Honda SXS700M2 - Service Manual

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Table of Contents

A few Words about Safety2
How to Use this Manual3
Symbols4
Table of Contents5
General Information7
Abbreviation8
Model Identification8
Service Rules8
- Serial Numbers/Labels9
- Specifications10
- Type Code9
- Electric Starter Specifications11
- Fuel System Specifications11
- Ignition System Specifications11
- PGM-FI System Specifications11
- Cooling System Specifications12
- Cylinder Head/Valve/Camshaft Specifications12
- Lubrication System Specifications12
- Alternator/Starter Clutch Specifications13
- Cylinder/Piston Specifications13
- Drivetrain System Specifications13
- Steering System Specifications13
- Battery/Charging System Specifications14
- Brake System Specifications14
- Drive Shaft/Final Gear Specifications14
- Wheel/Suspension Specifications14
- Engine & Frame Torque Values15
- Lights/Meters/Switches Specifications15
- Standard Torque Values15
General Information17
- Engine20
- Lubrication & Seal Points20
- Frame21
- Cable & Harness Routing23
- Lift and Support Points39
  - Noise Emission Control System39
  - Rebuilt Engine39
- Technical Features40
- Bed Tilt Prevention System (4 Person Type)40
- Bolted Frame Connections40
- Drive Shaft Boots with Low-Profile Boot Bands40
2. Frame/Body Panels/Exhaust System41
- Service Information42
- Tool42
- Troubleshooting42
- Body Panel Locations43
- Backrest Removal/Installation44
- Front Seat44
  - Seat Cushion Removal/Installation44
  - Headrest Removal/Installation45
  - Seat Frame Removal/Installation45
- Rear Seat (4 Person Type Only)46
  - Seat Damper Removal/Installation46
  - Seat Removal/Installation46
- Rear Center Cover (4 Person Type Only)47
  - Removal/Installation47
  - Seat Disassembly/Assembly47
  - Left Middle Fender Removal/Installation48
  - Right Middle Fender Removal/Installation48
  - Right Seat Bottom Cover Removal/Installation48
  - Left Seat Bottom Cover Removal/Installation49
- Mud Protector (2 Person Type Only)49
- Rear Step (4 Person Type Only)49
- Left Rear Foot Well Removal/Installation50
- Rear Foot Well (4 Person Type Only)50
- Rear Side Cover50
- Right Rear Foot Well Removal/Installation50
- Floor Panel51
- Front Side Cover51
- Front Grille52
- Front Heat Guard52
- Front Hood52
- Front Door Panel Removal/Installation53
- Front Fender53
  - Door Handle and Latch Removal/Installation54
  - Door Hinge Removal/Installation54
  - Rear Door Panel Removal/Installation (4 Person Type Only)54
  - Rear Seat Latch Cover Removal/Installation (4 Person Type Only)55
  - Rear Seat Latch Removal/Installation (4 Person Type Only)55
- Instrument Panel56
- Front Bumper57
- Front Floor Cover57
- Cargo Bed58
- Maintenance Lid58
- Bed Damper Removal/Installation58
- Cargo Bed Removal/Installation58
- Bed Side Cover Removal/Installation59
- Rear Step Guard Removal/Installation (4 Person Type Only)59
- Bed Center Cover Removal/Installation (4 Person Type Only)60
- Bed Front Panel Removal/Installation60
- Bed Top Cover Removal/Installation61
- Bed Release Lever Removal/Installation62
- Bed under Cover Removal/Installation62
- Tailgate Removal/Installation63
- Front Side Net Removal/Installation64
- Rear Side Net Removal/Installation (4 Person Type Only)64
- Front OPS Removal/Installation65
- Occupant Protective Structure (OPS)65
- Upper Middle OPS Removal/Installation65
- Rear Lower OPS Removal/Installation (4 Person Type Only)66
- Rear Side OPS Removal/Installation (4 Person Type Only)66
- Rear Upper OPS Removal/Installation (4 Person Type Only)66
- Front Seat Belt/Retractor67
- Seat Belt Instructions67
- Front Buckle68
- Rear Buckle68
- Rear Seat Belt/Retractor Person Type Only)68
- Front under Guard Removal/Installation69
- Middle under Guard Removal/Installation69
- Rear under Guard Removal/Installation69
- Exhaust System Removal/Installation70
- Exhaust Pipe Disassembly/Assembly71
- Muffler Disassembly/Assembly71
Maintenance73
- Maintenance Minder Indicator74
- Service Information74
- Maintenance Schedule75
- Fuel Line76
- Throttle Operation76
- Air Cleaner77
- Air Cleaner Housing Drain Tube78
- Battery79
- Spark Plug79
- Valve Clearance80
- Engine Oil81
  - Level Check81
  - Oil Change82
- COOLING System83
  - Oil Filter Replacement83
  - Radiator Coolant83
  - Recommended Antifreeze83
- Drive Shaft Boots84
- Inspection84
- Final Drive Oil85
  - Front Final Gear Case85
  - Rear Final Gear Case85
- Brake Fluid86
- Brake Light Switch87
- Brake Pads Wear87
- Brake Pedal Height88
- Brake System88
  - Hydraulic Brake88
  - Parking Brake89
- Underbody89
- Spark Arrester90
- Suspension90
- Exhaust System91
- Tie-Rod and Joint Boot91
  - Wheels/Tires91
  - Gear Box Boot and Operation Check92
  - Rotational Play Check92
- STEERING System92
  - Rack Guide Adjustment93
  - Turning Load Check93
  - Front Toe Inspection94
  - Wheel Alignment94
- Side Net95
- Turning Radius Inspection95
- Chassis Lubrication Points96
PGM-FI System97
- Service Information98
- Symptom Troubleshooting99
- Component Location100
- PGM-FI System Diagram101
- PGM-FI Troubleshooting Information102
- PGM-FI DTC Index105
- DTC 1-1 (Map Sensor Low Voltage)106
- Pgm -Fi Dtc Troubleshooting106
- Tp Sensor/Map Sensor (Sensor Unit)110
- ECT Sensor123
- IAT Sensor123
- VS Sensor123
- Pcm124
- Power Input Line124
- Engine Idle Speed125
- Power/Ground Line Inspection124
- Idle Speed Inspection125
Ignition System127
- Component Location128
- System Diagram128
- Ignition Coil133
- Ignition Timing134
- Electric Starter135
- Component Location136
- Starter Motor136
- System Diagram136
- Starter Relay Switch142
  - Function Inspection143
  - Ground Line143
- Brake Inhibitor Relay144
Diode143
- Relay Inspection144
- Fuel System147
- System Components148
- Service Information150
- Fuel Line Inspection151
- Fuel Pump155
- Air Cleaner Housing162
- Accelerator Pedal163
- Intake Air Duct163
- Throttle Body165
- Iacv169
- Fuel Injector170
Lubrication System173
- Lubrication System Diagram174
- Oil Pressure Check176
- Oil Pump176
- Oil Cooler182
- Cooling System185
- System Flow Pattern186
- Service Information187
- Troubleshooting187
  - Coolant (Hydrometer Test)188
  - System Testing188
  - Coolant Replacement189
  - Preparation189
  - Radiator Cap/System Pressure Inspection189
  - Replacement/Air Bleeding190
- Thermostat191
- Mechanical Seal Inspection192
- Water Pump192
- Cooling Fan/Shroud194
- Radiator196
- Radiator Reserve Tank197
- Cylinder Head/Valve/Camshaft199
- Cylinder Compression203
- Cylinder Head Cover Removal/Disassembly203
- Cam Follower205
- Push Rod205
- Rocker Arm/Shaft205
- Cylinder Head Removal206
- Cylinder Head Disassembly207
- Cylinder Head Inspection207
- Valve Spring208
- Valve/Valve Guide208
- Valve Guide Replacement209
- Valve Seat Inspection/Refacing209
- Valve Seat Refacing210
- Camshaft211
- Cylinder Head Assembly214
- Cylinder Head Installation215
- Cylinder Head Cover Assembly/Installation216
Shaft216
- Cam Chain Tensioner Lifter219
- Cylinder/Piston221
- System Components222
- Cylinder/Piston Removal224
- Cylinder/Piston Inspection225
- Cylinder/Piston Installation228
- Piston Ring Installation228
- Cylinder Installation229
- Alternator/Starter Clutch231
Alternator/Starter Clutch233
- Alternator Cover Removal235
- Alternator Stator/Starter Reduction Gears235
- Stator/Ckp Sensor Removal/Installation237
- Alternator Cover Installation238
- Bearing Replacement238
- Flywheel/Starter Clutch240
- Starter Clutch Disassembly/Inspection241
- Starter Clutch Assembly242
13. Sub-Transmission/Gearshift Linkage245
- System Components246
- Service Information247
- Troubleshooting248
- Rear Crankcase Cover249
  - Output Shaft Bearing250
  - Countershaft Bearing251
- Sub-Transmission253
  - Countershaft255
  - Output Shaft255
  - Gearshift Spindle256
- Gear Selector Lever Linkage260
- Reverse Idle Gear256
- Shift Drum256
- Shift Fork and Shaft256
- Gear Selector Cable Adjustment261
- Crankcase/Crankshaft/Balancer263
- Crankcase Separation267
- Crankshaft268
- Crankshaft and Balancer Installation270
- Crankcase Bearing Replacement271
- Rear Crankcase271
- Front Crankcase272
- Crankcase Assembly273
- Engine Removal/Installation277
- Engine Removal280
Engine Removal/Installation282
Engine Installation284
16. Drivetrain System289
- System Components290
- Service Information291
- A/T Clutch PC Solenoid Valve Operation Inspection293
- Symptom Troubleshooting293
  - Shift Solenoid Valve Operation Inspection294
  - Line Oil Pressure295
  - Shift Clutch Oil Pressure296
  - Hydraulic Circuit Troubleshooting Chart297
  - Drivetrain System Diagram299
- Drivetrain Troubleshooting Information300
  - Fail-Safe Function300
  - Self-Diagnosis System300
- Drivetrain DTC Index301
  - Drivetrain DTC Troubleshooting302
  - Dtc 4-1, Dtc 4-3302
  - DTC 4-2 (A/T Clutch PC Solenoid Valve High Input)303
  - DTC 15·1 (Shift Solenoid Valve A-Short)304
  - DTC 15-2 (Shift Solenoid Valve A-Open)305
  - DTC 16-1 (Shift Solenoid Valve B-Short)306
  - DTC 16-2 (Shift Solenoid Valve B-Open)307
  - DTC 31-1 (System Voltage Low)308
  - DTC 32-1 (Fail Safe Relay Circuit)309
  - DTC 41 -1 (Gear Position Switch Circuit)309
  - DTC 44-1 (EOT Sensor Low Voltage)311
  - DTC 44-2 (EOT Sensor High Voltage)312
  - Emergency Valve Function313
- Shift Valve Body313
  - Disassembly/Inspection314
  - Solenoid and Emergency Valves314
  - Orifice Control and Shift Valves316
  - Shift and Orifice Control Valves318
  - Front Crankcase Cover322
- Torque Converter328
  - Torque Converter Installation330
  - 1St Shift Clutch Removal332
  - Mainshaft Disassembly332
  - Shift Clutch/Mainshaft/Countershaft332
  - Countershaft Disassembly333
  - Shift Clutch Disassembly333
  - Mainshaft/Countershaft334
  - Clutch Disc and Plate335
  - Clutch Drum and Piston335
  - Clutch Return Spring335
  - Shift Clutch Assembly336
  - Clutch Initial Clearance Check338
  - Countershaft Assembly339
  - 1 St Shift Clutch Installation341
- Gear Position Switch342
- EOT Sensor343
- Mains Haft Assembly341
- Steering System345
- Steering Column and Shaft348
- Steering Wheel348
- Tie-Rod Ball Joint351
- Steering Gear Box353
- Drive Shaft/Final Gear363
- Front System Components364
- Rear System Components365
- Front Drive Shaft Removal370
- Rear Drive Shaft Removal370
- Front Drive Shaft Installation375
- Rear Drive Shaft Installation375
- Front Final Drive Removal376
- Operation Check378
- Front Propeller Shaft379
- Front Final Clutch381
- Pinion Joint Ball Bearing Replacement382
- Differential Lock Clutch387
- Half Shaft Bearing Replacement389
- Backlash Inspection392
- Front Final Gear Disassembly/Inspection392
- Differential Removal393
- Gear Tooth Contact Pattern Check394
- Differential Inspection396
- Pinion Gear Removal396
- Ring Gear Removal396
- Differential Bearing398
- Front Final Gear Case Bearing Replacement398
- Pinion Joint Needle Bearing Replacement398
- Pinion Needle Bearing399
- Front Final Gear Assembly401
- Pinion Gear Installation401
- Ring Gear Installation402
- Final Gear Case Assembly403
- Front Final Drive Installation404
- Rear Final Drive Removal407
- Propeller Shaft409
- Universal Joint409
- Universal Joint Disassembly/Assembly410
- Rear Final Drive Disassembly/Inspection411
- Final Gear Case Disassembly412
- Pinion Gear Bearing/Shim Replacement416
- Rear Final Drive Gear Case Bearing Replacement417
- Ring Gear Bearing417
- Rear Final Drive Assembly419
- Ring Gear Clearance Inspection421
Drive Shaft/Final Gear423
- Rear Final Drive Installation423
- Drive Mode Selector Lever Linkage425
- Drive Mode Selector Cable Adjustment427
- Wheel/Suspension431
Wheel/Suspension432
- System Components432
- Service Information434
- Troubleshooting435
- Tires436
- Wheels436
  - Tire Repair438
  - Recommended Tire Pressure Front439
- Front Wheel Hub/Knuckle440
- Brake Disc Replacement442
- Front Suspension Arm445
- Front Shock Absorber450
- Rear Wheel Hub/Knuckle451
- Rear Suspension Arm453
  - Stabilizer Arm and Link453
  - Suspension Arm Fastener Tightening456
- Rear Shock Absorber457
20. Brake System459
- System Components460
- Service Information462
- Troubleshooting463
- Brake Fluid Draining464
- Brake Fluid Replacement/Air Bleeding464
- Brake Fluid Filling/Bleeding465
- Brake Pad/Disc466
  - Front Brake Pad Replacement466
  - Rear Brake Pad Replacement467
  - Brake Disc Inspection468
- Master Cylinder470
- Front Brake Caliper474
- Rear Brake Caliper478
- Brake Pedal484
- Parking Brake Lever485
  - Battery/Charging System487
  - Battery Charging489
  - Battery Testing489
  - Voltage Inspection490
  - Charging System Inspection491
  - Charging Voltage Inspection491
  - Current Leakage Inspection491
  - Alternator Charging Coil492
  - Regulator/Rectifier492
  - Wire Harness Inspection492
  - Lights/Meters/Switches493
- Component Location494
- Service Information494
  - Bulb Removal/Installation495
  - Headlight495
  - Brake/Taillight496
- Combination Meter496
  - Digital Clock Adjustment497
  - Serial Communication Line498
  - Speedometer499
- Accessory Socket500
- Ignition Switch501
- Headlight Relay502
- Headlight Switch502
- Headlight Relay Circuit Inspection503
- Cooling Fan Motor504
  - Fuel Level Sensor Inspection506
  - Fuel Meter Inspection506
- Brake Light Switch507
- Fuel Level Sensor Removal/Installation507
- Parking Brake Switch508
L=~~~~~~~============================= WIRING DIAGRAM509
Index512

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Honda SXS700M2 Specifications

General

Brand	Honda
Model	SXS700M2
Category	Offroad Vehicle
Language	English

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