The Wrench, October 2011
Contents
1. All Models Maintaining Inventory Units It seems a strange concept maintaining brand new units that haven t been put into service yet But it s a necessity if you expect the vehicle to sail through the Set Up PDI process without issues thereby assuring your customer of a timely deliv ery and a trouble free first ride There are three main areas of concern for units stored in inventory for extended periods batteries tires and fuel Tak ing a few preventative maintenance steps will make sure units are ready to go when the deal is closed Batteries e Check the battery voltage when a unit arrives into Inventory and charge it as necessary e Periodically check and charge the battery of long term inventory units e Use the Pro Honda Optimate 3 automatic bat tery charger on showroom units The charger can be conveniently plugged into an extension cord and moved between units for overnight battery charging Tires e Check and correctly set the tire pressures when units are uncrated This will help prevent side wall cracks and flat spots on long term Inventory units e Periodically check and set tire pressures on showroom and demo units This will assure the customer of a sure footed demo ride Fuel e Today s gasoline formulation has a shelf life of about 30 days So don t store long term sup plies of gasoline e Use Pro Honda Fuel Stabilizer in the shop fuel Supply and any long term storage or demo units to prevent2. e Verify the correct transmission oil level using the procedure in the Service Manual e Check and if necessary correct the valve clear ance Proper valve clearance Is critical to easy Starting e Set the idle speed to specification 1700 rom using a tachometer This will ensure easy Starting Repair Procedure Tip e If you are performing a starter clutch repair be sure to replace the reduction gear B 9 191 P N 06220 HP1 305 This gear acts as a slip torque gear to help dissipate the load if the engine kicks back during cranking You cannot tell it s bad by looking at it and if the starter clutch is damaged then It Is likely that this gear is also damaged TRX650 680 MUV700 Engine Runs But Vehicle Won t Accelerate If you have a machine where the engine runs OK but It won t accelerate while in gear slipping and there are no DICs set there may be low oil pres sure within the transmission First make a couple of preliminary checks before troubleshooting the mechanical side of the drivetrain system Preliminary Checks e Check the engine oil level Low oil level can pre vent the transmission trom working properly e Warm up the engine thoroughly before riding especially in cold weather In very cold weather use OVV 30 engine oil to shorten the warm up time Drivetrain Troubleshooting NOTE The following procedure sidesteps some service Manual troubleshooting procedures so that failed clutch o
3. gumming of the fuel system October 2011 Honda Technician Newsletter On Road 2012 GL1SOO A Keyless Transmitter Registration Registering an additional or replacement keyless transmitter to the 2012 Gold Wing Is the same pro cedure as previous years with one exception The 2012 keyless transmitter now has a small red light that lets you know the transmitter is sending a sig nal and has battery lite Although the procedure described in the Service Manual page 21 56 to register a transmitter is correct if you press and hold the trunk opener button until the red light comes on the registration will fail Press the trunk opener button only briefly so that the red light does not come on This should ensure that the reg istration procedure goes smoothly the first time TRUNK OPENER BUTTON RED LIGHT Stainless Steel Exhaust System Care some Honda on road motorcycles such as CB1000R and NT 700V come with high luster stainless steel exhaust header pipes Over time it is natural for these pipes to change color and often times become stained from road debris or other contaminants These stainless steel header pipes are similar to painted bodywork in that they require care and maintenance to keep their factory fresh appear ance Scrubbing the header pipes when they re cool mind you with a little Hondabrite soap on a light gray 3M ScotchBrite 7448 hand pad will return them to a new looking silver color Be
4. sure to completely rinse the pipes with water For an even finer finish after the ScotchBrite use Pro Honda Metal Polish on a shop towel Please share this procedure with any customers that are con cerned with the restoring the finish of these parts ATV MUV 06 12 TRX450ER Hard Starting Issues This model is equipped with a very high perfor mance engine based on the potent CRF450X Most customer complaints related to hard starting come down to incorrect engine starting habits and or an out of tune engine Below are some proven strategies for ensuring that the TRX450ER will start easily and also a repair tip for a damaged starter reduction gear train Customer Education e Review the correct starting procedure as out lined in the Owner s Manual with the cus tomer It is extremely important not to open the throttle when starting Opening the throt tle even slightly can cause the engine to kick back This can damage the starter clutch and starter reduction gear train e Advise the customer not to lower the idle speed from the specified rom 1700 as this makes the engine hard to start increasing the temptation to open the throttle when starting the engine Many customers think the engine idles too high and have mistakenly lowered the idle speed e Advise the customer to use fresh premium unleaded fuel with no more than 10 etha nol E10 Maintenance Checks e Verify completion of all applicable PUD repairs
5. e cus tomer may have used It to limp the machine home FRONT CRANKCASE PIPE B LOCK PLATE STOPPER BOLT Turn the stopper bolt all the way out to deactivate the emergency a PAi lr ee L RAU Pl PE A C LLA O RING S SETTING COLLAR valve Ri N AN5 f A If the oil feed pipes their O rings and the O rings a taal for the setting collar are all OK follow the Symp ee nee NOS tom Troubleshooting procedures in the Service COVER Manual from the beginning The Tool Chest MUV Wheel Dolly New from the Honda Tool and Equipment Pro gram the Stinger Easy Roller wheel dolly provides a simple and efficient method of moving a disabled MUV around a shop environment You ll need four dollys Check it out on IN by following this path Service gt Tools gt Tool and Equipment Program gt Lift ing Equipment gt Vehicle Maneuvering Locating The Source of Abnormal Noise Customer complaints of noises or vibrations are among the most difficult to pinpoint especially in a noisy shop environment If the noise or a vibration can be duplicated in the shop a mechanic s stethoscope is an essential but often overlooked diagnostic tool Stethoscope styles range from a simple inexpensive hose type up to electronically amplified units with headphones Their extension probe can get into tight areas and help you locate the source of abnormal noise Z HONDA Stethoscopes are available from the Ho
6. il feed pipes and or O rings can be detected without going through lengthy shift e f oil pressure is lost low at the first valve body inspection procedures first gear clutch check oil feed pipe A for cracks and the condition of its O ring located on the inside of the front crank case cover as shown 1 Warm up the engine and then turn the ignition switch OFF Put the gear shift lever into Drive position Using a mechanic s stethoscope eOnT H r INSIDE OF FRONT ee ED PIPE A Yo confirm that the A T Clutch Pressure Control CRANKCASE Solenoid linear valve solenoid clicks when tated the ignition switch is turned ON uy e Solenoid clicks go to step 2 e Solenoid does not click troubleshoot using the A T Clutch Pressure Control Sole noid Operation Check in the Service Manual 2 Using the procedure in the Service Manual check the A T line pressure and shift clutch oil pressures 1st 2nd 3rd at the f oil pressure is lost low at 2nd or 3rd shift valve body gear clutches check the oil feed pipes B and C for cracks condition of their O rings e f there IS no low line pressure inspect and the O rings on the setting collar all are the oil pump and its drive chain accessible from the outside of the front e f the line oil pressure is OK but pressure crankcase cover as shown is lost at any clutch first check if the emergency valve is engaged as th
7. information on IN by clicking on Online University and follow ing the link to the 2011 2012 Training Schedule 2011 American Honda Motor Co Inc All Rights Reserved Published by AHM Motorcycle Service Communications 1919 Torrance Blvd Torrance CA 90501 All suggestions become the property of American Honda Motor Co Inc Sending a suggestion gives American Honda permission to publish it without further consideration The information in this article is for authorized Honda PWC or MUV dealers only applicable only if a PWC or MUV article is included in the issue Editor Robert Heilbron E mail The Wrench at EditorTheWrench ahm honda com MSN 13836 1109
8. nda Tool and Equipment program by following this path on IN Service gt Tools gt Tool and Equipment Program gt Engine Diagnostic and Electrical Equipment Warranty Corner Customer Signature Required On R O Because the Repair Order is the basis of a dealer s claim for warranty reimbursement it must be complete accurate legible and autho rized signed by the customer Also In many states a customer s authorization via a signa ture is required by law whether for warranty or customer pay repairs Please ensure that all repair orders are signed by the customer as outlined in the Warranty Pol icy amp Procedure Manual under Writing a Repair Order located on page 18 An electronic signa ture paper copy with signature or scanned copy is sufficient for AHM policy AHM Warranty Dept and your DSM must enforce this policy when administering warranty claims submitted by your store Claims that Tail to meet the minimum requirements are subject to debit Incomplete repair orders can also put your dealership at needless risk for Infraction of state laws and consumer conflicts disputes Training Corner The 2011 2012 HondaPro training season is now underway Investing in technician training is one of the best ways to make your Service Depart ment more efficient and profitable Service Man agers should plan now to enroll technicians at one of our five Honda training centers Remem ber you can find schedules and class
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