Repair Manual
CHAPTER TWO / TROUBLESHOOTING
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
CHAPTER FOUR / ENGINE
Removal installation / Rocker arms and pushrods / Cylinder head / Valves and components / Cylinder / Pistons and rings / Pushrods / Valve lifters / Oil pump / Oil tank and oil lines / Camshaft support plate / Crankcase and crankshaft / Counter balancer assembly / Engine break-in
CHAPTER FIVE / CLUTCH AND PRIMARY DRIVE
Primary chaincase cover / Clutch assembly / Clutch shell, compensating sprocket and primary drive chain / Clutch shell, clutch hub and sprocket / Primary chain and guide inspection / Primary chain alignment / Compensating sprocket inspection / Primary chaincase housing / Starter jackshaft / Clutch cable replacement
CHAPTER SIX / TRANSMISSION
Shifter assembly / External shift mechanism / Transmission top cover / Shift cam / Shift arm assembly / Shift forks / Transmission side door and transmission shaft assemblies / Transmission shafts / Main drive gear / Transmission clutch release mechanism cover / Transmission drive sprocket / Transmission case
CHAPTER SEVEN / FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
Air filter backplate / Carburetor / Intake manifold / Electronic fuel injection / Depressurizing the fuel system / Induction module / Throttle and idle cables / Starting enrichment valve (choke) cable replacement / Throttle and idle cables / Fuel tank console / Fuel hose and clamps / Fuel tank / Fuel tank inspection / Fuel pump and fuel filter / Fuel shutoff valve / Fuel tank gauge / Exhaust system / Evaporative emission control system
CHAPTER EIGHT / ELECTRICAL SYSTEM
Electrical connectors / Battery / Charging system / Alternator / Voltage regulator / Ignition system / Starting system / Lighting system / Switches / Horn / Electrical panel / Turn signal module / Turn signal module and turn signal/security module / Speedometer speed sensor / Starter relay switch replacement / Speedometer and indicator lights / Fuses / Circuit breaker / Electrical connector service / Wiring diagrams
CHAPTER NINE / WHEELS, HUBS AND TIRES
Motorcycle stands / Front wheel / Rear wheel / Front and rear hubs / Driven sprocket assembly / Drive sprocket / Drive belt / Wheel runout / Rim and laced wheel service / Disc and cast wheels / Wheel balance / Tires / Tire changing / Tire repairs / Tire runout
CHAPTER TEN AND ELEVEN / FRONT SUSPENSION AND STEERING (TELESCOPIC FORK AND SPRINGER FORK)
Springer service precautions / Handlebar and risers / Shock absorber / Fork rockers / Springer fork / Rigid fork / Steering stem / Steering play adjustment
CHAPTER TWELVE / REAR SUSPENSION
Spring preload adjustment / Shock absorbers / Rear swing arm
CHAPTER THIRTEEN / BRAKES
Brake service / Front brake pad replacement / Front brake caliper / Brake reaction link / Front brake caliper / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Rear master cylinder / Brake hose and line replacement / Brake disc / Bleeding the system / Rear brake pedal
CHAPTER FOURTEEN / BODY
Seat / Front fender / Rear fender inner panel / Rear fender / Windshield / Saddlebags / Footboards and footrests / Jiffy stand
SUPPLEMENT / 2004-2005 MODEL SERVICE INFORMATION
WIRING DIAGRAMS |
