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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.
Date of Issue: Nov, 2005
©Honda Motor Co., Ltd.
HOW TO USE THIS MANUAL
This service manual describes the service procedures for the TRX680FA
and TRX680FGA.
Follow the Maintenance Schedule (Section 4) recommendations to
ensure that the vehicle is in peak operating condition and the emission
levels are within the standards set by the California Air Resources Board
(CARB).
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 vehicle. Section 3 illustrates
procedures for removal/installation of components that may be required
to perform service described in the following sections.
Sections 5 through 23 describe parts of the vehicle, 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 procedure.
If you are not familiar with this vehicle, read Technical Features in section
2.
If you don't know the source of the trouble, go to section 25
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
FRAME/BODY PANELS/EXHAUST
SYSTEM
TECHNICAL FEATURES
MAINTENANCE
LUBRICATION SYSTEM
FUEL SYSTEM
COOLING SYSTEM
ENGINE REMOVAL/INSTALLATION
CYLINDER HEAD/VALVE/CAMSHAFT
CYLINDER/PISTON
ALTERNATOR/STARTER CLUTCH
SUB-TRANSMISSION/GEARSHIFT LINKAGE
CRANKCASE/CRANKSHAFT/BALANCER
DRIVE TRAIN SYSTEM
FRONT WHEEL/SUSPENSION/STEERING
REAR WHEEL/SUSPENSION
FRONT DRIVING MECHANISM
REAR DRIVING MECHANISM
BATTERY/CHARGING SYSTEM
IGNITION SYSTEM
ELECTRIC STARTER
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
LIGHTS/METERS/SWITCHES
23
ENGINE
CHASSIS
ELECTRICAL
BRAKE SYSTEM
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
25
24
26
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
Âź
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
Âź
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 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.
1-1
1
1. GENERAL INFORMATION
SERVICE RULES ············································ 1-2
MODEL IDENTIFICATION······························ 1-3
GENERAL SPECIFICATIONS························· 1-5
LUBRICATION SYSTEM
SPECIFICATIONS··········································· 1-7
FUEL SYSTEM SPECIFICATIONS················· 1-7
COOLING SYSTEM SPECIFICATIONS ········· 1-7
CYLINDER HEAD/VALVE/CAMSHAFT
SPECIFICATIONS··········································· 1-8
CYLINDER/PISTON SPECIFICATIONS ········· 1-8
ALTERNATOR/STARTER CLUTCH
SPECIFICATIONS··········································· 1-8
SUB-TRANSMISSION/GEARSHIFT
LINKAGE SPECIFICATIONS ·························· 1-9
CRANKCASE/CRANKSHAFT/BALANCER
SPECIFICATIONS··········································· 1-9
DRIVETRAIN SPECIFICATIONS ···················· 1-9
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS··········································· 1-9
REAR WHEEL/SUSPENSION
SPECIFICATIONS············································1-9
BRAKE SYSTEM SPECIFICATIONS·············1-10
FRONT DRIVING MECHANISM
SPECIFICATIONS··········································1-10
REAR DRIVING MECHANISM
SPECIFICATIONS··········································1-10
BATTERY/CHARGING SYSTEM
SPECIFICATIONS··········································1-10
IGNITION SYSTEM SPECIFICATIONS ········1-11
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 ··················1-17
CABLE & HARNESS ROUTING ···················1-20
EMISSION CONTROL SYSTEMS ················1-39
GENERAL INFORMATION
1-2
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not 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 1-20).
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
PGM-FI Programmed Fuel Injection
MAP sensor Manifold Absolute Pressure sensor
TP sensor Throttle Position sensor
ECT sensor Engine Coolant Temperature sensor
IAT sensor Intake Air Temperature sensor
CKP sensor Crankshaft Position sensor
VS sensor Vehicle Speed sensor
EOT sensor Engine Oil Temperature sensor
IACV Idle Air Control Valve
PCM
(ECM/TCM)
Powertrain Control Module
(Engine Control Module/Transmission Control Module)
EEPROM Electrically Erasable Programmable Read Only Memory
DLC Data Link Connector
SCS connector Service Check Short connector
HDS Honda Diagnostic System
DTC Diagnostic Trouble Code
MIL Malfunction Indicator Lamp
A/T Automatic Transmission
Clutch PC solenoid Clutch Pressure Control solenoid
4WD 4 Wheel Drive
ESP Electric Shift Program
GPS Global Positioning System
GENERAL INFORMATION
1-3
MODEL IDENTIFICATION
SERIAL NUMBERS
The Vehicle Identification Number (V.I.N) is stamped on the front side
of the frame.
The engine serial number is stamped on the right side of the
crankcase.
VEHICLE IDENTIFICATION NUMBER (VIN)
ENGINE SERIAL NUMBER
GENERAL INFORMATION
1-4
The throttle body identification number is stamped on the left side of
the throttle body.
LABELS
The name plate (U.S.A. and AUSTRALIA type) is located on the left
frame down tube.
The safety certification label (Canada type only) is locate on the right
frame down tube.
The color label is attached on the right side of the frame under the seat.
When ordering color coded parts, always specify the designated color
code.
THROTTLE BODY
IDENTIFICATION NUMBER
NAME PLATE
U.S.A./AUSTRALIA type:
SAFETY CERTIFICATION LABEL
Canada type:
COLOR LABEL
GENERAL INFORMATION
1-5
The Vehicle Emission Control Information Label is attached on the left
side of the rear fender under the seat.
GENERAL SPECIFICATIONS
EMISSION CONTROL INFORMATION LABEL
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,113 mm (83.2 in)
Overall width 1,189 mm (46.8 in)
Overall height 1,207 mm (47.5 in)
Wheelbase 1,289 mm (50.7 in)
Front tread 915 mm (36.0 in)
Rear tread 945 mm (37.2 in)
Seat height 875 mm (34.5 in)
Footpeg height 341 mm (13.4 in)
Ground clearance 234 mm (9.2 in)
Curb weight 291 kg (642 lbs)
Maximum weight capacity 220 kg (485 lbs)
FRAME Frame type Double cradle
Front suspension Double wish-bone
Front wheel travel 175 mm (6.9 in)
Front damper Double tube
Rear suspension Double wish-bone
Rear wheel travel 203 mm (8.0 in)
Rear damper Single tube
Front tire size AT25 x 8R12
Rear tire size AT25 x 10R12
Front rim size 12 x 6.0 AT
Rear rim size 12 x 7.5 AT
Front tire brand KT515 (DUNLOP)
Rear tire brand KT511 (DUNLOP)
Front brake Hydraulic disc brake
Rear brake Hydraulic/mechanical disc brake
Caster angle 1.6°
Trail length 2.1 mm (3/16 in)
Camber angle 0°
Fuel tank capacity 17 liters (4.5 US gal, 3.7 lmp gal)
Fuel tank reserve capacity 4.1 liters (1.08 US gal, 0.90 lmp gal)
GENERAL INFORMATION
1-6
ENGINE Cylinder arrangement Single cylinder, longitudinally installed
Bore and stroke 102 x 82.6 mm (4.02 x 3.25 in)
Displacement 674.9 cm
3
(41.19 cu-in)
Compression ratio 9.2: 1
Valve train OHV
Intake valve opens at 1 mm (0.04 in) lift 8° BTDC
Intake valve closes at 1 mm (0.04 in) lift 45° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 45° BBDC
Exhaust valve closes at 1 mm (0.04 in) lift 5° ATDC
Lubrication system Forced pressure (dry sump)
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Oiled urethane foam
Engine dry weight 60.4 kg (133.2 lbs)
CARBURATION Type PGM-FI (Programmed Fuel Injection)
Throttle bore 40 mm (1.57 in)
DRIVE TRAIN Transmission Automatic (Torque converter + 3-speed drive
system and reverse)
Shift clutch (1st, 2nd and 3rd clutches) Multi-plate, wet (hydraulic clutch with electric
controlled)
Primary reduction 1.333 (64/48)
Secondary reduction Forward 2.000 (38/19)
Reverse 2.375 (38/16)
Final reduction Front 3.231 (42/13)
Rear 3.154 (41/13)
Transmission ratio 1st 2.053 (39/19)
2nd 1.375 (33/24)
3rd 0.933 (28/30)
Reverse 2.138 (39/19 x 25/24)
Gearshift pattern Sub-transmis-
sion
D - N - R
D (Drive) 2-mode: 3-speed Automatic and Manual (ESP;
3 speeds)
R (Reverse) 1-mode (fixed low ratio)
ELECTRICAL Ignition system Full Transistorized Ignition
Starting system Electric starter motor and emergency recoil
starter
Charging system Triple phase output alternator
Regulator/rectifier FET shorted, triple phase full wave rectifica-
tion
Lighting system Battery
ITEM SPECIFICATIONS
GENERAL INFORMATION
1-7
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
FUEL SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 2.7 liters (2.9 US qt, 2.4 lmp qt) –
After draining/filter
change
2.9 liters (3.1 US qt, 2.6 lmp qt) –
After disassembly 4.1 liters (4.3 US qt, 3.6 lmp qt) –
Recommended engine oil Pro Honda GN4 4-stroke oil (USA &
Canada) or an equivalent motor oil
API service classification: SG or higher
JASO T 903 standard: MA
Viscosity: SAE 10W-30
–
Oil pressure at 5,000 rpm (min
-1
)/80°C (176°F) 785 kPa (8.0 kgf/cm
2
, 114 psi) –
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.12 – 0.22 (0.005 – 0.009) 0.25 (0.010)
Side clearance 0.02 – 0.09 (0.001 – 0.004) 0.11 (0.004)
ITEM SPECIFICATIONS
Throttle body identification number GQ67A
Idle speed 1,400 ± 50 rpm (min
-1
)
Throttle lever free play 3 – 8 mm (1/8 – 5/16 in)
ECT sensor resistance (20°C/68°F) 2.3 – 2.6 k℩
Fuel injector resistance (at 20°C /68°F) 11.1 – 12.3 ℩
Fuel pressure 284 – 304 kPa (2.9 – 3.1 kgf/cm
2
, 41 – 44 psi)
Fuel pump flow (at 12 V) 71 cm
3
(2.4 US oz, 2.5 lmp oz) minimum/10 seconds
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 2.0 liters (2.1 US qt, 1.8 Imp qt)
Reserve tank 0.46 liter (0.49 US qt, 0.40 Imp qt)
Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm
2
, 16 – 20 psi)
Thermostat Begin to open 80 – 84°C
Fully open 95°C
Valve lift 8 mm (0.3 in) minimum
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality
ethylene glycol antifreeze containing silicate-free corrosion
inhibitors
Standard coolant concentration 1:1 mixture with distilled water
GENERAL INFORMATION
1-8
CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS
Unit: mm (in)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 350 rpm (min
-1
) 550 kPa (5.6 kgf/cm
2
, 80 psi) –
Valve clearance IN 0.15 (0.006) –
EX 0.33 (0.013) –
Valve,
valve guide
Valve stem O.D. IN 5.475 – 5.490 (0.2156 – 0.2161) 5.45 (0.215)
EX 5.455 – 5.470 (0.2148 – 0.2154) 5.43 (0.214)
Valve guide I.D. IN/EX 5.500 – 5.512 (0.2165 – 0.2170) 5.53 (0.218)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.12 (0.005)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.14 (0.006)
Valve guide projection
above cylinder head
IN 14.8 – 15.2 (0.58 – 0.60) –
EX 17.3 – 17.7 (0.68 – 0.70) –
Valve seat width IN/EX 1.0 – 1.1 (0.039 – 0.043) 1.4 (0.06)
Valve spring Free length Inner 37.20 (1.465) 36.3 (1.43)
Outer 44.20 (1.740) 43.1 (1.70)
Rocker arm Arm I.D. IN/EX 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)
Shaft O.D. IN/EX 11.964 – 11.984 (0.4710 – 0.4718) 11.92 (0.469)
Arm-to-shaft clearance IN/EX 0.016 – 0.054 (0.0006 – 0.0021) 0.08 (0.003)
Camshaft and
cam follower
Cam lobe height IN 35.015 – 35.175 (1.3785 – 1.3848) 34.840 (1.3717)
EX 35.394 – 35.554 (1.3935 – 1.3998) 35.144 (1.3824)
Cam follower O.D. IN/EX 22.467 – 22.482 (0.8845 – 0.8851) 22.46 (0.884)
Follower bore I.D. IN/EX 22.510 – 22.526 (0.8862 – 0.8868) 22.54 (0.887)
Follower-to-bore clear-
ance
IN/EX 0.028 – 0.059 (0.0011 – 0.0023) 0.07 (0.003)
Cylinder head warpage – 0.05 (0.002)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 102.000 – 102.015 (4.0157 – 4.0163) 102.05 (4.018)
Out-of-round – 0.05 (0.002)
Taper – 0.05 (0.002)
Warpage – 0.05 (0.002)
Piston,
piston pin,
piston ring
Piston O.D. at 20 (0.8) from bottom 101.960 – 101.990 (4.0142 – 4.0153) 101.90 (4.012)
Piston pin hole I.D. 23.002 – 23.008 (0.9056 – 0.9058) 23.03 (0.907)
Piston pin O.D. 22.994 – 23.000 (0.9053 – 0.9055) 22.98 (0.905)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002)
Piston ring end
gap
Top 0.25 – 0.35 (0.010 – 0.014) 0.5 (0.02)
Second 0.40 – 0.55 (0.016 – 0.022) 0.7 (0.03)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.9 (0.04)
Piston ring-to-ring
groove clearance
Top 0.045 – 0.080 (0.0018 – 0.0031) 0.095 (0.0037)
Second 0.025 – 0.060 (0.0010 – 0.0024) 0.075 (0.0030)
Cylinder-to-piston clearance 0.010 – 0.055 (0.0004 – 0.0022) 0.19 (0.007)
Connecting rod small end I.D. 23.030 – 23.050 (0.9067 – 0.9075) 23.06 (0.908)
Connecting rod-to-piston pin clearance 0.030 – 0.056 (0.0012 – 0.0022) 0.08 (0.003)
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss O.D. 51.705 – 51.718 (2.0356 – 2.0361) 51.61 (2.032)
Torque limiter slip torque 53 – 84 N·m (5.4 – 8.6 kgf·m,
39 – 62 lbf·ft)
–
GENERAL INFORMATION
1-9
SUB-TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS
Unit: mm (in)
CRANKCASE/CRANKSHAFT/BALANCER SPECIFICATIONS
Unit: mm (in)
DRIVETRAIN SPECIFICATIONS
Unit: mm (in)
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
REAR WHEEL/SUSPENSION SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Shift fork I.D. 11.000 – 11.021 (0.4331– 0.4339) 11.04 (0.435)
Claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.5 (0.18)
Shaft O.D. 10.966 – 10.984 (0.4317 – 0.4324) 10.96 (0.431)
Reverse idle
gear
Collar I.D. 13.000 – 13.034 (0.5118 – 0.5131) 13.05 (0.514)
Shaft O.D. 12.966 – 12.984 (0.5105 – 0.5112) 12.93 (0.509)
Collar-to-shaft clearance – 0.10 (0.004)
ITEM STANDARD SERVICE LIMIT
Crankshaft Runout 0.05 (0.002) 0.15 (0.059)
Big end side clearance 0.05 – 0.65 (0.002 – 0.026) 0.8 (0.03)
Big end radial clearance 0.006 – 0.018 (0.0002 – 0.0007) 0.05 (0.002)
ITEM STANDARD SERVICE LIMIT
Oil pressure
at 5,000 rpm
(min
-1
)
Line 785 kPa (8.0 kgf/cm
2
, 114 psi) –
1st, 2nd and 3rd clutch 785 kPa (8.0 kgf/cm
2
, 114 psi) –
Shift clutch
(1st, 2nd and
3rd)
Initial clearance 0.7 – 0.9 (0.03 – 0.04) –
Disc thickness 1.88– 2.00 (0.074 – 0.079) worn out lining
Plate thickness 1.95– 2.05 (0.077 – 0.081) discoloration
Return spring free length 33.8 (1.33) 31.8 (1.25)
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth – 4 mm (0.16 in)
Cold tire pressure Standard 30 kPa (0.30 kgf/cm
2
, 4.4 psi) –
Minimum 26 kPa (0.26 kgf/cm
2
, 3.8 psi) –
Maximum 34 kPa (0.34 kgf/cm
2
, 5.0 psi) –
With cargo 30 kPa (0.30 kgf/cm
2
, 4.4 psi) –
Tie-rod distance between the ball joints 387.5 ± 1 mm (15.26 ± 0.4 in) –
Toe Toe-out: 10.9 ± 15 mm (7/16 ± 9/16 in) –
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth – 4 mm (0.16 in)
Cold tire pressure Standard 25 kPa (0.25 kgf/cm
2
, 3.6 psi) –
Minimum 22 kPa (0.22 kgf/cm
2
, 3.2 psi) –
Maximum 28 kPa (0.28 kgf/cm
2
, 4.0 psi) –
With cargo 25 kPa (0.25 kgf/cm
2
, 3.6 psi) –
GENERAL INFORMATION
1-10
BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in)
FRONT DRIVING MECHANISM SPECIFICATIONS
Unit: mm (in)
REAR DRIVING MECHANISM SPECIFICATIONS
Unit: mm (in)
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Recommended brake fluid Honda DOT 4 brake fluid –
Front brake Brake disc thickness 4.0 (0.16) 3.0 (0.12)
Brake disc runout – 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. 33.960 – 34.010 (1.3370 – 1.3390) 34.02 (1.340)
Caliper piston O.D. 33.878 – 33.928 (1.3338 – 1.3357) 33.87 (1.333)
Rear brake Brake disc thickness 7.5 (0.30) 6 (0.2)
Brake disc runout – 0.5 (0.02)
Master cylinder I.D. 15.870 – 15.913 (0.6248 – 0.6265) 15.925 (0.6270)
Master piston O.D. 15.827 – 15.854 (0.6231 – 0.6242) 15.815 (0.6226)
Caliper cylinder I.D. 30.230 – 30.280 (1.1902 – 1.1921) 30.29 (1.193)
Caliper piston O.D. 30.165 – 30.198 (1.1876 – 1.1889) 30.14 (1.187)
Rear (parking) brake lever free play 25 – 30 (1 – 1-3/16) –
ITEM STANDARD SERVICE LIMIT
Front differ-
ential
Oil capacity At draining 175 cm
3
(5.9 US oz, 6.2 Imp oz) –
At disassembly 220 cm
3
(7.4 US oz, 7.7 Imp oz) –
Recommended oil Hypoid gear oil SAE #80 –
Gear backlash 0.05 – 0.25 (0.002 – 0.010) 0.4 (0.02)
Backlash difference – 0.2 (0.01)
Slip torque 14 – 17 N·m (1.45 – 1.75 kgf·m,
10 – 13 lbf·ft)
12 N·m (1.2
kgf·m, 9 lbf·ft)
Face cam-to-housing distance 3.3 – 3.7 (0.13 – 0.15) 3.3 (0.13)
Differential ring gear depth 6.55 – 6.65 (0.2579 – 0.2618) 6.55 (0.2579)
Cone spring height 2.8 (0.11) 2.6 (0.10)
ITEM STANDARD SERVICE LIMIT
Final drive Oil capacity At draining 78 cm
3
(2.6 US oz, 2.7 Imp oz) –
At disassembly 90 cm
3
(3.0 US oz, 3.2 Imp oz) –
Recommended oil Hypoid gear oil SAE #80 –
Gear backlash 0.05 – 0.25 (0.002 – 0.010) 0.4 (0.02)
Backlash difference – 0.2 (0.01)
Ring gear-to-stop pin clearance 0.3 – 0.6 (0.01 – 0.02) –
ITEM SPECIFICATIONS
Battery
(YTX20L-
BS)
Capacity 12V – 18 Ah
Current leakage 1 mA max.
Voltage
(20°C/68°F)
Fully charged 13.0 – 13.2 V
Needs charging Below 12.3 V
Charging cur-
rent
Normal 1.8 A/5 – 10 h
Quick 9.0 A/1.0 h
Alternator Capacity 360 W/5,000 rpm (min
-1
)
Charging coil resistance (20°C/68°F) 0.1 – 1.0 ℩
GENERAL INFORMATION
1-11
IGNITION SYSTEM SPECIFICATIONS
ELECTRIC STARTER SPECIFICATIONS
Unit: mm (in)
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug Standard IFR5L11 (NGK)
VK16PRZ11 (DENSO)
For extended high speed
riding
IFR6L11 (NGK)
VK20PRZ11 (DENSO)
Spark plug gap 1.0 – 1.1 mm (0.039 – 0.043 in)
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing (“F” mark) 15° BTDC at idle
ITEM STANDARD SERVICE LIMIT
Starter motor brush length 12.0 – 13.0 (0.47 –0.51) 6.5 (0.26)
ITEM SPECIFICATIONS
Bulb Headlight 12V-40/40 W x 2
Brake/taillight 12V-21/5 W x 2
Neutral indicator LED
Reverse indicator LED
4WD indicator LED
Coolant/engine oil temperature
indicator
LED
MIL (PGM-FI indicator) LED
Meter light LED x 10
Fuse Main 30 A x 2
Sub-fuse 15 A x 1, 10 A x 4
GENERAL INFORMATION
1-12
STANDARD TORQUE VALUES
ENGINE & FRAME TORQUE VALUES
‱ Torque specifications listed below are for important fasteners.
‱ Others should be tightened to standard torque values listed above.
ENGINE
MAINTENANCE
LUBRICATION SYSTEM
FUEL SYSTEM
COOLING SYSTEM
CYLINDER HEAD/VALVE/CAMSHAFT
CYLINDER/PISTON
FASTENER TYPE N·m (kgf·m, lbf·ft) FASTENER TYPE N·m (kgf·m, lbf·ft)
5 mm hex bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)
6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head, small flange) 10 (1.0, 7)
10 mm hex bolt and nut 34 (3.5, 25) 6 mm flange bolt (8 mm head, large flange) 12 (1.2, 9)
12 mm hex bolt and nut 54 (5.5, 40) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)
8 mm flange bolt and nut 26 (2.7, 20)
10 mm flange bolt and nut 39 (4.0, 29)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Spark plug 1 14 22 (2.2, 16)
Valve adjusting screw lock nut 4 6 17 (1.7, 12)
Timing hole cap 1 14 10 (1.0, 7)
Engine oil drain bolt 1 12 25 (2.5, 18)
Engine oil filter center bolt 1 20 18 (1.8, 13)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Oil pump driven sprocket bolt 1 6 12 (1.2, 9) Apply locking agent
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Insulator band screw (throttle body side) 1 5 – page 6-42
Insulator band screw (engine side) 1 5 – page 6-46
Throttle drum cover screw 1 4 1.5 (0.15, 1.1)
Sensor unit mounting screw 3 5 3.4 (0.35, 2.5)
Fuel feed hose bracket screw 1 5 4.2 (0.43, 3.1)
Harness guide bracket screw 1 5 4.2 (0.43, 3.1)
Fuel injector/feed hose mounting bolt 2 5 5.1 (0.53, 3.8)
IACV mounting torx screw 2 5 2.1 (0.21, 1.5)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Water pump impeller 4 7 12 (1.2, 9)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder head cover cap nut 4 10 55 (5.6, 41) Apply engine oil
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder stud bolt 4 10 – page 10-7
⚠ Fin de la Vista Previa Gratuita

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