Honda NRX1800 Valkyrie Rune Service Repair Manual 2003-2005
Complete repair service manual with electrical wiring diagrams for Honda NRX1800, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Honda NRX1800 Valkyrie Rune 2003-2005 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Honda NRX1800 Valkyrie Rune Service Manual 2003-2005.pdf
PRODUCT DETAILS:
Total Pages: 552 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
MAIN SECTIONS
Service Information.......1
For Your Customer’s Safety.......1
For Your Safety.......1
Important Safety Precautions.......1
Symbols.......2
CONTENTS.......2
1. GENERAL INFORMATION.......4
GENERAL INFORMATION.......5
SERVICE RULES.......5
MODEL IDENTIFICATION.......5
GENERAL SPECIFICATIONS.......7
LUBRICATION SYSTEM SPECIFICATIONS.......9
FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS.......9
COOLING SYSTEM SPECIFICATIONS.......9
CYLINDER HEAD/VALVE SPECIFICATIONS.......10
CLUTCH SPECIFICATIONS.......10
GEARSHIFT LINKAGE/TRANSMISSION SPECIFICATIONS.......11
CYLINDER/PISTON/CRANKSHAFT SPECIFICATIONS.......11
FINAL DRIVE SPECIFICATIONS.......12
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS.......12
REAR WHEEL/SUSPENSION SPECIFICATIONS.......12
HYDRAULIC DISC BRAKE SPECIFICATIONS.......13
BATTERY/CHARGING SYSTEM SPECIFICATIONS.......13
IGNITION SYSTEM SPECIFICATIONS.......13
ELECTRIC STARTER SPECIFICATIONS.......14
LIGHTS/METERS/SWITCHES SPECIFICATIONS.......14
STANDARD TORQUE VALUES.......15
ENGINE & FRAME TORQUE VALUES.......15
ENGINE.......15
FRAME.......18
LUBRICATION & SEAL POINTS.......22
ENGINE.......22
FRAME.......23
CABLE & HARNESS ROUTING.......25
EMISSION CONTROL SYSTEMS.......48
SOURCE OF EMISSIONS.......48
CRANKCASE EMISSION CONTROL SYSTEM.......48
EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM).......49
EVAPORATIVE EMISSION CONTROL SYSTEM (California type only).......50
NOISE EMISSION CONTROL SYSTEM.......50
EMISSION CONTROL INFORMATION LABELS.......51
VACUUM HOSE ROUTING DIAGRAM LABEL (California type only).......51
2. TECHNICAL FEATURE.......52
TECHNICAL FEATURE.......53
STEERING LOCK-INTERLOCKING IMMOBILIZER SYSTEM.......53
IMMOBILIZER SYSTEM.......53
REMOTE STEERING LOCK.......53
3. FRAME/BODY PANELS/EXHAUST SYSTEM.......54
3. FRAME/BODY PANELS/EXHAUST SYSTEM.......54
FRAME/BODY PANELS/EXHAUST SYSTEM.......55
SERVICE INFORMATION.......55
GENERAL.......55
TORQUE VALUES.......55
TROUBLESHOOTING.......55
Excessive exhaust noise.......55
Poor performance.......55
SEAT.......56
SIDE COVER.......56
FRONT SIDE COVER.......57
FUEL TANK TOP COVER.......57
FRONT INNER COVER.......57
PIVOT COVER.......58
FRONT FENDER.......58
REAR FENDER.......59
RADIATOR COVER.......59
RIGHT RADIATOR COVER.......59
LEFT RADIATOR COVER.......59
EXHAUST SYSTEM.......60
REMOVAL.......60
INSTALLATION.......61
4. MAINTENANCE.......64
MAINTENANCE.......65
SERVICE INFORMATION.......65
GENERAL.......65
SPECIFICATIONS.......66
TORQUE VALUES.......66
TOOL.......66
MAINTENANCE SCHEDULE.......67
FUEL LINE.......68
THROTTLE OPERATION.......68
AIR CLEANER.......69
CRANKCASE BREATHER.......69
SPARK PLUG.......70
VALVE CLEARANCE.......70
INSPECTION.......70
ADJUSTMENT.......71
ENGINE OIL.......72
OIL LEVEL CHECK.......72
ENGINE OIL FILTER.......73
RADIATOR COOLANT.......74
COOLING SYSTEM.......75
SECONDARY AIR SUPPLY SYSTEM.......75
EVAPORATIVE EMISSION CONTROL SYSTEM (California type only).......76
FINAL DRIVE OIL.......76
OIL LEVEL CHECK.......76
OIL CHANGE.......77
BRAKE FLUID.......77
FRONT BRAKE.......77
REAR BRAKE.......78
BRAKE PAD WEAR.......79
BRAKE SYSTEM.......79
BRAKE LIGHT SWITCH.......79
HEADLIGHT AIM.......80
CLUTCH SYSTEM.......80
CLUTCH FLUID.......80
SIDE STAND.......81
SUSPENSION.......81
FRONT SUSPENSION INSPECTION.......81
REAR SUSPENSION INSPECTION.......82
NUTS, BOLTS, FASTENERS.......82
WHEELS/TIRES.......82
STEERING HEAD BEARINGS.......83
5. LUBRICATION SYSTEM.......84
LUBRICATION SYSTEM.......85
LUBRICATION SYSTEM DIAGRAM.......85
SERVICE INFORMATION.......86
GENERAL.......86
SPECIFICATIONS.......86
TORQUE VALUES.......86
TOOLS.......87
TROUBLESHOOTING.......87
Oil level too low.......87
Low oil pressure.......87
No oil pressure.......87
High oil pressure.......87
Oil contamination.......87
Oil emulsification.......87
OIL PRESSURE CHECK.......88
OIL STRAINER/PRESSURE RELIEF VALVE.......89
OIL STRAINER.......89
OIL PRESSURE RELIEF VALVE.......89
OIL PUMP.......90
REMOVAL.......90
DISASSEMBLY.......91
SCAVENGE PUMP SIDE:.......91
FEED PUMP SIDE:.......91
INSPECTION.......92
ASSEMBLY.......93
INSTALLATION.......95
6. FUEL SYSTEM (Programmed Fuel Injection).......96
FUEL SYSTEM (Programmed Fuel Injection).......97
SYSTEM COMPONENTS.......97
SERVICE INFORMATION.......98
GENERAL.......98
SPECIFICATIONS.......98
TORQUE VALUES.......99
TOOLS.......99
TROUBLESHOOTING.......100
Engine cranks but won't start.......100
Engine stalls, hard to start, rough idling.......100
Afterburn when engine braking is used.......100
Backfiring or misfiring during acceleration.......100
Poor performance (driveability) and poor fuel economy.......100
SYSTEM LOCATION.......101
SYSTEM DIAGRAM.......102
PGM-FI SELF-DIAGNOSIS INFORMATION.......103
SELF-DIAGNOSTIC DATA INDICATION PROCEDURE.......103
SELF-DIAGNOSTIC MEMORY RESET PROCEDURE.......104
PEAK VOLTAGE INSPECTION PREPARATION.......104
TEST HARNESS CONNECTION.......105
TEST PIN BOX TERMINAL LAYOUT.......105
MALFUNCTION INDICATOR LAMP (MIL) CHECK.......106
MALFUNCTION INDICATOR LAMP (MIL) FAILURE CODES.......107
MIL TROUBLESHOOTING.......109
MIL 1 BLINK (MAP SENSOR).......109
1. MAP Sensor Output Voltage Inspection.......109
MIL 2 BLINKS (MAP SENSOR).......111
1. MAP Sensor Hose Inspection.......111
MIL 7 BLINKS (ECT SENSOR).......112
1. ECT Sensor Output Voltage Inspection.......112
MIL 8 BLINKS (TP SENSOR).......114
1. TP Sensor Output Voltage.......114
MIL 9 BLINKS (IAT SENSOR).......116
1. IAT Sensor Output Voltage Inspection.......116
MIL 11 BLINKS (VEHICLE SPEED SENSOR).......117
1. Vehicle Speed Sensor Pulse Inspection.......117
MIL 12 BLINKS (No. 1 INJECTOR).......119
1. Injector Circuit Resistance Inspection.......119
MIL 13 BLINKS (No. 2 INJECTOR).......120
MIL 14 BLINKS (No. 3 INJECTOR).......120
MIL 15 BLINKS (No. 4 INJECTOR).......121
MIL 16 BLINKS (No. 5 INJECTOR).......121
MIL 17 BLINKS (No. 6 INJECTOR).......121
MIL 18 BLINKS (CAMSHAFT POSITION SENSOR).......122
1. Camshaft Position Sensor Peak Voltage Inspection at ECM.......122
MIL 19 BLINKS (IGNITION PULSE GENERATOR).......123
1. Ignition Pulse Generator Peak Voltage Inspection at ECM.......123
MIL 25 BLINKS (RIGHT KNOCK SENSOR).......124
1. Right Knock Sensor Connection Inspection.......124
MIL 26 BLINKS (LEFT KNOCK SENSOR).......125
1. Left knock Sensor Connection Inspection.......125
MIL 29 BLINKS (IAC VALVE).......126
1. IAC Valve Input Voltage Inspection.......126
MIL 33 BLINKS (E.......128
1. Recheck MIL Blinks 1.......128
FUEL LINE INSPECTION.......129
FUEL PRESSURE INSPECTION.......129
FUEL FLOW INSPECTION.......130
FUEL TANK.......131
REMOVAL.......131
INSTALLATION.......132
FUEL PUMP.......133
INSPECTION.......133
REMOVAL.......134
FUEL FILTER REPLACEMENT.......134
INSTALLATION.......134
FUEL INJECTOR.......135
INSPECTION.......135
REMOVAL.......135
INSTALLATION.......136
THROTTLE BODY.......137
REMOVAL.......137
THROTTLE BODY VACUUM HOSE ROUTING.......141
INSTALLATION.......142
PRESSURE REGULATOR.......146
REMOVAL.......146
INSTALLATION.......146
FUEL PUMP RELAY.......147
INSPECTION.......147
MAP SENSOR.......149
OUTPUT VOLTAGE INSPECTION.......149
REPLACEMENT.......149
IAT SENSOR.......150
REPLACEMENT.......150
CAMSHAFT POSITION SENSOR.......150
REPLACEMENT.......150
KNOCK SENSOR.......151
REPLACEMENT.......151
VEHICLE SPEED SENSOR.......151
REPLACEMENT.......151
ECM (ENGINE CONTROL MODULE).......152
POWER/GROUND LINE INSPECTION.......152
POWER INPUT LINE.......152
ENGINE STOP SWITCH LINE.......153
GROUND LINE.......153
SECONDARY AIR SUPPLY SYSTEM.......153
SYSTEM INSPECTION.......153
PAIR CONTROL SOLENOID VALVE INSPECTION.......154
PAIR CHECK VALVE REPLACEMENT.......154
VARIABLE AIR INTAKE CONTROL SYSTEM.......155
SYSTEM INSPECTION.......155
EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (California type only).......156
EVAP CANISTER REMOVAL/ INSTALLATION.......156
EVAP PURGE CONTROL SOLENOID VALVE INSPECTION.......157
ENGINE IDLE SPEED.......157
7. COOLING SYSTEM.......160
COOLING SYSTEM.......161
SYSTEM FLOW PATTERN.......161
SERVICE INFORMATION.......162
GENERAL.......162
SPECIFICATIONS.......162
TORQUE VALUES.......162
TROUBLESHOOTING.......163
Engine temperature too high.......163
Engine temperature too low.......163
Coolant leak.......163
SYSTEM TESTING.......164
COOLANT (HYDROMETER TEST).......164
RADIATOR CAP/SYSTEM PRESSURE INSPECTION.......165
COOLANT REPLACEMENT.......165
PREPARATION.......165
REPLACEMENT/AIR BLEEDING.......166
RADIATOR/COOLING FAN.......167
REMOVAL.......167
DISASSEMBLY.......168
ASSEMBLY.......169
INSTALLATION.......170
WATER PUMP/THERMOSTAT.......170
MECHANICAL SEAL INSPECTION.......170
REMOVAL.......171
INSPECTION.......172
INSTALLATION.......172
8. ENGINE REMOVAL/INSTALLATION.......176
ENGINE REMOVAL/INSTALLATION.......177
SYSTEM COMPONENTS.......177
SERVICE INFORMATION.......178
GENERAL.......178
SPECIFICATIONS.......178
TORQUE VALUES.......178
TOOL.......179
ENGINE REMOVAL.......180
ENGINE INSTALLATION.......187
9. CYLINDER HEAD/VALVE.......196
CYLINDER HEAD/VALVE.......197
SYSTEM COMPONENTS.......197
SERVICE INFORMATION.......198
GENERAL.......198
SPECIFICATIONS.......198
TORQUE VALUES.......199
TOOLS.......200
TROUBLESHOOTING.......201
Compression too low, hard starting or poor performance at low speed.......201
Compression too high.......201
Excessive smoke.......201
Excessive noise.......201
Rough idle.......201
CYLINDER COMPRESSION.......202
CYLINDER HEAD COVER REMOVAL.......202
CAMSHAFT REMOVAL.......203
INSPECTION.......207
CAMSHAFT.......207
CAMSHAFT JOURNAL.......207
CAMSHAFT OIL CLEARANCE.......208
CAM SPROCKET REPLACEMENT.......209
CAM CHAIN REMOVAL.......209
INSPECTION.......210
TIMING SPROCKET/CAM CHAIN.......210
CAM CHAIN TENSIONER/GUIDE.......211
CYLINDER HEAD REMOVAL.......211
CYLINDER HEAD DISASSEMBLY.......213
INSPECTION.......214
CYLINDER HEAD.......214
VALVE LIFTER.......214
VALVE SPRING.......214
VALVE/VALVE GUIDE.......215
VALVE GUIDE REPLACEMENT.......216
VALVE SEAT INSPECTION/REFACING.......217
INSPECTION.......217
VALVE SEAT REFACING.......218
CYLINDER HEAD ASSEMBLY.......220
CYLINDER HEAD INSTALLATION.......222
CAM CHAIN INSTALLATION.......223
CAMSHAFT INSTALLATION.......225
CYLINDER HEAD COVER INSTALLATION.......228
10. CLUTCH.......232
CLUTCH.......233
SYSTEM COMPONENTS.......233
SERVICE INFORMATION.......235
GENERAL.......235
SPECIFICATIONS.......235
TORQUE VALUES.......235
TOOLS.......236
TROUBLESHOOTING.......236
Clutch lever pressure stiff.......236
Clutch slips.......236
Clutch will not disengage or motorcycle creeps with clutch disengaged.......236
CLUTCH FLUID REPLACEMENT/AIR BLEEDING.......237
CLUTCH FLUID DRAINING.......237
CLUTCH FLUID FILLING/BLEEDING.......237
CLUTCH MASTER CYLINDER.......238
DISASSEMBLY.......238
INSPECTION.......240
ASSEMBLY.......241
CLUTCH SLAVE CYLINDER.......243
DISASSEMBLY.......243
INSPECTION.......244
ASSEMBLY.......245
CLUTCH.......246
CLUTCH COVER REMOVAL.......246
CLUTCH DISASSEMBLY.......247
INSPECTION.......250
LIFTER JOINT PIECE, LIFTER BEARING.......250
CLUTCH DISC.......250
CLUTCH PLATE.......250
JUDDER SPRING, SPRING SEAT.......251
CLUTCH SPRING, LIFTER SPRING.......251
CLUTCH CENTER.......251
PRESSURE PLATE.......251
CLUTCH OUTER.......252
CLUTCH OUTER REMOVAL.......252
CLUTCH OUTER INSTALLATION.......252
CLUTCH ASSEMBLY.......254
CLUTCH COVER INSTALLATION.......258
11. GEARSHIFT LINKAGE/TRANSMISSION.......260
GEARSHIFT LINKAGE/TRANSMISSION.......261
SYSTEM COMPONENTS.......261
SERVICE INFORMATION.......263
GENERAL.......263
SPECIFICATIONS.......263
TORQUE VALUES.......264
TOOLS.......264
TROUBLESHOOTING.......266
Hard to shift.......266
Transmission jumps out of gear.......266
Gearshift pedal will not return.......266
GEARSHIFT LINKAGE.......267
DISASSEMBLY.......267
ASSEMBLY.......269
REAR CRANKCASE COVER REMOVAL.......272
CLUTCH REGULATOR VALVE CHECK.......274
PRIMARY GEARS/OUTPUT SHAFT REMOVAL.......274
STARTER DRIVE GEAR BEARING REPLACEMENT.......277
DRIVEN GEAR BOSS BEARING REPLACEMENT.......278
OUTPUT SHAFT DISASSEMBLY/ INSPECTION.......279
OUTPUT SHAFT ASSEMBLY.......280
REAR CRANKCASE COVER BEARING REPLACEMENT.......282
PRIMARY GEARS/OUTPUT SHAFT INSTALLATION.......283
REAR CRANKCASE COVER INSTALLATION.......288
TRANSMISSION DISASSEMBLY.......290
RIGHT CRANKCASE.......290
SHIFT FORK AND SHIFT DRUM:.......290
COUNTERSHAFT:.......291
LEFT CRANKCASE.......292
MAINSHAFT:.......292
GEARSHIFT SPINDLE:.......293
INSPECTION.......293
TRANSMISSION ASSEMBLY.......295
COUNTERSHAFT.......296
SHIFT DRUM AND SHIFT FORK.......298
MAINSHAFT.......299
GEARSHIFT SPINDLE.......300
12. CYLINDER/PISTON/CRANKSHAFT.......302
CYLINDER/PISTON/CRANKSHAFT.......303
SYSTEM COMPONENTS.......303
SERVICE INFORMATION.......304
GENERAL.......304
SPECIFICATIONS.......304
TORQUE VALUES.......304
TOOLS.......305
TROUBLESHOOTING.......306
Cylinder compression is too low, hard to start, or poor performance at low speed.......306
Cylinder compression too high, overheats or knocks.......306
Excessive smoke.......306
Abnormal noise.......306
CRANKCASE SEPARATION.......307
PISTON/CONNECTING ROD REMOVAL.......308
SIDE CLEARANCE INSPECTION.......308
PISTON/CONNECTING ROD REMOVAL.......309
PISTON/PISTON RING REMOVAL.......309
PISTON INSPECTION.......310
CYLINDER INSPECTION.......311
CONNECTING ROD SELECTION.......312
CRANKPIN BEARING.......312
BEARING INSPECTION.......312
OIL CLEARANCE INSPECTION.......313
BEARING SELECTION.......313
BEARING INSTALLATION.......314
CRANKSHAFT REMOVAL.......315
CRANKSHAFT INSPECTION.......315
MAIN JOURNAL BEARING.......316
BEARING INSPECTION.......316
OIL CLEARANCE INSPECTION.......316
BEARING SELECTION.......317
BEARING INSTALLATION.......318
CRANKSHAFT INSTALLATION.......318
PISTON/CONNECTING ROD INSTALLATION.......319
PISTON INSTALLATION.......319
PISTON RING INSTALLATION.......320
PISTON/CONNECTING ROD INSTALLATION.......321
LEFT CYLINDER SIDE.......321
RIGHT CYLINDER SIDE.......322
CRANKCASE ASSEMBLY.......323
13. FINAL DRIVE.......328
FINAL DRIVE.......329
SYSTEM COMPONENTS.......329
SERVICE INFORMATION.......330
GENERAL.......330
SPECIFICATIONS.......330
TORQUE VALUES.......330
TOOLS.......331
TROUBLESHOOTING.......332
Excessive noise.......332
Oil leakage.......332
FINAL DRIVE REMOVAL.......333
INSPECTION.......333
FINAL DRIVE DISASSEMBLY/ INSPECTION.......334
BACKLASH INSPECTION.......334
FINAL GEAR CASE SEPARATION.......335
GEAR TOOTH CONTACT PATTERN CHECK.......336
RING GEAR BEARING/SHIM REPLACEMENT.......337
PINION GEAR REMOVAL.......338
PINION BEARING/SHIM REPLACEMENT.......339
CASE BEARING REPLACEMENT.......339
RING GEAR BEARING.......339
PINION NEEDLE BEARING.......340
FINAL DRIVE ASSEMBLY.......341
PINION GEAR INSTALLATION.......342
RING GEAR INSTALLATION.......343
FINAL GEAR CASE ASSEMBLY.......344
FINAL DRIVE INSTALLATION.......345
14. FRONT WHEEL/SUSPENSION/STEERING.......348
FRONT WHEEL/SUSPENSION/STEERING.......349
SYSTEM COMPONENTS.......349
SERVICE INFORMATION.......350
GENERAL.......350
SPECIFICATIONS.......350
TORQUE VALUES.......350
TOOLS.......351
TROUBLESHOOTING.......355
Hard steering.......355
Steers to one side or does not track straight.......355
Front wheel wobbles.......355
Wheel turns hard.......355
Soft suspension.......355
Stiff suspension.......355
Front suspension noise.......355
HANDLEBAR.......356
REMOVAL.......356
INSTALLATION.......358
FRONT WHEEL.......361
REMOVAL.......361
INSPECTION.......362
AXLE.......362
WHEEL RIM.......363
WHEEL AND STAY BEARINGS.......363
DISASSEMBLY.......363
ASSEMBLY.......364
WHEEL BALANCE.......365
STAY BEARING REPLACEMENT.......366
FENDER STAY.......366
CALIPER STAY.......367
INSTALLATION.......368
SUSPENSION LINKAGE/SHOCK ABSORBER.......370
REMOVAL.......370
INSPECTION.......372
SUSPENSION PIVOT BEARING REPLACEMENT.......373
SHOCK ABSORBER (A).......373
SHOCK ARM (B).......373
PUSH ROD (C).......374
PIVOT ARM (D).......374
FORK TUBE (E).......375
FENDER LINK (F).......375
INSTALLATION.......376
STEERING STEM.......377
REMOVAL.......377
STEERING BEARING REPLACEMENT.......380
U.S.A. Only.......382
INSTALLATION.......384
STEERING BEARING PRE-LOAD.......389
15. REAR WHEEL/SUSPENSION.......390
REAR WHEEL/SUSPENSION.......391
SYSTEM COMPONENTS.......391
SERVICE INFORMATION.......392
GENERAL.......392
SPECIFICATIONS.......392
TORQUE VALUES.......392
TOOLS.......393
TROUBLESHOOTING.......394
Soft suspension.......394
Stiff suspension.......394
Rear suspension noise.......394
Rear wheel wobbles.......394
Wheel turns hard.......394
REAR WHEEL.......395
REMOVAL.......395
REAR BRAKE DISC REPLACEMENT.......395
INSPECTION.......396
WHEEL RIM.......396
WHEEL BALANCE.......396
INSTALLATION.......396
SUSPENSION LINKAGE/SHOCK ABSORBER.......397
LINKAGE REMOVAL.......397
SHOCK ABSORBER REMOVAL.......397
INSPECTION.......398
SHOCK ABSORBER DISPOSAL.......398
LINKAGE PIVOT BEARING REPLACEMENT.......399
SHOCK LINK.......399
SHOCK ARM.......399
INSTALLATION.......400
SWINGARM.......401
REMOVAL.......401
INSPECTION.......403
PIVOT BEARING OUTER RACE REPLACEMENT.......403
INSTALLATION.......404
16. HYDRAULIC DISC BRAKE.......406
HYDRAULIC DISC BRAKE.......407
SYSTEM COMPONENTS.......407
SERVICE INFORMATION.......409
GENERAL.......409
SPECIFICATIONS.......409
TORQUE VALUES.......410
TOOLS.......410
TROUBLESHOOTING.......411
Brake lever/pedal soft or spongy.......411
Brake lever/pedal hard.......411
Brake drag.......411
BRAKE FLUID REPLACEMENT/AIR BLEEDING.......412
BRAKE FLUID DRAINING.......413
LEVER BRAKE LINE (Front Brake).......413
PEDAL BRAKE LINE (Rear Brake).......413
LEVER BRAKE LINE FLUID FILLING/ AIR BLEEDING.......415
FLUID FILLING.......415
AIR BLEEDING.......416
PEDAL BRAKE LINE FLUID FILLING/ AIR BLEEDING.......417
FLUID FILLING.......417
AIR BLEEDING.......418
BRAKE PAD/DISC.......419
FRONT BRAKE PAD REPLACEMENT.......419
REAR BRAKE PAD REPLACEMENT.......419
BRAKE DISC INSPECTION.......420
FRONT MASTER CYLINDER.......420
DISASSEMBLY.......420
INSPECTION.......421
ASSEMBLY.......422
FRONT BRAKE CALIPER.......424
DISASSEMBLY.......424
INSPECTION.......426
TORQUE ROD BEARING REPLACEMENT.......427
ASSEMBLY.......427
REAR MASTER CYLINDER/BRAKE PEDAL.......430
REMOVAL.......430
MASTER CYLINDER DISASSEMBLY.......432
INSPECTION.......432
MASTER CYLINDER ASSEMBLY.......433
INSTALLATION.......434
REAR BRAKE CALIPER.......436
DISASSEMBLY.......436
INSPECTION.......437
ASSEMBLY.......438
PROPORTIONAL CONTROL VALVE (PCV).......440
REMOVAL.......440
INSTALLATION.......440
17. BATTERY/CHARGING SYSTEM.......442
BATTERY/CHARGING SYSTEM.......443
COMPONENT LOCATION.......443
SYSTEM DIAGRAM.......443
SERVICE INFORMATION.......444
GENERAL.......444
BATTERY CHARGING.......444
BATTERY TESTING.......444
SPECIFICATIONS.......445
TORQUE VALUE.......445
TOOLS.......445
TROUBLESHOOTING.......446
BATTERY IS DAMAGED OR WEAK.......446
BATTERY.......447
REMOVAL/INSTALLATION.......447
VOLTAGE INSPECTION.......447
BATTERY TESTING.......447
BATTERY CHARGING.......448
CHARGING SYSTEM INSPECTION.......449
CURRENT LEAKAGE INSPECTION.......449
CHARGING VOLTAGE INSPECTION.......450
WIRE HARNESS INSPECTION.......450
BATTERY CHARGING LINE.......450
BATTERY VOLTAGE LINE.......450
ALTERNATOR.......451
REMOVAL.......451
DISASSEMBLY.......452
INSPECTION.......452
ROTOR COIL.......452
ROTOR BEARING.......453
BRUSH LENGTH.......453
STATOR COIL.......454
RECTIFIER.......454
BRUSH REPLACEMENT.......455
ROTOR BEARING REPLACEMENT.......456
ASSEMBLY.......457
INSTALLATION.......459
18. IGNITION SYSTEM.......462
IGNITION SYSTEM.......463
COMPONENT LOCATION.......463
SYSTEM DIAGRAM.......463
SERVICE INFORMATION.......464
GENERAL.......464
SPECIFICATIONS.......464
TORQUE VALUES.......464
TOOLS.......465
TROUBLESHOOTING.......466
No spark at spark plugs.......466
IGNITION SYSTEM INSPECTION.......467
IGNITION COIL SIGNAL PEAK VOLTAGE.......467
IGNITION PULSE GENERATOR PEAK VOLTAGE.......468
IGNITION COIL.......469
POWER/GROUND LINE INSPECTION.......469
POWER INPUT LINE.......470
GROUND LINE.......470
REPLACEMENT.......470
No. 1 & 2 IGNITION COIL.......470
No. 3 & 4 IGNITION COIL.......471
No. 5 & 6 IGNITION COIL.......471
IGNITION PULSE GENERATOR.......471
REPLACEMENT.......471
BANK ANGLE SENSOR RELAY.......472
SYSTEM INSPECTION.......472
BANK ANGLE SENSOR.......473
INSPECTION.......473
IGNITION TIMING.......474
19. ELECTRIC STARTER.......476
ELECTRIC STARTER.......477
COMPONENT LOCATION.......477
SYSTEM DIAGRAM.......477
SERVICE INFORMATION.......478
GENERAL.......478
SPECIFICATIONS.......478
TORQUE VALUES.......478
TROUBLESHOOTING.......479
Starter motor does not turn.......479
Starter motor turns slowly.......480
Starter motor turns, but engine does not turn.......480
Starter relay switch clicks, but engine does not turn over.......480
STARTER MOTOR.......481
REMOVAL.......481
DISASSEMBLY.......482
INSPECTION.......483
ARMATURE.......483
BRUSH/MOTOR CASE.......484
REDUCTION GEAR.......485
ASSEMBLY.......485
INSTALLATION.......487
STARTER RELAY SWITCH.......488
OPERATION INSPECTION.......488
RELAY COIL GROUND LINE INSPECTION.......489
RELAY COIL INPUT VOLTAGE INSPECTION.......489
CONTINUITY INSPECTION.......489
DIODE.......489
REMOVAL/INSTALLATION.......489
INSPECTION.......490
STARTER INHIBITOR RELAY.......490
SYSTEM INSPECTION.......490
20. LIGHTS/METERS/SWITCHES.......492
LIGHTS/METERS/SWITCHES.......493
COMPONENT LOCATION.......493
SERVICE INFORMATION.......494
GENERAL.......494
SPECIFICATIONS.......494
TORQUE VALUE.......494
TROUBLESHOOTING.......495
LIGHTING SYSTEM.......495
Low beam headlight does not light with the ignition switch turned to "ON".......495
High beam headlight does not light with the dimmer switch pushed to ".......495
HEADLIGHT.......496
BULB REPLACEMENT.......496
CASE REMOVAL/INSTALLATION.......499
TURN SIGNAL LIGHT.......499
BULB REPLACEMENT.......499
FRONT.......499
REAR.......500
BRAKE/TAILLIGHT.......500
REPLACEMENT.......500
LICENSE LIGHT.......501
BULB REPLACEMENT.......501
SPEEDOMETER.......501
REMOVAL/INSTALLATION.......501
DISASSEMBLY.......502
ASSEMBLY.......503
POWER/GROUND LINE INSPECTION.......504
POWER INPUT LINE.......504
BACK-UP VOLTAGE LINE.......504
GROUND LINE.......504
SENSOR GROUND LINE.......504
SPEEDOMETER LINE INSPECTION.......504
INDICATOR BOX.......505
REMOVAL.......505
INSTALLATION.......506
POWER/GROUND LINE INSPECTION.......506
POWER INPUT LINE.......507
GROUND LINE.......507
COOLANT TEMPERATURE INDICATOR/ THERMOSENSOR.......507
SYSTEM INSPECTION.......507
THERMOSENSOR INSPECTION.......508
FUEL GAUGE/FUEL LEVEL SENSOR.......509
INSPECTION.......509
FUEL LEVEL SENSOR INSPECTION.......511
OIL PRESSURE SWITCH.......511
INSPECTION.......511
Indicator does not come on with the ignition switch turned to "ON".......511
Indicator stays on while the engine is running.......512
IGNITION SWITCH.......512
INSPECTION.......512
REPLACEMENT.......513
HANDLEBAR SWITCHES.......513
BRAKE LIGHT SWITCH.......514
FRONT.......514
REAR.......515
CLUTCH SWITCH.......515
NEUTRAL SWITCH.......515
INSPECTION.......515
SIDE STAND SWITCH.......516
INSPECTION.......516
REMOVAL.......516
INSTALLATION.......516
HORN.......517
HEADLIGHT RELAY.......518
SYSTEM INSPECTION.......518
FAN CONTROL RELAY.......519
SYSTEM INSPECTION.......519
TURN SIGNAL/POSITION LIGHT RELAY.......520
SYSTEM INSPECTION.......520
POWER INPUT LINE.......520
TURN SIGNAL LIGHT LINES.......521
TURN SIGNAL SWITCH LINES.......521
21. IMMOBILIZER SYSTEM (HISS).......522
IMMOBILIZER SYSTEM (HISS).......523
COMPONENT LOCATION.......523
SYSTEM DIAGRAM.......523
SERVICE INFORMATION.......524
GENERAL.......524
TOOL.......524
KEY REGISTRATION PROCEDURES.......525
When the key has been lost, or additional spare key is required:.......525
When the ignition switch is faulty:.......526
When all keys have been lost, or the Engine Control Module (ECM) is faulty.......527
DIAGNOSTIC CODE INDICATION.......528
DIAGNOSTIC CODE.......528
TROUBLESHOOTING.......530
IMMOBILIZER SYSTEM.......530
Immobilizer indicator does not light when the ignition switch is turned to "ON".......530
Immobilizer indicator remains lit with the ignition switch turned to "ON".......532
Diagnostic code.......534
STEERING LOCK SYSTEM.......536
Steering lock indicator does not light when the ignition switch is turned to "ON" with the steeri.........536
Steering lock indicator does not go out after the steering is unlocked.......537
Steering is not unlocked when the ignition switch is turned to "ON".......538
INNER LOCK UNIT.......540
REMOVAL/INSTALLATION.......540
22. WIRING DIAGRAM.......542
WIRING DIAGRAM.......543
WIRING DIAGRAM.......543
23. TROUBLESHOOTING.......545
TROUBLESHOOTING.......546
ENGINE DOES NOT START OR IS HARD TO START.......546
1. Spark Plug Inspection.......546
ENGINE LACKS POWER.......546
1. Drive Train Inspection.......546
POOR PERFORMANCE AT LOW AND IDLE SPEED.......548
1. Intake Air Leak Inspection.......548
POOR PERFORMANCE AT HIGH SPEED.......549
1. Ignition Timing Inspection.......549
POOR HANDLING.......549
Steering is heavy.......549
Either wheel is wobbling.......549
Motorcycle pulled to one side.......549
24. INDEX.......551
Honda NRX1800 Valkyrie Rune Service Repair Manual 2003-2005
