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MUV700 big red
Honda MUV700 big red Manuals
Manuals and User Guides for Honda MUV700 big red. We have
1
Honda MUV700 big red manual available for free PDF download: Service Manual
Honda MUV700 big red Service Manual (600 pages)
Brand:
Honda
| Category:
Automobile
| Size: 66 MB
Table of Contents
A few Words about Safety
2
Safety Information
2
Important Safety Precautions
2
Contents
3
Symbols
4
General Information
5
Table of Contents
5
Service Rules
6
Abbreviation
6
Model Identification
7
Serial Numbers
7
Labels
8
General Specifications
9
Lubrication System
9
Specifications
11
Fuel System Specifications
11
Cooling System Specifications
11
Cylinder Headivalve/Camshaft Specifications
12
Alternator/Starter Clutch Specifications
12
Sub-Transmission/Gearshift Linkage Specifications
13
Crankcase/Crankshaft/Balancer Specifications
13
Drivetrain System Specifications
13
Front Wheel/Suspension Specifications
13
Steering System Specifications
13
Rear Wheel/Suspension
20
Brake System Specifications
20
Front Driving Mechanism
21
Lubrication & Seal Points
22
Cable & Harness Routing
25
Emission Control Systems
50
Source of Emissions
50
Exhaust Emission Control System
50
Crankcase Emission Control System
50
Noise Emission Control System
51
Fuel Permeation Emission Control System
51
Rebuilt Engine
51
Lift and Support Points
52
Technical Features
53
Muv Overview
54
Outline
54
Occupant Protecteve Structure (Ops), Door and Cargo Bed
54
Muv Steering System
55
Elr (Emergency Locking Retractor) Seat Belt
55
Pgm-Fi System
56
Integrated Sensor Throttle Body
56
IACV (Idle Air Control Valve)
57
Automatic Transmission System
59
Torque Converter
60
Hydraulic Valve Function
61
Shift Clutch Hydraulic Circuit and Operation
62
Selectable 4WD and Differential Lock System
66
2WD/4WD Final Clutch Operation
66
2WD to 4WD
67
4WD to 2WD
67
Differential Lock Clutch Operation
68
Normal Operation to Differential Lock
69
Differential Lock to Normal Operation
69
Frame/Body Panels/Exhaust System
71
Frame/Body Panels/Exhaust System Service Information
72
Frame/Body Panels/Exhaust System Torque Values
72
Frame/Body Panels/Exhaust System Tools
72
Frame/Body Panels/Exhaust System Troubleshooting
72
Body Panel Locations
73
Seat Cushion
74
Seat Frame
74
Seat Center Cover
75
Headrest
75
Backrest
75
Seat under Cover
76
Engine Front Cover
76
Parking Brake Lever Bracket
77
Center Frame Cover
77
Crossbar
78
Door Panel
79
Door Hinge
79
Door Handle and Latch
79
Side Panel
81
Mudguard
82
Floor Panel
82
Floor Cross Plate
83
Instrument Panel
83
Footrest Panel
84
Front Hood Removal/Installation
84
Front Grille
85
Front Hood Disassembly/Assembly
85
Front Bumper
86
Maintenance Lid
86
Cargo Bed Damper
86
Cargo Bed Damper Removal/Installation
87
Cargo Bed Damper Disassembly/Assembly
87
Bed Side Panel
87
Bed Base Panel
88
Bed Front Panel
88
Tailgate
89
Release Lever
90
Side Net
91
Occupant Protective Structure (OPS)
91
Top OPS
91
Front OPS
92
Rear OPS
92
Seat Belt Instructions
92
Belt/Retractor
93
Retractor Function Check
93
Fuel Tank Plate/Cover
94
Buckle
94
Exhaust System Removal
95
Exhaust System Installation
96
Exhaust Pipe Disassembly/Assembly
97
Maintenance
99
Maintenance Service Information
100
Maintenance Torque Values
101
Maintenance Tool
101
Maintenance Schedule
102
Fuel Line
103
Throttle Operation
103
Air Cleaner
104
Air Cleaner Housing Drain Tube
106
Spark Plug
106
Battery
107
Valve Clearance
108
Clearance
109
Engine Oil Level Check
110
Engine Oil Change
111
Engine Oil Filter Replacement
112
Cooling System
113
Radiator Coolant
113
Cooling System Inspection
113
Recommended Antifreeze
113
Drive Shaft Boots
114
Differential Oil
114
Front Final Gear Case
114
Rear Final Gear Case
115
Brake Fluid
116
Brake Pads Wear
117
Foot Brake Switch
117
Brake System
118
Hydraulic Brake
118
Brake Pedal Height
119
Parking Brake
119
Underbody
120
Suspension
121
Spark Arrester
121
Exhaust System
122
Wheels/Tires
122
Tire Rotation
122
Wheels/Tires Inspection
122
Tie- Rod and Joint Boot
123
Steering System
123
Gear Box Boot and Operation Check
123
Rotational Play Check
124
Turning Load Check
124
Rack Guide Adjustment
124
Wheel Alignment
125
Front Toe Inspection
125
Turning Radius Inspection
126
Chassis Lubrication Points
127
Lubrication System
129
Lubrication System Diagram
130
Lubrication System Service Information
131
Lubrication System Specifications
131
Lubrication System Torque Values
131
Lubrication System Tools
131
Lubrication System Troubleshooting
132
Oil Pressure Check
133
Oil Pump Removal
134
Oil Pump Disassembly
134
Oil Pump Inspection
136
Oil Pump Assembly
137
Oil Pump Installation
139
Oil Cooler Removal
141
Oil Cooler Disassembly
141
Oil Cooler Assembly
142
Oil Cooler Installation
143
Fuel System (PGM-FI)
145
Fuel System (PGM-FI) Components
146
Fuel System (PGM-FI) Service Information
148
Fuel System (PGM-FI) Specifications
148
Fuel System (PGM-FI) Torque Values
148
Fuel System (PGM-FI) Tools
149
Fuel System (PGM-FI) Symptom Troubleshooting
150
Fuel System (PGM-FI) Component Location
151
Fuel System (PGM-FI) Diagram
152
PGM-FI Connector Location
153
PGM-FI Troubleshooting Information
155
PGM-FI System Description
155
HDS Pocket Tester Information
156
DTC Readout
156
MIL Blink Pattern
156
Mil Check
156
Erasing DTC
157
Circuit Inspection
157
Inspection at PCM Connector
157
PGM-FI DTC Index
158
DTC Troubleshooting
159
DTC 1-1 (Map Sensor Low Voltage)
159
DTC 1-2 (Map Sensor High Voltage)
160
DTC 7-1 (ECT Sensor Low Voltage)
161
DTC 7-2 (ECT Sensor High Voltage)
162
DTC 8-1 (TP Sensor Low Voltage)
163
DTC 8-2 (TP Sensor High Voltage)
165
DTC 9-1 (IAT Sensor Low Voltage)
166
DTC 9-2 (IAT Sensor High Voltage)
167
DTC 11-1 (VS Sensor)
168
DTC 12-1 (Fuel Injector)
169
Dtc 29-1 (Iacv)
170
Dtc 33-2 (Eeprom)
172
DTC 64-1 (Drive Power Low Voltage)
172
DTC 64-2 (Drive Power High Voltage)
173
Mil Circuit Inspection
174
Fuel Line Inspection
175
Fuel Pressure Relieving
175
Quick Connect Fitting Removal
175
Quick Connect Fitting Installation
177
Fuel Pressure Test
179
Fuel Flow Inspection
180
Fuel Pump Inspection
180
Fuel Pump Removal
181
Fuel Pump Installation
181
Main Relay/Fuel Pump Relay Removal/Installation
182
Relay Inspection
182
Main Relay Circuit Inspection
183
Fuel Pump Relay Circuit Inspection
183
Power Input Line Inspection
183
Relay Coil Ground Line Inspection
183
Fuel Tank Removal/Installation
184
Air Cleaner Housing Removal/Installation
185
Intake Air Duct Removal/Installation
186
Accelerator Pedal Removal/Installation
186
Throttle Body Removal
189
Throttle Body Installation
190
IACV Inspection
192
IACV Removal
192
IACV Installation
193
Fuel Injector Replacement
193
TP Sensor/Map Sensor (Sensor Unit) Replacement
195
TP Sensor Reset Procedure
196
ECT Sensor Replacement
197
VS Sensor Removal/Installation
197
Pcm
198
Power/Ground Line Inspection
198
Power Ground Line
198
Engine Idle Speed
199
Idle Speed Inspection
199
Cooling System Flow Pattern
202
Cooling System Service Information
203
Cooling System Troubleshooting
203
Cooling System Specifications
203
Cooling System Torque Value
203
Cooling System Testing
204
Coolant (Hydrometer Test)
204
Standard Coolant Concentration
204
Radiator Cap/System Pressure Inspection
205
Coolant Replacement Preparation
205
Cooling System Replacement/Air Bleeding
206
Thermostat Removal
207
Thermostat Inspection
207
Thermostat Installation
208
Water Pump
209
Mechanical Seal Inspection
209
Water Pump Removal
209
Water Pump Installation
210
Cooling Fan Removal/Installation
211
Cooling Fan Disassembly/Assembly
212
Radiator Removal/Installation
213
Radiator Reserve Tank Removal/Installation
214
Engine Removal/Installation
215
Engine Removal/Installation System Components
216
Engine Removal/Installation Service Information
217
Engine Removal
218
Oil Cooler
218
Engine Installation
223
Cylinder Head/Valve/Camshaft
231
Cylinder Head/Valve/Camshaft System Components
232
Cylinder Head/Valve/Camshaft Service Information
233
Cylinder Head/Valve/Camshaft Tools
234
Cylinder Head/Valve/Camshaft Troubleshooting
235
Cylinder Compression
236
Cylinder Head Cover Removal/Disassembly
236
Rocker Arm/Shaft
238
Push Rod
238
Cam Follower
238
Cylinder Head Removal
239
Cylinder Head Disassembly
240
Cylinder Head Inspection
240
Valve Spring
241
Valve/Valve Guide
241
Valve Guide Replacement
242
Valve Seat Inspection/Refacing
243
Camshaft Removal
246
Camshaft Inspection
247
Camshaft Installation
247
Cylinder Head Assembly
249
Cylinder Head Installation
250
Cylinder Head Cover Assembly/Installation
251
Cylinder/Piston
255
Cylinder/Piston System Components
256
Cylinder/Piston Service Information
257
Cylinder/Piston Troubleshooting
257
Cylinder/Piston Torque Values
257
Cylinder/Piston Specifications
257
Cylinder/Piston Removal
258
Cylinder/Piston Inspection
259
Piston/Piston Ring
260
Connecting Rod
261
Cam Chain Tensioner Lifter
261
Cylinder Stud Bolt Replacement
261
Cylinder/Piston Installation
262
Piston Ring Installation
262
Alternator/Starter Clutch
265
Alternator/Starter Clutch System Components
266
Alternator/Starter Clutch Service Information
267
Alternator/Starter Clutch Specification
267
Alternator/Starter Clutch Torque Values
267
Alternator/Starter Clutch Tools
267
Alternator/Starter Clutch Troubleshooting
268
Alternator Stator/Starter Reduction Gears
269
Alternator Cover Removal
269
Alternator Cover Inspection
270
Stator/Ckp Sensor Removal/Installation
271
Bearing Replacement
272
Alternator Cover Installation
272
Flywheel/Starter Clutch Removal
274
Starter Clutch Disassembly/Inspection
275
Starter Clutch Assembly
276
Sub-Transmission/Gearshift Linkage
279
Sub-Transmission/Gearshift Linkage System Components
280
Sub-Transmission/Gearshift Linkage Service Information
281
Sub-Transmission/Gearshift Linkage Specifications
281
Sub-Transmission/Gearshift Linkage Torque Values
281
Sub-Transmission/Gearshift Linkage Tools
281
Sub-Transmission/Gearshift Linkage Troubleshooting
282
Rear Crankcase Cover Removal
283
Rear Crankcase Cover Bearing Replacement
284
Rear Crankcase Cover Installation
285
Sub-Transmission Disassembly
287
Sub-Transmission Inspection
289
Reverse Idle Gear
290
Shift Fork and Shaft
290
Shift Drum
290
Gearshift Spindle
290
Gear Selector Lever Linkage Disassembly
293
Gear Selector Lever Linkage Assembly
294
Gear Selector Cable Adjustment
294
Crankcase/Crankshaft/Balancer
297
Crankcase/Crankshaft/Balancer System Components
298
Crankcase/Crankshaft/Balancer Service Information
299
Crankcase/Crankshaft/Balancer Specifications
299
Crankcase/Crankshaft/Balancer Tools
299
Crankcase/Crankshaft/Balancer Troubleshooting
301
Crankcase Separation
302
Crankshaft Removal
303
Crankshaft Inspection
304
Crankshaft and Balancer Installation
305
Crankcase Bearing Replacement
306
Rear Crankcase
306
Front Crankcase
307
Crankcase Assembly
308
Drivetrain System
311
Drivetrain System Components
312
Drivetrain System Service Information
313
Drivetrain System Tools
314
Drivetrain System Symptom Troubleshooting
316
A/T Clutch PC Solenoid Valve Operation Inspection
316
Shift Solenoid Valve Operation Inspection
317
Line Oil Pressure
319
Shift Clutch Oil Pressure
319
Hydraulic Circuit Troubleshooting Chart
320
Drivetrain Component Location
321
Drivetrain System Diagram
322
Drivetrain Connector Location
323
Drivetrain Troubleshooting Information
325
Self-Diagnosis System
325
Fail-Safe Function
325
Drivetrain Dtc Index
326
Troubleshooting
326
Drivetrain DTC Troubleshooting
327
Dtc 4-1
327
Dtc 4-3
327
DTC 4-2 (A/T Clutch PC Solenoid Valve High Input)
328
DTC 15-1 (Shift Solenoid Valve)
329
DTC 15-2 (Shift Solenoid Valve)
330
DTC 16-1 (Shift Solenoid Valve B-Short)
331
DTC 16-2 (Shift Solenoid Valve B-Open)
332
DTC 31-1 (System Voltage Low)
333
Dtc 32-1
334
DTC 41-1 (Gear Position Switch Circuit)
334
DTC 44-1 (EOT Sensor Low Voltage)
336
DTC 44-2 (EOT Sensor High Voltage)
337
Shift Valve Body
338
Emergency Valve Function
338
Shift Valve Body Removal
338
Shift Valve Body Disassembly/Inspection
339
Shift and Orifice Control Valves
343
Solenoid and Emergency Valves
345
Front Crankcase Cover Removal
347
Front Crankcase Cover Inspection
348
Front Crankcase Cover Bearing Replacement
349
Front Crankcase Cover Installation
349
Torque Converter Removal
352
Torque Converter Inspection
353
Torque Converter Installation
354
1St Shift Clutch Removal
357
Mainshaft Disassembly
357
Shift Clutch/Mainshaft Icountershaft
357
Countershaft Disassembly
358
Shift Clutch Disassembly
358
Clutch Drum and Piston
360
Clutch Disc and Plate
360
Clutch Return Spring
360
Shift Clutch Assembly
361
Clutch Initial Clearance Check
363
Countershaft Assembly
364
Mainshaft Assembly
365
1St Shift Clutch Installation
366
Gear Position Switch Replacement
367
EOT Sensor Replacement
368
Front Wheel/Suspension
369
Front Wheel/Suspension System Components
370
Front Wheel/Suspension Service Information
371
Front Wheel/Suspension Specifications
371
Front Wheel/Suspension Torque Values
371
Front Wheel/Suspension Tools
372
Front Wheel/Suspension Troubleshooting
373
Front Wheel Removal
374
Front Wheel Installation
374
Tires Removal
374
Tire Repair
376
Tire Assembly
377
Front Wheel Hub and Knuckle Removal
378
Front Wheel Hub and Knuckle Inspection
380
Brake Disc Replacement
380
Ball Joint Replacement
381
Front Wheel Hub and Knuckle Installation
382
Front Suspension Arm Removal
385
Front Suspension Arm Inspection
386
Front Suspension Arm Ball Joint Replacement
386
Front Suspension Arm Installation
387
Front Shock Absorber Removal
389
Front Shock Absorber Inspection
389
Front Shock Absorber Installation
389
Steering System Components
392
Steering System Service Information
393
Steering System Specifications
393
Steering System Torque Values
393
Steering System Tools
393
Steering System Troubleshooting
394
Steering Wheel Removal/Installation
395
Steering Column and Shaft Removal
395
Steering Column and Shaft Inspection
396
Steering Column and Shaft Installation
396
Tie-Rod Ball Joint Removal
397
Tie-Rod Ball Joint Inspection
398
Tie-Rod Ball Joint Installation
399
Steering Gear Box Removal
399
Steering Gear Box Disassembly
403
Steering Gear Box Inspetion
404
Steering Gear Box Assembly
405
Steering Gear Box Installation
409
Rear Wheel/Suspension
413
Rear Wheel/Suspension System Components
414
Rear Wheel/Suspension Service Information
415
Rear Wheel/Suspension Specifications
415
Rear Wheel/Suspension Torque Values
415
Rear Wheel/Suspension Tools
415
Rear Wheel/Suspension Troubleshooting
416
Rear Wheel Removal
417
Rear Wheel Installation
417
Rear Wheel Hub/Knuckle Removal
417
Rear Wheel Hub/Knuckle Inspection
418
Rear Wheel Hub/Knuckle Brake Disc Replacement
419
Rear Wheel Hub/Knuckle Bearing Replacement
419
Rear Wheel Hub/Knuckle Installation
420
Rear Suspension Arm Removal
423
Upper Arm
424
Stabilizer Arm and Link
424
Rear Suspension Arm Inspection
425
Rear Suspension Arm Installation
425
Suspension Arm Fastener Tightening
427
Rear Shock Absorber Removal
428
Rear Shock Absorber Inspection
428
Rear Shock Absorber Installation
428
Brake System Components
430
Brake System Service Information
432
Brake System Specifications
432
Brake System Torque Values
432
Brake System Troubleshooting
433
Brake System Tools
433
Brake Fluid Replacement/Air Bleeding
434
Brake Fluid Draining
434
Brake Fluid Filling/Bleeding
435
Brake Pad/Disc
436
Front Brake Pad Replacement
436
Rear Brake Pad Replacement
437
Brake Disc Inspection
438
Master Cylinder Disassembly
439
Master Cylinder Inspection
440
Master Cylinder Assembly
440
Front Brake Caliper Disassembly
443
Rear Brake Caliper Disassembly
447
Rear Brake Caliper Assembly
451
Brake Pedal Removal
455
Brake Pedal Installation
455
Brake Pedal Disassembly
455
Brake Pedal Assembly
456
Parking Brake Lever Removal/Installation
457
Front Driving Mechanism
459
Front Driving Mechanism System Components
460
Front Driving Mechanism Service Information
461
Front Driving Mechanism Specifications
461
Front Driving Mechanism Tools
462
Front Driving Mechanism Troubleshooting
464
FRONT DRIVE SHAFT Removal
465
FRONT DRIVE SHAFT Disassembly/Inspection
465
Front Drive Shaft Assembly
467
Front Drive Shaft Installation
469
Front Final Drive Removal
470
Front Final Drive Operation Check
472
Front Propeller Shaft Disassembly/Inspection
473
Front Propeller Shaft Assembly
474
Front Final Clutch Disassembly/Inspection
475
Pinion Joint Ball Bearing Replacement
476
Clutch
476
Pinion Joint Ball Assembly
478
Front Differential Lock Clutch Disassembly/Inspection
481
Half Shaft Bearing Replacement
483
Front Final Gear Disassembly/Inspection
486
Backlash Inspection
486
Differential Removal
487
Bearing Inspection
488
Gear Tooth Contact Pattern Check
488
Differential Inspection
490
Ring Gear Removal
490
Pinion Gear Removal
490
Pinion Ball Bearing and Shim Replacement
491
Pinion Joint Needle Bearing Replacement
492
Case Bearing Replacement
492
Pinion Needle Bearing
493
Front Final Gear Assembly
494
Pinion Gear Installation
495
Ring Gear Installation
495
Final Gear Case Assembly
496
Front Final Drive Installation
497
Drive Mode Selector Lever Linkage Removal
500
Drive Mode Selector Lever Linkage Installation
501
Drive Mode Selector Cable Adjustment
502
Rear Driving Mechanism
505
Rear Driving Mechanism System Components
506
Rear Driving Mechanism Service Information
507
Rear Driving Mechanism Specifications
507
Rear Driving Mechanism Torque Values
507
Rear Driving Mechanism Tools
508
Rear Driving Mechanism Troubleshooting
510
Rear Drive Shaft Removal
511
Rear Drive Shaft Disassembly/Inspection
511
Rear Drive Shaft Assembly
513
Rear Final Drive Removal
516
Rear Final Drive Inspection
517
Propeller Shaft
517
Universal Joint Disassembly/Assembly
518
Operation Check
518
Rear Differential Lock Clutch
519
Rear Final Gear Disassembly/Inspection
525
Pinion Gear Bearing and Shim Replacement
530
Differential Bearing
530
Case Bearing Replacement
530
REAR FINAL GEAR Assembly
533
Rear Final Drive Installation
536
Battery/Charging System
539
Battery/Charging System Component Location
540
Battery/Charging System Diagram
540
Battery/Charging System Service Information
541
Battery/Charging System Specifications Battery/Charging System Tools
542
Battery/Charging System Troubleshooting
543
Battery Removal/Installation
544
Voltage Inspection
544
Battery Testing
544
Battery Charging
544
Charging System Inspection
545
Current Leakage Inspection
545
Charging Voltage Inspection
545
Alternator Charging Coil Inspection
546
Regulator/Rectifier
546
Wire Harness Inspection
546
Ignition System
547
Ignition System Component Location
548
Ignition System Diagram
548
Ignition System Service Information
549
Ignition System Specifications
549
Ignition System Torque Values
549
Ignition System Tools
549
Ignition System Troubleshooting
550
Ignition System Inspection
551
Peak Voltage Adaptor Connection
551
Ignition Coil Primary Peak Voltage
551
CKP Sensor Peak Voltage
552
Ignition Coil Removal/Installation
553
Ignition Timing
554
Electric Starter
555
Troubleshooting
555
Electric Starter Component Location
556
Electric Starter System Diagram
556
Electric Starter Service Information
557
Electric Starter Specification
557
Electric Starter Troubleshooting
558
Starter Motor Removal
560
Starter Motor Disassembly/Inspection
560
Starter Motor Assembly
563
Starter Motor Installation
565
Starter Relay Switch Operation Inspection
566
Starter Relay Switch Circuit Inspection
566
Ground Line
566
Power Input Line
566
Starter Relay Switch Function Inspection
567
Diode Inspection
567
Brake Inhibitor Relay Removal/Installation
568
Brake Inhibitor Relay Inspection
568
Brake Inhibitor Relay Circuit Inspection
569
Lights/Meters/Switches
571
Lights/Meters/Switches Component Location
572
Indicators
572
IGNITION Switch
572
Lights/Meters/Switches Service Information
573
Lights/Meters/Switches Specifications
573
Lights/Meters/Switches Torque Values
573
Lights/Meters/Switches Tools
573
Headlight Bulb Replacement
574
Headlight Removal/Installation
574
Brake/Taillight Replacement
575
Indicators Bulb Replacement
575
Accessory Socket Inspection
576
Accessory Socket Replacement
576
Ignition Switch Inspection
577
Ignition Switch Replacement
577
Lighting/Dimmer Switch Inspection
578
Lighting/Dimmer Switch Replacement
578
Engine Temperature Indicator System Inspection
579
Cooling Fan Motor System Inspection
581
Low Fuel Indicator System Inspection
583
Foot Brake Switch Inspection
586
Foot Brake Switch Replacement
586
Parking Brake Switch Inspection
587
Parking Brake Switch Replacement
587
Wiring Diagram
589
Engine Does Not Start or Is Hard to Start
592
Engine Lacks Power
593
Poor Performance at Low and Idle Speed
595
Poor Performance at High Speed
596
Index
597
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