January 2016

All Models
Sticking Wave Key Lock
Cylinder
If a customer complains that their ignition switch
or other lock cylinder is sticking or hard to turn,
the problem is likely accumulated debris on the
face of the key, and also within the lock cylinder.
If this is the case, first clean the grooves of the
key of all debris [1]. Next, insert and remove the
clean key from the lock cylinder several times to
remove debris from the contact faces of the tumblers [2]. Lastly, insert the key and turn the lock
cylinder both ways several times to remove debris
from between the key cylinder and lock cylinder
[3]. Do not spray any chemicals/lubricants into the
lock cylinder as it will wash away the factory
applied grease, resulting in premature key/lock
cylinder wear.

Here’s a recipe for a handy catch bottle that
scores well on both counts.
Use an empty engine or gear oil bottle that has a
clear strip and graduations on one side. Drill a 3/8
inch hole into the upper surface and install a grommet and suitable hose as shown. Make sure the
hose is long enough to extend to the bottom of
the bottle to prevent air from re-entering the hose
during the bleeding process. Also, make sure the
bottle cap is off or loose so the bottle can vent as
fluid accumulates.
GROMMET
P/N 83501-MG7-000

CARB VENT HOSE
P/N 95003-07008-60M
Approx. 30–35 inches.
[1]

TRX & SXS

[2]
POCKET LINT/DIRT
Clean the key.

[3]

The Tool Chest
Brake Bleeding Catch Bottle
When bleeding brake systems it will be necessary
to capture the excess fluid that comes through
the brake bleeder valve(s). And, as in the case of
Service Bulletin GL1800 #23, you may be required
to measure the amount of expelled brake fluid.

TRX420FA/FPA/FA5/FA6; TRX500FA5/FA6/FA7/FM5/FM6/FM7;
TRX650FA/FGA; TRX680FA/FGA;
SXS500M2; SXS700 All

Rear Brake Caliper Piston
Boot Installation
When rebuilding the rear brake caliper on these
models, the rear caliper piston boot can be very
tricky to install correctly. So tricky that we’ve
developed an alternative method of installation
from the one described in the Service Manual.
Follow the rear brake caliper assembly instruction
until the point where the piston seal [1], piston
boot [2], and piston [3] will be installed. Note that

no matter what the installation method, the seal,
boot, and piston must be properly lubricated with
the indicated chemicals.

boot lip will drop into the piston groove.

[2]

GROOVE

[3]
LOCK NUT WRENCH
P/N 07716-0020100
[1]

Proceed with the remainder of Service Manual
procedures for rear caliper assembly.

First, slide the piston boot over the piston so that
it extends beyond the bottom edge of the piston
as shown.

PISTON BOOT

PISTON

SXS1000 Series

Exhaust Rocker Arm Shaft
Removal
If the intake valves require clearance adjustment
on this model, the camshaft must be removed to
gain access to the valve lifters and shims. However to remove the camshaft, the exhaust rocker
arm shaft and rocker arms have to be removed
first. If the rocker arm shaft bumps into the frame
before it can be fully extracted from the engine,
place a jack under the right-side motor mount and
jack up the engine a little until the rocker arm shaft
clears the frame.

Next, set the piston into the caliper and work the
piston boot flange into the caliper groove with a
blunt tipped tool until it is fully seated.

FRAME

ROCKER ARM SHAFT

PISTON BOOT
Work it into the caliper groove.

Last, slowly install the piston onto the adjuster
screw with the lock nut wrench as shown. Once
the piston is screwed all the way down, the piston

RIGHT MOTOR MOUNT

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 EditorTheWrench@ahm.honda.com

MSN 15678 (1512)