Honda NRX1800 Valkyrie Rune 2003-2005 Workshop Service Repair Manual PDF - MHONNRX1800OPEK.zip

A full service and repair guide featuring electrical wiring schematics for the Honda NRX1800, packed with every technical detail needed to maintain, troubleshoot, and fix your bike the way trained technicians do.

Covering the 2003-2005 Honda NRX1800 Valkyrie Rune, this workshop service & repair manual contains:

* 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