2008-2009 Honda TRX700XX Service & Repair Manual

HOW TO USE THIS MANUAL ThIs ..vICe manual descnO. I/le .. ~ ptI)08dUrttS br It. Tru(700XX Follow IN Malnlenal'lO!l Schedule (Sectoon .j recommendatIOnS IQ en.ure tn.1 !tie vehode IS In puk operaur>g c:oodilion and lhe eml&soQn l.veIs ale wl1hln the standard. sel by !ha US EnVIronmental Prolecbon Ag&ney tEPA) and C.I,\orn,. Air Re$OUrt:eS Board (CARB) ~rlorrntog !he lirsl scheduled IT\I,meoanca • VIIry ,mpOltiUlI It compensates lor the ,"I~al wear thai occurs dunng the break-In "' ... s.et.oos 1 and 4 apply 10 the whole vehde SecbotI 3 Illuslr8UIII pn;x;edures lor recTIOY3VlI'Istaliabon 01 componentS thai m.y be leqUlrad 10 perform servw::e Olltcnbed In the toIlowIng secIlOn$. Sec:t1Oll1 5 Ihrough 21 dllScnbe poll", 01 me vehiellf, ~ aa:onlllf'lllO Iocallon FIOd It1e $8CtIOIl you WIInl on Itlts pa~ then lurn 10 lha table 01 conIlI'U' on lhe lirs! paga 011'" MClIOf1 Mosl sections start wHh an .saemllly Of system IIII.IS1rstlOn. servICe Info/malion and troubleshoolmg for the MCIOOf1 The 5UbseQl.Ien1 pages grve <ieta.led pi'ocedur8 II you Ire not tamilJa, W1th 1m wllllele read Techrncal Feature$ "' ~2 .. VOIJ 001\1 know !he SOItfl:e 01 tI'Ie trouble. go 10 $«bOn 23 T ...... _ '\"out safely. and Ihe salIfy 01 Others. IS very Imponant To help you make .,tormea ~ ~ t\ave prOVIded salety m.sages ana 0Ih8< onbmabOn throughout !hoI manual 01 course, ~ IS no! pr8C\ICIIl Of posIlOie 10 warn you aboYl all the haurds 85!lQC1al00 Wflh HMCIIIQ In,. .... hd. You mull use your own good 1udge1Tlflf11 You WIll lir'od amporlan! salely Inlo'rnallOl'1 In a vanety o! lorms InchMjing • Salety Laools- 01'1 the vehcle • Salety Messages - prece<le<l by • safely alen IYmboI J. and one of In,," sigrlaJ word$ DANGER WARNING, or CAU- noN TheM SI!11itl words mean iN.H 4 tA4-i 'rtJu WILL tie KIu.ED or SERIOUSLY _ Ah._.'_ HURT~YOUOOn'ltoIIowIOSII1lCU005 ~ CAN be KILLED or SERIOUSLY m"";l;r W ~Lf' HURT II)'OU dorn follow II"IIiII1lCllOn$ ti1l@ •• iI.g. :::,~tIe HURT If you dorfl toIIow • Ill$tructlOflS - how 10 S81'V1Ce lhl ..... 1l1C1e eo<reclly and sately. AI you r&ad thIS manual, you will lind lniofm"l011 tha t 15 preceoed by a NOncl. 5)'ffiboI. The purpose 01 In .. masaoe Is to help prevent Qlmage 10 your vehtele. OIher property. or the enYIfonrnenL w ;!; " Z W '" iii '" '" I U ..J '" u ii: .... u W ..J W CONTENTS GENERAL INFORMATION TECHNICAL FEATURES FRAME/BOOY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM (PGM-FI) COOLING SYSTEM ENGINE REMOVALJINSTALLATION CYLINDER HEADNALVE CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH FRONT WHEELJSUSPENSION/STEERING REAR WHEELJSUSPENSION HYDRAULIC BRAKE DRIVING MECHANISM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/SWITCHES WIRING OIAGRAMS TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughoullhis manual show specific service procedures. If supplementary information is required pertaming to these symbols. it would be explained specifically In the text wllhoul the use of the symbols. tI Replace the parl(S) with new one(s) before assembly. . ~ I Use the recommended engine oil , unless otherwise specified. r- - 78 Use molybdenum oil solution (mixture oltha engine oil and molybdenum grease In a raho of 1 :1). ~..u;;;.. Use multi·purpose grease (lithium based muUi-purpose grease NlGI #2 or equivalent). I Use molybdenum disulfide grease (containing more than 3"10 molybdenum disulfide, NLGI 112 or equIValent) , ~ Example: Molykol e8 BR·2 plus manufactured by Dow Corning U.S.A. Multi-purpose M·2 manufactured by Mitsubishl 011 , Japan f- I Use mOlybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: MoIykole8 G-n Paste manufactured by Dow Corning U.S.A. ...w Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by RocOi limited, U.K. Roeol Paste manufactured by Sumico Lubricant, Japan , ~ Use sl1lcone grease. --- " - l'l1! I Apply a locking agent. Use a medium strength locking agent unless otherwise specified , ", '€Ill! Apply sealant l- I Use DOT 4 brake flUid . Use the recommended brake flUid unless otherwise specified. I . .. Use fork or suspension lIuld .

1. GENERAL INFORMATION SERVICE RULES ........ ................................. ' ·2 MODEL IDENTIFICATION ··························· '· 3 GENERAL SPEC IFICA nONS ······················ '·5 LUBRICATION SYS TEM SPECIFI CA nONS ........................................ ' ·7 FUEL SYSTEM SPECIFICATIONS ·············· '·7 COOLING SYSTEM SPECIFICATIONS ...... ' ·7 CYLINDER HEADIVALVES SPECIFI CA nONS ......... .. ... ... .. .. ........ ..... ...... ' ·8 CYLINDER/ PISTON SPECIFICATIONS ...... ' ·8 CLUTCH / GEARSHIFT LINKAGE SPECIFICATIONS ········································ ' ·8 ALTERNATOR/ STARTER CLUTCH SPECIFICATIONS ········································ '·9 FINAL REDUCTION / CRANKCASE/ TRANSMISSION/ BALANCER/ CRANKSHAFT SPECiFiCATIONS ········································ ' ·9 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ..... ................................ 1-10 REAR WHEEL/ SUSPENSION SPECIFICATIONS ········ ·· ·· ··· ·· ····· ···· ···· ··.... ·'· '0 HYDRAULIC BRAKE SPECIFICATIONS··· ' · '0 DRIVING MECHANISM SPECIFICATIONS .. .. ..... ..... ... .................... '· '0 BATTERY/ CHARGING SYSTEM SPECIFICATIONS ............ ... ... . .. ....... .. . .. .... '· '0 IGNITION SYSTEM SPECiFiCATIONS ···· ' ·" ELECTRIC STARTER SPECIFICATIONS .. ................................... ,." LIGHTS/ SWITCHES SPECIFICATIONS ··· ' · " TORQUE VALUES ········ .. ·························· ' · '2 LUBRICATION & SEAL POINTS .. .... ........ '· '9 CABLE & HARNESS ROUTING ............... '·2' EMISSION CONTROL SYSTEMS ... .. .. . .... '·35 .. 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genu i ne Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the vehicle. 2. Use the special tools designed fo r this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nu ts and scr ews are not inte r changeable with En glish fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the large r diamete r 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. Lub ricate any sliding surfaces before r eassembly . 7. After reassembly, check all parts fo r p roper installation and operation. 8. Route all electrical wires as show in the Cable and Harness Routing (page 1-21). 9. Do not bend or twist control cables. Damage the control cables will not operates smoothly and may stick or bind . ABBREVIATION Th r oughout this manual, the following abbreviations are used to identify the respective parts or systems. 1-2 i i Programmable Read Only Memory connect or Position sensor sensor

GENERAL INFORMATION MODEL IDENTIFICATION SERIAL NUMBERS The Vehicle Identification Number (VIN ) is stamped on the left side of 1":':;0:0:::::": ' :0:: the rear frame. The engine serial number is stamped on the left side of the crankcase. ENGINE SERIAL NUMBER 1-3

GENERAL INFORMATION The throttle body identification number is stamped on the left side of the throttle body. LABELS THROTTLE BODY IDENTIFICATION NUMBER The name plate (U.S.A. type only) is located on the left side of the front upper arm pipe. NAME PLATE (U.S.A type) The safety certification label (Canada type only) is located on the left side of the front upper arm pipe. The color label is attached on the left side of the frame under the mud guard. When ordering color coded parts, always specify the designated color code. The Vehicle Emission Control Information Label is attached on the right side of the front upper arm pipe. 1-4 SAFETY CERTIFICATION LABEL (Canada type) COLOR LABEL flri v!l!! )) .! e:::::: ~~ EMISSION CONTROL INFORMATION LABEL (U.S.A. and Canada) EMISSION CONTROL INFORMATION LABEL (Canada type only)

GENERAL SPECIFICATIONS ~ ITEM OIMEN~S"IO~N~S----"O'v~e~ ,~al"I"'e~n~g~thC------------- Overall width FRAME ENGINE CARBURATIQN Overall height Wheelbase Front tread Rear tread Seat height Foatpeg height Ground clearance Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Front camber angle Rear camber angle Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens at 1 mm (0.04 in) tift Intake valve closes at 1 mm (0.04 in) lift Exhaust valve opens at 1 mm (0.04 in) tift Exhaust valve closes at 1 mm (0.04 in) lift Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Type - Throttle bore GENERAL INFORMATION S PECIFICATIONS 1,815 mm (71.5 in) 1,165mm( 45.9 in) 1,135 mm (44.7 in) 1,260 mm (49.6 in) 993 mm (39.1 in) 958 mm (37.7 in) 830 mm (32.7 in) 336 mm 03.2 in) 260 mm (to .2 in) 229 kg (505 Ibs) 110 kg (243 Ibs) Double cradle Double wish-bone 267 mm (10.5 in) Double tube Double wish-bone 235 mm (9 .3 in) Single tube AT21 x 7Rl0 * * AT22x9R11*** 10x5.5AT llx7.0AT KT363 (DUNLOP) KT378A (DUNL OP ) Hydraulic disc brake x 2 Hydraulic disc brake 5.3 Q 23.2 mm (0.91 in) _ 0.3 0 _ 1.5° 11.4 liters (3.01 US gal, 2.5 1 Imp gal) 3.6 liters (0.95 US gal, 0.79 Imp gal) Single cylinder . transversely installed 102.0 x 84.0 mm (4.02 x 3.31 in) 686.4 em] (41.87 cu-;n) 10.0 : 1 Chain dri ve and SOHC with rocker arm 10 0 BTDC 45° ABDC 45° BBDC 10 0 ATDe Forced pressure (dry sump) Trochoid liquid cooled Oiled urethane foam 51.4 kg ( 113.3Ibs) PGM-FI 44 mm (1.7 in) 1-5

GENERAL INFORMATION I DRIVE TRAIN ELECTRICAL l 1-6 ITEM Clutch system Clutch operation system Transmission Primary reduction Final reduction Sub-transmission Gear ratio Gearshift pattern Ignition system Starting system Charging system Reg ulata f/rectifia r lighting system ,,, 2nd 3,d 4th 5th Reverse SPECIFICATlONS I Multi-plale, wet '-"== ---- -- Cable operated Constant mesh, 5-speed + Reverse 2.027 (75/37) 0.378 (14137) 1.087 (25/26 x 26123) 3.166 (381 12) 2.187 (35116) 1.631 (31 /19) 1.272 (28/22) 1.040 (26125) 2.750 (33/ 21 x 21 112) Left foot operated return system, R-l-N-2-3-4-5 Full Transistorized Igniti~ o~ n---------j Electric starter motor Trip le phase output alternator SeR shortedfTripte phase full wave rectifica- tion Batte~. ________________________ --"

2008-2009 Honda TRX700XX Service & Repair Manual

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