2003-2005 Honda NRX1800 Valkyrie Rune Motorcycle Service & Repair 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. 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 recommended 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. 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. 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. 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.

HOW TO USE THIS MANUAL This service manual describes the service procedures for the NRX1800. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition and emission levels are within the standards set by the U.S. Environmental Protection Agency, California Air Resources Board and Transport Canada. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 4 apply to the whole motorcycle. Section 3 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 5 through 21 describe parts of the motorcycle, grouped according to location. 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 procedures. If you are not familiar with this motorcycle, read Technical Features in Section 2. If you don't know the source of the trouble, go to Section 23 Troubleshooting. 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, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST 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 OBLI- GATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITH- OUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTE- NANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMATION TECHNICAL FEATURE FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM ENGINE AND DRIVE TRAIN FUEL SYSTEM (Programmed Fuel Injection) COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVE CLUTCH GEARSHIFT LINKAGE/TRANSMISSION CYLINDER/PISTON/CRANKSHAFT FRONT WHEEL/SUSPENSION/ STEERING HYDRAULIC DISC BRAKE BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING CHASSIS ELECTRICAL 23 22 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 INDEX 24 Date of Issue: May, 2003 © Honda Motor Co., Ltd. IMMOBILIZER SYSTEM 21 REAR WHEEL/SUSPENSION FINAL DRIVE

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1) Use multi-purpose grease (Lithium based multi-purpose grease 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 a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use Fork or Suspension Fluid.

1-1 1 1. GENERAL INFORMATION SERVICE RULES ············································ 1-2 MODEL IDENTIFICATION······························ 1-2 GENERAL SPECIFICATIONS························· 1-4 LUBRICATION SYSTEM SPECIFICATIONS · 1-6 FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS··········································· 1-6 COOLING SYSTEM SPECIFICATIONS ········· 1-6 CYLINDER HEAD/VALVE SPECIFICATIONS 1-7 CLUTCH SPECIFICATIONS ··························· 1-7 GEARSHIFT LINKAGE/TRANSMISSION SPECIFICATIONS··········································· 1-8 CYLINDER/PISTON/CRANKSHAFT SPECIFICATIONS··········································· 1-8 FINAL DRIVE SPECIFICATIONS···················· 1-9 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS··········································· 1-9 REAR WHEEL/SUSPENSION SPECIFICATIONS············································1-9 HYDRAULIC DISC BRAKE SPECIFICATIONS··········································1-10 BATTERY/CHARGING SYSTEM SPECIFICATIONS··········································1-10 IGNITION SYSTEM SPECIFICATIONS ········1-10 ELECTRIC STARTER SPECIFICATIONS ······1-11 LIGHTS/METERS/SWITCHES SPECIFICATIONS··········································1-11 STANDARD TORQUE VALUES ···················1-12 ENGINE & FRAME TORQUE VALUES ········1-12 LUBRICATION & SEAL POINTS ··················1-19 CABLE & HARNESS ROUTING ···················1-22 EMISSION CONTROL SYSTEMS ················1-45 EMISSION CONTROL INFORMATION LABELS ·························································1-48

GENERAL INFORMATION 1-2 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 1-22). MODEL IDENTIFICATION The Vehicle Identification Number (VIN) is located on right side of the frame near the steering head. VEHICLE IDENTIFICATION NUMBER

GENERAL INFORMATION 1-3 The frame serial number is stamped on the right side of the steering head. The engine serial number is stamped on the right side of the crankcase. The throttle body identification numbers are stamped on the inside of all the throttle bodies. The color label is attached on the rear fender under the seat. When ordering color-coded parts, always specify the designated color code. FRAME SERIAL NUMBER ENGINE SERIAL NUMBER THROTTLE BODY IDENTIFICATION NUMBER COLOR LABEL

GENERAL INFORMATION 1-4 GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,560 mm (100.8 in) Overall width 920mm (36.2 in) Overall height DA, EA, BA model: 1,090 mm (42.9 in) DB, EB, BB model: 1,070 mm (42.1 in) Wheel base 1,750 mm (68.9 in) Seat height 690 mm (27.2 in) Footpeg height 244 mm (9.6 in) Ground clearance 135 mm (5.3 in) Dry weight 49 state and Canada type: 368 kg (811 lbs) California type: 369 kg (813 lbs) Curb weight 49 state and Canada type: 398 kg (877 lbs) California type: 399 kg (880 lbs) Maximum weight capacity 125 kg (276 lbs) FRAME Frame type Diamond Front suspension Bottom link Front axle travel 100 mm (3.9 in) Rear suspension Swingarm Rear axle travel 100 mm (3.9 in) Front tire size 150/60R18M/C 67V Rear tire size 180/55R17M/C 73V Front tire brand D251F (Dunlop) Rear tire brand D251 (Dunlop) Brake system Combined brake system Front brake Hydraulic double disc Rear brake Hydraulic single disc Caster angle 29°00’ Trail length 125 mm (4.9 in) Fuel tank capacity 23 liters (6.1 US gal, 5.1 lmp gal) ENGINE Cylinder arrangement Flat six Bore and stroke 74.0 x 71.0 mm (2.91 x 2.80 in) Displacement 1,832 cm 3 (111.8 cu-in) Compression ratio 9.8 : 1 Valve train Silent cam chain driven, OHC Intake valve opens 0° BTDC at 1 mm lift Intake valve closes 25° ABDC at 1 mm lift Exhaust valve opens 35° BBDC at 1 mm lift Exhaust valve closes –5° ATDC (5° BTDC) at 1 mm lift Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Viscous paper element Engine dry weight 118.6 kg (261.5 lbs) Firing order 1-4-5-2-3-6 Cylinder number FUEL DELIV- ERY SYSTEM Type Programmed Fuel Injection (PGM-FI) Throttle bore 32 mm (1.3 in) Front 1, 3, 5 2, 4, 6

GENERAL INFORMATION 1-5 DRIVE TRAIN Clutch system Multi-plate, wet (hydraulically assisted) Clutch operation system Hydraulically operated Transmission Constant mesh, 5-speeds Primary reduction 1.591 (78/49) Secondary reduction 1.028 (36/35) Final reduction 2.917 (35/12) Gear ratio 1st 1.944 (35/18) 2nd 1.347 (31/23) 3rd 1.035 (29/28) 4th 0.843 (27/32) 5th 0.705 (24/34) Gearshift pattern Left foot operated return system, 1-N-2-3-4-5 ELECTRICAL Ignition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier Triple phase full-wave rectification with field coil Lighting system Battery ITEM SPECIFICATIONS

GENERAL INFORMATION 1-6 LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS COOLING SYSTEM SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Engine oil capacity After draining 3.6 liters (3.8 US qt, 3.2 lmp qt) – After draining/ filter change 3.7 liters (3.9 US qt, 3.3 lmp qt) – After disassembly 4.6 liters (4.9 US qt, 4.0 lmp qt) – Recommended engine oil Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil API service classification SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-40 – Oil pressure (at oil pressure switch) 530 kPa (5.4 kgf/cm 2 , 77 psi) at 5,000 rpm/80°C (176°F) – Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance Feed side 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014) Scavenge side 0.15 – 0.22 (0.006 – 0.009) 0.35 (0.014) Side clearance 0.02 – 0.09 (0.001 – 0.004) 0.12 (0.005) ITEM SPECIFICATIONS Throttle body identification number 49 state and Canada type GQ81B California type GQ81A Starter valve vacuum difference 20mm Hg Base throttle valve for synchronization No. 4 Throttle grip free play 2 – 6 mm (1/16 – 1/4 in) Intake air temperature sensor resistance (at 20°C/68°F) 2.2 – 2.7 kΩ Engine coolant temperature sensor resistance (at 20°C/68°F) 2.3 – 2.6 kΩ Throttle position sensor resistance (at 20°C/68°F) 5 – 7.6 Ω Fuel injector resistance (at 20°C/68°F) 10.5 – 14.5 Ω Camshaft position sensor peak voltage 0.7 V minimum Ignition pulse generator peak voltage 0.7 V minimum Manifold absolute pressure at idle 250 – 300 mmHg (9.8 – 11.8 inHg) Fuel pressure at idle 343 kPa (3.5 kgf/cm 2 , 50 psi) Fuel pump flow (at 12 V) 133 cm 3 (4.5 US oz, 4.7 lmp oz) minimum/10 seconds Idle speed 49 state and Canada type 850 ± 100 rpm California type 950 ± 100 rpm ITEM SPECIFICATIONS Coolant capacity Radiator and engine 4.3 liters (4.5 US qt, 3.8 lmp qt) Reserve tank 0.50 liter (0.53 US qt, 0.44 lmp qt) Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm 2 , 16 – 20 psi) Thermostat Begin to open 76 – 80 °C (169 – 176 °F) Fully open 90 °C (194 °F) Valve lift 8 mm (0.3 in) minimum Recommended antifreeze Pro Honda HP Coolant or equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibi- tors Standard coolant concentration 1:1 mixture with distilled water

GENERAL INFORMATION 1-7 CYLINDER HEAD/VALVE SPECIFICATIONS Unit: mm (in) CLUTCH SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 300 rpm 1,383 kPa (14.1 kgf/cm 2 , 201 psi) – Valve clearance IN 0.15 ± 0.03 (0.006 ± 0.001) – EX 0.22 ± 0.03 (0.009 ± 0.001) – Camshaft Cam lobe height (49 state/Canada type) IN 41.610 – 41.690 (1.6382 – 1.6413) 41.58 (1.637) EX 41.680 – 41.760 (1.6409 – 1.6441) 41.65 (1.640) Cam lobe height (California type) IN 40.810 – 40.890 (1.6067 – 1.6098) 40.78 (1.606) EX 41.680 – 41.760 (1.6409 – 1.6441) 41.65 (1.640) Runout – 0.03 (0.001) Journal O.D. 27.959 – 27.980 (1.1007 – 1.1016) 27.96 (1.101) Journal I.D. 28.000 – 28.021 (1.1024 – 1.1032) 28.05 (1.104) Oil clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004) Valve lifter Valve lifter O.D. IN/EX 28.978 – 28.993 (1.1409 – 1.1415) 28.97 (1.141) Valve lifter bore I.D. IN/EX 29.010 – 29.026 (1.1421 – 1.1428) 29.04 (1.143) Valve, valve guide Valve stem O.D. IN 4.970 – 4.995 (0.1957 – 0.1967) 4.96 (0.195) EX 4.955 – 4.980 (0.1951 – 0.1961) 4.95 (0.195) Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.04 (0.198) Stem-to-guide clearance IN 0.005 – 0.042 (0.0002 – 0.0017) 0.075 (0.0030) EX 0.020 – 0.057 (0.0008 – 0.0022) 0.085 (0.0033) Valve guide projection above cylinder head IN/EX 11.8 – 12.0 (0.46 – 0.47) – Valve seat width IN/EX 0.9 – 1.1 (0.035 – 0.043) 1.5 (0.06) Valve spring Free length IN/EX 38.20 (1.504) 37.0 (1.46) Cylinder head warpage – 0.10 (0.004) ITEM STANDARD SERVICE LIMIT Recommended clutch fluid DOT 4 brake fluid – Clutch master cylinder Cylinder I.D. 14.000 – 14.043 (0.5512 – 0.5529) 14.055 (0.5533) Piston O.D. 13.957 – 13.984 (0.5495 – 0.5506) 13.945 (0.5490) Clutch Clutch spring free height 4.8 (0.19) 4.6 (0.18) Clutch lifter spring free height 2.9 (0.11) 2.5 (0.10) Disc thickness 3.72 – 3.88 (0.146 – 0.153) 3.5 (0.14) Plate warpage – 0.30 (0.012)

2003-2005 Honda NRX1800 Valkyrie Rune Motorcycle Service & Repair Manual

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