2006-2011 Honda TRX680FA TRX680FGA Rincon Service Repair Manual Instant Download

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(No Transcript)
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HOW TO USE THIS MANUAL Thìs service manual
describes the servira procedures for the TRX680FA
and TRX680FGA. rollow fhe Maimenance Schedule
(Section 4) reoommengaóons to 8nsure fhat th8
vehicle is In peak operating c0lld8lon and the
emission level9 are wi?hin lhe stsnderds set by
lbe Califorrï_at_ Air Resources Board
(CARB). Pedorming the first 8chedMled mafntenanoe
is v8ry important. It œmpensetes !or the initial
wear that occurs during the break-in
penod. Sacllons J and 4 apply to the whole
vahide. Saclion 3 illLtStrates procedures lor
removal/inatallation of components that may be
reHlred to perform œrvice described in the
aiIowing sections. Sacllons 5 through 23 describe
parts ol the vehicle grouped acœrding to
location. Find ihe section you mans on this page,
then turn to one labIe oî contents on1h8 fir6t
page of Ìhe section. Most sections start with an
assembly or system illustration, service
information and troubleshooting for the section.
The subcequem pages give deIail8d proceduæ. tl
you are not familiar with this vehicie, read
TechniCal Features in æctlon If you don't know
the 9oMrce of the trouble, go to eection 2S
Troubleshoosng.
CONTENTS ONE NER L N ORM T ECHN C L FE TURES
A NTEN hICE LUBRICATION SYSTEM FUEL SYSTEM
.
COOLING SYSTEM
ENGINE REMOVAMNSTALLATION CYLINDER
HEAD/VALVE/CAMSHAFT
.

CYLINDER/PISTON

• Your safety, and the safety of others, is very
  important. To help you make informed decisions we
  have provided eafety msaBages and other
  inlormaúc'n throughout this manual. Of course, li
  ie 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 infxmation in a
  variety of forms including
• Saiefy Labeis - on the vehicle
• Safely Messages preceded by a safeiy alert
  symbol _at_ and one of thraa signal wads, DANGER,
  WARNING, or CAUTiON. Theae eignal worde mean
• You WILL be KLLED or gERiOUSLY HMRT if you don't
  iollo\v instruclion6.
• You CAN be KILLED or SERIOUSLY NURT
• if you don't foIkw instructions.
• You CAN be HURT if yaU don't îolIow
• lnslruc1ions - how to service tt1is vehicle
  correciiy and safely.
• As yau read Ihis manual, you will find
  information that is preceded by a symbol. The
  purpose or this message is to hep present
• damage to your vehicla, other property, or the
  environment.

SUB-TRANSMISSIDN/GEARSHIFT LINKAGE CRANKCASE/CRANK
SHAFT/BALANCER DRIVE TRAIN SYSTEM FRONT
WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION BR
AKE SYSTEM FRONT DRIVING MECHANISM REAR DRIVING
MECHANISM BATTERY/CHARGING SYSTEM


IGNITION SYSTEM ELEOTRCSTARTER LIGHTS/METERS/SWITC
HES WIRING DIAGRAM

TROUBLESHOOTING
INDEX

" "
3
SYMBOLS The symbols used throughout this manual
sh0w 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 olherwise specified.
Replace The part(s) with new one(s) before assembly. Use the recommended engine oil, unless olherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1!1). 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 multi purpose grease (lithium based multi-purpose grease NLGI 2 or equivalent).
Use molybdenum disulfide grease (containing more than 3 molybdenum disulfide, NLGI g2 or equivalent. Example Molykot_at_ BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide grease (containing more than 3 molybdenum disulfide, NLGI g2 or equivalent. Example Molykot_at_ BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing mDFB than 404 motybdenum disu)fide, NLGI dJ or equivalent). Example MolykotW G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Racal Limited. U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use molybdenum disulfide paste (containing mDFB than 404 motybdenum disu)fide, NLGI dJ or equivalent). Example MolykotW G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Racal Limited. U.K. Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone greass. Use silicone greass.
Apply a locking agent. Use a medium strength locking agent uPIBSS otherwise specifieil. Apply a locking agent. Use a medium strength locking agent uPIBSS otherwise specifieil.
Apply sealant. Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid. Use fork or suspension fluid.
4
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1. GENERAL iuroRMATlON
1-2
REAR WHEEL/SUSPENSION SPECIFICATIONS--
1-9 BRAKE SYSTEM
SPECIFICATIONS t-10
1-3 -s
FRONT DRIVING MECHANISM
SPECIFICATjONS....................................
......j.j0
LUBRICATION SYSTEM gE/z Ç \j
...........................................
1-7 FUEL SYSTEM SPECIFICATIONS------- 1-7
COOLING SYSTEM SPECIFICATIONS---- 1-7
IGNITION SYSTEM SPECIFICATIONS ---1-11 ELECTRIC
STARTER SPECIFICATIONS ------1-11
CYLÎNDER/PISTON SPECIFICATIONS--1-8
ALTERNATOR/STARTER CLUTCH
pE F _at_" \j .................................
.......... 1-8
STANDARD TORtUE VALUES - -- 112 ENGINE
FRAME TORQUE VALUES ------112 LUBRICATION
SEAL POINTS------1-17 CABLE HARNESS
ROUTINE -------------------1-20 EMISSION CONTROL
SYSTEMS ----- --------- 1-39
SUB-TRANSMISSION/GEARSHIFT LINKAGE
SPECIFICATIONS --- - - 1-9
19
DRIVETRAIN SPECIFICATIONS------------1-9
1-9
1-1
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• GENERAL INFORMATION
• SERVICE RULES
• Use genuine Honds or Honda-recommended parts and
  lubricants or their equivalents. Parts that do
  not meet Honda's design specifications may cause
  damage to the motorcycle.
• Use the special tools designed for this product
  to avoid damage and incorrect assembly.
• Use only metric tools when servicing the
  motorcycle. Metric bows, nuts and screws are not
  intarCh8ngeable with English fasteners.
• Install nsw gasksts, O-rings, cotter pins, anl
  lock plates when reassembling.
• When tightening bolts or nuts, begin with the
  IBrger diameter or inner bolt first. 1"hen
  tighten to the specified torque diagonally in
  incremental steps unless a particular sequence is
  specified.
• Clean parts in cleaning solvent upon disassembly.
  Lubricate any sliding surfaces before reassembly.
• After reassemblY,check all parts for proper
  installation and operation.
• 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 PGM-FI rull term Programmed Fuel Injection
MAP sensor Manifold Absolute Pressure sensor MAP sensor Manifold Absolute Pressure sensor
JP sensor Throttle Position sensor JP sensor Throttle Position sensor
t ELT sensor Engine coolant Temperature sensor
IAT sensor Intake Air Temperature sensor IAT sensor Intake Air Temperature sensor
CKP sensor Cranlcshaft Position sensor CKP sensor Cranlcshaft Position sensor
VS sensor Vehicle S3eed Seri6OF EOT sensor Engine Oil Temperature sensor VS sensor Vehicle S3eed Seri6OF EOT sensor Engine Oil Temperature sensor
IACV Idle Air Control Valve
I 'CM Powertra n Control Module
(ECM/TCM) (Engine Control Module/Transmission Control Module) (ECM/TCM) (Engine Control Module/Transmission Control Module)
El6ctricaHy Erasable Programmable Read On!YMemory Data LinkConnactor El6ctricaHy Erasable Programmable Read On!YMemory Data LinkConnactor
SCS connector Service Check Short connector SCS connector Service Check Short connector
HDS Honda Diagnostic System HDS Honda Diagnostic System
DTC i Diagnostic Trouble Code DTC i Diagnostic Trouble Code
MIL , Malfunction Indicator Lamp MIL , Malfunction Indicator Lamp
A/T t Automatic Tran9mi9sion A/T t Automatic Tran9mi9sion
ClutCh PC solenoid C)utCh Pressure Control solenoid
4WD ESP 4 Wfiael Drive Electric Shift Program ""
GPS Global Positioning System
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GENERAL INFORMATION
MODEL IDENTIFICATION
SERIAL NUMBERS The Vehicle Identification Number
(V.I.N) is stamped on the front side of the frama.
VEHICLE IDENTIFICATION NUMBER (VIN)
The engine serial number is stamped on the right
side of the
ENGINE SERIAL NUMBER
crankcase.
1-3
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GENERAL INFORMATION

The throttle body identification number is
stamped on the left side of the throttlB body.
THROTTLE BODY IDENTIFICATION NUMBER
LABELS The name plate U.S.A. and AUSTRALIA typel
is located on the frame down tube.
' U,S.A,/AUSTRALIAtype
''
T ! i.I
The safety certification labet (Canada type only)
is locate on the right frama down tube.
SAFETY CEflTlFlCATlON LABEL
The color labal is attached on the righi sidu of
the frame under the segt. When ordering color
coded parts, always specify the designated color
code.
t COLOR LABEL
1-4
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GENERAL INFORMATION
The Vehicle Emission Control Information Label is
attached on the left side uf the rear fender
uncler the seet.
EMISSION CONTROL IhIFORMAT1ON LA8EL
GENERAL SPECIFICATIONS IYEM
SPECIFICATIONS 2,113 mm 183.2 in) 1,189 mm (46.8
ii) 1,207 mm (47.5 in) 1,289 mm (50.7 in) g15 mm
(3b.0 in 945 mm \37.2 inl B75 mm f34.5 in) 341
mm I13.4 in) 234 mm (9.2 in) 29a kg (642 lbs) Z20
kg t4B5 lbs) Double cradle Double wish-bone 175
mm (6.9 in) Double tube Oouble wish-hone 203 mm
(8.0 in) Single tube AT25 x 8R12y g AT25 x 10R
12 w 12 x 6.0 AT 12 x 7.5 AT KT515 (DUNLOP)
KT511 (DUNLOP) Hydraulic disc brake
Hydraulic/mectJunical disc hraku
DIME NSIONS
Overal isngth Overall width Overall height
Wheelbase Front tread Rear tread Seat height
Footpeg height Ground clearance Curb
weight Maximum weight capacity Frame TYPE Front
suspension Front wheel travel Front damper Real
suspension Rear wheel travel Rear damper Front
tire size Rear tire size Front rim size Rear rim
size Front tire brand Rear yire brand Front
brake Rear brake Caster angle Trail length Camber
angle Fuel tank capacity Fuel tank reserve
capacity
FRAME
2.1 mm (3/16 in) 0 17 Iitrs 14.5 US gal, 3.7
Irrip gal) 4.1 liters (1.08 US gal, 0.90 lmp gall
1-5
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GENERAL INFORMATION
ITEM ITEM SPECIFICATIONS
ENGINE Cyfjnae arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens at 1 mm (0.04 in) lift Intaka valve closes at 1 mm (0.04 in) lift Exhaust valve opens at 1 mm (0.04 in) lift Exhaust valve closes at 1 mm (0.04 in) lift Lubrication system Oil pump fype Cooling systam Air filtration Engine dry weight Single cylinder, IOngitudinally installed 102 x 82.8 mm (4.02 x 3.25 in) 674.9 cmm (41.19 cu-in) 9.2 1 OHV 8 BTDC 45 ABDC 45 BBDC 5 ATDC Forced pre5sur6 (dry sump) Trochoid Liquid cooled Oiled urethane foam 60.4 kg t33.2 lbs)
CARBURATION Typ0 Throttle bore PGM-FI (Programmed Fuel Injectionl 40 mm (1.57in)
DRIVE TRAIN Transmission Shift clutch l1st, 2nd and 3rd clutches) Primary reduction Secondaw reduction Forward Reverse Final reduction Front Raar Transmission ratio 1st 2nd 3rd Reverse Gearshift pattern Sub-transmis- sion D (DrivB) R (Reverse) Automatic (Torque converter 3-speed drive system and reverse) Multi-p1ata, wet (hydraulic clutch with electric coniroIIedI 1.333 (64/48) 2.000 (38/191 2.375 (ZB/16) 3.231 (42/13) 3,154 141/13) 2.053 t39/19I 1.375 (33/24) 0.933 (2B/301 2.138 (29/19 x 25/24) D - N R 2-mode 3-speed Automatic and Manual(ESP 3 speeds) 1mode \fixed low ratio)
ELECTRICAL Ignition system Starting system Charging system Regulator/rectifier Lighting system Full Transistorizsd Ignition Electric starter motor and emergency recoil starter Triple phase output alternator FET shartod, triple phase full wave rectifica- tion Battery
1-6
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GENERAL INFORMATION LUBRICATION SYSTEM
SPECIFICATIONS
Unit mm (in SERVICE LIMIT
ITEM After draining
STANDARD 2.7 Iiters (2.9 US qt, 2.4 Imp qt)
Engine oiI capacity
I Ãfter draining/filter
2.9 liters (3.1 US qt, 2.6 Imp qt) 4.1 Iiters
(4.3 US qt, 3.6 Imp qt)
,I change After disassembly
Recommended engine oil
Pro Honda GN4 or HP4 (without molyb-
denum additives 4-stroke oil (USA Canada), or
Honda 4-stroke oil (Canada onlv), or an
equivalent motorsysle oil API service
classification SG or Higher (except oils labeled
as energy conserv- ing on the circular API
service label) JASO T 903 standard MA Viscosity
SAE 10W-40, SW-30
Öilpressure at 5,000 rpm min')/80C (176F)
Oil pump rotor t Tip clearance
785 kPa (8.0 kgf/cm, 114 psi) 0.15 0.006)
-
0.20 (0.008)
Body clearance Side clearance
0.IZ 0.22 (0,005 0.009) õ.02 0.09 (0.001
0.004)
0.25 (0.0101 0.11 (0.004)
FUEL SYSTEM SPECIFICATIONS ITEM Throttle body
identification number Idle speed Throttle lever
free play ECT sensor resistance (20"C/6BFI Fuel
injector resistance (at 2ßC /68F) Fuel
pressure Fuel pump flow (Bt 12 V)
SPECIFICATIONS GQ67A 1,400 z SO rpm (mint 3 8
mm (1/8 5/16 ink 2.3 2.6 ksz 11.1 12.3
LJ 284 - 304 kPa (2.9 3.1 kgf/cm , 41 44
psi) 71 cm (2.4 US oz, 2.5 lmp oz) mintmum/10
seconds
I
COOLING SYSTEM SPECIFICATiONS ITEM
SPECIFICATIONS 2.0 liters (2.1 US qt, 1.8 Imp
qt) 0.46 liter (0.49 US qt, 0.40 Imp qt) 108
137 kPa (1.1 1.4 kgf/cm , 16 20 psi) BO
84C 95C
Coolant capacity
Radiator and engine Reserve tank Begin to open
Fully open Valve lift
Radiator cap relief pressure Thermostat
8 mm f0.3 in) minimum Pro Honda HP Coolant or an
equivalent high quality eihyTene glycol
antifreeze containing siIicaie-free corrosion inh
b to s 11 mixture with distilled water
Recommended antifreeze
Standard coolant concentration
1-7
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GENERAL INFORMATION CYLINDER HEAD/VALVE/CAMSHAFTSP
ECIFICATIONS
Unit mm (in Unit mm (in Unit mm (in Unit mm (in Unit mm (in Unit mm (in Unit mm (in
ITEM ITEM ITEM STANDARD SERVICE MMIT
Cylinder compression at 350 rpm (min ') Cylinder compression at 350 rpm (min ') Cylinder compression at 350 rpm (min ') SSO kPa (5.6 kgf/cm, 80 psil
Valve clearance Valve clearance Valve clearance IN 0.15 (0.00g)
Valve clearance Valve clearance Valve clearance EX 0.33 (0.013)
Valve, Valve stem U.D. Valve stem U.D. IN 5.475 - 5.490 (0.2156 0.216\) 5.45 10.215)
valve guide Valve stem U.D. Valve stem U.D. IN 5.475 - 5.490 (0.2156 0.216\) 5.45 10.215)
valve guide Valve stem U.D. Valve stem U.D. EX 5.455 - 5.470 (0.214B 0.2154) 5.43 (0.214)
Valve guide I.D. Stem-to-guide clearance Valve guide I.D. Stem-to-guide clearance IN/EX 5.500 5.512 10.2165 0.2170) 5.53 (0.218)
Valve guide I.D. Stem-to-guide clearance Valve guide I.D. Stem-to-guide clearance IN 0.010 0.037 (0.00D4 0.0015) 0.12 (0.005)
Valve guide I.D. Stem-to-guide clearance Valve guide I.D. Stem-to-guide clearance EX 0.030 0.057 (0.0012 0.0022) 0.14 (0.006)
Valve guide projection Valve guide projection IN 14.8 - 15.2 (0.58 - 0.60)
above cylinder head above cylinder head IN 14.8 - 15.2 (0.58 - 0.60)
above cylinder head above cylinder head EX 173 - 17.7 (0.6B - 0.701
I Ig dth I Ig dth IN/EX 1.D 1.1 (0.039 0.041 1.4 (0.0g)
Valve spring ee Ien inner 3y20 (1.465) 36.3 (1.43
Valve spring ee Ien Outer I 44.2D (1.740) 43.1 (1.70)
Rocker arm Arm I,O. Arm I,O. IN/EX 12.000 - 12.018 ID.4724 - 0.4731I 12.05 10.474)
Rocker arm Shaft O.D. Shaft O.D. IN/EX 11.964 11.984 (0.4710 - D.4718) 11.92 (0.469)
Rocker arm Arm-to-shaft clearance Arm-to-shaft clearance IN/EX 0.016 0.D54 (0.000d - 0.0021) 0.0B (0.0031
Camshaft and Cam lobe height Cam lobe height IN ! 35.015 - 35.175 (1.3785 -1.38481 34.840 (1.3717)
cam follower Cam lobe height Cam lobe height Ex is.394 35.554 (1.3935 1.Z998) 35.144 11.3824)
Cam follower O.D. Cam follower O.D. IN/EX 22.467 -22.482 (0.8B45 0.8851I 22.46 (0.884)
Follower bore I.D. Follower bore I.D. IN/EX 22.510 22.526 (0.8862 0.8868) 22.54 (0.887)
Follower-to-bore clear- Follower-to-bore clear- IN/EX 0.028 0.059 (0.0011 - 0.0023) 0.07 (0.0031
ance ance IN/EX 0.028 0.059 (0.0011 - 0.0023) 0.07 (0.0031
Cylinder head warpage Cylinder head warpage Cylinder head warpage - 0.05 (0.002)
CYLINDER/PISTON SPECIFICATIONS
Unit mm (in
ITEM
STANDARD 102.000 102,015 14.9157 - 4.0163)
SERVICE LIMIT 102.05 (4.018)
Cylinder
t I.D.
Out-of-round
0.05 10.0021
spar
0.05 10.0021
Warpage
0.05 10.002)
Piston,
Piston O.D. at 20 0.8) from bottom
101.960101.990 (4.01424.0153) 23.002
-23.00B(0.9056 - D.905B)
10t.90 (4.012) 23.03 (0.907)
piston pin, piGton ring
Piston pin hale I.D.
I

• stan pin U.D.

22.994 -23.000t0.90530.9055)
I
Piston-to-piston pin clearance
0.002 0.014 (D.0001 - 0.0006)
004 IO 0021 ""OSS(0.02)" 0.7 (0.03)
Pi9ton ring end Top
a.25 0.35 0.010 0.014s
gap Second
0.40 0.55 0.016 0.022)
( Oil (side reil)
0.20 0.70 (0.00B 0.O2B)
0.9 (0.04)
Top Second
0.045 0.080 (0.0018 0.0UJ1) 0.025 0.060
(0.0010 - 0-D024)
Piston ring-to-ring groove clearance Cylinder-to
-piston clearance
O.OW5 0.0037
0.075 (0.00301
I
0.19 0.007 23.D6 0.90B)
0.010 0.055 (0.0004 - 0.00211
connecting rod small end LU. Connecting
rod-to-plSton pn clearance '
23.030 23.050 (0.9067 - D.9D75) 0.030 - 0.056
(0.0 i2 - 0.00221
0,08 0.003)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
Unii mm (in) SERVICE LIMIT 51.61 (2.0321
ITEM Starter driven gear boss O.D. Torque limiter
slip torcue
STANDARD 51.705 - 51.718 (2.0356 - 2.0361) 53
84 N-m (5.4 B.6 kgfm, 39 - 62 Ibf ft)
1-8
14
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