QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers and information labels / Shop supplies / Tools / Measuring tools /Electrical system fundamentals / Service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Final drive / Front suspension and steering / Brake system
CHAPTER THREE / LUBRICATION, MAINTENANCE, and TUNE-UP
Tune-up / Air filter / Engine compression test / Spark plugs / Ignition timing / Valve clearance / Idle speed adjustment / Fuel system hose inspection / Fuel filter / Throttle cable / Clutch cable and clutch lever / Engine oil and filter / Engine oil pressure check / Cooling system / Front fork oil change / Specifications
CHAPTER FOUR and FIVE / ENGINE
Removal installation / Cylinder head covers and rocker arms / Camshafts / Cam chain tensioner and cam chain / Cylinder head / Valves and valve components / Cylinder / Piston and piston rings / Cylinder stud / Crankcase / Crankcase seal and bearing / Crankshaft / Connecting rods / Balancer shafts / Oil pump / Output gear / Specifications
CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
Right crankcase cover / Clutch release assembly / Primary drive and driven gears and oil pump chain and sprockets / External shift mechanism / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM
Specifications
CHAPTER EIGHT / CARBURETOR AND EMISSION CONTROL SYSTEMS
Fuel system differences / Fuel tank / Fuel valve / Air filter housing / Carburetor / Intake manifold / Pilot screw adjustment idle drop procedure / High altitude adjustment / Throttle cable replacement / Choke cable replacement / Fuel pump and fuel filter / Crankcase breather system / Pulse secondary air supply system / Evaporative emission control system / (California models) / Specifications
CHAPTER NINE / FUEL & INJECTION & EMISSION CONTROL SYSTEMS
CHAPTER TEN / ELECTRICAL SYSTEM
Electrical component replacement / Electrical connectors / Battery / Battery box / Charging system / Stator coil, ignition pulse generator and left crankcase cover / Flywheel, starter clutch and starter drive gears / Ignition system testing / Ignition coils / Ignition pulse generator / Ignition control module ICM / Ignition timing / Throttle position sensor / Starter / Starter relay switch / Clutch diode / Lighting system / Vehicle speed sensor VSS / Coolant temperature indicator and engine coolant temperature ECT sensor / Fan switch / Oil pressure switch and oil pressure indicator / Neutral switch / Sidestand / Clutch switch / Brake light switch / Ignition switch / Handlebar switch / Turn signal relay / Fuel cutoff relay / Horn / Fuses / Specifications
CHAPTER ELEVEN / COOLING SYSTEM
Temperature warning system / Cooling system inspection / Radiator / Cooling fan / Coolant reserve tank / Thermostat / Thermostat housing / Coolant pipe / Water pump / Specifications
CHAPTER TWELVE / WHEELS AND TIRES
Motorcycle lift / Front wheel / Rear wheel / Front and rear hubs / Driven flange / Wheel service (cast wheels) / Wheel service (lace wheels) / Tire safety / Tire changing / Wheel balance / Specifications
CHAPTER THIRTEEN/ FRONT SUSPENSION AND STEERING
Handlebar / Handlebar grips / Front fork / Steering assembly / Steering head and stem / Steering bearing preload check / Steering bearing replacement / Specifications
CHAPTER FOURTEEN / REAR SUSPENSION
Shock absorber / swing arm / Final drive unit and drive shaft / Ring and pinion gear measurements / Specifications
CHAPTER FIFTEEN / BRAKES
Linked braking system LBS / Brake service / Brake bleeding / Brake fluid draining / Brake pads / Brake caliper removal and installation / Brake caliper overhaul / Front master cylinder / Rear master cylinder / Proportional control valve / Brake hose and brake line replacement / Brake disc / Rear brake pedal / Specifications
CHAPTER SIXTEEN / ANTI-LOCK BRAKE SYSTEM
CHAPTER SEVENTEEN / BODY AND EXHAUST SYSTEM
Seat / Side covers / Left crankcase rear cover / Front fender / Rear fender / Rider footrests / Sidestand / Windshield / Backrest and saddlebags / Exhaust system / Specifications
INDEX
COLOR WIRING DIAGRAMS