2009 Honda NSA700A / DN-01 Service Manual (P/N 61MEH00)

• Coverage and edition: A 654-page Honda OEM service manual PDF for the 2009 NSA700A (DN-01). The February 2009 base issue includes revised ABS pages dated June 2009 and revised HFT pages dated December 2010, with coverage for standard and California-spec configurations.
• HFT service: Explains the infinitely variable hydraulic transmission, separate HFT oil circuit, starting and N/D clutches, lockup system, swash-plate control, TCM logic, and D, S, and six-speed manual modes. Procedures include oil-pressure testing, DTC diagnosis, in-frame checks, removal/installation, and HFT initialization.
• Engine repair: Covers engine removal and installation, compression testing, camshaft timing, cylinder-head disassembly, valve-guide replacement and seat refacing, piston/cylinder inspection, crankcase separation, crankshaft and connecting-rod service, and color-coded bearing selection.
• PGM-FI and electrical diagnosis: Includes symptom charts, MIL/DTC fault isolation, connector views, fuel-pressure and flow tests, ECM power/ground checks, injector and sensor testing, charging and ignition diagnosis, starter-motor repair, and meter/switch circuits.
• Final drive, chassis, and brakes: Details final-drive backlash and tooth-contact inspection, shim and bearing replacement, fork overhaul, steering-head and swingarm service, brake-fluid replacement and air bleeding, master-cylinder and caliper repair, parking-brake adjustment, and ABS problem-code diagnosis.
• Factory reference material: Provides component-specific torque tables, fluid and lubrication data, clearances, service limits, pressure and electrical test specifications, cable/harness routing, system diagrams, connector locations, and separate full-color wiring diagrams for California and non-California models.

Honda states that this manual is written for readers with basic maintenance knowledge of Honda motorcycles, scooters, or ATVs, while the service and repair information is intended for qualified professional technicians. Routine maintenance sections can suit an experienced owner with that background; HFT, PGM-FI, ABS, internal-engine, and final-drive work assumes the specified diagnostic equipment, measuring tools, and safe lifting support.

HFT Diagnosis and Repair Limits

The HFT chapter is the defining section of this manual. It traces torque through the cam damper and primary drive gear, hydraulic pump and motor sections, N/D clutch, side gear, driveshaft, and final drive. The technical-feature material also explains the independent HFT lubrication circuit, electronic lockup, low-oil fail-safe strategy, and swash-plate control used to vary the transmission ratio.

Diagnostic coverage goes well beyond a system overview. The manual provides HDS Pocket Tester data access, shift-indicator blink-code readout, DTC and fail-safe tables, freeze-data handling, sensor and solenoid circuit checks, pressure inspection, and separate turning/movement checks for the pump and motor sides. It also documents TCM reset and HFT initialization after HFT installation, TCM replacement, or swash-plate angle-sensor service.

The HFT itself is not rebuildable; Honda directs replacement of the complete factory-preset unit if diagnosis confirms internal damage. Associated parts are serviceable, including the N/D clutch, cam damper/primary drive gear, crankcase-cover spool valve and oil passages, swash-plate control motor and angle sensor, oil-pressure and temperature sensors, solenoid valves, selector switches, relays, and TCM.

Mechanical, Fuel, and Chassis Scope

The engine chapters address the 680.2 cc, liquid-cooled, 52-degree V-twin and distinguish jobs that can be done in-frame from those requiring engine removal. Camshaft, cylinder-head, N/D clutch, cam-damper, side-gear-case, flywheel/starter-clutch, and starter-motor service remain in-frame; crankshaft and oil-pump repair, plus HFT-unit removal, require the engine to come out. Final-drive work includes preload, backlash, gear-tooth contact, bearing and seal replacement, shim selection, and side-gear-case service.

Fuel-system coverage identifies the non-California GQ6BB and California GQ6BC throttle-body versions. It follows both upper and lower fuel tanks and covers the throttle body, injectors, IACV, MAP/IAT/ECT/CMP sensors, bank-angle sensor, ECM, PAIR system, oxygen sensors, and California EVAP canister and purge control. Diagnostic graphics include the PGM-FI and HFT system diagrams, lubrication circuit, cooling-system flow pattern, ABS system diagram, cable/harness routing, connector views, and the two market-specific wiring schematics.

Tools, Cautions, and Shop Safety

Honda identifies the SCS connector (070PZ-ZY30100) for HFT DTC work and TCM initialization, plus an HFT pressure gauge and hose (07YAJ-0010200 and 07KPJ-VD60210). The PGM-FI section specifies fuel-pressure gauge 07406-0040004 and ECM test harness 070MZ-MCA0100. N/D clutch work calls for spring-compressor attachment A (07LAE-PX40100; two required in the U.S.) and bolt set 07GAE-PG40200/07GAE-PG4020A; incorrect positioning can damage the spring retainer.

Two HFT cautions matter during repair: pinching the O-rings on the locating dowels can compromise the transmission oil passages, while contamination in those passages can cause HFT malfunction. The crankshaft section also requires its select-fit bearing inserts to stay matched by code; incorrect oil clearance can cause major engine damage.

Engine removal requires a hoist or equivalent support and an adjustable jack. Fuel-pressure tests, brake bleeding, hot-coolant work, and running-engine HFT checks should be performed with proper ventilation, PPE, and stable support for the motorcycle.