Honda MUV700 BIG RED UTV Service Manual, 2009–2012

This Honda service manual covers maintenance, diagnosis, and repair of the 2009–2012 MUV700 BIG RED side-by-side, including its engine, automatic transmission, chassis, and electrical systems.

PDF Search, Bookmarks and Wiring Detail

Search and navigation: An OCR text layer supports searches through most service chapters, although recognition errors and several pages without searchable text limit results. Embedded bookmarks provide access to the chapters and index. The full-color wiring diagram is not text-searchable; its small connector and wire labels require zooming.

The manual is supplied as one English-language, printable 599-page PDF, including one cover page, three introductory pages, and 11 blank memo pages.

Engine, Drivetrain and Electrical Service

The following selected service topics show the manual’s repair and diagnostic coverage. Additional sections include cargo-bed removal and seat-belt retractor checks.

• Engine service: Scheduled maintenance, engine removal, cylinder-head repair, valve-seat refacing, piston inspection, and crankshaft and balancer service.

• PGM-FI diagnosis: Symptom troubleshooting, diagnostic trouble codes, fuel-pressure and flow tests, injector checks, and throttle-position sensor reset procedures.

• Lubrication and cooling: Oil-pressure testing, oil-pump inspection, oil-cooler service, radiator pressure testing, thermostat checks, water-pump replacement, and coolant bleeding.

• Automatic transmission: Shift-solenoid tests, hydraulic-pressure diagnosis, valve-body service, shift-clutch disassembly, and sub-transmission and gearshift-linkage repair.

• Final drives: Front and rear differential-lock clutch service, drive-shaft work, bearing replacement, gear-backlash measurement, and tooth-contact pattern checks.

• Chassis and brakes: Rack-and-pinion steering gear box repair, suspension-arm and wheel-bearing service, brake-caliper overhaul, master-cylinder repair, and hydraulic bleeding.

• Electrical troubleshooting: Charging-system tests, ignition checks, starter-motor repair, relay diagnosis, wiring diagrams, and cable and harness routing illustrations.

This manual is written for qualified professional technicians with service training, appropriate tools, and the equipment required for the procedures.

PGM-FI and Circuit Diagnosis

The fuel-system section distinguishes faults recorded by the PCM from running problems without a stored code. HDS pocket-tester information covers stored and current data; MIL blink-code instructions provide an alternative way to retrieve main fault codes, but not their subcodes.

The PGM-FI System Diagram and connector-location views connect sensor and injector tests to the relevant terminals. Together with the cable and harness routing illustrations, they support tracing faults between components and the PCM.

Throttle-body service includes IACV inspection and TP/MAP sensor-unit replacement. The associated TP sensor reset procedure is included, rather than leaving sensor replacement at mechanical installation alone.

Transmission and Final-Drive Repair

For shifting faults, the Hydraulic Circuit Troubleshooting Chart relates pressure-test results to possible hydraulic causes. The Drivetrain System Diagram supports the electrical side of the same investigation, including clutch-pressure-control and shift-solenoid circuits.

Torque-converter scope: The procedures cover removal, one-way-clutch and bearing inspection, and installation. A faulty torque converter is replaced as an assembly; the manual does not describe an internal converter rebuild.

Shift-clutch work extends to piston and disc inspection, reassembly, and initial-clearance checks. The manual distinguishes engine-removal work from procedures requiring crankcase separation, while sub-transmission and forward/reverse linkage service can be performed with the engine installed.

Front and rear final-drive sections include shim selection and gear tooth contact pattern views. An excessively thick ring-gear shim can lock the gears even with light tightening of the case-cover bolts.

Engine, Cooling and Chassis Work

Step-by-step procedures cover cylinder-head disassembly, valve-guide replacement, and valve-seat refacing. Component inspection tables distinguish standard dimensions from service limits, while engine and frame torque tables support reassembly.

The Cooling System Flow Pattern accompanies pressure testing and component service. The coolant guidance addresses a specific repair risk: silicate-containing coolant can cause premature water-pump seal wear or block radiator passages.

Steering coverage includes rack-guide adjustment, turning-load checks, and wheel alignment. The steering gear box has disassembly procedures, while a faulty steering column is replaced as an assembly.

Secure the vehicle on level ground and follow the manual’s support and safety precautions for raised-vehicle work, brake service, and running-engine tests.

Examples of Valve, Fuel-Flow and Final-Drive Specifications

For valve-clearance inspection, the manual specifies an intake clearance of 0.15 ± 0.02 mm with the engine cold, below 35°C/95°F.

The fuel-system specifications give a minimum pump delivery of 86 cm³ per 10 seconds at 12 V, accompanying the fuel-flow inspection procedure.

Front final-drive oil capacity is listed as 665 cm³ after draining. The capacity tables distinguish this service-fill condition from filling after disassembly.