News Letter

March 2016
iNFormation
Update Your MCS
Software and MCI Tester
The current software update (MCS_2.013) for the
MCS diagnostic tool was released on February 29,
2016. This latest software update supports diagnostic functions for all MCS compatible models
released to date.
Make sure your MCS software and the MCI (diagnostic tool) are up to date for the latest models.
Download the software update to your service
department laptop PC from iN by following this
path:
iN > Service > TechLine > Diagnostic Tools > MCS
>Software Download
Installing Engine Covers
Proper alignment is critical for engine covers on
torque converter equipped engines, DCT type
transmissions where the oil feed tubes could be
damaged if the cover is not installed correctly; or an
engine cover with a gear position switch which has
to be indexed correctly and could be knocked out of
alignment during the installation. Potential problems can be avoided by using a pair of guide pins
installed on the engine-side of the assembly to
ensure the cover goes on correctly. Guide pins can
be easily fashioned from long case cover bolts by
cutting off the head of the bolt and slotting the tip
for a flat-blade screwdriver. Install the guide pins on
opposite sides of the cover so that it is supported
evenly. Use caution when installing alternator covers this way as the cover is magnetically attracted
to the flywheel and may pinch your fingers.
All Models
2015 & Later Water Cooled Models
New Type 2 HP Coolant
ENGINE COVER
GUIDE PIN
Due to emerging environmental regulations,
Honda Type 2 Blue coolant will now be “factory
fill” in Powersports products, starting with model
year 2015. Pro Honda Oils and Chemicals is
pleased to introduce the state-of-the-art Type 2
formulation of HP Coolant.
This advanced new coolant is compatible with the
previous generation green HP Coolant and
replaces it for all applications, so there’s no problem if you need to mix them. Also good news; the
price is lower than the previous formula. Available
through normal parts channels:
Pro Honda HP Coolant, Type 2
(32 oz)
P/N 08C50-C321S02
(12 bottles/case)
On-Road
2016 GL1800
Decoding Trim Level by VIN
It is often necessary to know the area code and
corresponding trim level of the GL1800 you’re
working on in order carry out certain service procedures or when ordering replacement parts. The
key to positively identifying trim level lies within
the unit’s VIN. The following table identifies the
trim level by the key letter in the VIN (in bold).
Although there are now ten “area code” types of
GL1800 for model year 2016, as with past model
years there are only four different trim levels.
VIN ID
Area Code
Equipment Package
JH2SC68G*
2YA, 2AC,
4AC
Audio, Comfort
JH2SC68H*
3YA, 3AC,
5AC
Audio, Comfort,
Navi-XM
JH2SC68N*
6YA, 6AC,
7AC
Audio, Comfort,
Navi-XM, ABS
JH2SC68Z*
9YA
Audio, Comfort, NaviXM, ABS, Airbag
1. Choose the side of the tool that best fits the
differential splines; “A” side is smaller than
“B” side. In this example the “B” side fits the
TRX420/500 differential shown here.
2. Clamp the parallel edges of the “A” side of
the tool in a bench vise so that the “B” side
sticks up about 60 mm as shown.
“B” SIDE
TRX & SXS
“A” SIDE
3. Install the differential assembly onto the “B”
side of the tool as shown.
TRX 4WD Models 2000 & Later
Front Differential Slip
Torque Inspection
Checking the differential slip torque allows you to
assess the condition of the differential without
having to disassemble it. However, the tool
depicted in the Differential Inspection section of
the Service Manual is not available from American
Honda. The tool that is available in the U.S. (P/N
07KMK-HC5010A), looks like an almost square bar
of steel that couldn't possibly fit into the female
splines of the front drive unit. Yet it does as the
trapezoid shape perfectly engages the female
splines within the front differential.
4. Install the “B” side of the second tool into the
other side of the differential as shown.
SLIP TORQUE INSPECTION TOOL
P/N 07KMK-HC5010A (Two required)
“B” SIDE
Here’s how to set-up the tools and measure the
slip torque of a TRX front differential:
5. Apply the torque wrench to the hex fitting
on the end of the tool and check that the
differential slips somewhere between the
lowest and highest value of the specified
torque range.
STANDARD:
14 – 17 N·m (1.45 – 1.75 kgf·m, 10 – 13 lbf·ft)
SERVICE LIMIT:
12 N·m (1.2 kgf·m, 9 lbf·ft)
• If the engine does not shut off, the BAS is
faulty - replace it.
• If the engine shuts off within 10 seconds,
the BAS is OK. Connect the MCS tester and
proceed to troubleshoot for DTC 54-1 or 542 (Bank Angle Sensor Circuit) by following
the procedure in the Service Manual.
Engine Will Not Start or Starts, Runs and
Then Quits - No MIL Flashing
1. Disconnect the BAS connector from the BAS
body and then start the engine.
• If the engine starts and continues to run, the
BAS is faulty - replace it.
• If the engine does not start, proceed to troubleshoot the cause by following the SYMPTOM TROUBLESHOOTING table within the
PGM-FI section of the appropriate Service
Manual.
Bank Angle Sensor Location
If the slip torque is out of specification, disassemble the differential and perform the components
inspection as the differential may be faulty.
2014 & Later TRX420 - All,
2014 & Later TRX500 - All
The BAS is located on the frame just ahead and to
the left of the steering shaft as shown. The Service Manual advises removing the front fender/
carrier to access BAS, but it can be accessed by
turning the handlebar fully to the right as shown.
Engine Will Not Start,
Engine Starts - Then Stops
Reports from the field indicate that a faulty bank
angle sensor (BAS) is often to blame when the
engine fails to start, or starts and then quits. There
are also BAS failures that don’t cause the engine
to stop, but cause the MIL (check engine light) to
flash. But, before troubleshooting the BAS specifically, check all the simple stuff like fuel level,
engine stop switch, and battery voltage.
Engine Starts & Runs and MIL is Flashing
“DTC 54”
Confirm the Diagnostic Trouble Code (DTC) is
“54” by counting five long blinks and four short
blinks.
1. Unbolt the BAS from the frame and let it rest
in its upright position on the frame.
2. Start the engine and let it run for at least 10
seconds.
3. With the engine running, invert the BAS and
note whether the engine shuts off within 10
seconds.
BANK ANGLE SENSOR
New Style Driveshaft Joint
Boot and Band
Starting with model year 2015, several TRX and all
SXS models feature new super tough plastic CV
joint boots on the drive shafts. The removal and
installation of these new boots is easier than with
previous designs, but requires new CV joint band
pliers to install the boot bands. Be sure to refer to
the Service Manual when servicing the CV joints
on late-model TRX and SXS as each joint requires
a unique boot and band combination. Also, the
Service Manual outlines the correct installation
direction for the boot bands as well as the technique for using the boot band tool.
The best way to refill the oil on this machine is to
pre-measure the amount of oil and slowly pour it
into the engine. Once filled, run the engine for
three to five minutes, turn it off and then check
the oil level after waiting two or three minutes for
the level to settle. Use the following volume
specs, and the oil level should be spot-on.
Engine Oil Capacity:
TRX420FA1/2/5/6
TRX500FA5/6/7
3.6 qt after draining
3.8 qt after draining/filter change
CV JOINT BAND PLIERS
Model #: OET14100134
SXS700 and SXS1000
Make sure your service department is properly
equipped. Order the new boot band pliers from
the Honda Tool and Equipment Program by logging on to iN and following this path:
Service > Tools > Tool and Equipment Program
TRX420FA/FPA/FA1/FA2,
TRX500FA5/6/7
Oil Changing Tip
These models utilize a semi-dry sump oiling system where the oil tank is integrated into the crankcase. Because of this feature, when refilling the
oil tank it appears that oil will come out of the filler
hole before anything shows up on the dipstick.
This is a normal condition as the oil needs to fill up
to the top portion of the oil tank before it flows
over the spill way and then down into the front
crankcase cover where the dipstick is located.
Rear Seatbelt Retractor...
Won’t
If you’re testing the rear seat belt retractor before
it is mounted to the vehicle and you find the belt is
stuck in its housing and won’t pull out or retract,
that’s because it’s designed to lock the belt when
the vehicle tilts.
The rear seat belt retractor has an internal locking
mechanism within the housing that will lock the
belt if the housing is at an angle other than how it
is normally mounted in the vehicle. If the belt gets
stuck, hold the housing in the orientation that it
would normally be mounted in the vehicle as
shown. Then, feed a small amount of the belt back
into its housing, then gently pull it back out. This
should de-activate the locking mechanism and it
should operate normally again. This method can
also be used to free a customer's stuck seat belt.
SXS700:
OIL FILLER/
OIL TANK
SEATBELT RETRACTOR
Must be in this position in
order for internal belt lock
to release.
SPILL WAY
DIPSTICK
THE WRENCH
©2016 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 [email protected]
MSN 15742 (1602)