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HOW TO USE THIS MANUAL
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe condition that can cause your customer or others 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 professional 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 feel confident about your knowledge of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task.
Failure to properly 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 of the following:
•Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely.
•Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
•Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
•Protect yourself and others whenever you have the vehicle up in the air. Any time you 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 otherwise. 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 nonflammable solvent, not gasoline, to clean parts.
•Never drain or store gasoline in an open container.
•Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
0-1
HOW TO USE THIS MANUAL
How To Use This Manual
This manual describes the service procedures for the NC700X/XA/XD/S/SA/SD-C.
Sections 1, 2 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections.
Section 4 through 23 describe parts of the motorcycle, grouped according to location. If you are not familiar with this motorcycle, read Technical Feature in Section 1.
Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure.
Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI section troubleshooting first.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
•Safety Labels – on the vehicle
•Safety Messages – preceded by a safety alert symbol 
and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a 
symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN 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 WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: February 2012
0-2
HOW TO USE THIS MANUAL
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent).
Example:
•Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
•Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent).
Example:
•Molykote® G-n Paste manufactured by Dow Corning U.S.A.
•Honda Moly 60 (U.S.A. only)
•Rocol ASP manufactured by Rocol Limited, U.K.
•Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.
0-3
CONTENTS
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GENERAL INFORMATION |
1 |
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FRAME/BODY PANELS/EXHAUST SYSTEM |
2 |
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MAINTENANCE |
3 |
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PGM-FI SYSTEM |
4 |
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ELECTRICAL |
IGNITION SYSTEM |
5 |
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ELECTRIC STARTER |
6 |
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FUEL SYSTEM |
7 |
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COOLING SYSTEM |
8 |
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TRAIN |
LUBRICATION SYSTEM |
9 |
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CYLINDER HEAD/VALVES |
10 |
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ENGINE/DRIVE |
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CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) |
11 |
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DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) |
12 |
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ALTERNATOR/STARTER CLUTCH |
13 |
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CRANKCASE/TRANSMISSION/BALANCER |
14 |
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CRANKSHAFT/PISTON/CYLINDER |
15 |
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ENGINE REMOVAL/INSTALLATION |
16 |
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CHASSIS |
FRONT WHEEL/SUSPENSION/STEERING |
17 |
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REAR WHEEL/SUSPENSION |
18 |
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HYDRAULIC BRAKE |
19 |
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ANTI-LOCK BRAKE SYSTEM (ABS) |
20 |
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FRAME ELECTRICAL |
BATTERY/CHARGING SYSTEM |
21 |
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LIGHTS/METERS/SWITCHES |
22 |
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IMMOBILIZER SYSTEM (HISS) |
23 |
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WIRING DIAGRAM |
24 |
INDEX
MEMO
1. GENERAL INFORMATION
1
SERVICE RULES ··········································1-2
MODEL IDENTIFICATION ····························1-3
SPECIFICATIONS·········································1-6
TORQUE VALUES ······································1-15
LUBRICATION & SEAL POINTS ···············1-23 CABLE & HARNESS ROUTING·················1-25 EMISSION CONTROL SYSTEMS ··············1-86 TECHNICAL FEATURES····························1-87
1-1
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.
2.Use the special tools designed for this product to avoid damage and incorrect assembly.
3.Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners.
4.Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5.When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified.
6.Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7.After reassembly, check all parts for proper installation and operation.
8.Route all electrical wires as show in the Cable and Harness Routing (page 1-25).
9.Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term |
Full term |
ABS (NC700XA/XD/SA/SD) |
Anti-lock Brake System |
CKP sensor |
Crankshaft 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 |
IACV |
Idle Air Control Valve |
IAT sensor |
Intake Air Temperature sensor |
MAP sensor |
Manifold Absolute Pressure sensor |
MIL |
Malfunction Indicator Lamp |
O2 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 following codes are used to identify individual types for each region.
DESTINATION CODE |
REGION |
E |
U.K. |
III E |
U.K. type III |
ED |
EUROPEAN DIRECT SALES |
II ED |
EUROPEAN DIRECT SALES type II |
F |
France |
II F |
France type II |
KO |
Korea |
RU |
Russia |
U |
Australia, New Zealand |
1-2
GENERAL INFORMATION
MODEL IDENTIFICATION
NC700XA shown:
NC700SA shown:
This manual covers following types of NC700 models:
TYPE |
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NC700X |
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NC700S |
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NC700X |
NC700XA |
NC700XD |
NC700S |
NC700SA |
NC700SD |
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Standard brake |
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– |
– |
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– |
– |
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ABS |
– |
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– |
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DCT |
– |
– |
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– |
– |
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Be sure to refer to the procedure for the appropriate version of the NC700.
1-3
GENERAL INFORMATION
SERIAL NUMBERS
The Vehicle Identification Number (V.I.N) [1] is stamped on the right side of the steering head.
[1]
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 left side of the throttle body as shown.
[1]
[1]
[1]
1-4
GENERAL INFORMATION
LABELS
The color label [1] is attached on the right side of the rear frame. When |
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[1] |
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ordering color-coded parts, always specify the designated color code. |
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The Safety Certification Label (KO type) [1] is located on the left side of the |
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[1] |
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rear frame. |
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The Emission Control Information Label (KO type) [2] is located on the left |
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[1] |
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side of the rear frame. |
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1-5
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
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ITEM |
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SPECIFICATIONS |
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DIMENSIONS |
Overall length |
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NC700X/XA/XD |
2,210 mm (87.0 in) |
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NC700S/SA/SD |
2,195 mm (86.4 in) |
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Overall width |
E, ED, F, |
NC700X/XA/XD |
830 mm (32.7 in) |
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RU, U type |
NC700S/SA/SD |
760 mm (29.9 in) |
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KO type |
NC700XA |
825 mm (32.5 in) |
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Overall height |
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NC700X/XA/XD |
1,285 mm (50.6 in) |
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NC700S/SA/SD |
1,130 mm (44.5 in) |
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Wheelbase |
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NC700X/XA/XD |
1,540 mm (60.6 in) |
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NC700S/SA/SD |
1,525 mm (60.0 in) |
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Seat height |
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NC700X/XA/XD |
830 mm (32.7 in) |
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NC700S/SA/SD |
790 mm (31.1 in) |
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Footpeg height |
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NC700X/XA/XD |
341 mm (13.4 in) |
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NC700S/SA/SD |
310 mm (12.2 in) |
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Ground clearance |
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NC700X/XA/XD |
165 mm (6.5 in) |
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NC700S/SA/SD |
140 mm (5.5 in) |
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Curb weight |
E, ED, F, |
NC700X |
214 kg (472 lbs) |
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RU, U type |
NC700XA |
218 kg (481 lbs) |
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NC700XD |
228 kg (503 lbs) |
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NC700S |
211 kg (465 lbs) |
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NC700SA |
215 kg (474 lbs) |
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NC700SD |
225 kg (496 lbs) |
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KO type |
NC700XA |
220 kg (485 lbs) |
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Maximum weight capacity |
E, ED, F, RU, U type |
209 kg (461 lbs) |
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KO type |
189 kg (417 lbs) |
FRAME |
Frame type |
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Diamond |
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Front suspension |
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Telescopic fork |
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Front axle travel |
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NC700X/XA/XD |
137 mm (5.4 in) |
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NC700S/SA/SD |
107 mm (4.2 in) |
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Rear suspension |
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Swingarm |
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Rear axle travel |
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NC700X/XA/XD |
150 mm (5.9 in) |
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NC700S/SA/SD |
120 mm (4.7 in) |
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Front tire size |
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120/70ZR17M/C (58W) |
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Rear tire size |
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160/60ZR17M/C (69W) |
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Front tire brand |
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BRIDGESTONE |
BT023F G |
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METZELER |
ROADTEC Z8 INTERACT E |
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Rear tire brand |
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BRIDGESTONE |
BT023R G |
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METZELER |
ROADTEC Z8 INTERACT |
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Front brake |
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Hydraulic single disc |
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Rear brake |
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Hydraulic single disc |
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Caster angle |
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27° |
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Trail length |
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110 mm (4.3 in) |
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Fuel tank capacity |
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14.1 liters (3.73 US gal, 3.1 Imp gal) |
1-6
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GENERAL INFORMATION |
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ITEM |
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SPECIFICATIONS |
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ENGINE |
Cylinder arrangement |
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2 cylinders in-line, slant angle 55° |
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Bore and stroke |
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73.0 x 80.0 mm (2.87 x 3.15 in) |
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Displacement |
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670 cm3 (40.9 cu-in) |
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Compression ratio |
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10.7:1 |
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Valve train |
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Chain driven, OHC with rocker arm |
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Intake valve |
opens |
at 1 mm (0.04 in) lift |
No.1: – 20° BTDC |
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No.2: – 25° BTDC |
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closes |
at 1 mm (0.04 in) lift |
27° ABDC |
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Exhaust valve |
opens |
at 1 mm (0.04 in) lift |
30° BBDC |
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closes |
at 1 mm (0.04 in) lift |
No.1: – 15° ATDC |
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No.2: – 20° ATDC |
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Lubrication system |
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Forced pressure and wet sump |
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Oil pump type |
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Trochoid |
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Cooling system |
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Liquid cooled |
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Air filtration |
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Paper element |
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Engine dry weight |
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NC700X/XA/S/SA |
60.5 kg (133.4 lbs) |
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NC700XD/SD |
67.3 kg (148.4 lbs) |
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Firing order |
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1 - 2 |
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FUEL DELIVERY |
Type |
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PGM-FI (Programmed Fuel Injection) |
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SYSTEM |
Throttle bore |
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36 mm (1.4 in) |
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DRIVE TRAIN |
Clutch system |
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NC700X/XA/S/SA |
Multi-plate, wet |
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NC700XD/SD |
2 Multi-plate wet clutches |
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Clutch operation system |
NC700X/XA/S/SA |
Cable operating |
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NC700XD/SD |
Automatic |
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Transmission |
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Constant mesh, 6-speeds |
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Primary reduction |
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NC700X/XA/S/SA |
1.731 (71/41) |
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NC700XD/SD |
1.921 (73/38) |
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Final reduction |
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NC700X/XA/S/SA |
2.687 (43/16) |
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NC700XD/SD |
2.437 (39/16) |
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Gear ratio |
NC700X/XA/S/SA |
1st |
2.812 (45/16) |
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2nd |
1.894 (36/19) |
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3rd |
1.454 (32/22) |
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4th |
1.200 (30/25) |
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5th |
1.033 (31/30) |
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6th |
0.837 (31/37) |
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NC700XD/SD |
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1st |
2.666 (40/15) |
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2nd |
1.904 (40/21) |
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3rd |
1.454 (32/22) |
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4th |
1.200 (30/25) |
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5th |
1.033 (31/30) |
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6th |
0.837 (31/37) |
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Gearshift pattern |
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NC700X/XA/S/SA |
Left foot operated return system, |
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1 - N - 2 - 3 - 4 - 5 - 6 |
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NC700XD/SD |
Automatic and electric shift (left hand |
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operated) return system, |
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N - 1 - 2 - 3 - 4 - 5 - 6 |
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ELECTRICAL |
Ignition system |
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Computer-controlled digital |
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transistorized with electric advance |
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Starting system |
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Electric starter motor |
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Charging system |
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Triple phase output alternator |
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Regulator/rectifier |
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FET shorted/triple phase full wave |
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rectification |
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Lighting system |
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Battery |
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1-7
GENERAL INFORMATION
PGM-FI SPECIFICATIONS
ITEM |
SPECIFICATIONS |
IAT sensor resistance (at 20°C/68°F) |
2.2 – 2.7 kΩ |
ECT sensor resistance (at 40°C/104°F) |
1.0 – 1.3 kΩ |
Injector resistance (at 20°C/68°F) |
11 – 13 Ω |
IGNITION SYSTEM SPECIFICATIONS
ITEM |
SPECIFICATIONS |
Spark plug (Iridium) |
IFR6G-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
|
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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 |
1,200 ± 100 min-1 (rpm) |
Throttle grip freeplay |
2 – 6 mm (1/16 – 1/4 in) |
Fuel pressure at idle |
343 kPa (3.5 kgf/cm2, 50 psi) |
Fuel pump flow (at 12 V) |
230 cm3 (7.8 US oz, 8.1 Imp oz) minimum/10 seconds |
COOLING SYSTEM SPECIFICATIONS
ITEM |
SPECIFICATIONS |
||
Coolant capacity |
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Radiator and engine |
1.69 liters (1.79 US qt, 1.49 Imp qt) |
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|
At draining |
1.41 liters (1.49 US qt, 1.24 Imp qt) |
|
|
Reserve tank |
0.13 liter (0.14 US qt, 0.11 Imp qt) |
Radiator cap relief pressure |
|
|
108 – 137 kPa (1.1 – 1.4 kgf/cm2, 16 – 20 psi) |
Thermostat |
|
Begin to open |
80 – 84°C (176 – 183°F) |
|
|
Fully open |
95°C (203°F) |
|
|
Valve lift |
8 mm (0.3 in) minimum |
Recommended antifreeze |
|
|
High quality ethylene glycol antifreeze containing silicate-free |
|
|
|
corrosion inhibitors |
Standard coolant concentration |
|
1:1 (mixture with distilled water) |
|
1-8
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) |
– |
|
capacity |
|
After draining/ |
3.4 liters (3.6 US qt, 3.0 Imp qt) |
– |
|
|
|
filter change |
|||
|
|
|
|
|
|
|
|
After |
3.7 liters (3.9 US qt, 3.3 Imp qt) |
– |
|
|
|
disassembly |
|||
|
|
|
|
|
|
|
NC700XD/SD |
After draining |
3.2 liters (3.4 US qt, 2.8 Imp qt) |
– |
|
|
|
After draining/ |
3.4 liters (3.6 US qt, 3.0 Imp qt) |
– |
|
|
|
filter change |
|||
|
|
|
|
|
|
|
|
After |
4.1 liters (4.3 US qt, 3.6 Imp qt) |
– |
|
|
|
disassembly |
|||
|
|
|
|
|
|
Recommended |
engine oil |
|
Honda "4-stroke motorcycle oil" or an |
|
|
|
|
|
equivalent |
|
|
|
|
|
API service classification: SG 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 filter |
|
470 kPa (4.8 kgf/cm2, 68 psi) |
– |
||
|
|
|
at 5,000 min-1 (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) |
– |
CYLINDER HEAD/VALVES SPECIFICATIONS
|
|
|
|
|
|
Unit: mm (in) |
|
|
ITEM |
|
STANDARD |
SERVICE LIMIT |
|
Cylinder compression at 470 min-1(rpm) |
|
1,775 kPa (18.1 kgf/cm2, 257 psi) |
– |
|||
Valve clearance |
|
|
IN |
0.17 ± 0.02 (0.007 ± 0.001) |
– |
|
|
|
|
|
EX |
0.28 ± 0.02 (0.011 ± 0.001) |
– |
Rocker arm, |
|
Rocker arm I.D. |
|
|
20.012 – 20.030 (0.7879 – 0.7886) |
20.041 (0.7890) |
rocker arm |
|
Rocker arm shaft O.D. |
|
19.972 – 19.993 (0.7863 – 0.7871) |
19.961 (0.7859) |
|
shaft |
|
|
|
|
||
|
Rocker arm-to-shaft clearance |
0.019 – 0.058 (0.0007 – 0.0023) |
0.08 (0.003) |
|||
Cam chain tensioner wedge B length |
|
– |
6.0 (0.24) |
|||
Camshaft |
|
Cam lobe height |
|
IN |
34.7897 – 35.0297 (1.36967 – 1.37912) |
34.7697 |
|
|
|
|
(1.36888) |
||
|
|
|
|
|
|
|
|
|
|
|
EX |
34.9227 – 35.1627 (1.37491 – 1.38436) |
34.9027 |
|
|
|
|
(1.37412) |
||
|
|
|
|
|
|
|
|
|
Runout |
|
|
– |
0.04 (0.002) |
|
|
Camshaft journal O.D. |
|
41.935 – 41.950 (1.6510 – 1.6516) |
41.927 (1.6507) |
|
Valve, valve |
|
Valve stem O.D. |
|
IN |
4.975 – 4.990 (0.1959 – 0.1965) |
4.965 (0.1955) |
guide |
|
|
|
EX |
4.965 – 4.980 (0.1955 – 0.1961) |
4.955 (0.1951) |
|
|
Valve guide I.D. |
|
IN/EX |
5.000 – 5.012 (0.1969 – 0.1973) |
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) |
– |
|
|
projection above |
|
EX |
19.6 – 19.9 (0.77 – 0.78) |
– |
|
|
cylinder head |
|
|||
|
|
|
|
|
|
|
|
|
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 journal I.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) |
|||
1-9
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (NC700X/XA/S/SA)
|
|
|
|
|
Unit: mm (in) |
|
ITEM |
STANDARD |
SERVICE LIMIT |
||
Clutch lever freeplay |
|
|
10 – 20 (3/8 – 13/16) |
|
– |
Clutch |
|
Spring free 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 |
|
I.D. |
21.991 – 22.016 (0.8658 – 0.8668) |
22.03 (0.867) |
|
|
|
O.D. |
31.959 – 31.975 (1.2582 – 1.2589) |
31.92 (1.257) |
|
Mainshaft O.D. at clutch outer |
guide |
21.967 – 21.980 (0.8648 – 0.8654) |
21.95 (0.864) |
||
Clutch outer guide-to-mainshaft clearance |
0.011 – 0.049 (0.0004 – 0.0019) |
0.08 |
(0.003) |
||
Primary driven gear I.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) |
||
DUAL CLUTCH TRANSMISSION SPECIFICATIONS (NC700XD/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 kΩ |
– |
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
|
|
Unit: mm (in) |
ITEM |
STANDARD |
SERVICE LIMIT |
Starter driven gear boss O.D. |
57.749 – 57.768 (2.2736 – 2.2743) |
57.73 (2.273) |
Starter clutch outer I.D. |
74.412 – 74.442 (2.9296 – 2.9308) |
74.46 (2.931) |
CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS
NC700X/XA/S/SA |
|
|
|
|
|
|
|
|
Unit: mm (in) |
|
ITEM |
|
STANDARD |
SERVICE LIMIT |
Transmission |
Gear I.D. |
M5, M6, C1 |
28.000 – 28.021 (1.1024 – 1.1032) |
28.04 (1.104) |
|
|
C2, C3, C4 |
31.000 – 31.025 (1.2205 – 1.2215) |
31.04 (1.222) |
|
Gear bushing |
M5, M6 |
27.959 – 27.980 (1.1007 – 1.1016) |
27.94 (1.100) |
|
O.D. |
C2 |
30.955 – 30.980 (1.2187 – 1.2197) |
30.93 (1.218) |
|
|
C3, C4 |
30.950 – 30.975 (1.2185 – 1.2195) |
30.93 (1.218) |
|
Gear-to-bushing |
M5, M6 |
0.020 – 0.062 (0.0008 – 0.0024) |
0.08 (0.003) |
|
clearance |
C2 |
0.020 – 0.070 (0.0008 – 0.0028) |
0.10 (0.004) |
|
|
C3, C4 |
0.025 – 0.075 (0.0010 – 0.0030) |
0.11 (0.004) |
|
Gear bushing I.D. |
M5 |
25.000 – 25.021 (0.9843 – 0.9851) |
25.04 (0.986) |
|
|
C2 |
27.985 – 28.006 (1.1018 – 1.1026) |
28.02 (1.103) |
|
Mainshaft O.D. |
At M5 bushing |
24.972 – 24.993 (0.9831 – 0.9840) |
24.95 (0.982) |
|
Countershaft O.D. |
At C2 bushing |
27.967 – 27.980 (1.1011 – 1.1016) |
27.95 (1.100) |
|
Bushing-to-shaft |
M5 |
0.007 – 0.049 (0.0003 – 0.0020) |
0.09 (0.004) |
|
clearance |
C2 |
0.005 – 0.039 (0.0002 – 0.0015) |
0.06 (0.002) |
Shift fork, |
Fork I.D. |
|
12.000 – 12.018 (0.4724 – 0.4731) |
12.03 (0.474) |
fork shaft |
Claw thickness |
|
5.93 – 6.00 (0.233 – 0.236) |
5.9 (0.23) |
|
Shift fork shaft O.D. |
|
11.957 – 11.968 (0.4707 – 0.4712) |
11.95 (0.470) |
1-10
GENERAL INFORMATION
NC700XD/SD |
|
|
|
|
|
|
|
|
Unit: mm (in) |
|
ITEM |
|
STANDARD |
SERVICE LIMIT |
Transmission |
Gear I.D. |
M5 |
33.000 – 33.025 (1.2992 – 1.3002) |
33.04 (1.301) |
|
|
M6 |
43.000 – 43.025 (1.6929 – 1.6939) |
43.04 (1.694) |
|
|
C1 |
31.010 – 31.035 (1.2209 – 1.2218) |
31.06 (1.223) |
|
|
C2 |
25.000 – 25.021 (0.9843 – 0.9851) |
25.03 (0.985) |
|
|
C3, C4 |
31.000 – 31.025 (1.2205 – 1.2215) |
31.04 (1.222) |
|
Gear bushing |
M5 |
32.955 – 32.980 (1.2974 – 1.2984) |
32.93 (1.296) |
|
O.D. |
M6 |
42.950 – 42.975 (1.6909 – 1.6919) |
42.93 (1.690) |
|
|
C1 |
30.970 – 30.995 (1.2193 – 1.2203) |
30.94 (1.218) |
|
|
C2 |
24.959 – 24.980 (0.9826 – 0.9835) |
24.94 (0.982) |
|
|
C3, C4 |
30.950 – 30.975 (1.2185 – 1.2195) |
30.93 (1.218) |
|
Gear-to-bushing |
M5 |
0.020 – 0.070 (0.0008 – 0.0028) |
0.10 (0.004) |
|
clearance |
M6 |
0.025 – 0.075 (0.0010 – 0.0030) |
0.11 (0.004) |
|
|
C1 |
0.015 – 0.065 (0.0006 – 0.0026) |
0.10 (0.004) |
|
|
C2 |
0.020 – 0.062 (0.0008 – 0.0024) |
0.09 (0.004) |
|
|
C3, C4 |
0.025 – 0.075 (0.0010 – 0.0030) |
0.11 (0.004) |
|
Gear bushing I.D. |
M5 |
29.985 – 30.006 (1.1805 – 1.1813) |
30.03 (1.182) |
|
|
M6 |
40.007 – 40.028 (1.5751 – 1.5759) |
40.038 (1.5763) |
|
|
C1 |
28.000 – 28.021 (1.1024 – 1.1032) |
28.04 (1.104) |
|
|
C2 |
21.985 – 22.006 (0.8655 – 0.8664) |
22.02 (0.867) |
|
Inner mainshaft |
At M5 bushing |
29.957 – 29.970 (1.1794 – 1.1799) |
29.93 (1.178) |
|
O.D. |
|||
|
|
|
|
|
|
Outer mainshaft |
At M6 bushing |
39.975 – 39.991 (1.5738 – 1.5744) |
39.965 (1.5734) |
|
O.D. |
|||
|
|
|
|
|
|
Countershaft O.D. |
At C1 bushing |
27.967 – 27.980 (1.1011 – 1.1016) |
27.95 (1.100) |
|
|
At C2 bushing |
21.952 – 21.965 (0.8643 – 0.8648) |
21.94 (0.864) |
|
Bushing-to-shaft |
M5 |
0.015 – 0.049 (0.0006 – 0.0019) |
0.09 (0.004) |
|
clearance |
M6 |
0.016 – 0.053 (0.0006 – 0.0021) |
0.10 (0.004) |
|
|
C1 |
0.020 – 0.054 (0.0008 – 0.0021) |
0.08 (0.003) |
|
|
C2 |
0.020 – 0.054 (0.0008 – 0.0021) |
0.08 (0.003) |
Shift fork, |
Fork I.D. |
|
12.000 – 12.018 (0.4724 – 0.4731) |
12.03 (0.474) |
fork shaft |
Claw thickness |
|
5.93 – 6.00 (0.233 – 0.236) |
5.9 (0.23) |
|
Shift fork 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 |
Crankshaft |
Connecting rod side clearance |
0.15 – 0.35 (0.006 – 0.014) |
0.45 (0.018) |
|
|
Runout |
Right side |
– |
0.03 (0.001) |
|
|
Left side |
– |
0.03 (0.001) |
|
Main journal bearing |
oil clearance |
0.019 – 0.037 (0.0007 – 0.0015) |
0.05 (0.002) |
Cylinder |
I.D. |
|
73.000 – 73.015 (2.8740 – 2.8746) |
73.07 (2.877) |
|
Out-of-round |
|
– |
0.10 (0.004) |
|
Taper |
|
– |
0.10 (0.004) |
|
Warpage |
|
– |
0.10 (0.004) |
Piston, piston |
Piston O.D. at 13 mm (0.5 in) from |
72.976 – 72.990 (2.8731 – 2.8736) |
72.970 (2.8728) |
|
rings |
bottom |
|
||
|
|
|
||
|
Piston pin bore I.D. |
|
18.010 – 18.013 (0.7091 – 0.7092) |
18.023 (0.7096) |
|
Piston pin O.D. |
|
17.996 – 18.000 (0.7085 – 0.7087) |
17.988 (0.7082) |
|
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 (0.006 – 0.012) |
0.6 (0.02) |
|
gap |
Second |
0.30 – 0.42 (0.012 – 0.017) |
0.6 (0.02) |
|
|
Oil (side rail) |
0.20 – 0.70 (0.008 – 0.028) |
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 I.D. |
|
17.964 – 17.977 (0.7072 – 0.7078) |
17.985 (0.7081) |
|
Crankpin bearing 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) |
||
Cold tire |
|
Driver only |
|
250 kPa (2.50 kgf/cm2, 36 psi) |
– |
pressure |
|
Driver and passenger |
250 kPa (2.50 kgf/cm2, 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 free |
NC700X/XA/XD |
394.9 (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 fork fluid |
Honda ULTRA CUSHION OIL SS-47 |
– |
|
|
|
|
|
(10W) or equivalent |
|
|
|
|
|
|
|
|
|
Fluid level |
NC700X/XA/XD |
104 (4.1) |
– |
|
|
|
NC700S/SA/SD |
103 (4.1) |
– |
|
|
Fluid capacity |
NC700X/XA/XD |
514 ± 2.5 cm3 (17.4 ± 0.08 US oz, 18.1 ± |
– |
|
|
|
0.09 Imp oz) |
||
|
|
|
|
|
|
|
|
|
NC700S/SA/SD |
518 ± 2.5 cm3 (17.5 ± 0.08 US oz, 18.2 ± |
– |
|
|
|
0.09 Imp oz) |
||
|
|
|
|
|
|
REAR WHEEL/SUSPENSION SPECIFICATIONS
|
|
|
|
|
|
Unit: mm (in) |
|
|
ITEM |
|
STANDARD |
SERVICE LIMIT |
|
Minimum tire tread depth |
|
|
|
– |
2.0 (0.08) |
|
Cold tire pressure |
|
Driver only |
|
290 kPa (2.90 kgf/cm2, 42 psi) |
– |
|
|
|
|
Driver and passenger |
290 kPa (2.90 kgf/cm2, 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 |
DID520V0-114LE |
– |
chain |
|
|
XA/S/SA |
RK |
RK520MKO-114LE |
– |
|
|
|
NC700XD |
DID |
DID520V0-112LE |
– |
|
|
|
/SD |
RK |
RK520MKO-112LE |
– |
|
Slack |
|
NC700X/XA/XD |
|
30 – 40 (1.2 – 1.6) |
– |
|
|
|
NC700S/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 fluid |
|
|
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 I.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 I.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 I.D. |
|
Cylinder A |
22.650 – 22.700 (0.8917 – 0.8937) |
|
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) |
|
Rear |
Specified brake fluid |
|
|
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 I.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 I.D. |
|
|
38.18 – 38.23 (1.503 – 1.505) |
|
38.24 (1.506) |
|
|
Caliper piston O.D. |
|
|
38.098 – 38.148 (1.4999 – 1.5019) |
|
38.09 (1.500) |
|
|
Brake pedal height |
|
|
85.0 – 87.0 (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 12.4 V |
|
||
|
|
|
charging |
|
|||
|
|
|
|
|
|
||
|
Charging current |
|
Normal |
1.1 A/5 – 10 h |
|
||
|
|
|
Quick |
5.5 A/1 h |
|
||
Alternator |
Capacity |
|
|
|
0.42 kW/5,000 min-1 (rpm) |
|
|
|
Charging coil resistance (20°C/68°F) |
0.1 – 0.5 Ω |
|
||||
1-13
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES SPECIFICATIONS
|
ITEM |
|
SPECIFICATIONS |
Bulbs |
Headlight |
|
12 V – 60/55 W |
|
Position light |
|
12 V – 5 W |
|
Brake/tail/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 (NC700XA/XD/SA/SD) |
LED |
|
|
Parking brake indicator (NC700XD/SD) |
LED |
|
Fuse |
Main fuse |
|
30 A |
|
PGM-FI fuse |
|
15 A |
|
Sub fuse |
|
15 A x 2, 7.5 A x 4 |
|
ABS fuse (NC700XA/XD/SA/SD) |
30 A x 2, 7.5 A |
|
|
DCT fuse (NC700XD/SD) |
30 A, 7.5 A |
|
ECT sensor resistance |
40°C (104°F) |
1.0 – 1.3 kΩ |
|
|
|
100°C (212°F) |
0.1 – 0.2 kΩ |
Fuel level sensor resistance |
Full |
4 – 6 Ω |
|
|
|
Empty |
80 – 83 Ω |
1-14
GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
FASTENER TYPE |
TORQUE |
FASTENER TYPE |
TORQUE |
||||
N·m (kgf·m, lbf·ft) |
N·m (kgf·m, lbf·ft) |
||||||
|
|
||||||
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 flange bolt) |
10 (1.0, 7) |
6 mm screw |
9.0 |
(0.9, |
6.6) |
||
and nut |
|
|
6 mm flange bolt (Include NSHF) and |
12 (1.2, 9) |
|||
8 mm bolt and nut |
22 |
(2.2, 16) |
nut |
|
|
|
|
10 mm bolt and nut |
34 |
(3.5, 25) |
8 mm flange bolt and nut |
27 |
(2.8, |
20) |
|
12 mm bolt and nut |
54 |
(5.5, 40) |
10 mm flange bolt and nut |
39 |
(4.0, |
29) |
|
ENGINE & FRAME TORQUE VALUES
FRAME BODY PANELS/EXHAUST SYSTEM |
|
|
|
|
||
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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 |
12 (1.2, 9) |
|
||
bolt |
|
|
|
|
|
|
Luggage box lid hinge nut |
1 |
6 |
12 (1.2, 9) |
U-nut |
||
Gearshift 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 |
8 |
17.5 (1.8, 13) |
|
||
Exhaust pipe joint nut |
3 |
8 |
28 |
(2.9, 21) |
See page 2-34 |
|
Exhaust pipe stud bolt |
3 |
8 |
|
– |
See page 2-35 |
|
1-15
GENERAL INFORMATION
MAINTENANCE |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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 surface. |
|
Camshaft 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 filter cartridge |
1 |
20 |
26 |
(2.7, 19) |
Apply engine oil to the threads. |
|
Oil filter boss |
1 |
20 |
|
– |
See page 3-14 |
|
|
|
|
|
|
Apply locking agent to the threads. |
|
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
|
0.04 in) from tip |
|
Rear axle nut |
1 |
18 |
98 (10.0, 72) |
U-nut |
||
Drive chain adjuster lock nut |
2 |
8 |
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 master cylinder push rod lock |
1 |
8 |
17 |
(1.7, 13) |
|
|
nut |
|
|
|
|
|
|
Parking brake adjuster bolt lock |
1 |
8 |
17 |
(1.7, 13) |
|
|
nut (NC700XD/SD) |
|
|
|
|
|
|
Sidestand pivot bolt |
1 |
10 |
|
– |
See page 3-27 |
|
|
|
|
|
|
Apply grease to the sliding surface. |
|
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 |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
ECT sensor |
1 |
10 |
12 (1.2, 9) |
|
||
Bank angle sensor mounting bolt |
2 |
6 |
10 (1.0, 7) |
|
||
O2 sensor |
1 |
12 |
24.5 (2.5, 18) |
|
||
IGNITION SYSTEM |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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. |
||
bolt (NC700XD/SD) |
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
|
0.04 in) from tip |
|
ELECTRIC STARTER |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
Starter motor terminal nut |
1 |
6 |
10 (1.0, 7) |
|
||
FUEL SYSTEM |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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 |
|
1-16
|
|
|
|
|
GENERAL INFORMATION |
|
COOLING SYSTEM |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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 fan mounting nut |
1 |
3 |
1.0 |
(0.1, 0.7) |
Apply locking agent to the threads. |
|
LUBRICATION SYSTEM |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
Engine oil filter cartridge |
1 |
20 |
26 |
(2.7, 19) |
Apply engine oil to the threads. |
|
CYLINDER HEAD/VALVES |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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 ± 1.0 mm (0.26 ± |
|
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
|
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. |
|
CLUTCH/GEARSHIFT LINKAGE (NC700X/XA/S/SA) |
|
|
|
|||
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
Clutch center lock nut |
1 |
18 |
128 |
(13.1, 94) |
Apply engine oil to the threads and |
|
|
|
|
|
|
seating surface. |
|
|
|
|
|
|
Lock nut; replace with a new one and |
|
|
|
|
|
|
stake. |
|
Clutch lifter 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. |
|
Shift drum stopper arm pivot bolt |
1 |
6 |
12 (1.2, 9) |
Apply locking agent to the threads. |
||
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
|
0.04 in) from tip |
|
Shift drum center socket bolt |
1 |
8 |
23 |
(2.3, 17) |
Apply locking agent to the threads. |
|
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
|
0.04 in) from tip |
|
Gearshift pedal adjuster lock nut |
2 |
6 |
10 (1.0, 7) |
|
||
Gearshift pedal pivot bolt |
1 |
8 |
27 |
(2.8, 20) |
|
|
1-17
GENERAL INFORMATION
DUAL CLUTCH TRANSMISSION (DCT) (NC700XD/SD) |
|
|
|||
|
|
|
|
|
|
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
|
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
||||
|
|
|
|||
Solenoid valve stopper plate bolt |
1 |
6 |
12 (1.2, 9) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width: 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
Right crankcase cover wire clamp |
2 |
6 |
12 (1.2, 9) |
Apply locking agent to the threads. |
|
bolt |
|
|
|
Coating width: 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
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 |
3 |
6 |
14 (1.4, 10) |
|
|
TR sensor bolt |
1 |
6 |
12 (1.2, 9) |
|
|
Shift control motor bolt |
3 |
6 |
14 (1.4, 10) |
|
|
Shift drum center bolt |
1 |
8 |
23 (2.3, 17) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width: 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
Drum shifter guide plate bolt |
2 |
6 |
12 (1.2, 9) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width: 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
Clutch line EOP sensor |
3 |
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 |
|
|
|
|
|
|
|
|
|
|
|
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
|
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
||||
|
|
|
|||
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 |
8 |
30 (3.1, 22) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
Alternator stator mounting bolt |
4 |
6 |
10 (1.0, 7) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
Alternator wire clamp bolt |
1 |
6 |
10 (1.0, 7) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
1-18
|
|
|
|
GENERAL INFORMATION |
|
CRANKCASE/TRANSMISSION/BALANCER |
|
|
|
||
|
|
|
|
|
|
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
|
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
||||
|
|
|
|||
Mainshaft bearing set plate bolt |
3 |
6 |
12 (1.2, 9) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
Shift drum bearing set plate bolt |
2 |
6 |
12 (1.2, 9) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
Balancer shaft bearing set plate |
3 |
6 |
12 (1.2, 9) |
Apply locking agent to the threads. |
|
bolt |
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
0.04 in) from tip |
|
Crankcase 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 (2.4, 18) |
Apply locking agent to the threads. |
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
0.04 in) from tip |
|
Crankcase 6 mm bolt |
8 |
6 |
12 (1.2, 9) |
|
|
CRANKSHAFT/PISTON/CYLINDER |
|
|
|
|
|
|
|
|
|
|
|
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
|
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
||||
|
|
|
|||
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 surface. |
|
Crankcase main journal bolt |
6 |
9 |
20 (2.0, 15) + 120° |
See page 15-9 |
|
(retightening) |
|
|
|
Apply engine oil to the threads and |
|
|
|
|
|
seating surface. |
|
ENGINE REMOVAL/INSTALLATION |
|
|
|
|
|
|
|
|
|
|
|
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
|
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
||||
|
|
|
|||
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 |
|
1-19
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING |
|
|
|
|
||
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
Handlebar holder bolt |
4 |
8 |
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 surface. |
|
Front axle pinch bolt |
1 |
8 |
22 |
(2.2, 16) |
|
|
Fork socket bolt |
2 |
8 |
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 |
8 |
22 |
(2.2, 16) |
|
|
Front brake caliper mounting bolt |
2 |
8 |
30 |
(3.1, 22) |
ALOC bolt; replace with a new one. |
|
Steering stem adjusting nut |
1 |
26 |
23 |
(2.3, 17) |
See page 17-38 |
|
|
|
|
|
|
Apply engine oil to the threads. |
|
Steering stem adjusting 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 surface. |
|
(NC700X/XA/S/SA) |
|
|
|
|
|
|
Clutch lever pivot nut |
1 |
6 |
6.0 |
(0.6, 4.4) |
|
|
(NC700X/XA/S/SA) |
|
|
|
|
|
|
REAR WHEEL/SUSPENSION |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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 |
8 |
32 |
(3.3, 24) |
|
|
Gearshift arm pinch bolt |
1 |
6 |
12 (1.2, 9) |
ALOC bolt; replace with a new one. |
||
(NC700X/XA/S/SA) |
|
|
|
|
|
|
1-20
|
|
|
|
|
GENERAL INFORMATION |
|
HYDRAULIC BRAKE |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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 |
17 |
(1.7, 13) |
|
|
Rear brake caliper mounting bolt |
1 |
8 |
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 oz) silicone |
|
|
|
|
|
|
grease to the sliding surface. |
|
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 |
8 |
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 master cylinder push rod lock |
1 |
8 |
17 |
(1.7, 13) |
|
|
nut |
|
|
|
|
|
|
Front brake caliper pin |
1 |
8 |
22 |
(2.2, 16) |
Apply locking agent to the threads. |
|
|
|
|
|
|
Apply 0.4 g (0.01 oz) silicone grease |
|
|
|
|
|
|
to the sliding surface. |
|
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 surface. |
|
Front brake caliper mounting bolt |
2 |
8 |
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 surface. |
|
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 |
17 |
(1.7, 13) |
ALOC bolt; replace with a new one. |
|
(NC700XD/SD) |
|
|
|
|
|
|
Parking brake adjuster bolt lock |
1 |
8 |
17 |
(1.7, 13) |
|
|
nut (NC700XD/SD) |
|
|
|
|
|
|
Parking brake cable mounting nut |
1 |
10 |
10 (1.0, 7) |
|
||
(NC700XD/SD) |
|
|
|
|
|
|
ANTI-LOCK BRAKE SYSTEM (ABS) (NC700XA/XD/SA/SD) |
|
|
|
|||
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
Step holder mounting socket bolt |
4 |
8 |
32 |
(3.3, 24) |
|
|
Brake pipe joint nut |
14 |
10 |
14 |
(1.4, 10) |
Apply brake fluid to the threads and |
|
|
|
|
|
|
sliding surface. |
|
PCV mounting bolt |
2 |
6 |
12 (1.2, 9) |
|
||
Delay valve mounting bolt |
2 |
6 |
12 (1.2, 9) |
|
||
1-21
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
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 (NC700S/SA/SD) |
|
|
|
|
|
|
EOP switch |
1 |
PT 1/8 |
18 |
(1.8, 13) |
Apply sealant to the threads. |
|
Ignition switch mounting bolt |
2 |
8 |
25 |
(2.5, 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) |
|
|
|
|
|
|
OTHERS |
|
|
|
|
|
|
|
|
|
|
|
||
ITEM |
Q'TY |
THREAD |
TORQUE |
REMARKS |
||
DIA. (mm) |
N·m (kgf·m, lbf·ft) |
|||||
|
|
|
||||
Cam chain tensioner set plate bolt |
1 |
6 |
12 (1.2, 9) |
Apply locking agent to the threads. |
||
|
|
|
|
|
Coating width; 6.5 ± 1.0 mm (0.26 ± |
|
|
|
|
|
|
0.04 in) except 2.0 ± 1.0 mm (0.08 ± |
|
|
|
|
|
|
0.04 in) from tip |
|
Camshaft cap |
1 |
20 |
30 |
(3.1, 22) |
|
|
Gearshift spindle return spring pin |
1 |
8 |
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 |
Oil pan mating surface |
See page 9-12 |
(Three Bond 1207B or |
Right crankcase cover mating surface |
See page 11-6 |
equivalent) |
|
|
CKP sensor wire grommet |
|
|
|
Linear solenoid valve wire grommet (NC700XD/SD) |
|
|
Alternator wire grommet |
|
|
Alternator cover mating surface |
See page 13-7 |
|
Crankcase mating surface |
See page 14-28 |
Molybdenum oil solution |
Rocker arm sliding surface |
|
(a mixture of 1/2 engine oil |
Rocker arm shaft outer surface |
|
and 1/2 molybdenum |
|
|
Camshaft lobes, journals and thrust surface |
|
|
disulfide grease) |
|
|
Valve stem (valve guide sliding surface) and stem end |
|
|
|
Clutch outer guide sliding surface (NC700X/XA/S/SA) |
|
|
Starter reduction and idle gear shaft outer surface |
|
|
M3/4, C5, C6 gear (shift fork grooves) (NC700X/XA/S/SA) |
|
|
M3, M4, C5, C6 gear (shift fork grooves) (NC700XD/SD) |
|
|
Each transmission spline collar outer surface |
|
|
Each transmission collar inner and outer surface |
|
|
Shift fork guide area and guide pin |
|
|
Shift fork shaft outer surface |
|
|
Main journal bearing sliding surface |
|
|
Crankpin bearing sliding surface |
|
|
Crankshaft thrust surface |
|
Engine oil |
Oil filter cartridge O-ring |
|
|
Oil filler cap O-ring |
|
|
Timing hole cap O-ring |
|
|
Crankshaft hole cap O-ring |
|
|
Clutch oil filter 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 (NC700X/XA/S/SA) |
|
|
Clutch lifter rod A sliding surface (NC700X/XA/S/SA) |
|
|
Clutch lifter rod B sliding surface (NC700X/XA/S/SA) |
|
|
Mainshaft seal rings (NC700XD/SD) |
|
|
Starter one-way clutch |
|
|
Piston sliding surface |
|
|
Piston ring sliding surface |
|
|
Piston pin outer surface |
|
|
Each bearing |
|
|
Each gear teeth and rotating surface |
|
|
Each O-ring (except water sealing) |
|
|
Other rotating area and sliding surface |
|
Multi-purpose grease |
Each oil seal lips |
|
Locking agent |
CKP sensor mounting bolt threads |
Coating width; 6.5 ± 1.0 |
|
|
mm (0.26 ± 0.04 in) |
|
|
except 2.0 ± 1.0 mm (0.08 |
|
|
± 0.04 in) from tip |
Templex N3 grease (ESSO) |
Electric shift reduction gear teeth and journal (NC700XD/SD) |
2 – 4 g (0.07 – 0.14 oz) |
1-23
GENERAL INFORMATION
FRAME
MATERIAL |
LOCATION |
REMARKS |
Urea based multi-purpose |
Steering head bearing sliding surface |
3 – 5 g (0.1 – 0.2 oz) |
grease with extreme |
Steering head dust seal lips |
|
pressure |
|
|
(example: Kyodo Yushi |
|
|
EXCELITE EP2, Shell |
|
|
Stamina EP2 or equivalent) |
|
|
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 surface |
|
|
(NC700XD/SD) |
|
|
Parking brake lever, washer sliding surface (NC700XD/SD) |
|
|
Parking brake switch spring sliding surface (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, B inside |
|
|
Clutch cable inside (NC700X/XA/S/SA) |
|
|
Parking brake cable inside (NC700XD/SD) |
|
Honda bond A, Cemedine |
Handlebar grip rubber inside |
|
#540 or equivalent |
Brake pad retainer mating surface |
|
Silicone grease |
Front brake lever sliding surface and lever-to-master piston |
0.10 g (0.004 oz) |
|
contacting area |
|
|
Rear brake master cylinder push rod sliding surface and boot |
|
|
fitting 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 |
0.4 g (0.01 oz) minimum |
|
surface (NC700XD/SD) |
|
|
Parking brake shaft boot lips (NC700XD/SD) |
0.4 g (0.01 oz) minimum |
|
Parking brake caliper bracket pin sliding surface (NC700XD/ |
0.4 g (0.01 oz) minimum |
|
SD) |
|
|
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 fluid |
Fork cap O-ring |
|
|
Fork dust seal and oil seal lips |
|
Drive chain lubricant |
Drive chain whole surface |
|
designed specifically for use |
|
|
with O-ring chains, #80 – 90 |
|
|
gear oil or equivalent |
|
|
1-24
GENERAL INFORMATION
CABLE & HARNESS ROUTING
NC700X/XA:
CLUTCH SWITCH WIRE
LEFT HANDLEBAR
SWITCH WIRE
NC700XD:
LEFT HANDLEBAR
SWITCH WIRE
BRAKE LIGHT SWITCH
CONNECTOR
RIGHT HANDLEBAR
SWITCH WIRE
THROTTLE CABLE A
BRAKE LIGHT SWITCH RIGHT HANDLEBAR CONNECTOR SWITCH WIRE
THROTTLE CABLE B
RIGHT HANDLEBAR
SWITCH WIRE
1-25
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