover shaft [2] and drive out the bearing Irom the wheel hub. TOOLS: Bearing remover head, 20 mm 07746-0050600 Bearing remover shaft D7GGD-001D100 Remove the distance collar and drive out the other bearing. ASSEMBLY g DRIVEN FLANGE 42 N-m (4.3 mm, 31 IbI-It) BEARING (22 X 50 X15) DUST SEAL BRAKE DISC PULSER RING _ (NC700XA/XD/SA/SD) . \a /@ D @ a DUST SEAL 105 Mm (11.0 kgi-m, ao IbI-It) ~ DRIVEN SPROCKET DAMPER RUBBER REAR WHEEL w DISTANCE COLLAR B “it 'w‘ n 9), BEARING (6204UU) 9! BEARING (6204UU) DISTANCE COLLAR 1 8-9 REAR WHEEL/SUSPENSION Nevermstallme aid Drive in a new right side bearing [1] squarely until it IS bearing, once the lully seated. . a B bearlng has been V removed the TOOLS: bearing mus! [75 Driver [2] 07749-0010000 replaced with new Attachment, 42 x 47 mm [3] 07746-0010300 ones. Pilot, 20 mm [4] 07746-0040500 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 llange bearing [2]. [3] [4]/[5] TOOLS: Driver [3] 07749-0010000 [1] Attachment, 28 x 30 mm [4] 07946-18701 00 Pilot, 20 mm [5] 07745-0040500 N! Drive in the driven llange bearing/collar [1] squarely with its collar side facing down until it is fully seated. [2] TOOLS: Driver [2] 07749-0010000 Attachment, 42 x 47 mm [3] 07746-0010300 Pilot, 20 mm [4] 07745-0040500 [3144] Install the driven sprocket [1] to the driven flange. NOTE Install the driven sprocket with its marked side facing out. Temporarily install the driven sprocket nuts [2]. 18-10 REAR WHEEL/SUSPENSION Apply grease to a new O-ring [1]. Install the damper rubbers [2] and the O-ring into the left wheel hub. Install the driven Ilange assembly [1] into the left wheel hub. Tighten the driven sprocket nuts [2] to the specified torque in a crisscross pattern in 2 or 3 steps. TORQUE: 108 N-m (11.0 kgf-m, 80 Ibf—ll) Apply grease to a new dust seal lips. Install the dust seal [3] to the driven flange. Install the pulser ring (NC700XA/XD/SA/SD) [1] onto right wheel hub. Install the rear brake disc [2] with its arrow mark [3] lacing out. Install and tighten new brake disc bolts [4] to the specified torque in a crisscross pattern in 2 or 3 steps. TOROUEMZ NM (4.3 kgf—m, 31 lbf—ll) Apply grease to a new dust seal lips. Install the dust seal [5] to the right wheel hub. NOTE Do not get grease on the brake disc. INSTALLATION Install the right side collar [1] and Ielt side collar [2]. 18-11 REAR WHEEL/SUSPENSION I tall the brake caliper/bracket assembly [1] to the ‘ 33mm NOTE Align the bracket groove with swingarm tab. Be care/ulnar [0 Install the rear wheel in the swingarm aligning the brake damage the brake disc between the brake pads. pads‘ Install the drive chain [1] over the driven sprocket. Apply a thin coat ol grease to the rear axle outer surlace. Install the rear axle [2] from the lelt side through the axle adjusting plate [3], swmgarm, rear wheel and collars. Install the adjusting plate. washer [4] and rear axle nut [5]- Tighten the rear axle nut to the specified torque. TORQUESB N-m (10.0 kgl-m, 72 Ibl-ft) Adjust the drive chain slack (page 3-16). N0700XA/XD/SA/ Install the rear wheel speed sensor [1] and bolts [2]. SD: Tighten the bolts securely. Check the air gap between the rear wheel speed sensor and pulser ring (page 20-24). N0700XD/SD: Check the parking brake lock operation (page 3-24). 18-12 REAR WHEEL/SUSPENSION SHOCK LINKAGE REMOVAL/INSTALLATION Support the motorcycle using a satety stand or hoist, raise the rear wheel ott the ground. Remove the tollowing: — 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 ot removal. TORQUE: Shock absorber mounting nut: 44 N-m (4.5 kgf—m, 32 lbt-tt) Shock arm nut: 44 N-m (4.5 kgf—m, 32 lbt-tt) Shock link nut: 44 N-m (4.5 kgf—m, 32 lbt-tt) [1 1/[2] [31/[4] DISASSEMBLY/INSPECTION/ ASSEMBLY Remove the shock link bolt [1], nut [2] and shock links [4] [3] trom the shock arm [4]. V [3] [1]/[2] Remove the collars [1] from the shock arm [2]. [2] Check the collars tor wear, damage or fatigue. Check the shock arm tor cracks or damage. Replace them it necessary. Check the needle bearings [3] tor damage or loose tit. It the needle bearings are damaged, replace them (page 18-14). Assembly l5 in the reverse order ot disassembly. TORQUE: Shock link nut: 44 N-m (4.5 kgf—m, 32 lbt-tt) 18-13 REAR WHEEL/SUSPENSION Never Install the old bearing, once the bearing has been removed the bearing mus! be replaced with new ones. BEARING REPLACEMENT Remove the needle bearings [1] using the special tools. TOOLS: Bearing remover set, 17 mm [2] 0793643710300 Remover handle [3] 0793643710100 Remover weight [4] 07741-0010201 Apply molybdenum disullide grease to new needle bearings rotating area. Install the needle bearings [1] with the marked and dust seal side lacing out until it is flush with the shock arm surlace using a hydraulic press and special tools as shown. SHOCK ABSORBER TOOLS: Driver [2] 07749-0010000 Attachment, 22 x 24 mm [3] 07746-0010800 Pilot, 17 mm [4] 07746-0040400 REMOVAL/INSTALLATION Support the motorcycle using a salety stand or hoist, raise the rear wheel oll the ground. Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the shelter/side cover (NC7OOS/SA/SD) (page 2-15). 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 ol removal. TORQUE: Shock absorber mounting nut: 44 N-m (4.5 kgl-m, 32 lbt-fl) Shock arm nul: 44 N-m (4.5 kgl-m, 32 lbt-fl) [21‘ [1] [31/ [4] [31/ [4] [1]/[fl 18-14 REAR WHEEL/SUSPENSION Never install me old bearing, once the bearing has been removed the bearing mus! be replaced with new ones. INSPECTION Visually inspect the shock absorber lor wear or damage. Check the tolloWing: — Damper rod [1] for bend or damage — Damper unit [2] iordeiormation or oil leaks — Rubber bumper [3] lor wear or damage — Bushing [4] for wear or damage Replace the shock absorber as an assembly it necessary. Remove the collar [1] and dust seals [2]. Check the needle bearings [3] lor damage or loose lit, replace it il necessary (page 18-15). Check the collar for wear or damage, replace it it necessary. Apply molybdenum disuliide grease to the needle bearings rotating area and new dust seal lips. Install the dust seals until it is ilush with the shock absorber surlace. Install the collar. BEARING REPLACEMENT Drive the needle bearing [1] out ol the lower pivot using a hydraulic press and special tool. TOOLS: Driver [2] Attachment, 22 x 24 mm [3] Pilot, 17 mm [4] 07749-0010000 07746-0010300 07746-0040400 Apply molybdenum disullide grease to new needle bearings rotating area. Install the needle bearing [1] into the lower pivot to the specified range using a hydraulic press and special tools as shown. TOOLS: Driver [2] Attachment, 22 x 24 mm [3] Pilot, 17 mm [4] 07749-0010000 07746-0010300 07746-0040400 l4] [4] 5.0 - 5.5 mm (0.20 — 0.22 in) 18-15 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. - Do not use a dull drill bit which could cause a build- up 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 gelling metal shavings in your eyes when the gas pressure is released. The plastic bag is only intended to shield you from [he 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 REMOVAL Remove the following: [Ncmox/XA/S/Sk — Rear wheel (page 18-6) — Muffler (page 2-32) NC700X/XA/S/SA: Remove the gearshift arm pinch bolt [1] and gearshift arm [2]. Remove the step holder mounting socket bolts [1] and left step holder [2]. 18-16 REAR WHEEL/SUSPENSION Remove the socket bolts [1] and drive chain case [2]. NC700X/XA/S/SA: Remove the socket bolts [1] and brake hose guide [2]. Release the brake hose [3] and rear wheel speed sensor wire (NC700XA/SA) [4] lrom the brake hose guide. NC700XD/SD: 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. , Remove the screws [5] and parking brake cable guides [6]. NC700XD/SD: Remove the shock link bolt [1] and nut [2]. Remove the shock absorber lower mounting bolt [3] and nut [4]. [1 1/[2] [Si/[4] 18-17 REAR WHEEL/SUSPENSION Remove the step holder mounting socket bolts [1] and right step holder [2]. NOTE Do not Mist the brake hose. Remove the swmgarm pivot nut [1], washer [2], pivot bolt [3] and swingarm [4]. DISASSEMBLY/INSPECTION Remove the drive chain slider mounting screws [1] and washers [2]. Remove the drive chain slider [3] by releasing the slider slit [4] lrorn the swingarm tab and slider tabs [5] from the swingarm holes. [5] [1 1/[2] , ’ , Remove the pivot collars [1], dust seals [2] and distance collar [3] trom the swingarm pivot. Check the collar lor wear, damage or latigue. Check the needle bearings [4] tor damage or loose lit, replace it il necessan/ (page 18-19). 18-18 REAR WHEEL/SUSPENSION Remove the collar [1] lorm the shock absorber bracket. Check the collar lor wear, damage or latigue. Check the needle bearings [2] lor damage or loose lit, replace it il necessary (page 18-19). Turn the inner race of the right side pivot ball bearings with your linger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the swingarm pivot. Remove and discard the hearing if the race does not turn smoothly and quietly, or if it fits loosely in the swingarm pivot (page 18-19). PIVOT BEARING REPLACEMENT Remove the snap ring [1] lrom the right pivot. Drive the needle bearing [1] and ball bearing [2] out of the right pivot using a hydraulic press and special tool. TOOLS: Driver, 15 x 280L [3] 07949-3710001 Pilot, 28 mm [4] 07746-0041100 18-19 REAR WHEEL/SUSPENSION Drive the needle bearing [1] out ol the left pivot using a hydraulic press and special tool. TOOLS: Driver, 15 x 280L [2] 07949-3710001 Pilot, 32 mm [3] 07MAD-PR90200 Remove the needle bearings [1] out oi the shock absorber bracket using the special tools. TOOLS: Bearing remover set, 17 mm [2] 0793643710300 Remover handle [3] 0793643710100 Remover weight [4] 07741-0010201 Apply molybdenum disultide grease to a new needle bearing rotating area. Install the needle bearing [1] into the left pivot with the marked side lacing up to the specilied range using a 4.5 — 5.0 mm (0.18—0.20 in) hydraulic press and special tools as shown. TOOLS: Driver [2] 07749-0010000 Attachment, 37 mm [3] D7ZMD-MBW0200 Pilot, 28 mm [4] 07746-0041100 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: Driver [2] 07749-0010000 Attachment, 37 mm [3] D7ZMD-MBW0200 Pilot, 20 mm [41 (0745-0040500 18-20 REAR WHEEL/SUSPENSION Apply molybdenum disulfide grease to a new needle bearing rotating area. [2] [317m Install the needle 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: Driver [2] 07749-0010000 Attachment, 37 mm [3] 07ZMD-MBW0200 Pilol, 30 mm [4] 07745-0040700 Apply molybdenum disulfide grease to a new needle bearing rotating area. Install the needle bearings [1] into the shock absorber bracket with the marked side lacing out until it is llush with the bracket surlace using a hydraulic press and special tools as shown. TOOLS: Driver [2] 07749-0010000 Attachment, 22 x 24 mm [3] 07746-0010300 Pilol, 17 mm [4] 07745-0040400 Install the snap ring [1] into the right pivot groove securely. NOTE - Do not reuse the snap ring which could easily spin in the groove. - Make sure that the snap ring is lirmly seated in the groove. 18-21 REAR WHEEL/SUSPENSION ASSEMBLY SNAP RING DUST SEAL xfil ~p PIVOT COLLAR @ fl NEEDLE BEARING g ,6 BEARIN% / DISTANCE COLLAR \fi NEEDLE BEARING fl 3? g xfil NEEDLE BEARING g xfil DUST SEAL PIVOT COLLAR DRIVE CHAIN SLIDER n x WASHE j K NEEDLE BEARING DRIVE CHAIN ADJUSTERS 5.9 N-m (0.6 kgf-m, 4.4 IbI-Il) COLLAR Install the collar [1] to the shock absorber bracket. ‘ SWINGARM Apply molybdenum disulfide grease to new dust seal rips. Install the distance collar [1] and dust seals [2] to the swingarm pivot. [4] NOTE 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 [1] pivot. @ 18-22 REAR WHEEL/SUSPENSION Install the drive chain slider [1]. NOTE - Align the drive chain slider slit [2] from the swingarm tab. - Align the drive chain slider tabs [3] lrom the swingarm holes. [41/ [5] [1 l [3] c I 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 kgl-m, 4.4 lbl-ft) INSTALLATION Apply a thin coat ol 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. TORQUEQB N-m (10.0 kgl-m, 72 Ibl-ft) Install the right step holder [1] and step holder mounting socket bolts [2]. Tighten the step holder mounting socket bolts to the specified torque. TORQUEKSZ N-m (3.3 kgf‘m, 24 let) 1 8-23 REAR WHEEL/SUSPENSION NC700X/XA/S/SA: NC7DUXD/SD: Install the shock arm [1] and shock absorber lower mounting bolt [2] to the shock absorber. Install and tighten the shock absorber lower mounting nut [3] to the specilied torque. TORQUE“ N-m (4.5 kgf‘m, 32 let) Install the shock links [4] and shock link bolt [5] to the swingarm. Install and tighten the shock link nut [6] to the specified torque. TORQUE“ N-m (4.5 kgf‘m, 32 let) Install the rear wheel speed sensor wire (NC700XA/SA) [1] and brake hose [2] to the brake hose guide [3]. Install the brake hose guide and socket bolts [4]. Tighten the socket bolts securely. Install the rear wheel speed sensor Wire [1] and brake hose [2] to the brake hose guide [3]. Install the brake hose guide and socket bolts [4]. Tighten the socket bolts securely. Install the parking brake cable guides [5] and screws [6]- Tighten the screws securely. NC700XD/SD: Install the drive chain case [1] and socket bolts [2]. Tighten the socket bolts securely. 18-24 REAR WHEEL/SUSPENSION Install the left step holder [1] and step holder mounting socket bolts [2]. Tighten the step holder mounting socket bolts to the specified torque. TOROUE:32 N-m (3.3 kgf—m, 24 lbf—ll) NC7OOX/XA/S/SA shown: NC700X/XA/S/SA: Install the gearshift arm [1] to the gearshilt spindle. NOTE Align the gearshift arm slit with the gearshift spindle punch mark. Install and tighten a new gearshilt arm pinch bolt [2] to the specified torque. TORQUE: 12 NM (1.2 kgf—m, 9 Ibf—fl) Install the Iollowmg: — Muffler (page 2-32) — Rear wheel (page 18-11) 1 8-25 MEMO 19. HYDRAULIC BRAKE COMPONENT LocA'n0N ........................ “19.2 SERVICE |NFORMAT|0N ......................... ..19.5 TROUBLESHoonNG ............................... ..19.7 BRAKE FLUID REPLACEMENT/AIR BLEEDmG (Nc7oox/s) ..................... “19.3 BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700XA/XD/SA/SD) -----------19-11 BRAKE FAD/DISC .................................. ..19.15 FRONT MASTER CYLINDER -- 19-20 REAR MASTER CYLINDER ------------------- --19-23 FRONT BRAKE CALIPER (NC700X/s) ............................................. ..19.25 FRONT BRAKE CALIPER (NC700XA/XD/SA/5D) ............................ ..19.23 REAR BRAKE CALIPER -- ---19-30 PARKING BRAKE CALIPER (NC700XD/5D) ........................................ ..19.32 BRAKE PEDAL ....................................... ..19.37 PARKING BRAKE LEVER (NC700XD/5D) ........................................ ..19.33 19-1 HYDRAULIC BRAKE COMPONENT LOCATION NC7OOXA/SA shown: 12 N-m (1.2 Kgl-m, 9 lbf-ft) 34 N-m (3.5 Kgl-m, 25 lbf-ft) 34 N-m (3.5 kgl-m, 25 lbf-ft) 17 N-m (1.7 Kgl-m,13|bf-ft) NC700X/S: 34 N-m (3.5 kgl-m, 25 mm) so N-m (3.1 kgf-m, 22 lbl-II) 1 9-2 HYDRAULIC BRAKE NC7DOX/XA/S/SA: NC7OOXA/SA shown: 34 N-m (3.5 kgf-m, 25 mm) 1o N-m (1.0 kgf-m, 7 lel) 32 N-m (3.3 kgl-m, 24 lbf-ft) 22 N-m (2.2 kgf-m, 16 lel) 1 9-3 HYDRAULIC BRAKE NC700XD/SD: 34 N-m (3.5 kgl-m, 25 lbf-fl) 32 N-m (3.3 Kgl-m, 24 \bf-ft) 31 N-m (3.2 kgf-m, 23 lbl-ft) 1 9-4 HYDRAULIC BRAKE SERWCEINFORMAHON GENERAL ACAUTION Frequent inhalation oi brake pad dust, regardless oi 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. Sp g d will severely damage instrument lenses and painted surface. It is also harmful to some rubber pans. Be careful whenever you remove the reservoir cover; make sure the Iron! 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 alter the air bleeding. Never allow contaminates (dirt, water, etc.) to get into an open reservoir. Once the hydraulic system has been opened, or ii the brake ieels spongy, the system must be bled. Always use lresh DOT 4 brake fluid lrom a sealed container when servicing the system. Do not mix dilterent types at lluid, they may not be compatible. - Always check brake operation beiore riding the motorcycle. - This section covers service oi the conventional brake components ot the brake system. For Anti-lock Brake System (ABS) service (page 20-4). SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specilied brake iluid DOT 4 — Brake disc thickness 4.8 — 5.2 (0.19 — 0.20) 4.0 (0.16) Brake disc warpage 0.30 (0.012) Master cylinder l.D. 11.000 — 11.043 (0.4331 — 0.4348 11.055 (0.4352) Master piston O.D. 10.957 — 10.984 (0.4314 — 0.4324 10.945 (0.4309) Caliper cylinder l.D. (NC700X/S) 27.000 — 27.050 (1.0630 — 1.0650 27.060 (1.0654) Caliper piston O.D. (NC700X/S) 26.918 — 26.968 (1.0598 — 1.0617 26.91 (1.059) Caliper cylinder l.D. Cylinder A 22.712 (0.8941) (NC700XA/XD/SA/SD) Cylinder B 27.000 — 27.050 (1.0630 — 1.0650 27.060 (1.0654) Caliper piston O.D. Piston A 22.585 — 22.618 (0.8892 — 0.8905 22.56 (0.888) (NC700XA/XD/SA/SD) Piston B 26.918 — 26.968 (1.0598 — 1.0617 26.91 (1.059) ) ) 3 22.650 — 22.700 (0.0917 — 0.0937) ) ) ) Rear Specilied brake iluid DOT 4 — Brake disc thickness 4.8 — 5.2 (0.19 — 0.20) 4.0 (0.16) Brake disc warpage 0.30 (0.012) Master cylinder l.D. 14.000 — 14.043 (0.5512 — 0.5529) 14.055 (0.5533) Master piston O.D. 13.957 — 13.984 (0.5495 — 0.5506) 13.945 (0.5490) Caliper cylinder l.D. 38.18— 38.23 (1.503 — 1.505) 30.24 (1.506) Caliper piston O.D. 38.098 — 38.148 (1.4999 — 1.5019) 30.09 (1.500) Brake pedal height 35.0 — 07.0 (3.35 — 3.43) 1 9-5 HYDRAULIC BRAKE TORQUE VALUES . THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgl-m, Ibl-lt) REMARKS Brake caliper bleed valve 2 B 5.4 (0.6, 4.0) (NC700X/S) Brake caliper bleed valve 3 B 5.4 (0.6, 4.0) (NC700XA/XD/SA/SD) Master cylinder reservoir cover 4 4 .5 (0.2, 1.1) screw Rear brake reservoir mounting bolt 1 6 10 (1.0, 7) Brake pad pin 2 10 17 (1.7, 13) Rear brake caliper mounting bolt 1 B 22 (2.2, 16) ALOC bolt; replace with a new one. Front master cylinder holder bolt 2 6 12 (1 .2, 9) Brake hose oil bolt 4 10 34 (3.5, 25) (NC700X/S) Brake hose oil bolt 5 10 34 (3.5, 25) (NC700XA/XD/SA/SD) Front brake light switch screw 1 4 1.2 (0 1, 0.9) Front brake lever pivot bolt 1 6 1.0 (0 1, 0.7) Apply 0.10 g (0.004 02) silicone grease to the sliding surface. From brake lever pivot nut 1 6 5 9 (0.6, 4 4) Rear master cylinder mounting 2 6 12 (1.2, 9) bolt Step holder mounting socket bolt 4 B 32 (3.3, 24) Rear master cylinder hose )oint 1 4 1.5 (0.2, 1.1) Apply locking agent to the threads. screw Rear masteroylinder push rod lock 1 B 17 (1.7, 13) nut Front brake caliper pin 1 B 22 (2.2, 16) Apply locking agent to the threads. Apply 0.4 g (0.01 oz) silicone grease to the sliding surlaoe. Front brake caliper bracket pin 1 8 12 (1 .2, 9) Apply locking agent to the threads. Apply 0.4 g (0.01 oz) silicone grease to the sliding surlaoe. Front brake caliper mounting bolt 2 B 30 (3.1 , 22) ALOC bolt; replace with a new one. Rear brake caliper pin 1 12 27 (2.8, 20) Apply 0.4 g (0.01 oz) silicone grease to the sliding surlaoe. Parking brake caliper mounting 2 B 31 (3.2, 23) ALOC bolt; replace with a new one. bolt (NC700XD/SD) Parking brake caliper pin bolt 1 B 22 (2.2, 16) Apply locking agent to the threads. (NC700XD/SD) Parking brake pad pin 2 B 7 (1.7, 13) ALOC bolt; replace with a new one. (NC700XD/SD) Parking brake ad)uster bolt lock 1 B 7 (1.7, 13) nut (NC700XD/SD) Parking brake cable mounting nut 1 10 10 (1.0, 7) (NC700XD/SD) 1 9-6 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 lluid passage - Warped/detormed 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/detormed brake disc - Caliper not sliding properly - Clogged/restricted hydraulic system - Sticking/worn caliper piston - Clogged master cylinder port - Sticking master cylinder piston HYDRAULIC BRAKE 1 9-7 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700X/S) Front brake: FIeaI brake: NOTE ' Do not allow loreign material to enter the system when filling the reservoir. ' When using a commercially available brake bleeder, follow the manufactures operating instructions. BRAKE FLUID DRAINING Turn the handlebar until the reservoir is parallel to the ground. Remove the reservoir cover screws [1], reservoir cover [2]. set plate [3] and diaphragm [4]. Support the motorcycle in an upright position. Remove the rear brake reservoir mounting bolt [1] and reservoir [2]. Remove the cover screws [3]. reservoir cover [4]. set plate [5] and diaphragm [6]. Temporarily install the reservoir and mounting bolt to the reservoir stay lower hole [7] using a 6 mm nut [8]. NOTE Align the reservoir tab [9] With the reservoir stay out out [1 0]. Connect a bleed hose [1] to the caliper bleed valve [2]. Loosen the bleed valve and pump the brake lever/pedal until no more fluid llows out of the bleed valve. [31,441 [2] [1] [7] [2] [9] [1] Front shown: [1] 1 9-8 HYDRAULIC BRAKE Do rim mix different types of fluid. There are not compatible. Ifai'r enrers me bleeder rmm around me bleed valve threads, seal the threads with when tape. BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir With DOT 4 brake fluid from a sealed container. Connect a automatic refill system to the reservoir. If an automatic refill system is not used, add fluid when the fluid level in the resenloir is low. NOTE ' 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. Connect a commercially available brake bleeder [1] to the bleed valve [2]. Operate the brake bleeder and loosen the bleed valve. 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. After bleeding the system completely, tighten the brake caliper bleed valve to the specified torque. TOROUE:5.4 NM (0.6 kgf-m, 4.0 lbf-ft) If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake Iever/ 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. TOROUE:5.4 NM (0.6 kgf-m, 4.0 lbf-ft) Front shown: Front shown: [1] Front shown: [1] * i2] 1 9-9 HYDRAULIC BRAKE Do rim mix different types of fluid. There are not compatible. Front brake: Flea! brake: Fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge [1]. Install the diaphragm [1], set plate [2], reservoir cover [3] and reservoir cover screws [4], then tighten the screws to the specilied torque. TORQUE:1.5 N-m (0.2 kgi-m, 1.1 lbl-ft) Remove the 6 mm nut [1], rear brake reservoir mounting bolt [2] and reservoir [3]. Install the diaphragm [4], set plate [5] and reservoir oover[6]. Install and tighten the cover screws [7] to the specified torque. TORQUE:1.5 N-m (0.2 kgi-m, 1.1 lbl-ft) Install the reservoir and rear brake reservoir mounting bolt. NOTE Align the reservoir tab [8] with the reservoir stay upper hole [9]. Tighten the bolt to the specilied torque. TORQUE: 1o N-m (1.0 kgf—m, 1mm) Front shown: [1] Front: [4] [3] 19-10 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC700XA/XD/SA/SD) NOTE ' Do not allow loreign material to enter the system when filling the reservoir. ' When using a commercially available brake bleeder, follow the manufactures operating instructions. BRAKE FLUID DRAINING LEVER BRAKE LINE Turn the handlebar until the reservoir is parallel to the ground. [3M4] Remove the reservoir cover screws [1], reservoir cover [2]. set plate [3] and diaphragm [4]. Connect a bleed hose [1] to the lront brake caliper upper bleed valve [2]. Loosen the upper bleed valve and pump the brake lever until no more fluid llows out of the bleed valve. PEDAL (COMBI) BRAKE LINE Support the motorcycle in an upright position. Remove the rear brake reservoir mounting bolt [1] and resen/oir [2]. Remove the cover screws [3]. resenloir cover [4]. set plate [5] and diaphragm [6]. Temporarily install the reservoir and mounting bolt to the resen/oir stay lower hole [7] using a 6 mm nut [8]. NOTE Align the reservoir tab [9] With the reservoir stay out out [10]. 19-11 HYDRAULIC BRAKE Connect a bleed hose [1] to the lront brake caliper center bleed valve [2]. Loosen the center bleed valve and pump the brake pedal until no more fluid llows out of the bleed valve. Tighten the bleed valve. Connect a bleed hose [1] to the rear brake caliper bleed valve [2]. Loosen the bleed valve and pump the brake pedal until no more fluid flows out of the bleed valve. Tighten the bleed valve. BRAKE FLUID FILLING/AIR BLEEDING BRAKE FLUID LINE ABS MODULATOR FRONT MASTER CYLINDER DELAY VALVE FRONT BRAKE CALIPER 19-12 HYDRAULIC BRAKE LEVER BRAKE LINE Close the bleed valves. Fill the reservoir With DOT 4 brake fluid from a sealed container. Connect an automatic refill system to the reservoir. NOTE ' If an automatic refill system is not used, add brake fluid when the fluid level in the reservoir is low. ' Check the fluid level often while bleeding the brakes to prevent air from being pumped into the system. ' When using a brake bleeding tool, follow the manufacturer's operating instructions. ' If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape. Connect a commercially available brake bleeder [1] to the front brake caliper upper bleed valve. Operate the brake bleeder and loosen the bleed valve. Perform the bleeding procedure until the system is completely flushed/bled. Close the bleed valve and operate the brake lever. If it is still spongy, bleed the system again. After bleeding the air completely, tighten the brake caliper bleed valve to the specified torque. TOROUE:5.4 N-m (0.6 kgf-m, 4.0 lbf-ft) If a brake bleeder is not available, use the following procedure: Fill the reservoir With DOT 4 brake fluid from a sealed container. Connect a bleed hose [1] to the front brake caliper upper bleed valve [2]. Pressurize the system with the brake lever until lever resistance is felt. 1. Squeeze the brake lever all the way and loosen the bleed valve 1/4 turn and then close the bleed valve. NOTE ' Do not release the lever until the bleed valve has been closed. 2. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. 3. Repeat steps 1. and 2. until air bubbles do not appear in the bleed hose. After bleeding the air completely, tighten the brake caliper bleed valve to the specified torque. TOROUE:5.4 N-m (0.6 kgf-m, 4.0 lbf-ft) Fill the reservoir With DOT 4 brake fluid from a sealed container to the casting ledge [1]. Install the diaphragm and set plate. Install the reservoir cover and tighten the screws to the specified torque. TOROUE:1.5 N-m (0.2 kgf-m, 1.1 lbf-ft) HYDRAULIC BRAKE PEDAL (COMBI) BRAKE FLUID FILLING Add fluid and bleed any air from the pedal brake line in the sequence as follow: 1. Front brake caliper center bleed valve 2. Rear brake caliper bleed valve Fill the reservoir with DOT 4 brake fluid from a sealed container. Operate the brake pedal several times to bleed any air from the master cylinder. Connect a commercially available brake bleeder [1] to the front brake caliper center bleed valve. NOTE If air is entering the bleeder from around the bleed valve threads, seal the threads with tellon tape. 1. Operate the brake bleeder and loosen the lront brake caliper center bleed valve. Add lluid when the fluid level in the master cylinder is low to prevent drawmg air into the system. 2. Repeat the above procedures until a sufficient amount of fluid flows out of the front brake caliper center bleed valve. It is not problem if the fluid flowing out from the center bleed valve contains air bubbles because the lines Will be bled later (page 19—15). Connect a commercially available brake bleeder [1] to the rear brake caliper bleed valve. Repeat above step 1. and 2. for rear brake caliper bleed valve. Bleed the hydraulic system (page 19-15). II a brake bleeder is not available, use the following procedure: Connect a bleed hose [1] to the front brake caliper center bleed valve [2]. 1. Pump the brake pedal several (5 — 10) times quickly, then push the brake pedal all the way down, loosen the front brake caliper center bleed valve 1/4 of turn. Wait several seconds and close the bleed valve. Release the brake pedal slowly and wait several seconds alter it reaches the end of its travel. 2. Repeat the above procedures until a sufficient amount of the fluid flows out from the front brake caliper center bleed valve. It is not a problem if the fluid flowing out from the front brake caliper center bleed valve contains air bubbles because the lines will be bled later (page 19-15). 19-14 HYDRAULIC BRAKE Connect a bleed hose [1] to the rear brake caliper bleed valve [2]. Repeat above steps 1. and 2. for the rear brake caliper bleed valve. Bleed the rear hydraulic system (page 19-15). PEDAL (COMBI) BRAKE AIR BLEEDING Connect a bleed hose [1] to the lront brake caliper center bleed valve [2]. 1. Pump the brake pedal several (5 — 10) times quickly, then push the brake pedal all the way down, loosen the lront brake caliper center bleed valve 1/4 of turn. Wait several seconds and close the bleed valve. Release the brake pedal slowly and wait several seconds after it reaches the end of its travel. 2. Repeat the above procedures until air bubbles do not appear in the transparent hose. Connect a bleed hose [1] to the rear brake caliper bleed valve [2]. Repeat above steps 1. and 2. for the rear brake caliper bleed valve. Note that you may leeI strong resistance on the rear (combi) brake pedal during pumping when bleeding air lrom the caliper. This symptom is caused by the PCV lunction. Be sure to apply the brake pedal fully. After there are no more air bubbles in the fluid, repeat the air bleeding procedure about 2 or 3 times at each bleed valve. Make sure the bleed valves are closed and operate the brake pedal. If it still feels spongy, bleed the system again. After bleeding the air completely, tighten the brake caliper bleed valve to the specilied torque. TORQUE:5.4 N-m (0.6 kgl-m, 4.0 lbl-l‘t) Fill the reservoir [1] with DOT 4 brake fluid from a sealed container to the "UPPER" level [2]. 19-15 HYDRAULIC BRAKE Remove the 6 mm nut [1], rear brake reservoir mounting bolt [2] and reservoir [3]. Install the diaphragm [4], set plate [5] and reservoir cover [6]. Install and tighten the cover screws [7] to the specified torque. TORQUE:1.5 N-m (0.2 kgf—m, 1.1 lbl-ft) Install the reservoir and rear brake reservoir mounting bolt. NOTE Align the reservoir tab [8] with the reservoir stay upper hole [9]. Tighten the bolt to the specilied torque. TORQUE: 1D N-m (1.0 kgf—m, 7 Ibf-ft) BRAKE PAD/DISC FRONT BRAKE PAD REPLACEMENT (NC700X/S) 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 brake pads [2]. NOTE Do not operate the brake lever after removing the brake pads. lnstall new brake pads to the brake caliper so their ends seat against the retainer. NOTE Make sure that the retainer and pad spring are installed to the brake caliper. Check that the brake pad pin stopper ring [3] is in good condition, replace il necessary. Apply silicone grease to the brake pad pin stopper ring and install it to the brake pad pin 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 brake pad pin to the specilied torque. TORQUE:17 N-m (1.7 kgf—m,13lbf—ll) Operate the brake lever to seat the caliper piston against the pads. [3] [2] [3] [8] [2] 19-16 HYDRAULIC BRAKE FRONT BRAKE PAD REPLACEMENT (NC700XA/XD/SA/SD) 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 nalapelate the Remove the brake pad pin [1] and brake pads [2]. brake level alter Iemai/Irig the brake pads. Install new brake pads [1] to the brake caliper so their ends seat against the retainer. NOTE Make sure that the retainer is installed to the caliper bracket. Check that the brake pad pin stopper ring [2] is in good condition, replace il necessary. Apply silicone grease to the brake pad pin stopper ring 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 NM (1.7 kngm, 13 let) Operate the brake lever to seat the caliper piston against the pads. 19-17 HYDRAULIC BRAKE REAR BRAKE PAD REPLACEMENT NOTE - Always replace the brake pads in pairs to assure even disc pressure. - Check the brake "Uld 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 naruperare the Lift the caliper [1] and remove the brake pads [2]. brake pedal alter removing the brake pads. Install new brake pads to the brake caliper so their ends seat against the retainer. NOTE Make sure that the retainer and pad spring [3] 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. 19-18 HYDRAULIC BRAKE Tighten the rear brake caliper mounting bolt [1] to the specified torque. TORQUE:22 N-m (2.2 kgf‘m, 16 let) Tighten the brake pad pin [2] to the specitied torque. TORQUE:17 N-m (1.7 kgf‘m, 13 let) Operate the brake pedal to seat the caliper pistons against the pads. PARKING BRAKE PAD REPLACEMENT (NC700XD/SD) Loosen the parking brake pad pins [1]. Remove the brake caliper mounting bolt [1] and caliper [2] trorn 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 specilied torque. TORQUE:31 N-m (3.2 kgf‘m, 23 let) Tighten the parking brake pad pins to the specified ' torque. TORQUE:17 N-m (1.7 kgf‘m, 13 let) 19-19 HYDRAULIC BRAKE BRAKE DISC INSPECTION Visually inspect the brake discs for damage or crack. Measure the brake disc thickness using a micrometer. SERVICE LIMITS: Front: 4.0 mm (0.1 Rear: 4.0 mm (0.1 In) Replace the brake disc if the smallest measurement is less than the service limit. Measure the brake discs warpage using a dial indicator. SERVICE LIMITS: Front: 0.30 mm (0.012 in) Rear: 0.30 mm (0.012 in) Check the wheel bearings lor excessive play, if the warpage exceeds the service limit. Replace the brake disc ii the wheel bearings are normal. FRONT MASTER CYLINDER REMOVAL/INSTALLATION Drain the brake lluid from the hydraulic system: — NC700X/S (page 19-8) — NC700XA/XD/SA/SD (page 19-11) 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]. NOTE When removing the oil bolt, cover the end ol the brake hose to prevent contamination. 19-20 HYDRAULIC BRAKE Remove the bolts [1], holder [2] and master cylinder [3]. [3] Installation is in the reverse order ot removal. NOTE ' Install the master cylinder holder with the "UP" mark [4] tacing up. ' Align the end at the master cylinder with the handlebar punch mark. Tightening the tront 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 kgt-m, 9 lbt-l‘t) Brake hose oil bolt: 34 N-m (3.5 kgt-m, 25 lbt-tt) Fill the reservoir to the upper level and bleed the tront brake system: — NC700X/Slpage19-9) — NC700XA/XD/SA/SD (page 19-12) 19-21 HYDRAULIC BRAKE SNAP RING ' MASTER PISTON DISASSEMBLY/ASSEMBLY Disassemble and assemble the iront master cylinder as lollcwing the illustration. NOTE ' Be carelul not to damage the boot. ' When removing and installing the snap ring, use the special tool. TOOL: Snap ring pliers 07914-SA50001 Replace the piston and cups as a set. Apply brake IIUld to the master piston and cups. Apply brake IIUld to the master cylinder inside. Do not allow the piston cup lips to turn inside out. Make sure the snap ring is lirmly seated in the groove. ' Align the brake light switch boss and master cylinder hole. ' Apply 0.10 g (0.004 oz) oi silicone grease to the brake lever sliding surlace and lever—to-master piston contacting area. ' Apply 0.10 g (0.004 oz) oi silicone grease to the brake lever pivot bolt sliding surface. (a 1.0 N-m (0.1 mm, 0.7 lbl-ll) (fii WASHER CUPS BRAKE LEVER 5.9 N-m (0.5 kgf-m, 4.4 lpl-ll) SCREWS RESERVOIR COVER SET PLATE DIAPHRAGM MASTER CYLINDER BRAKE LIGHT SWITCH 1.2 N-m (0.1 kgi-m, 0.9 lbf-ft) 19-22 HYDRAULIC BRAKE INSPECTION Check the master cylinder [1] for scoring, scratches or t 3 damage. I I Check the master piston [2] lor scoring. scratches or damage. Check the piston cups [3] for wear, deterioration or damage. Measure the master cylinder I.D. SERVICE LIMIT: 11.055 mm (0.4352 in) Measure the master piston O.D. SERVICE LIMIT: 10.945 mm (0.4309 in) REAR MASTER CYLINDER REMOVAL/INSTALLATION Drain the brake lluid from the hydraulic system: — NC700X/S (page 19-8) — NC700XA/XD/SA/SD (page 19-11) Remove the muiiler (page 2-32). Remove the brake hose oil bolt [1], sealing washers [2] and brake hose [3]. NOTE When removing the oil bolt, cover the end oi the brake hose to prevent contamination. Remove the step holder mounting socket bolts [1] and right step holder [2]. HYDRAULIC BRAKE Unhook the brake light sWitch spring [1]. Remove the brake light switch [2] from the right step holder [3], then remove the right step holder. Remove and discard the cotter pin [1]. Remove the [oint pin [2] and disconnect the push rod joint from the brake pedal. Remove the master cylinder mounting bolts [3] and ‘ $ master cylinder [4] trom the right step holder. ‘ I. \’ as? w v \ Installation is in the reverse order ot removal. NOTE ' 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 kgt-m, 9 lbt-ft) Step holder mounting socket bolt: 32 N-m (3.3 kgt-m, 24 lbt-t't) Brake hose oil bolt: 34 N-m (3.5 kgt-m, 25 Ibf—ft) Fill the reservoir to the upper level and bleed the rear brake system: — NC700X/S (page 19-9) — NC700XA/XD/SA/SD (page 19-12) 19-24 HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY Disassemble and assemble the rear master cylinder as lollowing the illustration. NOTE ' Be carelul not to damage the boot. ' When removing and installing the snap ring, use the special tool. TOOL: Snap ring pliers 07914-SA50001 ' Replace the piston, spring and cup as a set. ' Apply brake Iluid to the master piston and cups. ' Apply brake tluid to the master cylinder inside. ' Do not allow the piston cup lips to turn inside out. ' Apply silicone grease to the push rod sliding area and boot Iitting area. ' Make sure the snap ring is lirmly seated in the groove. ' Replace the hose joint O-ring with a new one. ' Apply brake tluid to a new hose joint O-ring. ' Apply locking agent to the rear master cylinder hose joint screw threads. MASTER CYLINDER @ . HOSE JOINT 1‘5 Nm (0'2 Wm’ 1'1 "MI v G O-RIN SPRING ' PISTON CUP 6} . MASTER PISTON I {fit PUSH ROD SNAP RING RESERVOIR COVER SET PLATE DIAPHRAGM RESERVOIR BOOT 17 N-m (1.7 kgf-m,13|bl-ll) PUSH ROD JOINT 1.5 N-m (0.2 kgl-m, 1.1 lbl-ll) firm II the push rod joint is disassembled, adjust the push 1 rod length so that the distance from the center oi the I I master cylinder lower mounting hole to the center of the joint pin hole is standard length as shown. STANDARD LENGTH: 85.0— 87.0 mm (3.35 — 3.43 in) After adjustment tighten the push rod lock nut [1] to the specified torque. TORQUE:17 N-m (1.7 kgf—m,13lbf—lt) 35.0 — 37.0 mm (3.35 — 3.43 in) 19-25 HYDRAULIC BRAKE INSPECTION Check the master cylinder [1] tor scoring, scratches or damage. Check the master piston [2] tor scoring, scratches or damage. Check the piston cup [3] tor wear, deterioration or damage. Measure the master cylinder l.D. SERVICE LIMIT: 14.055 mm (0.5533 in) Measure the master piston O.D. SERVICE LIMIT: 13.945 mm (0.5490 in) Check the iollowmg: — Push rod [1] tor bent — Boot [2] tor damage — Rod joint [3] tor damage Replace the damaged part it necessary. FRONT BRAKE CALIPER (NC700X/S) When removing me oil bait, cover the end 0/ brake hose m prevent contamination. REMOVAL/INSTALLATION Drain the brake Iluid Irom the hydraulic system (page 19-8). Remove the brake pads (page 19-16). Remove the brake hose oil bolt [1], sealing washers [2] and brake hose. Remove the brake caliper mounting bolts [3] and brake caliper/bracket assembly [4]. Installation is in the reverse order oi removal. NOTE ' Replace the Iront brake caliper mounting bolts and sealing washers with new ones. ' Install the brake hose eyelet joint between the brake caliper body. ' Route the hoses properly (page 1-25). TORQUE: Front brake caliper mounting bolt: so N-m (3.1 kgI-m, 22 lbf-t't) Brake hose oil bolt: 34 N-m (3.5 kgI-m, 25 lbf-t't) Fill the reservoir to the upper level and bleed the iront brake system (page 19-9). ’9‘ y I M. 1" fl \ ‘\ [3] [2] [1] [4] 19-26 HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY Disassemble the lront brake caliper as tollowing the illustratIon. NOTE ' Be carelul not to damage the piston sliding surface. ' It the caliper pIn boot and bracket pIn boot are hard or deterIorated, replace it with a new one. (a CALIPER FIN BOOT AD RETAINER CALIPER BRACKET CALIFER PISTON ED? (fit DUST SEAL . 402' PISTON SEAL BLEED VALVE ’ 5.4 N-m (0.6 kgl-m, 4.0 lbf-ft) CALIPER BODY (fiSTOFPER RING BRACKET PIN “M 12 N-m (1.2 kgl-m, 9 lbl-ll) BRAKE PAD PIN I7 N-m (1.7 kgl-m,13|bf-ft) \M Q 7 \ " CALIFER PIN “M (fit BRACKET PIN BOOT 22 N-m (22 Kai-m. 16 lb”) BRAKE PADS PAD SPRING Place a shop towel over the pistons. Dr; not use hIgh POSItion the caliper body WIth the pistons down and pressure airorbrmg apply small squirts oi air pressure to the lluid inlet to the nozzle ma close remove the pIstons. '0 me '"let‘ Clean the seal grooves with clean brake lluid. Assembly Is in the reverse order ol disassembly. NOTE ' Apply locking agent to the caliper pin and bracket pin threads. Replace the piston seals and dust seals with new ones. ' Apply brake lluid to the caliper pistons and new piston seals. ' Apply silIcone grease to new dust seals. ' Install the pistons with the opening toward the pads. ' Apply Honda Bond A, Cemedine #540 or equivalent to the brake pad retaIner mating surlace. ' Apply 0.4 g (0.01 02) pl silicone grease to the caliper pin and bracket pIn sliding surlace. 19-27 HYDRAULIC BRAKE INSPECTION Check the caliper cylinder for scoring or other damage. Measure the each caliper cylinder |.D. SERVICE LIMIT: 27.060 mm (1.0654 in) Check the caliper pistons lor scratches, scoring or other damage. Measure the each caliper piston O.D. SERVICE LIMIT: 26.91 mm (1.059 in) FRONT BRAKE CALIPER (NC700XA/ XD/SA/SD) REMOVAL/INSTALLATION Drain the brake lluid lrorn the hydraulic system (page 19-11). Remove the brake pads (page 19-17). Remove the bolt [1] and lront wheel speed sensor wire guide [2]. Remove the bolts [3] and lront wheel speed sensor [4]. Remove the brake hose oil bolts [1]. sealing washers [2] and brake hoses. NOTE When removing the oil bolt, cover the end of brake hose to prevent contamination. 19-28 HYDRAULIC BRAKE Remove the brake caliper mounting bolts [1] and brake caliper/bracket assembly [2]. Installation is in the reverse order ol removal. NOTE ' Replace the lront brake caliper mounting bolts and sealing washers with new ones. - Install the brake hose eyelet stopper against the caliper body. ' Route the hoses and wire properly (page 1-25). TORQUE: Front brake caliper mounting bolt: 30 N-m (3.1 kgf—m, 22 IbI-II) Brake hose oil bolt: 34 N-m (3.5 kgf—m, 25 IbI-II) Fill the reservoir to the upper level and bleed the lront brake system (page 19-12). Check the air gap between the lront wheel speed sensor and pulser ring (page 20-24). DISASSEMBLY/ASSEMBLY Disassemble the lront brake caliper as following the illustration. NOTE ' Be carelul not to damage the piston sliding surface. ' If the caliper pin boot and bracket pin boot are hard or deteriorated, replace it with a new one. CALIPER PIN BOOT g ,fii CAL'PEH PISTONS . DUST SEALS PAD RETAINER BLEED VALVE w, 5.4 N-m (0.6 Kgl-m, 4.0 lbl-ft) v PISTON SEALS ~ CALIPER PIN 22 N-m (2.2 kgf-m,16lbl-lt) BLEED VALVE / / <\ 5.4 N-m (0.6 mm, 4.0 lbl-lt) BRACKET BRACKET PIN W 12 N-m (1.2 kgf-m, 9 lbf-ft) CALIPER BODY (a STOPPER FlING BRACKET PIN BOOT (a BRAKE PAD PIN PAD SPRING 17 Nm (1.7 kgf-m,13|bl-ft) BRAKE PADS 19-29 HYDRAULIC BRAKE Place a shop towel over the pistons. Do not use high Position the caliper body with the pistons facing down pressure airurbrmg and apply small squirts of air pressure to the fluid inlet the nuzz/e ma close to remove the pistons. m "’9 we" Clean the seal grooves with clean brake lluid. Assembly is in the reverse order ol disassembly. NOTE - Apply locking agent to the caliper pin and bracket pin threads. - Replace the piston seals and dust seals With new ones. - Apply brake lluid to the caliper pistons and new piston seals. - Apply silicone grease to new dust seals. - Install the pistons with the opening toward the pads. - Apply Honda Bond A, Cemedine #540 or equivalent to the brake pad retainer mating surlace. - Apply 0.4 g (0.01 oz) ol silicone grease to the caliper pin and bracket pin sliding surIace. INSPECTION Check the caliper cylinders lor scoring or other damage. [4] Measure the each caliper cylinder |.D. SERVICE LIMIT: Cylinder A [1]: 2.712 mm (0.8941 in) Cylinder B [2]: 27.060 mm (1.0654 in) Check the caliper pistons lor scratches, scoring or other damage. Measure the each caliper piston O.D. SERVICE LIMIT: REAR BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake lluid from the hydraulic system: — NC700X/S (page 19-8) — NC700XA/XD/SA/SD (page 19-11) Remove the brake hose oil bolt [1], sealing washers [2] 9' and brake hose. NOTE When removing the oil bolt, cover the end of brake hose to prevent contamination. Remove the brake pads (page 19-18). 19-30 NC 700XA/XD/SA/ SD: HYDRAULIC BRAKE Remove the brake caliper [1] from the caliper bracket. Remove the rear wheel (page 18-6). Remove the caliper bracket Irom the swingarm. Installation is in the reverse order oI removal. NOTE Replace the sealing washers with new ones. Apply 0.4 g (0.01 oz) of SIIICOI'IE grease to the brake caliper pin sliding surlaoe. Install the brake hose eyelet stopper against the caliper body. Route the hoses and wire properly (page 1-25). TORQUE: Brake hose oil bolt: 34 Nm (3.5 kgrm, 25 mm) Fill the resen/olr to the upper level and breed the rear brake system: — NC700X/S (page 19-9) — NC700XA/XD/SA/SD (page 19-12) Check the air gap between the rear wheel speed sensor and pulser ring (page 20-24). DISASSEMBLY/ASSEMBLY Disassemble the rear brake caliper as lollowing the illustration. NOTE - Be carelul not to damage the piston sliding surface. - If the caliper pin boot and sleeve boot are hard or deteriorated, replace it with a new one. NC700XA/XD/SA/SD shown: @ zfil DUST SEAL . CALIPER PISTON d7 PISTON SEAL N! ‘ BLEED VALVE 5.4 N-m (0.6 KgI-m, 4.0 lbf-ft) g/ CALIPER BODY [I , CALIPER PIN 27 N-m (2.5 mm, 20 lbf-ft) Q 17 N-m (1.7 kgl-m,13|bf-ft) BRAKE PADS PAD SPRING A?!” BOOT SLEEVE 19-31 HYDRAULIC BRAKE Place a shop towel over the piston. Do not use high Position the caliper body with the piston facing down pressure airurbrmg and apply small squirts of air pressure to the fluid inlet the nuzz/e ma close to remove the piston. m "’9 we" Clean the seal grooves with clean brake lluid. Assembly is in the reverse order ol disassembly. NOTE - Replace the piston seal and dust seal with new ones. - Apply brake fluid to the caliper piston and new piston seal. ‘ Apply silicone grease to new dust seal. Install the piston with the opening toward the pads. Apply Honda Bond A, Cemedine #540 or equivalent to the brake pad retainer mating surlace. Apply 0.4 g (0.01 oz) ol silicone grease to the boot inside. INSPECTION Check the caliper cylinder for scoring. scratches or damage. Measure the caliper cylinder |.D. SERVICE LIMIT: 33.24 mm (1.506 in) Check the caliper piston for scoring. scratches or damage. Measure the caliper piston O.D. SERVICE LIMIT: 33.09 mm (1.500 in) PARKING BRAKE CALIPER (NC7OOXD/ SD) REMOVAL/INSTALLATION Remove the parking brake pads (page 19-19). Disconnect the parking brake cable [1] lrom the brake arm [2] and remove it from cable stay [3] of the caliper body. Installation is in the reverse order ol removal. Check the parking brake lock operation (page 3-24). 19-32 HYDRAULIC BRAKE DISASSEMBLY Remove the caliper pin bolt [1]. [1] Remove the lollowing: . [2] [1] Callper bracket [1] Pad spring [2] Bracket pin boot [3] Caliper pin boot [4] Sleeve [5] "/75 / [3] [51 [41 Remove the parking brake adjuster bolt lock nut [1] while holding the brake arm [2]. Remove the brake arm. Remove the brake shaft boot [1]. 19-33 HYDRAULIC BRAKE Remove the adjuster bolt/piston [1] while holding the brake Shaft [2]. Remove the brake shaft. NOTE Do not disassemble the adjuster bolUpiston. Remove the dust seal [1]. Clean the caliper cylinder and brake shalt sliding surlace. INSPECTION Check the caliper cylinder [1] and piston [2] for scoring, scratches or damage. [21 [1] [2] 19-34 HYDRAULIC BRAKE ASSEMBLY BRACKET DUST SEAL @ ADJUSTER BOLT/PISTON PAD PIN 17 N-m (1.7 mm, 13 lbl-lt) §p PAD SPRING SLEEVE (a CALIPEFI PIN BOOT CALIPEFI PIN BOOT /// ' CALIPER PIN BOLT 22 N-m (2.2 kgf-m,16|bl-lt) LOCK NUT 17 N-m (1.7 kgf-m, 13 lbl-lt) BRAKE ARM BRAKE PADS CALIPER BODY BRACKET PIN BOOT BRAKE SHAFT BOOT (a BRAKE SHAFT (6 Install a new dust seal [1] into the seal groove In the caliper. Apply 0.4 g (0.01 oz) minimum ol sIlicone grease to the outer surlace oi the brake shaft [1]. (a [1] PosItion the brake shaft so that the punch mark [2] Is [3] 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 lully installed. InstallatIoh 19-35 HYDRAULIC BRAKE Apply 0.4 g (0.01 oz) minimum ol silicone grease to the adjuster bolt threads and piston sliding surface. Install the adjuster bolt/piston [1] while holding the I brake shaft [2]. Apply 0.4 g (0.01 oz) minimum oi silicone grease to the brake shalt boot lips. [1] ’6‘ Install the brake shaft boot [1] to the caliper groove. Install the brake arm [1] by aligning with the punch marks. [1] Install the look nut [1] and tighten it to the specified torque while holding the brake arm [2]. TORQUE217 NM (1.7 kgf‘m,13lbf‘ft) 19-36 HYDRAULIC BRAKE Apply 0.4 g (0.01 oz) minimum ol silicone grease of silicone grease to the bracket pin and sleeve sliding [4] (a [5] surlace. Install the lollowmg: \ — Sleeve [1] ‘_ — Caliper pin boots [2] ‘//'». — Bracket pin boot [3] ’ — Pad spring [4] — Caliper bracket [5] ,6” /" ' [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. TORQUE222 N-m (2.2 kgf‘m, 16 let) BRAKE PEDAL REMOVAL/INSTALLATION Remove the mufller (page 2-32). Remove the step holder mounting socket bolts [1] and right step holder [2]. Unhook the brake light switch spring [1] from the brake pedal. Remove and discard the cotter pin [2]. Remove the joint pin [3] and disconnect the push rod lower joint from the brake pedal [4]. Remove the snap nng [5], washer [6], return spring [7] and brake pedal. HYDRAULIC BRAKE Installation is in the reverse order ol removal. NOTE - Apply grease to the brake pedal pivot sliding area. - Replace the cotter pin with a new one. TORQUE: Step holder mounting socket bolt: 32 N‘m (3.3 kgl-m, 24 let) PARKING BRAKE LEVER (NC700XD/ SD) REMOVAL/INSTALLATION Remove the tollowing: [4] [2] — Left rearview mirror (page 17-12) , — Parking brake switch (page 22-23) 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] trom the cable guide [4]. Turn the parking brake lever bracket [1] and remove the parking brake cable joint [2] lrom the bracket. Disconnect the parking brake cable [3]. 19-38 HYDRAULIC BRAKE Installallon is ln the reverse order ol removal. NOTE - Allgn the parking brake lever bracket locating pm with the handlebar hole. - go)ute the cables and wire harness properly (page 1- 5 . TORQUE: Parking brake adiuster bolt lock nut: 17 Nm (1.7 kgrm, 13 mm) Parking brake cable mounting nut: 10 NM (1.0 kngm, 7 Ibl-ft) Check the parking brake lock operation (page 3—24). DISASSEMBLY Remove the lower holder cap [1]. Remove the spnng pin [1] and release shaft [2]. [2] [1] Remove the E-olip [1], washer [2] and parklng brake 3 lever [3]. [ ] [1] [2] 19-39 HYDRAULIC BRAKE Remove the ratchet B [1]. Remove the ratchet A [1] and springs [2]. ASSEMBLY Apply grease to the ratchet A teeth and sliding surlace. Install the springs [1] and ratchet A [2]. Apply grease to the ratchet B teeth and sliding surlace. Install the ratchet B [1] with its tab [2]1acing up. 1 9-40 HYDRAULIC BRAKE Apply grease to the parking brake lever sliding surlace. Install the parking brake lever [1]. NOTE Align the parking brake lever hole with the ratchet B tab. Apply grease to the washer sliding surface. Install the washer [1] and E-clip [2]. Install the release shaft [1] and new spring pin [2] While aligning the hole of the release shalt, ratchet A and parking brake lever bracket. Install the lower holder cap [1]. 19-41 MEMO 20. ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM LocAT|0N ........................ “20.2 ABS SYSTEM D|AGRAM .......................... “20.3 SERVICE |NFORMAT|0N ......................... “20.4 ABS CONNECTOR LOCATIONS ------------- --20-5 ABS TROUBLESHOOTING |NF0RMAT|0N .......................................... “20.7 ABS INDICATOR PROBLEM CODE INDEX -- ---2o-1o ABS INDICATOR CIRCUIT TROUBLEsHoonNG ............................ .. 20.12 ABS TROUBLESHOOTING -------------------- -- 20-15 WHEEL SPEED SENSOR ...................... “20.24 pcv ......................................................... .. 20.23 DELAY VALVE ........................................ .. 20.23 ABS MODULATOR ................................. .. 20.29 20-1 ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM LOCATION BATTERY FRONT WHEEL SPEED SENSOR DELAY VALVE FUSE BOX ABS MODULATOR REAR WHEEL SPEED SENSOR 20-2 ABS SYSTEM DIAGRAM ANTI-LOCK BRAKE SYSTEM (ABS) FUSE on MAIN CLOCK’WRN mm asm N R N Rw I mamawE a uswswwm . aw aw . \GN‘TION swacH HP '_|_'_' j¢— ‘-——>¢—D ’ : i ON OFF Problem code —>‘ 4— n—y 513“ Signal 0.4 sec. 3.6 sec. 0.5 sec. Wx—V—x Lowest number problem code Highest number problem code (Example: Code 12) (Example: Code 23) When the problem code is not stored: ABS INDICATOR > 2 sec. 3.6 sec. . . ON rrrr ~- 3 ‘ ‘ OFF 4 I—I PROBLEM CODE READOUT NOTE ' The ABS indicator indicates the problem code by blinking a specitied number ol times. ' The problem code is not erased by turning the ignition switch to OFF while the problem code is being output. Note that turning the ignition switch to ON again does not indicate the problem code. To show the problem code again, repeat the problem code retrieval procedures from the beginning. ' Be sure to make a note oi the retrieval problem code(s). ' After diagnostic troubleshooting, erase the problem code(s) and perlorm the pre-start sell—diagnosis to be sure that there is no problem in the ABS indicator (indicator is operating normally). ' Do not apply the lront or rear brake during retrieval. Turn the ignition switch ON and engine stop switch to Start the engine and test ride the motorcycle above 10 km/h (6 mph). II the ABS indicator blinks or stays on, lollow the step 5 described below: 1. Turn the ignition switch OFF. Remove the maintenance lid (page 21-6). Remove the DLC [1] trom the battery box. Short the DLC terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 20-8 ANTI-LOCK BRAKE SYSTEM (ABS) . Turn the ignition switch ON and engine stop switch . The problem code is indicated by the number oi the . Turn the ignition sWitch OFF and remove the special .9 m The ABS indicator [1] should come on 2 seconds (start signal) (then goes off 3.6 seconds) and starts problem code indication. times ol the ABS indicator blinking. It the problem code is not stored, the ABS indicator stays on. tool lrorn the DLC. Install the DLC to the battery box. Install the maintenance lid (page 21-6). ERASING PROBLEM CODE 1. . Turn the ignition switch ON and engine stop switch . Release the brake lever immediately alter the ABS Turn the ignition switch OFF. Remove the maintenance lid (page 21-6). Remove the DLC [1] trom the battery box. Short the DLC terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 to while squeezing the brake lever. The ABS indicator should come on 2 seconds and go olt. indicator is oft. The ABS indicator should come on. . Squeeze the brake lever immediately alter the ABS indicator is on. The ABS indicator should go off. . Release the brake lever immediately alter the ABS indicator is off. When code erasure is complete, the ABS indicator blinks 2 times and stays on. it the ABS indicator does not blink 2 times, the data has not been erased, so try again. it the ABS indicator blinks 2 times and blinks, faulty ABS system, go to ABS troubleshooting (page 20—10) . Turn the ignition switch OFF and remove the special tool lrorn the DLC. install the DLC to the battery box. install the maintenance lid (page 21-6). 20-9 ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR PROBLEM CODE INDEX NOTE ~ The ABS indicator might blink in the lollowing cases. Correct the iaulty part. — lncorrect tire pressure. — Tires not recommended for the motorcycle were installed (incorrect tire size). — Deformation ol the wheel or tire. ~ The ABS indicator might blink while riding under the iollowing conditions. This is temporary iailure. Be sure to erase the problem code (page 20-9). Then, test ride the motorcycle above 10 km/h (6 mph) and check the problem code by retrieving the sell-diagnosis system (page 20-8). Ask the rider for the riding conditions in detail when the motorcycle is brought in lor inspection. — The motorcycle has continuously run bumpy roads. — The lront wheel leaves the ground tor a long time when riding (wheelie). — Only either the iront or rear wheel rotates. — The ABS operates continuously. — The ABS control unit has been disrupted by an extremely powerlul radio wave (electromagnetic interlerence). Piazzm Function failure 26mm”; Symptom/Fail-safe lunction Rae, - ABS modulator voltage input line - ABS indicator never come 2042 - Indicator related Wires ON at all — - Speedometer . ABS indicator stays ON at all - ABS modulator 20-13 ‘ ABS iuse 7.5 A (ABS MAIN) fl Front wheel speed sensor circuit mallunction O O - Stops ABS operation 204 5 - Wheel speed sensor or related wires 13 Rear wheel speed sensor mallunction O O 204 7 - Wheel speed sensor or related Wires Front wheel speed sensor circuit mallunction - Stops ABS operation 12 - Wheel speed sensor or related wires 0 20-15 - Electromagnetic interlerence Rear wheel speed sensor mallunction 14 - xi/ilrweesel speed sensor, pulserring or related 0 204 7 - Electromagnetic interference Front pulser ring - Stops ABS operation 21 - Pulser ring or related wires 0 2015 Rear pulser ring 23 - Pulser ring or related wires 0 20-17 31 Solenoid valve maliunction (ABS modulator) - Stops ABS operation 32 33 34 O 0 20-19 37 38 M Front wheel lock 0 - Stops ABS operation - Riding condition 204 5 42 Front wheel lock (Wheelie) - Riding condition Rear wheel lock 43 - Riding condition 0 20-17 Motor lock - Stops ABS operation 51 - 5:35p motor (ABS modulator) or related 0 O . ABS iuse 30 A (ABS M.) Motor stuck oil 52 - 5:35p motor (ABS modulator) or related 0 O 2020 ‘ ABS iuse 30 A (ABS M.) Motor stuck on - Pump motor (ABS modulator) or related 0 0 wires ‘ ABS iuse 30 A (ABS M.) Fail-saie relay maliunction - Stops ABS operation 54 - Sale-sale relay (ABS modulator) or related 0 O 202‘ ‘ ABS iuse 30 A (ABS SOL.) 53 20-10 ANTI-LOCK BRAKE SYSTEM (ABS) ngll‘eem Function failure gamma; Symptom/FaiI-safe lunction Riser Power circuit/Under voIIage - Stops ABS operation 61 - Input voltage (too low) 0 O - ABS iuse 7.5 A (ABS MAIN) 20-22 62 Power circuit/Over voltage 0 O - Stops ABS operation - Input voltage (too high) Tire maItunction - Stops ABS operation 71 - Tire size 0 2024 ABS control unit - Stops ABS operation 81 - ABS control LIHII malIuncIion (ABS 0 0 20-24 moduIator) (A) Pre-sIart seII-diagnosis (page 20-7) (B) Ordinary seII-diagnosis: diagnoses whiIe the motorcycIe is running (atter ore-start seII-diagnosis) 20-11 ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) 1. Combination Meter Power/ground Line Inspection Check the combination meter power and ground lines (page 22-10). Are the wires normal? YES — GO TO STEP 2. N0 — Open circuit in related Wires 2. Indicator Operation Inspection Pull up the lock lever [1] and disconnect the ABS modulator 25F connector [2]. Turn the ignition switch ON and engine stop switch to Check the ABS indicator. Does the ABS indicator came on? YES — Faulty ABS modulator N0 — GO TO STEP 3. 3. Indicator Signal Line Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the ABS modulator 25F connector [1] oi the wire harness side and ground. {.1 J i j Connection: Orange/black—Ground y/ i i 4 A i i 7 O/Bl TOOL: Test probe 07ZAJ-RDJA110 Q Is there continuity? YES — Short circuit in Orange/black Wire N0 — Faulty combination meter 20-12 ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR STAYS 0N (Indicator does not go off when the motorcycle is running, Problem code is not indicated by the retrieval procedure) 1. Service Check Line Short Circuit Inspection Disconnect the ABS modulator 25F connector [1]. Check Ior continuity between the ABS modulator 25F connector oi the wire harness side and ground. Connection: Brown — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES NO — Short circuit in Brown wire — GO TO STEP 2. 2. Indicator Operation Inspection Wlih the connector connected, short the comblnation meter 1GP (Gray) connector [1] oi the wire harness side and ground with a jumper wire [2]. Connection: Orange/black — Ground Turn the ignitlon switch ON and engine stop switch to (j . Check the ABS indicator. Does it go off? YES — GO TO STEP 3. N0 — Faulty comblnation meter 3. Indicator Signal Line Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wtre Irom the combination meter 16F (Gray) connector. Short the ABS modulator 25F connector [1] oI the wire harness side and ground with a jumper wire [2]. Connection: Orange/black — Ground TOOL: Test probe 07ZAJ-RDJA110 Turn the ignitlon switch ON and engine stop switch to Check the ABS indicator. Does it go off? YES — GO TO STEP 4. N0 — Open circuit in Orange/black wire [1] O/Bl [2] O/Bl [1] [2] 20-13 ANTI-LOCK BRAKE SYSTEM (ABS) 4. Logic Ground Line Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wire irorn the ABS modulator 25F connector [1 ]. ‘ l t i 7 Check tor contlnulty between the ABS modulator l l ‘ 1‘ Y ] 25F connector oi the wire harness side and ground. ,./ l 1 l 1 l 3 7 Connection: Green/yellow— Ground G/Y TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? f YES — GO TO STEP 5. N0 — Open circuit in Green/yellow wire [1] 5. Fuse Inspection Check the ABS iuse 7.5 A (ABS MAIN) [1] tn the iuse box tor blown. Is the fuse blown? YES — GO TO STEP 6. N0 — GO TO STEP 7. 6. Power Input Line Short Circuit Inspection Wlth the ABS iuse 7.5 A (ABS MAIN) removed, check tor continuity between the ABS modulator 25F connector [1] oi the wire harness side and ground. \4 t 1 t l . Connection: Fted/black— Ground 7/4) t ) L V A TOOL: WEI Test probe 07ZAJ-RDJA110 A Is there continuity? £2] YES — Short circuit in Red/black wire. Replace the ABS iuse 7.5 A (ABS MAlN) with a i new one, and recheck. N0 — Intermittent iailure. Replace the ABS iuse 7.5 A (ABS MAIN) with a new one, and recheck. 20-14 ANTI-LOCK BRAKE SYSTEM (ABS) 7. Power Input Line Open Circuit Inspection T rn the ignition switch ON and engine stop switch Measure the voltage between the ABS modulator 25F connector [1] ol wire harness side and ground. Connection: Red/black (+) — Ground (—) Standard: Batteryvoltage TOOL: Test probe 07ZAJ-RDJA110 Does the standard Voltage exist? YES — Faulty ABS modulator. N0 — Open circuit in Red/black Wire between the ABS modulator 25F connector and ignition SWitch ABS TROUBLESHOOTING NOTE Periorm inspection With the ignition SWitch OFF, unless otherwise specified. Reter to the ABS connector locations (page 20-5). All connector diagrams in the troubleshooting are viewed lrom the terminal side. Use a lully charged battery. Do not diagnose with a charger connected to the battery. When the ABS modulator assembly is detected to be iaulty, recheck the wire harness and connector connections closely belore replacing it. Alter diagnostic troubleshooting, erase the problem code (page 20-9) then test ride the motorcycle above 30 km/h (18 mph) and check the other problem code by retrieving the sell-diagnosis system (page 20-8). Betore starting the diagnosis and troubleshooting. check the ABS indicator circuit (page 20-12). PROBLEM CODE 11, 12, 21, 41 or 42 (Front Wheel Speed Sensor/Front Pulser Ring/Front Wheel Lock) NOTE The ABS indicator might blink under unusual riding or conditions (page 20-10). This is temporary lailure. Erase the problem code (page 20-9) then test ride the motorcycle above 30 km/h (18 mph) and check the problem code by retrieving the sell-diagnosis system (page 20-8). It the problem code 41 is indicated, check the lront brake tor drag. . Speed Sensor Air Gap Inspection Measure the air gap between the speed sensor and pulser ring (page 20-24). Is the air gap correct? YES —GOTOSTEP2. N0 —Check each part lor delormation and looseness and correct accordingly. Recheck the air gap. [1] #5 mi 20-15 ANTI-LOCK BRAKE SYSTEM (ABS) 2. Speed Sensor Condition Inspection Inspect the area around the speed sensor: Check that there is iron or other magnetic deposlts between the pulser ring [1] and wheel speed sensor [2], and the pulser ring slots for obstructlons. Check the installation condition ot the pulser rlng or wheel speed sensor tor looseness. Check the pulser rlng and sensor tlp tor deformation or damage (e.g., chipped pulser ring teeth). Are the sensor and pulser ring in good condition? YES — GO TO STEP 3. N0 — Remove any deposits. Install properly or [1] replace laulty part. 3. Front Wheel Speed Sensor Line Short Circuit Inspection (at sensor side) Turn the ignition switch OFF. Disconnect the tront wheel speed sensor 2P (Blue) connector [1]. Check for continuity between each terminal of the sensor side lront wheel speed sensor 2P (Blue) connector and ground. Connection: Blue— Ground White — Ground Is there continuity? YES — Faulty front wheel speed sensor N0 - GO TO STEP 4. 4. Front Wheel Speed Sensor Line Short Circuit Inspection (at wire harness side) Disconnect the ABS modulator 25F connector. Check for continuity between each terminal of the wire harness slde front wheel speed sensor 2P (Blue) connector [1] and ground. Connection: Blue/yellow — Ground White/yellow — Ground Is there continuity? YES — ~ Short clrcuitin Blue/yellow wne ' Short clrcuit in White/yellow wire N0 — GO TO STEP 5. 20-16 5. Speed Sensor Line Open Circuit Inspection Short the ABS modulator 25F connector [1] terminals 0? the wire harness side with ajumper wire [2]- Conneciion: Blue/yellow — White/yellow TOOL: Test probe 07ZAJ-RDJA110 Check for continuity between the terminals oi the wire harness slde tront wheel speed sensor 2P (Blue) connector [3]. Connection: Blue/yellow — White/yellow Is there continuity? YES — GO TO STEP 6. N0 — Open clrcult in Blue/yellow or White/yellow wire 6. Failure Reproduction with a New Speed Sensor Replace the lront wheel speed sensor Wllh a new one (page 20-25). Connect the ABS modulator 25F and tront wheel speed sensor 2P (Blue) connectors. Erase the problem code (page 20-9). Test rlde the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20-8) and recheck the ABS indicator [1]. Dose the ABS indicator indicate the code "11, 12, 21, 41 or 42"? YES — Faulty ABS modulator. N0 — Faulty removed wheel speed sensor PROBLEM CODE 13, 14, 23 or 43 (Rear Wheel Speed Sensor/Rear Pulser Ring/ Rear Wheel Lock) NOTE ' The ABS indicator mlght blink under unusual riding or conditions (page 20-10). This is temporary lailure. Erase the problem code (page 20-9) then test ride the motorcycle above 30 km/h (18 mph) and check the problem code by retrlevlng the sell-diagnosis system (page 20-8). ' It the problem code 43 is indicated, check the rear brake tor drag. 1. Speed Sensor Air Gap Inspection Measure the air gap between the speed sensor and pulser ring (page 20-24). Is the air gap correct? YES —GOTOSTEP2. N0 —Check each part lor delormatlon and looseness and correct accordingly. Recheck the air gap. ANTI-LOCK BRAKE SYSTEM (ABS) [2] mm [1] [3] Bu/Y 20-17 ANTI-LOCK BRAKE SYSTEM (ABS) 2. Speed Sensor Condition Inspection Inspect the area around the 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 ior obstructions. Check installation condition of the pulser ring or wheel speed sensor ior looseness. Check the pulser ring and sensor tip tor deiormation or damage (e.g., chipped pulser ring teeth). Are the sensor and pulser ring in good condition? YES — GO TO STEP 3. N0 — Remove any deposits. Install properly or replace iaulty 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 [1]. Check ior continuity between each terminal of the sensor side rear wheel speed sensor 2P (Gray) connector and ground. Connection: Blue — Ground White — Ground Is there continuity? YES — Faulty rear wheel speed sensor N0 — GO TO STEP 4. 4. Rear Wheel Speed Sensor Line Short Circuit Inspection (at wire harness side) Disconnect the ABS modulator 25F connector. Check ior continuity between each terminal of the wire harness side rear wheel speed sensor 2P (Gray) connector [1] and ground. Connection: Blue— Ground White — Ground Is there continuity? YES — ~ Short circuitin Blue wire ~ Short circuit in White wire N0 — GO TO STEP 5. 20-18 5. Speed Sensor Line Open Circuit Inspection Short the ABS modulator 25F connector [1] terminals oi the wire harness side with ajumper wire [2]- Connection: Blue — While TOOL: Test probe 07ZAJ-RDJA110 Check tor continuity between the terminals oi the wire harness side rear wheel speed sensor 2P (Gray) connector [3]. Connection: Blue — White Is there continuity? YES — GO TO STEP 6. N0 — Open circuit in Blue or White Wire 6. Failure Reproduction with a New Speed Sensor Replace the rear wheel speed sensor With a new one (page 20-26). Connect the ABS modulator 25F and rear wheel speed sensor 2P (Gray) connectors. Erase the problem code (page 20-9). Test ride the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20-8) and recheck the ABS indicator [1]. Dose the ABS indicator indicate the code "13, 14, 23 or 43"? YES — Faulty ABS modulator N0 — Faulty removed wheel speed sensor PROBLEM CODE 31,32, 33, 34, 37 or 38 (Solenoid Valve) 1. Failure Reproduction Erase the problem code (page 20-9). Test ride the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20-8) and recheck the ABS indicator [1]. Does the ABS indicator indicate the code "31, 32, 33, 34, 37 a! 38"? YES — Faulty ABS modulator N0 —Solenoid valve iailure). is normal (intermittent ANTI-LOCK BRAKE SYSTEM (ABS) [2] Eu [1] m i i i / . ‘E [3] 20-19 ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 51, 52 or 53 (Pump Motor) 1. Fuse Inspection Check the ABS iuse 30 A (ABS M.) [1] in the iuse . box or blown. Is the fuse blown? YES — GO TO STEP 2. N0 — GO TO STEP 3. 2. Motor Power Input Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 25F connector [1]. Check lor continulty between the ABS modulator » . 25F connector oi the wire harness side and ground. l l Connection: Violet/white —Ground ,/ l l TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Short circuit in Violet/whlte wire N0 — lntermittent iailure. Replace the ABS iuse 30 A (ABS M.) with a new one, and [1] recheck. 3. Motor Power Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 25F connector [1]. Measure the voltage between the ABS modulator \N l ‘ 25F connector oi the wire harness side and ground. l l Connection: Violet/white (+)— Ground (—) ’ ‘ Standard: Baiteryvollage TOOL: Test probe 07ZAJ-RDJA110 Does the standard Voltage exist? 9 YES — GO TO STEP 4. f N0 — Open clrcult ln Violet/white or Black ere between the battery and ABS modulator 25F connector 20-20 ANTI-LOCK BRAKE SYSTEM (ABS) 4. Failure Reproduction Connect the ABS modulator 25P connector. Erase the probiem code (page 20—9). Test ride the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20—8) and recheck the ABS indicator [1]. Does the ABS indicator indicate the code "51, 52 or 53"? YES — Faulty ABS moduiator N0 — Pump motor is normal (intermittent lailure). PROBLEM CODE 54 (Fail-sate Relay) 1. Fuse Inspection Check the ABS luse 30 A (ABS SOL.) [1] in the luse box tor blown. Is the fuse blown? YES — GO TO STEP 2. N0 — GO TO STEP 3. 2. Relay Power Input Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS moduiator 25F connector [1]. Check lor continuity between the ABS modulator 25P connector oi the wire harness side and ground. Connection: Black/white — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Short circuit in Black/white wire N0 — Intermittent lailure. Replace the ABS luse 30 A (ABS SOL.) with a new one, and recheck. [1] 20-21 ANTI-LOCK BRAKE SYSTEM (ABS) 3. Relay Power Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 25F connector [1]. Measure the voltage between the ABS modulator ‘ N i 1 ‘ 25F connector oi the wire harness side and ground. 1 1 1 Connection: Black/white (+)—Ground (—) / - Standard. Battery voltage GB TOOL: Test probe 07ZAJ-RDJA110 Does the standard Voltage exist? 9 YES — GO TO STEP 4. f N0 — Open cwrcuit in Black/white or Black wwre [1] between the battery and ABS modulator 25F connector 4. Failure Reproduction Connect the ABS modulator 25F connector. Erase the probiem code (page 20—9). Test nde the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20—8) and recheck the ABS indicator [1]. Does the ABS indicator indicate the code "54"? YES — Faulty ABS moduiator N0 —Fa1|—sale relay is normai (intermittent laiiure) PROBLEM CODE 61 or 62 (Power Circuit) 1. Fuse Inspection Check the ABS luse 7.5 A (ABS MAIN) [1] 1n the luse box lor blown. Is the fuse blown? YES — GO TO STEP 2. N0 — GO TO STEP 3. 20-22 2. Power Input Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 25F connector [1]. Wlih the ABS iuse 7.5 A (ABS MAIN) removed, check Ior continuity between the ABS modulator 25F connector oi the wire harness side and ground. Connection: Red/black — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES NO — Short circuit ln Red/black wtre — Intermittent Iailure. Replace the ABS tuse 7.5 A (ABS MAIN) with a new one, and recheck. 3. Power Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 25F connector [1]. Turn the ignitlon switch ON and engine stop switch Measure the voltage between the ABS modulator 25F connector oi the wire harness side and ground. Connection: Red/black (+) — Ground (—) Standard: Batteryvoltage TOOL: Test probe 07ZAJ-RDJA110 Does the standard Voltage exist? YES — GO TO STEP 4. N0 — Open circuit ln Red/black wire between the ABS modulator 25F connector and lgnltion SWliCh 4. Failure Reproduction Turn the ignition switch OFF. Connect the ABS modulator 25F connector. Erase the problem code (page 20-9). Test nde the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20-8) and recheck the ABS indicator [1]. Does the ABS indicator indicate the code "61 or 62"? YES NO — Faulty ABS modulator — Power circuit )5 normal (lntermlttentiailure) ANTI-LOCK BRAKE SYSTEM (ABS) [1] ., +5 R/Bl [1] ./ [1] 20-23 ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 71 (Tire Size) NOTE - Check the IoIIowing and correct the Iaulty part. — Incorrect tire pressure. — Tires not recommended for the motorcycle were installed (incorrect tire size). — Delormation ol the wheel or tire. 1. Failure Reproduction If the above items are normal, recheck the problem code indication: Erase the problem code (page 20—9). Test ride the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20—8) and recheck the ABS indicator [1]. Does the ABS indicator indicate the code "71"? YES — Faulty ABS modulator N0 — Tire size is normal (intermittent failure) PROBLEM CODE 81 (ABS Control Unit) 1. Failure Reproduction Erase the problem code (page 20—9). Test ride the motorcycle above 30 km/h (18 mph). Retrieve the problem code (page 20—8) and recheck the ABS indicator [1]. Does the ABS indicator indicate the code "81"? YES — Faulty ABS modulator N0 —ABS control unit is normal (intermittent Iailure) 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. II it IS not within specilication, check each part lor delormation, looseness or damage. Check the wheel speed sensor for damage, and replace it necessary. Check the pulse ring for delormation or damage, and replace it necessary. — Front pulser ring (page 17-22) — Rear pulser ring (page 18-7) 20-24 ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR REPLACEMENT NOTE Reier to procedure ior the pulser ring removal/ installation. — From pulser ring (page 17-22) — Rear pulser ring (page 18-7) FRONT WHEEL SPEED SENSOR REMOVAL! INSTALLATION Remove the bolts [1] and radiator lower stay [2]. Release the radiator boss irom the radiator mounting rubber [3]. Release the lan motor 3P (Gray) connector [1], air cleaner housing drain hose [2] and spark plug Wire [3] irom the radiator. NC7DoXA/XD: Remove the shroud/side cover (page 2-14). Remove the lront wheel speed sensor 2P (Blue) connector [1] lrom the lrame and disconnect the connector. 20-25 ANTI-LOCK BRAKE SYSTEM (ABS) NC7DoSA/SD: Remove the side cowl (page 2-13). Remove the front wheel speed sensor 2P (Blue) connector [1] from the side cover and disconnect the connector. l \ Release the sensor wire lrom the guide [2]. Release the sensor wire [1] lrom the clamps [2]. Remove the bolt [3] and speed sensor 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] lrom the clamp [2]. Remove the bolt [3] and lront wheel speed sensor wire guide [4]. Remove the bolts [5] and lront wheel speed sensor [6]. Clean around the mounting area of the caliper bracket thoroughly, and be sure that no loreign material is allowed to enter the mounting hole. Installation is in the reverse order ol removal. NOTE - Route the wire and hoses properly (page 1-25). - Make sure the radiator mounting rubber slits facing down. - Align radiator lower stay slit with cylinder head tab. REAR WHEEL SPEED SENSOR REMOVAU INSTALLATION Remove the lollowing: — Shroud/side cover (NC7ODXA/XD) (page 2-14) — Shelter/side cover (NC7ODSA/SD) (page 2-15) — Muffler (page 2-32) Remove the step holder mounting socket bolts [1] and right step holder [2]. 20-26 ANTI-LOCK BRAKE SYSTEM (ABS) Disconnect the rear wheel speed sensor 2P (Gray) connector [1]. Release the rear wheel speed sensor 2P (Gray) connector lrom the ECM box [2]. Release the clamp [3]. 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. speed sensor Wire [2]. Remove the bolts [3] and rear wheel speed sensor [4]. Clean around the mounting area ol the caliper bracket thoroughly, and be sure that no loreign material is allowed to enter the mounting hole. Installation is in the reverse order ot removal. NOTE Route the wire and hoses properly (page 1-25). TORQUE: Step holder mounting socket bolt: 32 Nm (3.3 kgrm, 24 mm) 20-27 ANTI-LOCK BRAKE SYSTEM (ABS) PCV REMOVAL/INSTALLATION Drain the brake fluid trom the lever/pedal brake line hydraulic systems (page 19-11). Remove the luggage box (page 2-19). Loosen the brake pipe joint nuts [1] and disconnect the brake pipe from the PCV [2]. Remove the PCV mounting bolt (long) [3], PCV mounting bolt (short) [4] and PCV. NOTE Be careful not to bent or damage the brake pipes. Installation is in the reverse order at removal. TORQUE: PCV mounting bolt: 12 Nm (1.2 kgt-m, 9 lbl-ft) Brake pipe ioint nut: 14 Nm (1.4 kgl-m,10lbtAft) NOTE Apply brake lluid to the joint nut threads and sliding surlace. DELAY VALVE REMOVAL/INSTALLATION Drain the brake tluid from the lever/pedal brake line hydraulic systems (page 19-11). Remove the luggage box (page 2-19). Loosen the brake pipe joint nut [1], and disconnect the brake pipe from the delay valve [2]. Remove the delay valve mounting bolts [3] and delay valve. NOTE Be careful not to bent or damage the brake pipes. Installation is in the reverse order at removal. TORQUE: Delay valve mounting bolt: 12 Nm (1.2 kgt-m, 9 lbl-ft) Brake pipe ioint nut: 14 Nm (1.4 kgl-m,10lbtAft) NOTE Apply brake lluid to the joint nut threads and sliding surlace. 20-28 ANTI-LOCK BRAKE SYSTEM (ABS) ABS MODULATOR EEVOVAL/INSTALLATION (NC700XA/ NOTE Be carelul not to bend or damage the brake pipes during assembly or removal. Remove the lollowing: — Delay valve (page 20-28) — PCV (page 20-28) Pull up the lock lever [1] and disconnect the ABS modulator 25F connector [2]. Release the main wire harness clamp(s) [3] lrom the ABS modulator stay. Loosen the brake pipe joint nuts [1] and disconnect the brake pipes lrom the ABS modulator. Remove the ABS modulator stay mounting bolts [1], collars [2] and ABS modulator assembly [3]. NOTE Be careful not to bent or damage the brake pipes. 20-29 ANTI-LOCK BRAKE SYSTEM (ABS) Remove the ABS modulator mountIng bolts [1] and ABS modulator [2] lrom the ABS modulator stay [3]. [1] Installation is in the reverse order ol removal. NOTE ' Apply brake lluid to the joint nut threads and sIIding surface. ' Route the wire harness properly (page 1-25). TORQUE: PCV mounting bolt: 12 N-m (1.2 kgl-m, 9 lbl-ft) Delay valve mounting bolt: 12 N-m (1.2 kgl-m, 9 lbl-ft) Brake pipe ioint nul: 14 N-m (1.4 kgl-m,10lbf—fl) BRAKE PIPE JOINT NUT PCV MOUNTING BOLT (LONG) 14 N-m (1.4 kgf-m,10|bf-ft) 12 N-m 1.2 mm, 9 lbl-lt) ( PCV MOUNTING BOLT (SHORT) ABS MODULATOR STAY 12 N," (12 mm 9 1b....) MOUNTING BOLTS/COLLARS Q. a' ABS MODULATOR 25F CONNECTOR DELAY VALVE MOUNTING BOLTS 12 N-m (1.2 kgf-m, 9 lbl-lt) DELAY VALVE ABS MODULATOR/STAY 20-30 ANTI-LOCK BRAKE SYSTEM (ABS) REMOVAL/INSTALLATION (NC700XD/ SD) NOTE Be carelul not to bend or damage the brake pipes during assembly or removal. Remove the lollowing: — Delay valve (page 20-28) — PCV (page 20-28) Remove the linear solenoid valve 4P (Green) connector [1] and shift spindle angle sensor 3P (Gray) connector [2] lrom the ABS modulator stay. Pull up the lock lever [1] and disconnect the ABS modulator 25F connector [2]. Release the main wire harness clamps [3] from the ABS modulator stay. Loosen the brake pipe joint nuts [1] and disconnect the brake pipes lrom the ABS modulator. Remove the center cross plate (page 2—32). Remove the TR sensor 3P (Black) connector [1] and Junction D 24F connector [2] from the ABS modulator stay. Remove the ABS modulator assembly [3]. NOTE Be careful not to bent or damage the brake pipes. ANTI-LOCK BRAKE SYSTEM (ABS) Remove the ABS modulator mounting bolts [1] and 3 ABS modulator [2] trOrn the ABS modulator stay [3]. l 1 Installation is in the reverse Order at removal. NOTE - Apply brake lluid to the joint nut threads and sliding surface. - Route the wire harness properly (page 1-25). TORQUE: PCV mounting bolt: 12 N-m (1.2 kgt-m, 9 lbt-ft) Delay valve mounting bolt: 12 N-m (1.2 kgt-m, 9 lbt-ft) Brake pipe ioint nut: 14 N-m (1.4 kgt-m,10lbt-ft) JUNCTION D TR SENSOR 24F CONNECTOR 3P (BLACK) CONNECTOR PCV MOUNTING BOLT (LONG) 12 N-m (1.2 mm, 9 let) ABS MODULATOR STAY MOUNTING BOLTS/(DOLLARS PCV PCV MOUNTING BOLT (SHORT) 12 N-m (1.2 mm, 9 let) BRAKE PIPE JOINT NUT 14 N-m (1.4 kgI-m,10|bf-ft) DELAY VALVE MOUNTING BOLTs 12 N-m (1.2 mm, 9 let) DELAY VALVE ABS MODULATOR/STAY LINEAR SOLENOID VALVE 4P (GREEN) CONNECTOR ABS MODULATOR SHIFT SPINDLE ANGLE SENSOR 25P CONNECTOR 3P (GRAV) CONNECTOR 20-32 21. BATTERY/CHARGING SYSTEM SYSTEM LOCATION---- BATTERy...... SYSTEM DIAGRAM CHARGING SYSTEM INSPECTION -------- --21-7 SERV|CE INFORMATION REGULATOR/RECTIHER TROUBLESHoonNG.................................21.5 ALTERNATOR CHARG|NG co||_ ............ “21.9 21-1 BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY REGULATOR/RECTIFIER MAIN FUSE 30 A ALTERNATOR SYSTEM DIAGRAM MAIN FUSE 30 A REGULATOR/RECTIFIER ALTERNATOR G: Green R: Red V: Yellaw BATTE RY 21-2 BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL AWARNING - The battery gives oii explosive gases; keep sparks, llames and cigarettes away. Provide adequate ventilation when charging. - The battery contains suliunc acid (electrolyte). Contact With skin or eyes may cause severe burns. Wear protective clothing and a lace shield. — II electrolyte gets on your skin, ilush with water. — II electrolyte gets in your eyes, ilush with water lor at least 15 minutes and call a physician immediately. - Electrolyte is poisonous. — Il swallowed, drink large quantities oi water or milk and call your local Poison Control Center or call a physician immediately. Always turn OFF the ignition sthcn 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 iulI charge, and store it in a cool, dry space. For maximum service lite, charge the stored battery every two weeks. For a battery remaining in a stored motorcycle, disconnect the negative battery cable irom the battery terminal. The maintenance lree (MF) battery must be replaced when it reaches the end oi its service Iiie. The battery can be damaged it overcharged or undercharged, or ii leit to discharge lor long period. These same conditions contribute to shortening the "lile span" oi the battery. Even under normal use, the penormance ol the battery deteriorates alter 2 — 3 years. Battery voltage may recover aiter battery charging, but under heavy load, the battery voltage will drop quickly and eventually die out. For this reason, the charging system is olten suspected as the problem. Battery overcharge often results lrom problems in the battery itseli, which may appear to be an overcharging symptom. ll one ol 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. ~ Belore troubleshooting the charging system, check ior proper use and maintenance oi the battery. Check ii the battery is lrequently under heavy load, such as having the headlight and taillight ON lor long periods ol time without riding the motorcycle. - The battery will sell-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent sullation irom occurring. When checking the charging system, always iollow the steps in the troubleshooting llow chart (page 21-5). For alternator service (page 13-13). The lollowmg 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 specilied 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 prelerred. BATTERY TESTING Reler to the battery tester’s Operation Manual tor the recommended battery testing procedure. The recommended battery tester puts a "load" on the battery so the actual battery condition ol the load can be measured. RECOMMENDED BATTERY TESTER: BM-21D or BATTERY MATE or equivalent 21-3 BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Type YTZ128 Capacity 12 V — 11 Ah Current ieakage 1.2 mA maximum Voilage Fuliy charged 13.0 —13.2 V (20 0/68 F) 533% Below 12.4 v Charging current Normai 1.1 A/S— 10 h Quick 5.5 A/1 h Aiterhator Capacity 0.42 kW/SDDO min‘ (rpm) Charging coii resistance (20°C/68°F) 0.1 — 0.5 0 21-4 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED 0R WEAK 1. BATTERY TEST Remove the battery (page 21-6). Check the battery conditlon uslng the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-21O or BATTERY MATE or equivalent Is the battery good condition? YES — GO TO STEP 2. NO — Faulty battery 2. CURRENT LEAKAGE TEST lnstall the battery (page 21-6). Check the battery current leakage test (page 21 -7). Is the current leakage below 1.2 mA? YES — GO TO STEP 3. NO — GO TO STEP 6. 3. CHARGING VOLTAGE INSPECTION Measure and record the battery voltage uslng a digltal multimeter (page 21 -6). Start the engine. Measure the charging voltage (page 21-7). Compare the measurement to result at the tollowmg 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 SVSTEM INSPECTION Check the voltage and resistance at the regulator/rectifier connector (page 21 -8). Are the results of checked voltage and resistance correct? YES — GO TO STEP 5. NO — ~ Open clrcultin related wire ~ Loose or poor contacts oi related termlnal ~ Shorted wire harness 5. ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil (page 21 -9). Is the alternator charging coil resistance within 0.1 — 0.5 fl (20°C/68°F)? YES — Faulty regulator/rectifier NO — Faulty charglng COlI 6. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTOR Disconnect the regulator/rectilier 2P (Black) connector and recheck the battery current leakage. Is the current leakage below 1.2 mA? YES — Faulty regulator/rectifier NO — ~ Shortedwire harness ~ Faulty ignition switch 21-5 BATTERY/CHARGING SYSTEM BATTERY Always tum the ignition switch OFF belare removing the battery. REMOVAL/INSTALLATION Open the luggage box lid using the ignition key. Remove the screws [1] and maintenance lid [2]. Remove the battery holder band [3]. Disconnect the battery negative (—) cable [4] first, then disconnect the battery positive (+) cable [5]. Remove the battery [6]. Installation is in the reverse order ol removal. NOTE ' Connect the positive (+) cable tirst, then connect the negative (—) cable. ' For digital clock setting procedure (page 22-14). VOLTAGE INSPECTION Remove the maintenance lid (page 21—6). Measure the batter 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 21-6). Reler to the instructions that are appropriate to the batter testing equipment available to you. TOOL: Battery tester BM-210 or BA'I'I'ERV MATE or equivalent 21-6 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENTLEAKAGETEST Remove the maintenance lid (page 21—6). Turn the ignition sWitch OFF, disconnect the negative (—) cable [1] lrom 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 tor current leakage. NOTE - When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current llow higher than the range selected may blow the luse in the tester. ' While measuring current, do not turn the ignition switch ON. A sudden surge oi current may blow the iuse in the tester. SPECIFIED CURRENT LEAKAGE: 1.2 mA maximum ll 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 belore perlorming this test. Start the engine and warm it up to the operating temperature; then stop the engine. Remove the maintenance lid (page 21—6). Connect the multimeter between the positive terminal [1] and negative terminal [2] oi 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 oil the ignition switch. Failure to lollow 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 min‘ (rpm). STANDARD: Measured BV < Measured CV < 15.5 V - BV = Battery Voltage (page 21-6) - CV = charging Voltage ll the charging voltage reading is out at the specification, inspect the regulator/rectifier (page 21 -8). 21-7 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER REMOVAL/INSTALLATION Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the shelter/side cover (NC7OOS/SA/SD) (page 2-15). Remove the bolt [1] and rear brake reservoir stay/ resen/oir [2]. Remove the socket bolts [3]. Lower the rear lender B [1]. Remove the bolts [2] and regulator/rectilier [3]. Disconnect the alternator 3P (Black) connector [4] and regulator/rectifier 2P (Black) connector [5]. Installation is in the reverse order ol removal. NOTE ' Route the wire harness and hoses properly (page 1- 25). ' Align the rear brake reservoir stay with the lrame tab. SYSTEM INSPECTION Check connectors for loose contact or corroded terminals. Inspect the following items: — Battery charging line (page 21—8) — Ground line (page 21-9) — Charging coil (page 21 -9) Il all components of the charging system are normal and there are no loose connections at the regulator/ rectilier connectors, replace the regulator/rectilier. BATTERY CHARGING LINE INSPECTION Turn the ignition switch OFF. [1] Disconnect the regulator/rectilier 2P (Black) connector [1] (page 21-8). Measure the voltage between the regulator/rectilier 2P (Black) connector terminal at the Wire side and ground. CONNECTION: Red (+) — Ground (—) STANDARD: Battery voltage ‘59 @— There should be battery voltage at all times. 21-8 BATTERY/CHARGING SYSTEM GROUND LINE INSPECTION Turn the ignition switch OFF. Disconnect the regulator/rectifier 2P (Black) connector [1] (page 21-8). Check tor continuity between the regulator/rectifier 2P (Black) connector at the wire side and ground. CONNECTION: Green — Ground There should be continuity at all times. ALTERNATOR CHARGING COIL It IS not necessary In remove me stator coil m make this test. CHARGING COIL INSPECTION Disconnect the alternator 3P (Black) connector [1] (page 21-8). Measure the resistance between the alternator 3P (Black) connector each terminals at the Wire side. CONNECTION: Vellow — Vellow STANDARD: 0.1 — 0.5 fl (ZINC/63°F) Check Ior continuity between the alternator 3P (Black) connector [1] each terminals at the wire side and ground. CONNECTION: Vellow — Ground STANDARD: No continuity Replace the stator iI the resistance is out oi specification, or II any wire has continuity to ground. For alternator/starter replacement (page 13-13). [1] 21-9 MEMO 22. LIGHTS/METERS/SWITCHES SYSTEM LOCATION ................................. “22.2 SERVICE INFORMATION ......................... ..22.3 TROUBLESHOOTING ............................... “22.4 HEADLIGHT .............................................. ..22.5 TURN SIGNAL LIGHT ............................... “22.5 POSITION LIGHT ..22_7 BRAKE/TAIL/LICENSE LIGHT ----------------- --22—8 COMBINATION METER ............................ ..22.3 SPEEDOMETER/VS SENSOR- 22-16 TACHOMETER ........................................ “22.13 HIGH COOLANT TEMPERATURE lNDICATOR/ECT SENSOR --------------------- --22-18 ENGINE OIL PRESSURE INDICATOR/EOP SWITCH ................................................... .. 22.19 FUEL LEVEL SENSOR ........................... .. 22.21 PARKING BRAKE INDICATOR/SWITCH (Ncmoxo/SD) ........................................ .. 22.22 IGNITION SWITCH-- 22.24 HANDLEBAR SWITCHES ...................... ..22.25 BRAKE LIGHT SW|TCH ......................... ..22.25 CLUTCH SWITCH (NC700X/XA/S/SA) -- -- 22-26 NEUTRAL SWITCH ................................ .. 22.27 SIDESTAND SW|TCH ............................. .. 22.23 HORN ...................................................... .. 22.29 TURN SIGNAL/HAZARD RELAY-------------22-30 22-1 LIGHTS/METERS/SWITCHES SYSTEM LOCATION NC700X/XA/S/SA: FRONT BRAKE LIGHT SWITCH ECT SENSOR CLUTCH SWITCH FUEL LEVEL SENSOR IGNITION SWITCH TURN SIGNAU HAZARD RELAY EOP SWITCH NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH VS SENSOR SIDESTAND SWITCH NC700XD/SD: FRONT BRAKE LIGHT SWITCH HORN ECT SENSOR FUEL LEVEL SENSOR PARKING BRAKE SWITCH IGNITION SWITCH TURN SIGNAU HAZARD RELAY EOP SWITCH NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH VS SENSOR SIDESTAND SWITCH 22-2 SERVICE INFORMATION GENERAL ' Note the following when replacing the halogen headlight bulb. LIGHTS/M ETERS/SWITCHES — 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. — I! 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 alter replacing the headlight bulb. - A halogen headlight bulb becomes very hot while the headlight is ON, and remains hot lor a while after it is turned OFF. Be sure to let it cool down belore servicing. - Check the battery condition belore perlorming any inspection that requires proper battery voltage. - Use an electric heating element to heat the water/coolant mixture lor the ECT sensor inspection. Keep flammable materials away lrom 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 lollowmg color codes are used throughout this section. Bu = Blue G = Green P = Pink V = Violet Y = Yellow Bl = Black Gr = Gray R = Red W = White SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight 12 V — 60/55 W Position light 12 V — 5 W Brake/tailllicense light 12 V — 21/5 W Turn signallight 12V—21Wx4 Instrument light LED Turn signal indicator LED High beam indicator LED Neutral indicator LED Engine oil pressure indicator LED High coolant temperature indicator LED MIL LED HISS indicator LED ABS indicator (NC700XA/XD/SA/SD) LED Parking brake indicator (NC700XD/SD) LED Fuse Main luse 30 A PGM-Fl luse 15 A Subiuse 15Ax2,7.5Ax4 ABS luse (NC700XA/XD/SA/SD) 30 A X 2, 7.5 A DCT luse (NC700XD/SD) 30 A, 7.5 A ECT sensor resistance 40°C (104°F) 1.0 — 1.3 km 100°C (212°F) 0.1 — 0.2 km Fuel level sensor resistance Full 4 — 6 0 Empty 80 — 83 Q TORQUE VALUES , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf—m, lbf-It) REMARKS Turn signal light mounting screw 4 6 2.5 (0.3, 1.8) Combination meter mounting 3 5 1.0 (0.1, 0.7) screw Combination meter back cover 4 3 0.3 (0.03, 0.2) mounting screw (NC7OOS/SAlSD) EOP sWitch 1 PT 1/8 18 (1.8, 3) Apply sealant to the threads. Ignition sWitch mounting bolt 2 B 25 (2. , 18) One way bolt; replace with a new one. Neutral sWitch 1 10 12 (1.2, 9) Parking brake sWitch screw 1 4 1.2 (0.1, 0.9) (NC700XD/SD) 22-3 LIGHTS/METERS/SWITCHES TROUBLESHOOTING SPEED SENSOR/SPEEDOMETER (NC700X/XA/S/SA) The speedometer operation is abnormal 1. Fuse Inspection Check ior biown main iuse or sub iuse. Is the fuse blown? YES — Replace the iuse. NO — GO TO STEP 2. 2. Battery Inspection Make sure the battery is lully charged and in good condition. Is the battery in good condition? YES — GO TO STEP 3. NO — Charge or replace the battery (page 21-6). 3. VS Sensor Power Input Voltage Inspection Disconnect the VS sensor 3P (Black) connector. Measure the voltage at the VS sensor 3P (Black) connector terminais with the ignition sWitch turned ON. CONNECTION: Pink/blue (+) — Green/red (—) STANDARD: Battery voltage Is there Battery Voltage? YES — GO TO STEP 4. NO — ~ Loose or poor contact at related terminals ~ Open circuit in Pink/blue wire ~ Open circuit in Green/red wire 4. VS Sensor Signal Line Inspection With the ignition switch OFF, check lor continuity between the VS sensor 3P (Black) connector and combination meter 16F (Gray) connector. CONNECTION: Pink/green — Pink/green Is there continuity? YES — GO TO STEP 5. NO — Open circuit in Pink/green wire 5. VS Sensor Signal Inspection Connect the VS sensor 3P (Biack) connector. Support the motorcycie using a hoist or other support to raise the rear wheel oil the ground. Measure the output voltage (sensor signai) at the speedometer with the ignition switch turned ON while slowly turning the rear wheel by your hand. CONNECTION: Pink/green (+) — Green/red (—) STANDARD: Repeat 0 to 5 V Is the voltage within specified Value? YES — Faulty combination meter NO — Faulty VS sensor 22-4 LIG HTS/M ETERS/SWITCHES HEADLIGHT NOTE For headlight unit removal/installation. — NC700X/XA/XD (page 2-26) — NC7OOS/SA/SD (page 2-27) BULB REPLACEMENT (NC700X/XA/ XD) Disconnect the headlight 3P (Black) connector [1 ]. Remove the dust cover [2]. Unhook the bulb retainer [3] and remove the headlight bulb [4]. Avoid touching halogen headlight bulb. Finger prints can create hotspots that cause a bulb to break. Install a new bulb, while aligning its tabs With the slots oi the headlight unit. Hook the bulb retainer into the headlight unit groove. Install the dust cover tightly against the headlight unit. NOTE Install the dust cover with its "TOP" mark [5] and arrow mark [6] iacing up. Connect the headlight 3P (Black) connector. gULB REPLACEMENT (NC7OOS/SA/ D) Remove the headlight/headlight stay (page 2-27). Remove the dust cover [1]. Unhook the bulb retainer [2] and remove the headlight bulb [3]. Avoid touching halogen headlight bulb. Finger prints can create hotspots that cause a bulb to break. Install a new bulb, while aligning its tabs With the slots oi the headlight unit. Hook the bulb retainer into the headlight unit groove. Install the dust cover tightly against the headlight unit. NOTE Install the dust cover with its "TOP" mark [4] and arrow mark [5] iacing up. Install the headlight/headlight stay (page 2-27). [1] [3] V 22-5 LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screws [1] and turn signal light lens [2]. While pushing in the bulb [3], turn it counterclockwise to remove it. Replace the bulb With a new one. Check the packing [4] is installed in position and is in good condition, replace it with a new one it necessary. Install the turn signal light lens and screw. Tighten the screw securely. REMOVAL/INSTALLATION FRONT (NC7OOX/XA/XD) Remove the tront side cowl (page 2-24). Remove the turn signal light mounting screw [1], setting plate [2] and turn signal light [3]. Remove the mounting rubber [4]. Installation is in the reverse order at removal. NOTE Route the wires properly (page 1-25). TORQUE: Turn signal light mounting screw: 2.5 N-m (0.3 kgf—m,1.8lbt-tt) FRONT (NC7OOS/SA/SD) Remove the headlight/headlight stay (page 2-27). Disconnect the tront turn signal light 3P connector [1]. Remove the turn signal light mounting screw [2], setting plate [3] and turn signal light [4]. Remove the mounting rubber [5]. Installation is in the reverse order at removal. NOTE Route the wires properly (page 1-25). TORQUE: Turn signal light mounting screw: 2.5 N-m (0.3 kgf—m,1.8lbt-tt) 22-6 LIG HTS/M ETERS/SWITCHES REAR Remove the tail light cover (page 2-10). Remove the turn signal light mounting screw [1], setting plate [2] and turn signal light [3]. Remove the mounting rubber [4]. Installation is in the reverse order ol removal. NOTE Route the wires properly (page 1-25). TORQUE: Turn signal light mounting screw: 2.5 N-m (0.3 kgf—m,1.8|bf—ft) POSITION LIGHT BULB REPLACEMENT (NC700X/XA/ XD) Pull out the position light bulb socket [1]. Remove the bulb [2] from the socket, replace it With a new one. Installation is in the reverse order ol removal. NOTE Route the wires properly (page 1-25). BULB REPLACEMENT (NC7OOS/SA/ SD) Remove the headlight/headlight stay (page 2-27). Pull out the position light bulb socket [1]. Remove the bulb [2] from the socket, replace it with a new one. Installation is in the reverse order ol removal. [4] ll] 22-7 LlGHTS/METERS/SWITCHES BRAKE/TAlL/LICENSE LIGHT NOTE For brake/taiI/license light removal/installation (page 2- 10). BULB REPLACEMENT Remove the tail light cover (page 2-10). Turn the bulb socket [1] counterclocKWise and remove it. While pushing in the bulb [2], turn it counterclockwise to remove it. Replace the bulb With a new one. Installation is in the reverse order ol removal. COMBINATION METER SEEM INSPECTION (NC700X/XA/S/ NOTE Check for loose or poor contact terminals at the combination meter 16F (Gray) connector. Turn the ignition switch ON and engine stop SWitch "(3", check that the tachometer segment [1] move to lull scale and then tachometer segment go oil. ll the tachometer segment does not show initial lunction, check the combination meter power input line (page 22-10). ll the power and ground lines are OK, replace the combination meter assembly. — NC700X/XA (page 22-9) — NC7OOS/SA (page 22-9) ll the MIL and engine oil pressure indicator are stay on and tachometer, high coolant temperature indicator and HlSS indicator does not come on, inspect the iollowing; — DTC with the H08 (page 4-12) — TXD/RXD line (page 22-11) 22-8 SYSTEM INSPECTION (NC700XD/SD) NOTE Check for loose or poor contact terminals at the combination meter 16F (Gray) connector. When the ignition sWitch is turned ON with the engine stop switch "C", the combination meter will show the entire digital display and the tachometer segments [1] will reduce from lull scale to zero. ll the tachometer segment does not show initial lunction, check the combination meter power input line (page 22-10). ll the power and ground lines are OK, replace the combination meter assembly. — NC700XD (page 22-9) — NC700$D (page 22-9) ll the MIL and engine oil pressure indicator are stay on and tachometer, high coolant temperature indicator and HISS indicator does not come on, inspect the following; — DTC with the HDS (page 4—12) — TXD/RXD line (page 22—1 1) REMOVAL/INSTALLATION (NC7OOX/ XA/XD) Remove the windscreen (page 2-23). Remove the dust cover [1]. Disconnect the combination meter 16F (Gray) connector [2]. Remove the screws [3], washer [4] and combination meter [5]. Installation is in the reverse order ol removal. TORQUE: Combination meter mounting screw: 1.0 N-m (0.1 kgf—m, 0.7 Ibf—ft) REMOVAL/INSTALLATION (NC7OOS/ SA/SD) Remove the headlight/headlight stay (page 2-27). Remove the combination meter back cover mounting screws [1] and combination meter back cover [2]. LIG HTS/METERS/SWITCHES 22-9 LIGHTS/METERS/SWITCHES Remove the dust cover [1]. Disconnect the combination meter 16F (Gray) connector [2]. Remove the combination meter mounting screws [3]. washer [4] and combination meter [5]. Installation is in the reverse order 0! removal. TORQUE: Combination meter mounting screw: 1.0 N-m (0.1 kgt-m, 0.7 lbt-tt) Combin on meter back cover mounting screw: 0.3 N-m (0.03 kgl-m, 0.2 lbt-ft) \ [1]/[2] [5] \ POWER/GROUND LINE INSPECTION Removethewmdscreen (page 2-23). Ncmox/XA/XD: [2] Memos/3mm Remove the dust cover [1] and disconnect the combination meter 16F (Gray) connector [2]. Check the Iollowmg at the wire harness side connector terminals of the combination meter. POWER INPUT LINE Measure the voltage at the combination meter 16F (Gray) connector [1] of the wire harness side and ground. CONNECTION: Pink/blue (+) — Ground (—) STANDARD: Batteryvoltage There should be battery voltage With the ignition switch turned ON. It there is no voltage, check the tollowmg: — Open circuit in the Pink/blue Wire — Blown sub luse 7.5 A (ILLUMI/STOP/HORN) BACK-UP VOLTAGE LINE Measure the voltage at the combination meter 16F (Gray) connector [1] of the wire harness side and ground. CONNECTION: Red/white (+) — Ground (—) STAN DARD: Battery voltage There should be battery voltage at all times. It there is no voltage, check the tollowmg: — Open circuit in the Red/white wire — Blown sub luse 7.5 A (CLOCK/TURN) __ 22-10 GROUND LINE Check ior continuity at the combination meter iGP (Gray) connector [1] ol the wire harness side and ground. CONNECTION: Green/red — Ground There should be continuity. ll there is no continuity, check tor open circuit in Green/ red wire. TXD/RXD LINE INSPECTION NC7ODX/XA/S/SA ll the MIL [1] and engine oil pressure indicator [2] are stay on and tachometer, high coolant temperature indicator and HISS indicator does not come on with the ignition switch turned ON and engine stop switch "(3", check the combination meter TXD/RXD line (page 22- 12). NOTE Ii the engine stop sWitch turned "g", the combination meter indicate same operation. NC7ODXD/SD Turn the ignition sWitch ON with the engine stop switch "0" and check the combination meter. The TXD/RXD line is abnormal ii the combination meter shows lollowing: — MIL [1] and en ' oil pressure indicator [2] stay on. — Shin indicator 3] is blinking. — Tachometer, high coolant temperature indicator and HISS indicator do not come on. NOTE Ii the ignition switch is turned ON with the engine stop switch turned "5a", the same condition will occur. Check the combination meter TXD/RXD line (page 22- 12). LIG HTS/M ETERS/SWITCHES [1] [3] 22-11 LIGHTS/METERS/SWITCHES MIL AND ENGINE OIL PRESSURE INDICATOR ARE STAY ON, TACHOMETER, HIGH COOLANT TEMPERATURE INDICATOR AND HISS INDICATOR DOES NOT COME ON AND SHIFT INDICATOR "—" (NCTOOXD/SD) IS BLINKING (when the ignition switch turned 0N) NOTE - Check the lollowing items before starting the inspection: —check for loose or poor contact on the combination meter 16F (Gray) connector and ECM/PCM 33F connector, then recheck the DTC. — Inspect the sub fuse 7.5 A (ENG STOP) - If the ECM/PCM is replaced, periorm the Iollowing: — Key Registration Procedure (page 23—6) —C|utch Initialize Learning Procedure (NC7ODXD/ SD) (page 12-120) 1. Combination Meter Serial Line Short Circuit Inspection Turn the ignition switch OFF. Remove the Windscreen (page 2-23). Remove the dust cover [1] and disconnect the combination meter 16F (Gray) connector [2]. NC700X/XA/XD: [2] NC7OOS/SA/SD: [2] Remove the following: — Shroud/side cover (NC7DOX/XA) (page 2-14) — Side cowl (NC7OOS/SA) (page 2-13) — Center cross plate (NC7DOXD/SD) (page 2-32) Disconnect the following: — ECM 33F (Black) connector (NC7ODX/XA/S/SA) 1 — PCM 3GP (Gray) connector (NC7DOXD/SD) [2] 22-12 LIGHTS/M ETERS/SWITCHES Checkiorcontinuity between the combination meter 16F (Gray) connector [1] ol the wire harness side and ground. Connection: Fled/blue — Ground Is there continuity? YES — Short circuit in Red/biue wire N0 — GO TO STEP 2. 2. Combination Meter Serial Line Open Circuit Inspection Check tor continuity between the combination meter 16F (Gray) connector [1] and ECM/PCM 33F connector [2] 0? the wire harness side. Connection: Fled/blue — Fled/blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 3. N0 — Open circuit in Red/biue wire 3. Combination Meter Serial Line Output Voltage Inspection Connect the combination meter 16F (Gray) connector. Turn the ignition switch ON and engine stop switch "1”," 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. Measure the voitage at the ECM/PCM 33F connector [1] ol the wire harness side and ground. Connection: Fled/blue (+) — Ground (—) Standard: 8 V or more (Every 5 seconds) TOOL: Test probe 07ZAJ-RDJA110 Does the standard Voltage exist? YES — GO TO STEP 4. N0 — ~ Repiace the combination meter assembly. — NC700X/XA/XD (page 22-9) — NC7OOS/SA/SD (page 22-9) ¢ QWNéL'CQQ 22-13 LIGHTS/METERS/SWITCHES 4. ECM Serial Line Output Voltage Inspection Turn the ignition switch OFF. Disconnect the combination meter 16F (Gray) connector. Connect the ECM/PCM 33F connector. Remove the maintenance |id (page 21-6). Remove the DLC [1] from the battery box. Short the DLC terminals using a special tool. Connection: Brown — Green TOOL: SCS connector [2] 070PZ-ZY30100 Rotate and hoId the throttle grip [1] to the lully open position. Turn the ignition sWitch ON while holding the throttIe grip at the lully open position over 10 seconds. NOTE The ECM/PCM enters the communication diagnostic mode. Measure the voltage at the combination meter 16F (Gray) connector [1] oi the wire harness side and ground. Connecl' n: Red/blue (ad—Ground (—) Standard: 8 V or more (Every 5 seconds) Does the standard Voltage exist? YES — Inspect the combination meter (page 22- 10). N0 — Replace the ECM/PCM with a known good one, and recheck. COMBINATION METER DIGITAL CLOCK SET PROCEDURE Turn the ignition switch ON. Push and hold both the combination meter A button [1] and B button [2] untiI the minute digits [3] indicate "1", "2.. or NOTE The combination meter enter the back light setting mode. [1] o owuenueé [3] ,z_t_Lr_:_r_r_z_r_ [2] 22-14 LIGHTS/M ETERS/SWITCHES Push the A button, then hour digits [1] start blinking. NOTE The combination meter enter the clock setting mode. Push the B button until the desired hour [1] and AM/PM are displayed. NOTE Push and hold to advance the houriast. Push the A button, then the minute digits [1] start blinking. Push the B button until the desired minute [1] is displayed. NOTE Push and hold to advance the minute last. Push the A button, then digital clock is set. Push the A button and B button. NOTE The combination meter return to the normal mode. [1] [1] 22-15 LIGHTS/METERS/SWITCHES SPEEDOMETER/VS SENSOR SYSTEM INSPECTION (NC700X/XA/S/ SA) PerIorm the combination meter system inspection (page 22-8). Remove the windscreen (page 2-23). Remove the dust cover [1]. II the system fails the inspection, shift the transmission into neutral, the combination meter 1GP (Gray) connector [2] is connected, then turn the ignition switch ON. Measure the voltage at the combination meter 16F (Gray) connector [1] ol the wire harness side. CONNECTION: Pink/green (+) — Green/red (—) STANDARD: Repeat 0 to 5 V Slowly turn the rear wheel by hand. There should be 0 to 5 V pulse voltage. — If pulse voltage appears, replace the combination meter assembly. — NC7DOX/XA (page 22-9) — NC7DOS/SA (page 22-9) — If pulse voltage does not appear, check for open or short circuit in Pink/green Wire. If the Pink/green wire is OK, check lor the VS sensor signal line (page 22-17) SYSTEM INSPECTION (NC700XD/SD) ll the speedometer does not operate, check the lollowing: — Combination meter system inspection (page 22-9) — MIL blinking: II the MIL blinks 11, check the VS sensor system (page 4-51) — Shift indicator "—" blinking: II the shift indicator "—" blinks 66, check the VS sensor system (page 12- 89). lithe above items are OK, check the VS sensor line as lollows: Remove the windscreen (page 2-23). Remove the dust cover [1] and disconnect the combination meter 16F (Gray) connector [2]. [2] NC7OOS/SA: [2] Newest): 22-16 LIG HTS/METERS/SWITCHES Turn the ignition sWitch ON with the engine stop switch Measure the voltage at the combination meter 16F (Gray) connector [1] ol the Wire harness side. CONNECTION: Pink/green (+) — Green/red (—) Slowly turn the rear wheel by hand. There should be 0 to 5 V pulse voltage. — If pulse voltage appears, replace the combination meter assembly. — NC700XD (page 22-9) — NC7DOSD (page 22-9) — If pulse voltage does not appear, the Pink/green wire has an open circuit. VS SENSOR SIGNAL LINE INSPECTION (NC700X/XA/S/SA) Remove the windscreen (page 2-23). Disconnect the combination meter 1GP (Gray) connector [1]. Disconnect the VS sensor 3P (Black) connector [1]. Check lor continuity between the combination meter 1GP (Gray) connector [1] and VS sensor 3P (Black) connector [2] of the wire harness side. CONNECTION: Pink/green — Pink/green ll there is no continuity, check lor open circuit in Pink/ green wire and loose contact of the wire harness connectors. [1] NC7OOS/SA: 22-17 LIGHTS/METERS/SWITCHES VS SENSOR REMOVAL/ INSTALLATION Disconnect the VS sensor 3P (Black) connector [1]. Remove the bolt [2] and VS sensor [3]. Remove the O-ring [4]. Installation is in the reverse order ol removal. NOTE ' Replace the O—ring with a new one. ' Apply engine oil to a new O-ring. TACHOM ETER SYSTEM INSPECTION II the tachometer does not operate, check the iollowing: — Combination meter system inspection — NC7DOX/XA/S/SA (page 22-8) — NC7DOXD/SD (page 22-9) — TXD/RXD line (page 22—1 1) — CKP sensor — NC7DOX/XA/S/SA (page 5-7) — NC7DOXD/SD (page 5-3) II the above items are OK, replace the combination meter assembly. — NC700X/XA/XD (page 22-9) — NC7OOS/SA/SD (page 22-9) HIGH COOLANT TEMPERATURE INDICATOR/ECT SENSOR SYSTEM INSPECTION II the high coolant temperature indicator does not 1 operate properly, check the lollowing: I I — Combination meter system inspection — NC7DOX/XA/S/SA (page 22-8) — NC7DOXD/SD (page 22-9) — — TXD/RXD line (page 22—1 1) — MIL blinking: it the ML blinks 7, check the ECT ’7‘ “m”, sensor system (page 4-45). _.5_!_.5_5__7_§_ — ECT sensor (page 22-19) II the above items are OK, replace the combination n meter assembly. A — NC700X/XA/XD (page 22-9) — NC7OOS/SA/SD (page 22-9) II the MIL and engine oil pressure indicator are stay on, tachometer, high coolant temperature indicator and HlSS indicator does not come on and shift indicator "—" (NC7DOXD/SD) is blinking, inspect the followmg; — DTC with the H08 (page 4-12) — TXD/RXD line (page 22—1 1) 22-18 LIG HTS/M ETERS/SWITCHES ECT SENSOR UNIT INSPECTION Remove the ECT sensor (page 4-64). Suspend the ECT sensor [1] in a pan ol 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) trom the bottom oi the pan to the bottom ol the sensor. ' Keep the temperature constant tor 3 minutes before testing. A sudden change ol 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 40°C (104°F) 100°C (212°F) Resistance 1.0 — 1.3 k!) 0.1 — 0.2 k0 Replace the ECT sensor il it is out oi speciiication. 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 all when the engine starts. II the engine oil pressure indicator does not come on with the ignition switch turned ON, check the combination meter system inspection. — NC700X/XA/S/SA (page 22-3) Li — NC700XD/SD (page 22-9) - (—7 i 42:34 r The engine oil pressure indicator does not go out when the engine running, check the iollowing: ‘\ "m ; L.” — Engine oil level (page 3-12) — TXD/RXD line (page 22-11) — MIL blinking: it the MIL blinks 87, check the EOP switch system (page 4-62) — Engine oil pressure (page 9-6) — EOP SWitch line (page 22-20) — Replace the EOP SWitch, and recheck (page 22-20). II the above items are OK, replace the combination meter assembly. — NC700X/XA/XD (page 22-9) — NC7OOS/SA/SD (page 22-9) II the MIL and engine oil pressure indicator are stay on and tachometer, high coolant temperature indicator and HlSS indicator does not come on, inspect the iollowing; — DTC with the HDS (page 4-12) — TXD/RXD line (page 22-11) 22-19 LIGHTS/METERS/SWITCHES EOP SWITCH LINE INSPECTION Turn the ignition switch OFF. Disconnect the EOP switch 1P (Gray) connector [1]. Check lor 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 ECM/PCM is replaced, perIorm the Iollowing: — Key Registration Procedure (page 23—6) — Clutch Initialize Learning Procedure (NC7DOXD/ SD) (page 12-120) Lg EOP SWITCH REMOVAL/ INSTALLATION Remove the radiator reserve tank (page 8-14). Disconnect the EOP switch 1P (Gray) connector [1]. Remove the EOP switch [2] lrom the crankcase. Installation is in the reverse order oI removal. TORQUEHB N-m (1.3 kgf‘m, 13 let) NOTE - Apply sealant to the EOP switch threads. - Route the wires and hoses properly (page 1-25). Check the engine oil level (page 3-12). 22-20 LIGHTS/M ETERS/SWITCHES FUEL LEVEL SENSOR FUEL LEVEL SENSOR INSPECTION Remove the Iuel pump unit (page 7-11). Connect the ohmmeter to the tuel pump unit 3P (Black) connector [1] terminals. CONNECTION: Red/black — Black/while Inspect the resistance oi the Iloat [2] at the top and bottom positions. FULL EMPTY Resistance 4 — 6 Q 80 — 83 0 [2] FUEL METER INSPECTION II the Iuei meter biinks as shown [1] with ignition switch is ON, periorm the inspection as toiiow: Disconnect the combination meter 16F (Gray) connector (page 22-8). Disconnect the iuel pump unit 3P (Black) connector (page 7-10). Check Ior continuity between the combination meter 16F (Gray) connector [2] and Iuel pump unit 3P (Biack) connector [3] oi the wire harness side. CONNECTION: Black/green — Black/green II there is no continuity, check Ior open circuit in Biack/ green wire and loose contact oi the wire harness connectors. [21 [3] 22-21 LIGHTS/METERS/SWITCHES PARKING BRAKE INDICATOR/SWITCH (NC700XD/SD) SYSTEM INSPECTION It the parking brake indicator [1] does not operate properly, check the combination meter system inspection (page 22-9). It 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. The parking brake indicator should come on. lithe indicator does not come on, check ior open circuit in the Black, Brown and Green wires. II the indicator comes on, check the parking brake switch (page 22-22). PARKING BRAKE SWITCH INSPECTION Disconnect the parking brake switch connectors. Check ior 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. It the parking brake switch does not operate properly, replace the switch (page 22-23). 22-22 LIG HTS/METERS/SWITCHES PARKING BRAKE SWITCH REMOVAL/ INSTALLATION Remove the parking brake lever holder cover [1]. Disconnect the parking brake switch connectors [1]. Remove the parking brake switch screw [2], parking brake switch [3] and switch spring [4]. Installation is in the reverse order ol removal. NOTE - Apply grease to the parking brake switch spring sliding surface. - Align the parking brake lever holder cover hole with the holder boss. TORQUE: Parking brake switch screw: 1.2 NM (0.1 mm, 0.9 let) 22-23 LlGHTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Remove the shroud/side cover (NC7ODX/XA/XD) (page _ I 24% NC7OOS/SA/SD. Remove the headlight/headlight stay (NC7OOS/SA/SD) (page 2-27). Disconnect the ignition switch 2P (Brown) connector [1]. Check Ior continuity between the wire terminals of the ignition swwch connector in each switch position. ReIer to the Wiring diagram Ior the terminals and switch status: — NC700X (page 24-2) — NC700XA (page 24-3) — NC700XD (page 24-4) — NC7OOS (page 24-5) — NC7OOSA (page 24-6) — NC700$D (page 24-7) REMOVAL/INSTALLATION Remove the top bridge (page 17-33). Remove the ignition switch mounting bolts [1] and ignition switch [2]. Installation is in the reverse order oI removal. TORQUE: Ignition switch mounting bolt: 25 N-m (2.5 kgI-m,18lbt-I’t) NOTE Replace the ignition switch mounting bolts with new ones. 22-24 LIG HTS/METERS/SWITCHES HANDLEBAR SWITCHES RIGHT HANDLEBAR SWITCH Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the headlight/headlight stay (NC7OOS/SA/SD) (page 2-27). Disconnect the following: NC7OOS/SA: — Right handlebar switch 8P (Blue) connector [1] — Right handlebar switch 6P (Black) connector (NC7ODXD) [2] — Right handlebar switch 7P (Green) connector (NC7ODSD) [3] 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: NC700X (page 24-2) NC700XA (page 24-3) NC700XD (page 24-4) NC700$ (page 24-5) NC700$A (page 24-6) NC700$D (page 24-7) LEFT HANDLEBAR SWITCHES Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the headlight/headlight stay (NC7OOS/SA/SD) (page 2-27). Disconnect the following: — Left handlebar switch 10F (Gray) connector [1] — Left handlebar switch 3P (Black) connector (NC700XD) [2] — Left handlebar switch 7P (Green) connector (NC7ODSD) [3] 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: NC700X (page 24-2) NC700XA (page 24-3) NC700XD (page 24-4) NC700$ (page 24-5) NC700$A (page 24-6) NC700$D (page 24-7) LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT Disconnect the lrbnt brake light sWitch connectors and check lor 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 shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the shelter/side cover (NC7OOS/SA/SD) (page -‘i- 2-15). Disconnect the rear brake light switch 3P (Black) * connector [1] and check lor 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 (NC700X/XA/S/SA) Disconnect the clutch switch connectors and check lor continuity between the terminals. There should be continuity With the clutch lever applied, and there should be no continuity With the clutch lever ¥ released. 22-26 LIG HTS/METERS/SWITCHES NEUTRAL SWITCH INSPECTION (NC700X/XA/S/SA) Make sure that the neutral indicator [1] come on with the ignition switch turned ON and transmission is in neutral. ll the neutral indicator does not come on, inspect as lollows: Remove the left rear cover (page 2-29). Disconnect the neutral switch connector [1]. Check for continuity between the switch terminal and engine ground. There should be continuity With the transmission is in neutral, and no continuity when the transmission is into geaL ll 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. ll the continuity inspection is abnormal, replace the neutral sWitch (page 22-28). INSPECTION (NC700XD/SD) Make sure that the neutral indicator [1] comes on when [1] the ignition switch is turned ON and transmission is in neutral and goes oil when the transmission is in gear. ll the neutral indicator does not operate properly, check the shilt indicator blinking ' the ignition switch ON and the engine stop switch " ' ll DTC 52 is indicated With the shift indicator, check the neutral sWitch system (page 12-78). ll the shift indicator does not indicate any DTC 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. ll the Light green wire is OK, replace the combination meter assembly. — NC700XD (page 22-9) — NC700$D (page 22-9) 22-27 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION (NC700X/ XA/S/SA) Drain the engine oil (page 3-13). Remove the left rear cover (page 2-29). 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 specilied torque. TORQUE: 12 N-m (1.2 kgf‘m, 9 lbtAl‘t) Connect the neutral switch connector. Fill the engine with the recommended engine oil (page 3-12). REMOVAL/INSTALLATION (NC700XD/ SD) Remove the shilt control motor/reduction gears (page 12-109). Disconnect the neutral switch connector [1]. Remove the neutral sWitch [2] and sealing washer [3] Irom the crankcase. Install the neutral switch with a new sealing washer and tighten it. TORQUE: 12 N-m (1.2 kgf‘m, 9 Ibf‘ft) Connect the neutral switch connector. Install the reduction gears/shilt control motor (page 12- 110). SIDESTAND SWITCH INSPECTION Remove the Iollowing: — Shroud/side cover (NC7ODX/XA/XD) (page 2-14) — Shelter/side cover (NC7ODS/SA/SD) (page 2-15) — Left rear cover (page 2-29) Disconnect the sidestand sWitch 3P (Green) connector [1]- Check Ior continuity between the wire terminals of the sidestand sWitch 3P (Green) connector switch side. CONNECTION: Green/while — Green Continuity should exist only when the sidestand is up. 22-28 LIG HTS/METERS/SWITCHES REMOVAL/INSTALLATION Sargon the shroud/side cover (NC7ODX/XA/XD) (page Elegy-w the shelter/side cover (NC7OOS/SA/XD) (page Bilsconnect the sidestand sWitch 3P (Green) connector Remove the sidestand switch Wire clamp [2]. Remove the wire band [1] and sidestand switch wire clamp [2]. Remove the sidestand switch mounting bolt [1] and sidestand swuch [2]. Installation is in the reverse order ol removal. NOTE - 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. - Route the wire properly (page 1-25). HORN INSPECTION Remove the lower cowl (page 2-28). Disconnect the wire connectors [1] from the horn [2]. Connect the 12 V batter to the horn terminal directly. The horn is normal it it sounds when the 12 V battery is connected across the horn terminals. 22-29 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the lower cowl (page 2—28). Disconnect the wire connectors [1] from the horn [2]. Remove the bolt [3] and horn. Installation is in the reverse order oi removal. NOTE ' Install the horn against the frame stopper [4]. ' Route the wire properly (page 1-25). TURN SIGNAL/HAZARD RELAY SYSTEM INSPECTION Remove the center cover (NC700X/XA/XD) (page 2- 16). Remove the side cowl (NC7OOS/SA/SD) (page 2-13). Turn the ignition switch OFF. Release the turn signal/hazard relay [1] from the luggage box. Disconnect the turn signal/hazard relay 4P connector [2] irom the turn signal/hazard relay. Check the iollowing at the wire harness side 4P connector. 1. Battery Power Source Line Open Circuit Inspection Measure the voltage between the 4P connector [1] terminal and ground. Connection: Red/white (+) — Ground (—) Is there battery voltage? YES — GO TO STEP 2. N0 — ' Open circuitinthe Red/white wire ~ Blown sub fuse 7.5 A (CLOCK/TURN) [1] 22-30 2. Ground Line Open Circuit Inspection Check lor continuity between the 4P connector [1] terminal and ground. Connection: Green — Ground Is there continuity? YES — GO TO STEP 3. N0 — Open circuit ln the Green wire 3. Turn Signal/hazard Switch Line Open Circuit Inspection Connect the 4P connector [1] termlnals with a jumper wire. 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. N0 — ~ Open clrcultin the Gray wrre ~ Faulty turn signal swrtch or hazard switch (lth handlebar switch) ~ Faulty turn signal light circuits 4. Ignition Switch Power Source Line Open Circuit Inspection Turn the ignition switch ON. Measure the voltage between the 4P connector [1] terminal and ground. Connection: Pink/blue (4») — Ground (—) Is there battery voltage? YES — System is normal, replace the turn slgnal/ hazard relay. N0 — ~ Open clrcultin the Pink/blue wire ~ Blown sup tuse 7.5 A (ILLUMI/STOP/ HORN) LIGHTS/M ETERS/SWITCHES [1] [1] P/Eu ('B 22-31 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the center cover (NC700X/XA/XD) (page 2- 16). Remove the side cowl (NC7OOS/SA/SD) (page 2-13). Release the turn signal/hazard relay [1] from the luggage box. Disconnect the turn slgnaI/hazard relay 4P connector [2] and remove the turn signal/hazard relay. Installation is in the reverse order ol removal. NOTE Route the wire properly (page 1-25). 22-32 23. IMMOBILIZER SYSTEM (HISS) SYSTEM LOCATION---- -----23-2 TROUBLESHOOTING ---23-8 SYSTEM DIAGRAM -----23-2 HISS INDICATOR ---------- -- ----23-10 SERVICE INFORMATION ECM (NC700X/XA/S/SA)/ pCM (Nc7ooxp/SD) ............................... .. 23.11 KEY REGISTRATION PROCEDURES -------23-3 IMMOB|L|ZER RECEWER ...................... ..23.12 DIAGNOSTIC CODE INDICATION -------------23-6 23-1 IMMOBILIZER SYSTEM (HISS) SYSTEM LOCATION IGNITION SWITCH/ IMMOBILIZER RECEIVER SYSTEM DIAGRAM ENGINE STOP SWITCH CKP SENSOR MAIN FUSE 30 A ECM BATTE RY /PCM BANK ANGLE SENSOR CLOCK/TURN MAIN 30 A 75 A Hlss R “ " WW INDICATOR 3' 3' ENGINE STOP ; T HT IJT SWITCH ® (:7 (9 R I I ‘ BATTERY W/v BI/R g1 '_I G/R IGNITION ENG STOP BF 7 i SWITCH 7.5 A ' (BLUE) 0 T c— R/BI -—‘./'— W/Y —I CKP SENSOR v W/V I | GA! P 2P Bu V/R (RED) I ‘ (BLACK) P G/V R/Bu G/O Bl: Black O/Bu V/R Y/R Bu Bl v I G G/O Bu: Blue G/O P L 1 l g 4 v J7» G: Green I | 7 , 0: Orange P: Pink IMMOBILIZER R: Red RECEIVER ECM/POM W: White V: Yellow 23-2 IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION GENERAL When checking the immobilizer system (HlSS), lolloW the steps in the troubleshooting lloW chart (page 23-8). Keep the immobilizer key away lrom the other vehicles immobilizer key when using it. The jamming oi the key code signal may occur and the proper operation at the system Will be obstructed. The key has built-in electronic part (transponder). Do not drop and strike the key against a hard material object, and do not leave the key on the dashboard in the car, etc. Where the temperature will rise. Do not leave the key in the water tor a prolonged time such as by Washing the clothes. The ECM/PCM as well as the transponder keys must be replaced it all transponder keys have been lost. The system does not iunction With a duplicated key code is registered into the transponder with the immobilizer system (HISS). The ECM/PCM can store up to lour key codes. (The lour keys can be registered.) Do not modin the immobilizer system as it can cause the system lailure. (The engine cannot be started.) For ignition system inspection (page 5-6). For ignition switch servicing (page 22-24). For engine stop switch inspection (page 22-25). For bank angle sensor inspection (page 4-65). The lolloWing color codes are used throughout this section. Bl = Black G = Green P = Pink W — White Bu = Blue 0 = Orange R = Red Y = Yellow KEY REGISTRATION PROCEDURES When the key has been lost, or additional spare key is required: 1. Obtain a new transponder key. 2. Grind the key in accordance with the shape at the original key. 3. Apply 12 V battery voltage to the CKP sensor lines ol the ECM/PCM using the special tool (page 23-6). 4. Turn the ignition sWitch ON with the original key and engine stop switch The HISS indicator comes on and it remains on. The code at the original key recognized by the ECM/PCM. ll there is any problem in the immobilizer system (HlSS), the system Will enter the diagnostic mode and the indicator Will remain on lor approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 5. Disconnect the red clip oi the inspection adaptor irom the battery positive (+) terminal lor two seconds or more, then connect it again. The indicator remains on lor approx. two seconds, then it blinks lour times repeatedly. ON OFF....... 2 sec. ~ The immobilizer system (HISS) enters the registration mode. Registrations at all key except the original key inserted in the ignition switch are cancelled. (Registration ol the lost key or spare key is cancelled.) The spare key must be registered again. 6. Turn the ignition sWitch OFF and remove the key. 7. Turn the ignition switch ON with a new key or the spare key. (Never use the key registered in previous steps.) The indicator comes on lor two seconds then it blinks lour times repeatedly. ON OFF— 2 sec. ~ The new key or spare key is registered in the ECM/PCM. ~ ll there is any problem in the registration, the system Will enter the diagnostic mode and the indicator will remain tor approx. ten seconds, then it will indicate the diagnostic code (page 23-7). ~ Keep the other transponder key aWay lrorn the immobilizer receiver more than 50 mm (2.0 in). 23-3 IMMOBILIZER SYSTEM (HISS) 8. Repeat the steps 6 and 7 when you continuously register the other new key. The ECM/PCM can store up to tour key codes. (The tour keys can be registered.) 9. Turn the ignition sWitch OFF, remove the inspection adaptor and connect the CKP sensor 2P (Red) connector. 10.Turn the ignition sWitch ON With the registered key. ~ The immobilizer system (HlSS) returns to the normal mode. 11.Check that the engine can be started using all registered key. When the ignition switch is faulty: 1. Obtain a new ignition switch assembly. 2. Remove the ignition switch (page 22-24). 3. Apply 12 V battery voltage to the CKP sensor lines ol the ECM/PCM using the special tool (page 23-6). 4 . Set the original (registered) key near the immobilizer receiver so that the transponder in the key can communicate With the receiver. 5. Connect a new ignition sWitch to the wire harness, then turn it to ON with a new transponder key. (keep the ignition sWitch away lrom the receiver) and engine stop switch The HISS indicator comes on and it remains on. The code oi the original key recognized by the ECM/PCM. ll there is any problem in the immobilizer system (HISS), the system will enter the diagnostic mode and the indicator will remain on lor approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 6. Disconnect the red c|ip ol the inspection adaptor irom the battery positive (+) terminal lor two seconds or more, then connect it again. The indicator remains on lor approx. two seconds then it blinks tour times repeatedly. ON m 2 sec. The immobilizer system (HISS) enters the registration mode. Registrations ol all key except the original key set near the receiver are cancelled. 7. Turn the ignition sWitch OFF and remove the key. 8. Install the ignition switch (page 22-24). 9. Turn the ignition sWitch ON With a lirst new key. The indicator comes on lor two seconds then it blinks tour times repeatedly. ON r m OFF — 2 sec. ~ The iirst key or spare key is registered in the ECM/PCM. ~ ll there is any problem in the registration, the system Will enter the diagnostic mode and the indicator will remain lor approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 10.Turn the ignition sWitch OFF and disconnect the red clip oi the inspection adaptor irom the battery positive (+) terminal. 11.Turn the ignition switch ON (With the iirst key registered in step 9). The HISS indicator comes on ior two seconds then it goes oll. ~ The immobilizer system (HlSS) returns to the normal mode. 12.Turn the ignition sWitch OFF and connect the red clip oi the inspection adaptor to the battery positive (+) terminal. 13.Turn the ignition sWitch ON (with the lirst key registered in step 9). The HISS indicator comes on and it remains on. ~ The code it the lirst key is recognized by the ECM/PCM. ~ ll there is any problem in the immobilizer system (HISS), the system will enter the diagnostic mode and the indicator will remain on lor approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 23-4 IMMOBILIZER SYSTEM (HISS) l4.Disconnect the red clip oi the inspection adaptor irom the battery positive (+) terminal lor two seconds or more, then connect it again. The indicator remains on lor approx. two seconds then it blinks tour times repeatedly. - The immobilizer system (HlSS) enters the registration mode. Registration ol the original key used in step 4 is cancelled. 15.Turn the ignition sWitch OFF and remove the key. 16.Turn the ignition switch ON with a second new key. (Never use the key registered in previous step.) The indicator comes on ior two seconds then it blinks tour times repeatedly. - The second key or spare key is registered in the ECM/PCM. - ll there is any problem in the registration, the system Will enter the diagnostic mode and the indicator will remain ior approx. ten seconds, then it will indicate the diagnostic code (page 23-7). - Keep the other transponder key away irom the immobilizer receiver more than 50 mm (2.0 in). 17.Repeat the steps 15 and 16 when you continuously register the other new key. The ECM/PCM can store up to lour key codes. (The lour keys can be registered.) 18.Turn the ignition sWitch OFF, remove the inspection adaptor and connect the CKP sensor 2P (Red) connector. 19.Turn the ignition sWitch ON with the registered key. - The immobilizer system (HlSS) returns to the normal mode. 20.Check that the engine can be started using all registered key. When all keys have been lost: 1. Obtain a new ECM/PCM and new key set. 2. Replace the ignition switch with a new one (page 22-24). 3. Replace the ECM/PCM With a new one (page 4-67). 4 . Turn the ignition sWitch ON With a iirst neW key and engine stop switch The HISS indicator comes on ior two seconds, then it blinks tour times repeatedly. - The lirst key is registered in the ECM/PCM. - ll there is any problem in the registration, the system Wi|| enter the diagnostic mode and the indicator will remain ior approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 5. Turn the ignition sWitch OFF and remove the iirst key. 6. Turn the ignition sWitch ON with a second new key. The HISS indicator comes on lor two seconds, then it blinks tour times repeatedly. - The second key is registered in the ECM/PCM. - ll there is any problem in the registration, the system Wi|| enter the diagnostic mode and the indicator will remain ior approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 7. Turn the ignition sWitch OFF and remove the second key. - The system (ECM/PCM) will not enter the normal mode unless the two keys are registered in ECM/PCM. ~ The third new key cannot be continuously registered. When it is necessary to register the third key, iollow the procedures "When the key has been lost, or additional key is required" (page 23-3). 8. Check that the engine can be started using all registered keys. 9. Replace the remaining key set parts. 23-5 IMMOBILIZER SYSTEM (HISS) When the ECM/PCM is taulty: 1. Obtain a new ECM/PCM and two new transponder keys. 2. Grind the keys in accordance with the shape oI the onginal key (or use the key number plate when all key have been lost). 3. Replace the ECM/PCM Wllh a new one (page 4-67). 4 . Turn the ignitlon swwch ON wwh a Iirst new key and engine stop swwch The HISS lndlcator comes on for two seconds, then it bllnks tour tlmes repeatedly. ~ The iirst key is registered In the ECM/PCM. ~ Ii there is any problem In the registratlon, the system wfll enter the diagnostlc mode and the mdlcator will remaln Ior approx. ten seconds, then it will indicate the diagnostlc code (page 23-7). 5. Turn the ignitlon switch OFF and remove the iirst key. 6. Turn the ignitlon swwch ON wwh a second new key. The HISS indicator comes on tor two seconds, then it blinks tour times repeatedly. ~ The second key IS registered In the ECM/PCM. ~ II there is any problem In the registratlon, the system wfll enter the diagnostlc mode and the mdlcator will remaln Ior approx. ten seconds, then it will indicate the diagnostlc code (page 23-7). 7. Turn the ignitlon swwch OFF and remove the second key. ~ The system (ECM/PCM) wfll not enter the normal mode unless the two keys are registered in ECM/PCM. ~ The third new key cannot be continuously registered. When it IS necessary to reglster the third key, lollow the procedures "When the key has been lost, or additional key is required" (page 23-3). 8. Check that the englne can be started using all reglstered keys. DIAGNOSTIC CODE INDICATION Remove the malntenance Iid (page 21-6). Disconnect the CKP sensor 2P (Red) connector [1]. Connect the Inspection adaptor [2] to the we side connector. Connect the Red clip oi the adaptor to the 12 V battery [3] posltive (+) terminal and Black clip to the negative (—) termmal. TOOL: Inspection adaptor 07XMZ-MBW0101 Turn the ignition switch ON with the properly reglstered key and engine stop swwch The HISS lndlcator [I] will come on for approx. ten seconds then It will start blinking to indicate the dlagnostic code iI the system IS abnormal. The blmkmg irequency is repeated. The HISS mdlcator remains on when the system IS normal. (The system is In the normal mode and the diagnostlc code does not appear.) 23-6 IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE When the system (ECM/PCM) enters the diagnostic mode from the normal mode: BLINKING PATTERN SVMPTOM PROBLEM PROCEDURE 02': Iii—m ECM/PCM data is abnormal. Fauity ECM/PCM Repiace the ECM/PCM. Code signals cannot send or receive. Fauity immobilizer receiver or Wire harness Follow the troubleshooting (page 23-8). Identilication code is disagree. J—lflflm Secret code is disagree. Jamming by the other transponder Keep the other vehicle's transponder key away lrom the immobiiizer receiver more than 50 mm (2.0 in). When the system (ECM/PCM) enters the diagnostic mode from the registration mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Registration is The key is already Use a new key or cancelled key. ON ---- overlapped. registered OH: H properiy. 4—» i0 sec. Code signals Communication Follow the troubleshooting (page J—lflflflJ—L cannot send or receive. lails 23-8). J—iflflflfl Registration is impossible. The key is already registered on the other system. Use a new key. 23-7 IMMOBILIZER SYSTEM (HISS) TROUBLESHOOTING The immobilizer indicator comes on tor approx. two seconds then it goes oft, when the ignition switch is turned ON With the properly registered key and the HISS tunctions normally. it there is any problem or the properly registered key is not used, the indicator will remains on. Immobilizer in icator does not come on when the ignition switch is turned ON 1. Fuse Inspection Check tor blown sub tuse 7.5 A (CLOCKFI'URN) and/or sub tuse 7.5 A (ENG STOP). Is the fuse blown? YES — Replace the tuse. NO — GO TO STEP 2. 2. Combination Meter Inspection Check that the neutral indicator come on With the ignition switch turned ON. Is the indicator come on? YES — GO TO STEP 4. NO — GO TO STEP 3. 3. Combination Meter Power Input Line Inspection Check the power input line (Red/white wire) at the combination meter 16F (Gray) connector (page 23-10). Is the voltage specified value? YES — Faulty combination meter. N0 — Open circuit in Red/White Wire 4. TXD/FtXD Line Inspection between The ECM/PCM and Combination Meter Check the TXD/RXD line (Red/blue Wire) between the ECM/PCM 33F connector and combination meter 16P (Gray) connector (page 23-10). Is there continuity? N0 — Open circuit in Red/blue wire YES — GO TO STEP 5. 5. Power Input Line Inspection at The ECM/PCM Connector Check the poWer input line (Black/red and Black wire) at the ECM/PCM 33F connector (page 23-11). Is the voltage specified value? YES — GO TO STEP 6. N0 — Open circuit in Black/red and Black wire 6. Ground Line Inspection at The ECM/PCM Connector Check the ground line (Green/orange and Green wire) at the ECM/PCM 33F connector (page 23-11). Is there continuity? YES — ~ Loose or poor contact ot the ECM/PCM 33F connector ~ Faulty ECM/PCM N0 — ~ Open circuitin Green/orange wire ~ Open circuit in Green wire Immobilizer indicator remains on with the i nition switch turned ON 1. Immobilizer Receiver Jamming lnspectl n Check that there is any metal obstruction or the other vehicles transponder key near the immobilizer receiver and key. Is there any metal obstruction or the other transponder key? YES — Remove it and recheck. NO — GO TO STEP 2. 23-8 IMMOBILIZER SYSTEM (HISS) 2. First Transponder Key Inspection Turn the ignition switch ON with the spare transponder key and check the immobilizer lndicator. The indicator snould came on tor 2 seconds then go oii. Is the indicator go off? YES — Faulty iirst transponder key N0 — GO TO STEP 3. 3. Diagnostic Code Inspection Perform the diagnostlc code indication procedure (page 23-6). Check that the immobilizer indicator comes on then rt starts blinking. Is the indicator brinks or stay lit? BRINKS—Read the dragnostic code (page 23-7). STAV LIT—GO TO STEP 4. 4. TXD/RXD Line Inspection between The ECM/PCM and Combination Meter Check the TXD/RXD Ilne (Red/blue wrre) between the ECM/PCM 33F connector and combinatlon meter 16P (Gray) connector (page 23-10). Is there continuity? YES — GO TO STEP 5. N0 — Open circuit ln Red/blue wire 5. CKP sensor Line Inspection Check the CKP sensor lines (Yellow, White/yellow and Green/orange wires) between the ECM/PCM 33F connector and CKP sensor 2P (Red) connector (page 23-11). Is there continuity? YES — ~ Open clrcult in Yellow wire ~ Open clrcult in White/yellow and/or Green/orange wire N0 — Faulty ECM/PCM Diagnostic code flflflj—lfl is indicated (Code signals cannot send or receive) 1. Immobilizer Receiver Power Input Line Inspection Check the power lnput Ilne (Yellow/red wire) at the immobllizer recelver 4P (Black) connector (page 23-12). Is there approx. 5 V? YES — GO TO STEP 2. N0 — Open or short circuit in Yellow/red wire 2. Immobilizer Receiver Ground Line Inspection Check the ground line (Green/yellow wrre) at the immobilizer receiver 4P (Black) connector (page 23-12). Is there continuity? YES — GO TO STEP 3. N0 — Open circuit in Green/yellow wire 3. Immobilizer Receiver Signal Line lnspection1 Check the slgnal Ilne (Plnk wire) at the immobllizer receiver 4P (Black) connector (page 23-12). Is there approx. 5 V? YES — GO TO STEP 4. N0 — Open or short circuit ln Pink wire 4. Immobilizer Receiver Signal Line Inspection 2 Check the signal line (Blue wire) between the immobilizer recelver 4P (Black) connector and ECM/PCM 33F connector (page 23-12). Is there continuity? YES — ~ Snort clrcult in Blue wire ~ Faulty immobllizer recelver. N0 — Open circuit ln Blue wrre 23-9 IMMOBILIZER SYSTEM (HISS) HISS INDICATOR INSPECTION NOTE II the MIL and engine oil pressure indicator are stay on and tachometer, high coolant temperature indicator and HISS indicator does not come on and shift indicator "—" (NC7DOXD/SD) is blinking, inspect the TXD/RXD line. Remove the windscreen (page 2-23). Perlorm the lollowing inspections with the combination meter 1GP (Gray) connector [1] connected. POWER INPUT LINE INSPECTION Measure the voltage between the combination meter 1GP (Gray) connector terminals. CONNECTION: Red/while (+) — Green/red (—) There should be battery voltage at all times. TXD/FIXD LINE INSPECTION Disconnect the lollowing: — ECM 33F (Black) connector (NC7OOX/XA/S/SA) [1] — PCM 33F (Gray) connector (NC700XD/SD) [1] — Combination meter 1GP (Gray) connector [2] Check for continuity between the ECM/POM 33F connector and combination meter 16F (Gray) connector. CONNECTION: Red/blue — Red/blue TOOL: Test probe 07ZAJ-RDJA110 There should be continuity. ll there is no continuity, replace the wire harness. NC7OOX/XA/XD: [2] NC7OOS/SA/SD: [2] [1] G/R [2] [1] 23-10 IMMOBILIZER SYSTEM (HISS) ECM (NC700X/XA/S/SA)/PCM (NC700XD/SD) INSPECTION NC700X/XA/S/SA: Remove the shroud/side cover (NC700X/XA) (page 2- NCmXNS/SA’ 14). . Remove the side cowl (NC7OOS/SA) (page 2-13). Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. Perlorm the lollowing lnspecIIOHS at the wire harness side connector of the ECM. N0700XD/SD: Remove the luggage box lid/hinge assembly (page 2- 19). Turn the ignition switch OFF. Disconnect the PCM 33F (Gray) connector [1]. Perlorm the lollowing inspections at the wire harness side connector of the PCM. NC7OOXD/SD: POWER INPUT LINE INSPECTION Turn the ignition switch ON and engine stop sztch " Measure the voltage between the ECM/POM 33F connector [1] terminal and ground. CONNECTION: Black (4-) — Ground (—) STANDARD: Battery voltage TOOL: Test probe 07ZAJ-RDJA110 There should be battery voltage. 23-11 IMMOBILIZER SYSTEM (HISS) GROUND LINE INSPECTION Check for continuity between the ECM/PCM 33F connector [1] terminals and ground. CONNECTION: Green/orange — Ground Green — Ground TOOL: Test probe 07ZAJ-RDJA110 There should be continuity at all times. CKP SENSOR LINE INSPECTION Disconnect the CKP sensor 2P (Red) connector [1] (page 23-6). Check for continuity between the ECM/PCM 33F connector [2] and CKP sensor 2P (Red) connector terminals. CONNECTION: Vellow — Vellow Green/orange — Green/orange TOOL: Test probe 07ZAJ-RDJA110 There should be continuity between the same color wire terminals. IMMOBILIZER RECEIVER INSPECTION Remove the shroud/side cover (NC700X/XA/XD) (page 2-14). Remove the headlight/headlight stay (NC7008/SA/SD) (page 2-27). Disconnect the immobilizer receiver 4P (Black) connector [1]. NC7OOXD: 23-12 IMMOBILIZER SYSTEM (HISS) POWER INPUT LINE INSPECTION Turn the ignition switch ON and engine stop sWitch [1] Measure the voltage between the immobilizer receiver 4P (Black) connector [1] terminal and ground at the wire side. CONNECTION: Vellow/red (1-) — Ground (—) A7,: \ :‘l .L ('9 fi 3: There should be approx. 5 V. GROUND LINE INSPECTION Check lor continuity between the immobilizer receiver 4P (Black) connector [1] terminal and ground at the wire [1] side. \ CONNECTION: Green/yellow — Ground There should be continuity at all times. L i (W SIGNAL LINE INSPECTION Turn the ignition switch ON and engine stop sWitch [1] Measure the voltage between the immobilizer receiver 4P (Black) connector [1] terminal and ground at the wire side. CONNECTION: Pink (1-) — Ground (—) ll, There should be approx. 5 V. : P .1. Disconnect the ECM/PCM 33F connector [1] (page 23- 11)_ [2] [1] Check tor continuity between the ECM/PCM 33F connector and immobilizer receiver 4P (Black) connector [2] terminals at the wire side. CONNECTION: Blue — Blue TOOL: Test probe 07ZAJ-FIDJA110 There should be continuity. 23-13 IMMOBILIZER SYSTEM (HISS) Route the receiver wire properly (page 1725). Check for continuity between the ECM/PCM 33F connector [1] terminal and ground at the wire side. CONNECTION: Blue — Ground TOOL: Test probe 07ZAJ-RDJA110 There should be no continuity. REMOVAL/INSTALLATION Remove the top bridge (page 17-33). Remove the screws [1] and the immobilizer receiver [2]. Install a new receiver and tighten the screws. Install the top bridge (page 17-38). REPLACEMENT PARTS FOR PROBLEM Replacement parts Problem Immobilizer receiver Transponder Key ECM/PCM Ignition switch assembly Key set ‘Accessory lock and key One Key has been lost, or additional spare key is 0 required All key has been lost ECM/PCM is Iaulty O O Immobilizer 0 receiver is iaulty Ignition switch is Iaulty *Accessbry lock is Iau lty *Accessory lock means the luggage box lid lock and seat lock. 23-14 24. WIRING DIAGRAM NC700X------ -----24-2 Nc7oos ---24-5 NC700XA---- -----24-3 NC700$A ----- -- ----24-5 Ncmosp ................................................... ..24.7 24-1 ABS CONNECTOR LOCATIONS-u- ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR PROBLEM CODE INDEX ABS MODULATOR ABS SYSTEM DIAGRAM ABS SYSTEM LOCATION ABS TROUBLESHOOTING- ABS TROUBLESHOOTING INFORMATION AIR CLEANER AIR CLEANER HOUSING AIR DUCT (NC7OOX/XA/XD) .- ALTERNATOR CHARGING COIL- ALTERNATOR COVER AT/MT MODE SWITCH TROUBLESHOOTING - BALANCER----~ BANK ANGLE SENSOR BATTERY- BATTERY BO BODY PAN EL LOCATIONS (NC7OOS/SA BODY PAN EL LOCATIONS (NC7OOSD)- BODY PAN EL LOCATIONS (NC700X/XA BODY PAN EL LOCATIONS (NC700XD)- BRAKE FLUID BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC7OOX/S)~---~ BRAKE FLUID REPLACEMENT/AIR BLEEDING (NC7OOXA/XD/SA/SD) BRAKE LIGHT SWITCH LIGHTS/METERS/SWITCHES ------- .- MAINTENANCE BRAKE LOCK OPERATION (NC700XD/SD) - BRAKE PAD/DISC- BRAKE PADS WEAR BRAKE PEDAL .- BRAKE SYSTEM BRAKEFFAIL/LICENSE LIGHT BRAKEFFAIL/LICENSE LIGHT/TAIL LIGHT COVER CABLE & HARNESS ROUTING- CAM CHAIN TENSIONER CAMSHAFT CENTER COVER (NC7OOX/XA/XD)- CENTER CROSS PLATE CENTER SEAT COWL- CHARGING SYSTEM INSPECTION CKP SENSOR CLUTCH-- CLUTCH EOP SENSOR CLUTCH INITIALIZE LEARNING (POM)- CLUTCH LEVER (NC7OOX/XA/S/SA) CLUTCH OIL FILTER (NC700XD/SD CLUTCH SWITCH (NC700X/XA/S/SA) CLUTCH SYSTEM (NC700X/XA/S/SA) COMBINATION METER ---- ‘- COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH CLUTCH/GEARSHIFT LINKAGE (NC7OOX/XA/S/SA)--- CRANKCASE/TRANSMISSION/BALANCER CRANKSHAFT/PISTON/CYLINDER CYLINDER HEAD/VALVES ---- .- DUAL CLUTCH TRANSMISSION (DOT) (NC7OOXD/SD) ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING - FUEL SYSTEM-m HYDRAULIC BRAKE REAR WHEEL/SUSPENSION COOLANT REPLACEMENT COOLING SYSTEM ---- .- CRANKCASE ASSEMBLY CRANKCASE BREATHER CRANKCASE SEPARATION CRANKPIN BEARING CRANKSHAFI' CYLINDER COMPRESSION TEST CYLINDER HEAD---- CYLINDER HEAD COVER DCT CONNECTOR LOCATIONS DCT ELECTRICAL SYSTEM LOCATION DCT SHIFT PEDAL (OPTIONAL)-~-- DCT SYMPTOM TROUBLESHOOTING DCT SYSTEM DIAGRAM ---- ‘- DCT TROUBLESHOOTING INFORMATION DELAY VALVE DIAGNOSTIC CODE INDICATION - DRIVE CHAIN DRIVE CHAIN SLIDER DTC INDEX DUAL CLUTCH TRANSMISSION (DCT) (NC7OOXD/SD PGM-Fl SYSTEM DTC TROUBLESHOOTING DUAL CLUTCH TRANSMISSION (DCT) (NC7OOXD/SD) PGM-Fl SYSTEM DUAL CLUTCH-m ECM (NC7OOX/XA/S/SA)/PCM (NC7OOXD/SD) IMMOBILIZER SYSTEM (HISS) PGM-Fl SYSTEM ECT SENSOR EMISSION CONTROL SYSTEMS ENGINE IDLE SPEED-m ENGINE INSTALLATION (NC700X/XA/S/SA ENGINE INSTALLATION (NC7OOXD/SD ENGINE OI ENGINE OIL FILTE ENGINE OIL PRESSURE INDICATOR/ EOP SWITCH--~ ENGINE REMOVAL (NC700X/XA/S/SA) ENGINE REMOVAL (NC700XD/SD EOT SENSOR EXHAUST PIPE/MUFFLE FAN CONT. RELAY- FLYWHEEL .... .. FRONT BRAKE CALIPER (NC7OOX/S)- FRONT BRAKE CALIPER (NC700XA/XD/SA/SD FRONT FENDER-m- FRONT MASTER CYLINDER FRONT SIDE COWL (NC7OOX/XA/XD)- FRONT UNDER COVER (NC7OOX/XA/XD FRONT WHEEL--- FUEL CUT RELAY FUEL LEVEL SENSOR FUEL LINE FUEL LINE REPLACEMENT- FUEL PUMP UNIT FUEL TANK-- GEARSHIFT LINKAGE CLUTCH/GEARSHIFT LINKAGE (NC7OOX/XA/S/SA) DUAL CLUTCH TRANSMISSION (DCT) (NC7OOXD/SD)~--- GEARSHIFT PEDAL GRAB RAIL GUARD PIPE (NC7OOXD/SD) HANDLEBAR-m HANDLEBAR SWITCHES- INDEX HEADLIGHT-u HEADLIGHT AIM HEADLIGHT COVER (NC7OOS/SA/SD) HEADLIGHT/FRONT CENTER COWL (NC700X/XA/XD) ----- .- HEADLIGHT/HEADLIGHT STAY (NC700S/SA/SD)- 2-27 HIGH COOLANT TEMPERATURE INDICATOR/ECT SENSOR - 22-18 HISS INDICATOR ~ -23-10 HORN -22-29 IACV . IGNITION COI 5-10 IGNITION SWITCH 22-24 IGNITION SYSTEM INSPECTION- -6 IGNITION TIMING-m- -9 IMMOBILIZER RECEIVER - INJECTOR 7-20 INNER UPPER COVER (NC7OOX/XA/XD 2-25 KEY REGISTRATION PROCEDURES- 23-3 LEFT REAR COVER- 2-29 LOWER COWL-~- LUBRICATION & SEAL POINTS LUBRICATION SYSTEM DIAGRAM- LUGGAGE BOX- LUGGAGE BO>< LI LUGGAGE Box LID/HINGE ASSEMBLY MAIN JOURNAL BEARING- MAINSHAFT SENSOR-m- MAINTENANCE SCHEDULE METER STAY (NC7OOX/XA/XD) MIL CIRCUIT TROUBLESHOOTING MIL TROUBLESHOOTING MODE/SHIFT INDICATOR CIRCUIT TROUBLESHOOTING - MODEL IDENTIFICATION MUD GUARD NEUTRAL DIODE (NC700X/XA/S/SA) - NEUTRAL SWITCH ---- ‘- NUTS, BOLTS, FASTENERS - og SENSOR OIL PRESSURE INSPECTION OIL PUMP (NC7OOX/XA/S/SA) OIL PUMP (NC7ODXD/SD OIL STRAINER-~- PARKING BRAKE CALIPER (NC700XD/SD)- PARKING BRAKE INDICATOR/SWITCH (NC700XD/SD) -------- .- PARKING BRAKE LEVER (NC700XD/SD PCV PGM-FI CONNECTOR LOCATIONS PGM-FI SYMPTOM TROUBLESHOOTING PGM-FI SYSTEM DIAGRAM PGM-FI SYSTEM LOCATION- PGM-FI TROUBLESHOOTING INFORMATION PILLION SEAT PISTON/CYLINDE POSITION LIGHT-- PRIMARY DRIVE GEAR/CKP SENSOR ROTOR CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) ---- ‘- DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) v RADIATOR ---- .- RADIATOR COOLANT- RADIATOR RESERVE TANK - REAR BRAKE CALIPER REAR FENDER A REAR FENDER B REAR FENDER MUD GUARD (U Iype) REAR MASTER CYLINDE REAR WHEEL REGULATOR/RECTIFIER RIGHT CRANKCASE COVER CLUTCH/GEARSHIFT LINKAGE (NC7OOX/XA/S/SA) DUAL CLUTCH TRANSMISSION (DCT) (NC7OOXD/SD) RIGHT ENGINE SIDE COVER (NC700XD/SD) ROCKER ARM-m- SEAT COWL-m- SENSOR UNIT POWER LINE INSPECTION SERVICE INFORMATION ALTERNATOR/STARTER CLUTCH ANTI-LOCK BRAKE SYSTEM (ABS)~ BATTERY/CHARGING SYSTEM-- CLUTCH/GEARSHIFT LINKAGE (NC7OOX/XA/S/SA) COOLING SYSTEM CRANKCASE/TRANSMISSION/BALANCER CRANKSHAFr/PISTON/CYLINDE CYLINDER HEAD/VALVES ------ .- DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) ELECTRIC STARTER ENGINE REMOVAL/INSTALLATION FRAME/BODY PANELS/EXHAUST SYSTEM- FRONT WHEEL/SUSPENSION/STEERING FUEL SYSTEM HYDRAULIC BRAKE - IGNITION SYSTEM mmLLm (backbone Loki; memp ombma IMMOBILIZER SYSTEM (HISS)- 3-3 LIGHTS/METERS/SWITCHES 2-3 LUBRICATION SYSTEM 9-4 MAINTENANCE -~ 3-2 PGM-FI SYSTEM 4-6 REAR WHEEL/SUSPENSION 8-4 SERVICE RULES-m 1-2 SHELTER/SIDE COVER (NC700S/SA/SD -15 SHIFT CONTROL MOTOR/REDUCTION GEARS 42-109 SHIFT INDICATOR TROUBLESHOOTING 12-61 SHIFT SPINDLE ANGLE SENSOR~ 12-116 SHOCK ABSORBER 18-14 SHOCK LINKAGE-m 18-13 SHROUD/SIDE COVER (NC700X/XA/XD) -14 SIDE COWL (NC700S/SA/SD)- SIDESTAND SIDESTAND SWITCH SINGLE SEAT SPARK PLUG SPECIFICATIONS SPEEDOMETER/VS SENSOR STARTER CLUTCH~ STARTER MOTOR STARTER RELAY (NC700XD/SD STARTER RELAY SWITCH STATOR 13-13 STEERING HEAD BEARINGS- STEERING STEM 17-33 SUSPENSION -28 SWINGARM 18-16 SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM ELECTRIC STARTER IGNITION SYSTEM IMMOBILIZER SYSTEM (HISS)- SYSTEM FLOW PATTERN SYSTEM LOCATION BATTERY/CHARGING SYSTEM~-- ELECTRIC STARTER - IGNITION SYSTEM-- IMMOBILIZER SYSTEM (HISS) LIGHTS/METERS/SWITCHE SYSTEM TESTING TACHOMETER -- TECHNICAL FEATURES- THERMOSTAT/THERMOSTAT HOUSING- THROTTLE BODY-m THROTTLE OPERATION TORQUE VALUES- TR SENSOR TRANSMISSION (NC700X/XA/S/SA) TRANSMISSION (NC700XD/SD) -- TROUBLESHOOTING ALTERNATOR/STARTER CLUTCH BATTERY/CHARGING SYSTE CLUTCH/GEARSHIFT LINKAGE (NC7OOX/XA/S/SA) COOLING SYSTEM - CRANKCASETI'RANSMISSION/BALANCER CRANKSHAFT/PISTON/CYLINDER CYLINDER HEAD/VALVES ELECTRIC STARTER-u FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEL/SUSPENSION/STEERING HYDRAULIC BRAKE- IGNITION SYSTEM IMMOBILIZER SYSTEM (HISS)- LIGHTS/METERS/SWITCHES LUBRICATION SYSTEM ~- REAR WHEEL/SUSPENSION- TURN SIGNAL LIGHT---~ TURN SIGNAL/HAZARD RELAY~ VALVE CLEARANCE WATER PUMP WHEEL SPEED SENSOR- WHEELSFTIRES WINDSCREEN - WIRING DIAGRAM NC7OOS- NC7OOSA NC7OOS NC700X- NC700XA NC700X